Calorex aa300 User manual

Page 28
TECHNICAL MANUAL
AA300AVH(F) HEAT PUMP
(SD611260 issue 3)
17/03/11
Health and Safety Warning
As the heat pump includes electrical components it is required that only trained and competent
persons should remove panels giving internal access to the unit.
Page 1

Page 29
Page 2
Contents
1.0 HOW THE CALOREX ‘AA300’ WORKS. ..............................................................................................................3
1.1 OPERATION ..........................................................................................................................................5
1.2 HUMIDITY AND AIR TEMPERATURE CONTROLS ...............................................................................6
1.3 TIME CLOCK SETTINGS ......................................................................................................................7
2.0 INSTALLATION ....................................................................................................................................................8
2.1 PLUMBING .......................................................................................................................................... 11
2.2 WATER CONNECTIONS ...................................................................................................................... 12
2.3 ELECTRICAL INSTALLATION ............................................................................................................. 13
2.4 COMMISSIONING CHECKLIST ......................................................................................................... 16
2.5 CIRCUIT DIAGRAMS .......................................................................................................................... 18
2.6 REGULAR PLANNED MAINTENANCE ................................................................................................ 22
3.0 CONTROLS ........................................................................................................................................................ 23
4.0 DATA SHEET ...................................................................................................................................................... 26
5.0 DIMENSION DRAWING ...................................................................................................................................... 27
6.0 WARRANTY CONDITIONS ................................................................................................................................. 28
7.0 CONTACTING CALOREX ................................................................................................................................... 29
8.0 REFRIGERATION DIAGRAMS ............................................................................................................................ 30
9.0 SPARE PARTS LISTS ........................................................................................................................................ 31

Page 3
1.0 HOW THE CALOREX ‘AA300’ WORKS
The Calorex ‘AA300’ is a packaged refrigerant type dehumidifier that is specifically designed to provide humidity
control and room heating (optional) for a swimming pool hall.
The Calorex ‘AA300 is designed to be connected into an air distribution system that will provide a uniform flow of
air through out the hall. An optional fresh air entry point is available.
The Calorex ‘AA300’ works by physically removing excess moisture from the pool hall air. This is achieved by
recirculating air from the pool hall through the unit and removing moisture from the air by use of the machines
internal refrigeration circuit.
As a by product of this process the Calorex ‘AA300’ will convert the energy it has absorbed into sensible heat.
This heat is added back into the return air stream and consequently provides supplementary hall heating. For every
1kw of power consumed the Calorex ‘AA300 ‘ will return approximately 2.5kW of heat. This process is controlled
by a humidistat that measures the pool hall humidity and controls the machine to a set point that can be adjusted
to suit the clients need.
As an option the Calorex ‘AA300’ can be supplied with a low pressure hot water (LPHW) air heater. The LPHW
should be fed with hot water at 80ºC# and will provide space heating for the pool hall. The LPHW is integrally fitted
into the Calorex ‘AA300’ and is supplied with an adjustable thermostat, three way control valve and a switch relay
to control a boiler or pump. The boiler and pump are not supplied with this option.
# Note.
Consult Calorex for heat exchangers that are suitable for lower flow temperatures.
Humid Air Dry,
Warm Air
20ºC
80%
28ºC
40%
Evaporator
Expansion
Condensate
to waste
Principles of operation - air to air dehumidifier
The process of dehumidification involves moisture laden air being drawn through a refrigerated
coil (evaporator). At this point the air is rapidly cooled below its dew point, condensing the water
vapour and recovering its latent heat energy for reuse. The cooled air is then passed across a
condenser where it is reheated and returned to the room as warm, dry air.
How a Calorex Dehumidifier Works
Condenser Compressor

