Calorex PPT8 User manual

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY R
OWNER/INSTALLATION MANUAL
FOR
PPT8/12/16/22L/LY
(SD617650 Iss.X 08/12/09)
Health and Safety Warning:
As the heat pump includes electrical and rotational components it is required that only trained
and competent persons should remove panels giving internal access to the unit.

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY
Page 2
R
Congratulations!
You are now an owner of a Calorex Heat pump!

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY R
Contents
1.0 Introduction and Function ........................................................................................... 4
1.1 Introduction ................................................................................................................ 4
1.2 Function .................................................................................................................... 5
2.0 Installation ................................................................................................................. 6
2.1 Siting ........................................................................................................................ 6
2.2 Air flow ...................................................................................................................... 7
3.0 Plumbing ....................................................................................................................8
3.1 Recommended Plumbing Schematic....................................................................... 10
3.2 Determining Water Flow .......................................................................................... 11
4.0 Electrolytic Corrosion in Swimming Pools................................................................ 12
4.1 Electrical (Machine Wiring and Supply). .................................................................. 13
4.2 Location of Mains Input and External Interlock Terminals .......................................... 14
5.0 Optional Features .................................................................................................... 15
5.1 Pool Pump Kit .......................................................................................................... 15
5.2 Remote Thermostat .................................................................................................. 17
6.0 Circuit Diagrams ..................................................................................................... 18
7.0 Regular planned maintenance ................................................................................. 25
8.0 Controls and indication lamps ................................................................................. 25
8.1 Digital Thermostat ................................................................................................... 27
9.0 Heat Pump Malfunction ............................................................................................ 27
10.0 Datasheets ........................................................................................................... 31
11.0 Installation Drawings .............................................................................................. 32
12.0 Winterisation Procedure ........................................................................................ 36
12.1 Start up Procedure After Winterisation ................................................................... 37
13.0 Warranty Conditions .............................................................................................. 38
14.0. Contacting Calorex ............................................................................................... 39

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY
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1.0 Introduction and Function
The Calorex ‘Propac’ range of air/water heat pumps are designed for swimming
pool heating and consists of 4 models. Heat pumps in this manual are
designed to heat pool water and spas within the range of 10°C to 40°C.
Standard units are suitable for outdoor pools operating in ambient temperatures
above 10ºC. Reverse cycle defrost models operate in ambient temperatures
down to -15ºC.The water heat exchanger is a full flow type, manufactured
from titanium tube, which is a highly corrosion resistant material. The heat
pumps are suitable for use in fresh water and salt water pools. PPT8/12 heat
pumps are fitted with rotary compressors and PP16/22 heat pumps are fitted
with scroll compressors. Both types of compressor are known for quiet running.
With these features the heat pump is designed to have a long, trouble free
life.
All units have integral safety devices to protect the heat pump from internal
and external faults. Indicator lamps indicate operating mode. An adjustable
digital thermostat controls water temperature. Also a 6 minute cycle time
delay is incorporated.
IMPORTANT NOTE
Calorex Heat Pumps Limited is an ISO9001:2000 certified company.
All Calorex heat pumps are CE approved
1.1 Introduction

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY R
1.2 Function The Calorex Swimming pool heat pump provides thermodynamic heating by
means of a vapour compression cycle, (similar to that employed in a
conventional refrigerator), in addition to acting as an active solar collector.
Coefficient of Performance
The efficiency of a Heat Pump is usually called its ‘Coefficient of Performance’ - (C.O.P.)
which is simply a ratio of heat output to energy input, both being expressed in kW. Thus a
Heat Pump absorbing 1 kW of electricity, collecting 4 kW of energy from the air, and
delivering 5 kW of heat to the pool water is said to have a C.O.P. of 5:1.
This ratio will vary according to the temperature of the water and the ambient air.
2. THE COMPRESSOR where
it is compressed and upgraded
to a much higher temperature.
The hot vapour now enters -
1. THE EVAPORATOR collects the heat from the outside
ambient air, pre-heated by the sun. In the Calorex swimming
pool heat pumps, high volumes of outside air are drawn into
the unit by the fan expelled through the evaporator fins. The
evaporator has liquid refrigerant passing through it which is at
a considerably lower temperature than the ambient air.
Therefore the air gives up its heat to the refrigerant which then
vaporises.This preheated vapour now travels to -
4. THE EXPANSION DEVICE and from there,
now at normal pressure, it is returned to the
evaporator and the cycle starts again.
3. THE CONDENSER where it is surrounded by
the pool water. The heat is given up to the cooler
pool water and the now cooler refrigerant returns
to its former liquid state but still under high
pressure from the compressor.
This pressure is released by passing the liquid
through -
POOL
WATER OUT
POOL
WATER IN
HOT GAS
HEAT
EXCHANGER
CONDENSED
REFRIGERANT
HIGH PRESSURE SIDE
COMPRESSOR
EXPANSION
VALVE
LOW PRESSURE SIDE
COOL LIQUID
REFRIGERANT
AMBIENT
AIR
COOL GAS
EVAPORATOR
1
2
3
4
THE HEAT PUMP CYCLE

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY
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a Ensure heat pump on site is as ordered, i.e. model, electrical supply and
factory fitted options.
b Inspect unit for damage, in particular inspect the evaporator (finned side) to
ensure that it is undamaged. (Minor indentations in the fins