Page 4
The CALOREX ‘AA300’.
FEATURES :-
1.Remote control panel
The Calorex ‘AA300’ is supplied as standard with a remote control panel that can be mounted up to 20m
away from the unit. (The cable supplied with the AA300 is 1.8m ).The control panel features 12V circuits and
interconnecting cable is easily connected to the unit by ‘D’ type fittings.
The control panel will indicate pool hall humidity through an adjustable set point digital humidistat, power on,
fault, machine ‘dehumidifying’ and defrost status. An on/off switch is also provided.
When the unit is supplied with an optional LPHW the panel will also indicate pool hall air temperature through
an adjustable set point thermostat. A time clock will allow ‘set back air temperature’ for unoccupied periods. An
indicator light will show when the unit is heating.
The power to each model in the range is fed via din rail mounted terminal blocks located in the electric
box of the unit.
CONTROL PANEL STANDARD UNIT
CONTROL PANEL WITH LPHW FITTED
2. Variable speed centrifugal fan.
When the AA300 is delivered the fan is set to run at two speeds: medium speed when the machine senses a
demand for dehumidification (and air heating) and low speed for when there are no demands.
If little or no ducting is fitted and the air flow is too high, the top speed of the fan can be changed from high to
medium. See instructions on page 10 and circuit diagram in section 2.5 for instructions on how to do this.
When fitting the remote sensor box it is possible to switch off the low speed fan MCB thus making the fan run
only when there are demand for dehumidification and/or air heating. See page 25.
3. Optional flexible duct fittings.
4. Rotary compressor
5. A non CFC refrigeration circuit.
HUMIDITY DISPLAY
AND LAMP
MAINS ON/OFF
SWITCH
MAINS LAMP
FAULT LAMP
DEFROST LAMP
AIR TEMPERATURE
DISPLAY AND LAMP
TIME CLOCK
HUMIDITY DISPLAY
AND LAMP
MAINS ON/OFF
SWITCH
MAINS LAMP
FAULT LAMP
DEFROST LAMP

Page 5
1.1 OPERATION
The AA300 is connected to the control panel and then to the isolated mains supply as described in section
2.3. The isolator is then energised. The MAINS light on the side of the heat pump will illuminate indicating mains
ON. If the AA300 is fitted with an LPHW the time clock will start to run. The time clock has a battery reserve fitted
which when charged will run for 100 hours so that isolating the machine for short periods will not affect the time
clock settings.
The AA300 unit is switched on to normal operation by an ON (I)/OFF (O) switch on the console.
When switched on the red indicator light will illuminate and digital controller(s) will light up.
Providing that the controls are set to the correct parameters; nominally 60% RH, (28ºC air temperature), the
machine will operate automatically.
For AA300s with LPHW fitted, the ‘unoccupied’ temperature is set on the digital air controller and will be
switched in/out by the time set on the time clock.
As the unit operates, the indicator lights will show the state of the control conditions, ie dehumidification,
heat to air.
See section 3.0 for control panel symbols.
PARAMETER CONTROLLERS
Each parameter, Relative Humidity (and Air Temperature) is sensed within the machine and the signal is taken to
the relevant digital controller.
The RH controller has two switching channels, OUT1 (the Set Point) which is set from the front panel, and OUT2
which is factory preset.
When fitted, the Air Temperature has three switching channels, one of which is for setting the OCCUPIED/
UNOCCUPIED air temperature. (See section 1.2)
Each channel has a switching differential which is also factory pre-set. None of the factory settings should be
tampered with.
When the re-settable channel is adjusted all other settings and differentials automatically follow at the correct
relationship.
Nominal set point values & diffs RH% = 60% diff 3%
Air temperature = 28ºC diff 0.5 ºC
Please note: on AA machines with LPHW, in occupied mode dehumidification stops once the Air temperature is
2.5ºC above set point.

Page 6
1.2. HUMIDITY & AIR TEMPERATURE AND CONTROLS
HUMIDITY DIGITAL CONTROLLERS
To Program the Set Point. Press down P, SP1 and Set Point value will be displayed alternately.
Press the or key to change the value of SP1. Once the desired value is displayed press P to memorise the
value. The display will revert to the present reading.
NOTE: If anything else shows on the display leave alone for 1 minute until the display returns to normal.
AIR TEMPERATURE DIGITAL CONTROLLER AND AA MACHINES WITH AIR HEATING
The digital controller for controlling air temperature can be changed as follows:-
To program the set point, press P button once and release it. SP1 (set point) and set point value
e.g. 28 will be displayed alternately. Press P again AL1 (-4.5) will show. This is the difference between
the set point and AL1 plus a constant 0.5 e.g. 28 - 4.5 + 0.5 = 24ºC (unoccupied) SP1 and AL1 can be
changed in the same way as described for humidity and air.
NOTE: AL1 can only be set -1 to -10 below SP1 value.
NOTE: If the readings on the digital controllers are not the same as the actual pool hall conditions, an offset into
the digital controller can be set. However, before this is done an inspection of the installation should be made to
ensure air conditions into the unit are the same as those in the pool hall. Air leakage into the units return air from
other spaces should be sealed before adjustments are made. See technical manual.
123
123
123
123
123
INCREASE SET
POINT
DECREASE SET
POINT
NOT USED
ACCESS SET POINT

Page 7
1.3 TIME CLOCK SETTINGS
TIME CLOCK AA 300 with LPHW only
The time clock is a quartz 24 hour clock with 100 hours battery reserve used to control the automatic operation on
the AA300 unit per 24 hour time cycles.
The time clock setting determines the OCCUPIED/UNOCCUPIED periods and is set to match the operators
requirements regarding opening and closing times for the pool and possible times where the pool is covered.
The two settings are OCCUPIED or day time, and UNOCCUPIED or night time (covered).
The most obvious action of this change is to lower the pool hall air temperature to a determined level to
conserve air heating energy. This lowering of temperature is allowable because of the quiescent, and ideally
covered, condition of the pool.
Pool water occupied (no pool cover)
Pool water unoccupied (pool covered)
SETTING ACTUAL TIME
Turn the large clock hand clockwise until the correct time of day is set, ensuring that the correct half of the day is
chosen (24 hour clock).
SETTING FOR AUTOMATIC OCCUPIED/UNOCCUPIED OPERATION WITH TIME CLOCK
To set for automatic time clock control of occupied/unoccupied, slide the lever to ‘A’. Each yellow segment
represents a 15 minute time period. Extend outward the segments for a period of time when the pool is occupied
(i.e. used or uncovered) per day.
SETTING FOR AUTOMATIC OCCUPIED/UNOCCUPIED OPERATION WITH REMOTE INTERFACE
To set for remote control of occupied/unoccupied, slide lever to ‘O’. See section 2.3.2, Note 1 for more information
on remote interface.
SETTING FOR MANUAL OCCUPIED/UNOCCUPIED OPERATION
To set for manual occupied period (or override automatic unoccupied period) slide the lever to ‘I’ for ‘occupied’.
=
=
O
SEGMENTS
AUTOMATIC
AND
MANUAL
SETTING
LEVER

Page 8
2.0 INSTALLATION
UNPACKING
CONTROL CONSOLE
%
REMOVABLE
PANEL
CONSOLE
DUCT
CONTROL CONSOLE
LPHW FITTED
ºC
%
=
=
= AUTO
CONTROL CONSOLE
CONNECTION POINT
On delivery the console for the AA300 will be inside the machine. To retrieve the console unfasten the removable
panel on the heat pump. The console should be in the position shown, protected by bubblewrap. Note: the
removable panel is on the opposite face of the heat pump to the water connections.

Page 9
800
AIR FILTER ACCESS
800
SERVICE ACCESS
TO ELECTRIC BOX
WATER CONNECTIONS
FILTER ACCESS PANEL
SERVICE
PANEL
CONSOLE
POSITION
ALTERNATIVE
CONSOLE
POSITION
AIR ON AIR OFF
CONTROL PANEL
CONNECTION POINT
RED LAMP 12V
REMOTE CONTROL
PANEL LIVE
INDICATION
SITING, MACHINE LOCATION
NOTE:
If the optional flexible ducting flange is not used, due consideration to resonant noise through the duct work must
be made.
If little or no ducting is fitted it is possible to lower the top speed of the fan. With the machine isolated move the
white/black wire connected to terminal 18 to terminal 17 in the electric box. See diagram section 2.5.

Page 10
INSTALLATION WITH OPTIONAL FEATURES
OPTIONAL FLEXIBLE
DUCTING FLANGE
FILTER ACCESS PANEL
OPTIONAL FLEXIBLE
DUCTING FLANGE
SERVICE
PANEL
CONSOLE
POSITION
ALTERNATIVE
CONSOLE
POSITION
SERVICE
ACCESS TO ELECTRIC BOX
800
AIR ON
BLANKING PLATE
FOR OPTIONAL
FRESH AIR GRILLE
4 HOLES DIA 6 ON
125mm DIA.
CONTROL PANEL
CONNECTION POINT
RED LAMP 12V
REMOTE CONTROL
PANEL ON
INDICATION
Ensure duct work pressure drop does not exceed resistance given in data sheet.
If little or no ducting is fitted it is possible to lower the top speed of the fan. With the machine isolated move the
white/black wire connected to terminal 18 to terminal 17 in the electric box. See diagram section 2.5.
If unit is located in a plant room at pool hall air temperatures, any ambient air ducting must be heavily insulated.
Recommend fresh air/spring return dampers to be fitted to Fresh air ductwork for sub zero ambient applications in
case of power failure.

Page 11
2.1 PLUMBING
CONDENSATE DRAIN
The condensate driptray in the ‘AA300VHF’ unit collects the water removed by the dehumidification process.
It is therefore necessary to ensure that the’AA300VHF’ unit is placed on a level plinth so that the condensate
can run away and not overflow the edges of the driptray inside the machine.
The ‘AA300VHF’ has a 3/4” BSPM threaded condensate drain connection. The drain pipe should
run away with adequate fall to waste ie 1/2” per foot minimum and must incorporate a ‘U’ trap & tun dish.
BOILER PLUMBING
The boiler connections on the machine are 3/4”BSPM. for connecting the boiler water flow and return.
Suitable breakable couplings, isolation, and drain down valves should be installed in the boiler water
flow and return pipes local to the ‘AA300VHF’ unit.
Refer to the boiler manufacturers instructions before designing the pipework system.
IMPORTANT GENERAL CONDITIONS
1) Do not route water pipes across service access panels or air inlet/outlets.
2) The water circuits to and from the ‘AA300VHF’ unit should be capable of maintaining the specified
water flow limits required by the machine. See Data sheet section 4.0.
3) All pipework must be adequately supported with allowance for expansion and contraction especially with
regard to the plastic pipework.
4) It is recommended that when installing water systems the last connections to be made should be
adjacent to the ‘AA300AVHF’ unit to avoid undue stresses on the unit connections.

Page 12
BOILER WATER SCHEMATIC
BOILER
PUMP RADIATORS IF
FITTED
FLOW
BALANCE
VALVE
INTERNAL 3 WAY MOTORISED VALVE
(DIVERTING) CONTROLLED BY VARIHEAT .
FLOW METER LPHW
CONNECTIONS
AW300AVHF
CABINET
(FACTORY
SET)
CONDENSATE DRAIN 3/4" BSPM
BOILER WATER OUT 3/4" BSPM
BOILER WATER IN 3/4" BSPM
CUSTOMERS "TUN DISH"
COPPER STUB
DRAIN TO WASTE
U TRAP
AA300 DRAIN
AA300 UNIT
2.2 WATER CONNECTIONS
(also see SECTION 2.1)

Page 13
2.3 ELECTRICAL INSTALLATION
ELECTRICAL SAFETY
It is important to ensure that all aspects of the installation comply with the latest I.E.E. Regulations.
It is also important to ensure that any remote devices which terminate within the pool hall are of the type and
voltage as specified in the latest I.E.E. Regulations.
The machine should be installed in accordance with EMC2004/108/EC.
PROTECTED SUPPLY
Whilst not mandatory, Calorex recommend that an R.C.C.B. is always fitted or that the supply is to local
electricity authority recommendations, and that all ducting is bonded in accordance with these regulations.
The supply to the machine should incorporate fuses or motor rated circuit breakers (type GU) to specified rating
(see data sheet) H.R.C. fuses are recommended. An all pole swtched isolator must be fitted within clear view of
the machine and not more than 2 metres away. The isolator must have a minimum of 3mm air gap when in the off
position.
INCONSISTENT ELECTRICAL SUPPLY.
The following limits of operation must not be exceeded if Calorex machines are to be guaranteed either in
performance or warranty terms :-
Voltage single phase - 207V min, 253V max
Frequency - 47.5Hz min, 52.5Hz max.
N.B The voltage must be measured at the heat pump mains terminals with all the fans/compressors
running at the rated condition.
CORRECT CABLE SIZING
The cable supplying electricity to a machine with a given load must increase in cross sectional area (CSA)
as the length increases in order that the voltage drop within the cable does not exceed recommended limits.
Cable sizing should be calculated by an approved electrician with due consideration to I.E.E. and local
codes of practice.
MAINS ENTRY
POINT
ELECTRIC BOX LIVE
INDICATOR LAMP
CONTROL CONSOLE
CONNECTION POINT
REMOVE LID TO GAIN
ACCESS TO ELECTRIC BOX
ELECTRIC BOX
REMOTE
OVERRIDE
SWITCH
REMOTE
ON/OFF
(12V)
N L
BOILER
DEMAND
REM O T E
POWE R
INDICATER
(12V)
F12.5A
F21.0A
COMP
FAN H
FAN L
CON T
A1
A2
12
34
56
21 22
COMP
CONT
RE1 R1 R2 R3 R4
4 5 6 7 8 9 1011 12
13141516171819202122232425262728293031

Page 14
2.3.1 MAINS SUPPLY TERMINAL BLOCK LAYOUT
TERMINAL
BLOCK UNDER
FLANGE IN
ELECTRIC BOX AIR
PROBE
HUMIDITY
SENSOR
P5 P6 P7P3 P4
345
12
TERMINALS IN
REMOTE
SENSOR BOX
OPTIONAL REMOTE SENSOR BOX
SWITCHED FUSED ISOLATOR TO BE WITHIN SIGHT OF FRONT OF UNIT & NOT MORE THAN 2M AWAY
N
SWITCHED FUSE
ISOLATOR SEE
DATA SHEET FOR
RATINGS
L
NOTE 'a'
LINK THESE TERMINALS WHEN REMOTE NOT REQUIRED
REMOVAL OF LINK WILL STOP FAN, COMPRESSOR &
DIGITAL CONTROLLERS .
1 2 3 4 5
NO LINK WIRES
NECESSARY IF TERM'S
6 TO 9 NOT IN USE
ELN
IF THIS FACILITY IS USED TIME CLOCK
(IF FITTED) MUST BE SET TO UNOCCUPIED
REMOTE OCC/UNOCCUPIED
SEE NOTE 1 SECTION 2.3.2
LOAD
N
LAA300 WITH LPHW ONLY
BOILER DEMAND
SEE NOTE 3 SECTION 2.3.2
BOILER
DEMAND
12V REMOTE
CONTROL PANEL ON INDICATION
REMOTE OCC/UNOCCUPIED
SOFT START
OPTIONS
23 24 ELECTRIC BOX
TERMINAL RAIL
67891011
REMOTE
ON/OFF
12V

Page 15
2.3.2 NOTES ON TERMINAL BLOCK CONNECTIONS
NOTE 1 - Remote occupied/unoccupied
These contacts (from terminals 10 & 11) are to enable the air temperature set back facility to be remotely
overridden.
There is a 12 V AC output from these terminals and closing a remote switch will enable the unit to regain the
normal operating air temperature for when the pool is in use.
This can be done via a voltage free pool cover switch or some other form of voltage free switch.
If this facility is used then the time clock (if fitted) on the control panel of the unit should be set to the
‘unoccupied’ (o) position. (See note on time clock and switch settings, section 1.3).
NOTE 2 - Boiler demand -AA+LPHW machines only
These are voltage free contacts (from terminals 6 & 7) rated at 3(1) Amp at 230 Volts.
If the low pressure hot water supply to the unit is to be governed by the Calorex unit then these contacts should
be utilised to bring water to the unit via the boiler, motorised valve, boiler pump etc. Remember the maximum
inductive load is one amp.
This is dependant on how the low pressure hot water supply to the unit has been designed.
If the supply of low pressure hot water to the unit is not dependant on a signal from the unit then these contacts
can be ignored.
NOTE 3 - RUNNING FAN IN ‘NON F’ MODE
If when the AA300 is installed the airflow is greater than necessary due to there being little or no ducting fitted,
the speed of the fan can be lowered, making the machine a non ‘F’. This is done by changing the fan speed from
high to medium by moving the white/black 1.0 wire from the electric box terminal 18 to terminal 17 (so that it is
now linked to blue fan lead).
CONTROL PANEL 25 WAY CABLE CONNECTION
Data signal between the console and the heat pump is via a 25 way cable with ‘D’ connection (plug & socket)
both ends. The cable provided with the heat pump is 1.8m in length. An optional 10m cable is available, part
number SD434052. A recommended maximum distance between the console and the heat pump is 20 metres, 2
cables being used.

Page 16
2.4 COMMISSIONING CHECKLIST
a) Is the building finished in accordance with the original plans and specification.
b) Is the plenum chamber and all ductwork insulated, special attention should be made to the insulation of the
fresh air inlet ducting to prevent condensation problems.
c) Are there any significant draughts in the pool hall or plant room (plenum installation) through poorly fitting doors,
windows, pipe ducts, etc. This will let in unwanted ambient air raising the heating duty required.
d) Is fresh air ducting (if fitted) perfectly sealed from plant room.
NOTE: (c) and (d) above should be checked by measuring plant room and pool hall air temperatures.If the plant
room is acting as a plenum chamber both temperatures should correspond. If the plant room temperature is
lower then ambient air is leaking in, this leak should be located and rectified.
e) Are the fresh air inlets free from obstructions ie, undersize grilles, objects in the path of exhaust air deflecting it
back to the fresh air inlet, etc.
f) Is ‘occupied / unoccupied’ set correctly, (set with air thermostat) see section 3.2.2.
g) Is the time clock set correctly.
h) Has the fan speed been set to match the sensors fitted.
j) Any sign of abnormal operation such as water dripping should be reported immediately to an installer or Calorex.
k) Has fan run amps been recorded against datasheet.
l) Has the unit been installed to allow service personnel access to all areas.

Page 17
BLANK PAGE

Page 18
ELECTRICAL CONTROL & POWER CIRCUIT ‘AA’ VERSION
2.5 CIRCUIT DIAGRAMS
9
6
SEE FAN POWER CIRCUIT BELOW
SEE FAN POWER CIRCUIT BELOW
CONTROL MCB
L1
MAINS
LAMP
N
12V AC
240V
TRANSFORMER
F1 2.5A
F2 1A
R1
10
11
7
4
12v 12v
P7 P6
HUMIDITY SENSOR
12V AC
5
REMOTE ON/OFF
ON/OFF
SWITCH
CONTROL
POWER LAMP
4
6A 4A 16A
FAN MCB'S COMP MCB
MODEL
AA300AVHF LPHW
HIGH DEVICE VALUELOW
LINK FOR NORMAL RUN (BREAK TO STOP M/C)
'R' LETTER RELAY'S ARE 12v
'RE' LETTER RELAY'S ARE 230v
'P' LETTERS ARE CONNECTOR BLOCK PIN NUMBERS
NOTES
D25 = 25 WAY 'D' PLUG PIN NUMBERS
D=DELAYTIMER
15 = DIN RAIL MOUNTED TERMINAL BLOCK NUMBERS
2 ISOLATE LOW SPEED FAN CIRCUIT BREAKER
WHEN REMOTE SENSORS KIT IS FITTED
D604450
CIRCUIT DIAGRAM
AA300AVHF
R03
R0
4
R0
5
R02
R01
D2
D1
D3
D4
8
9D17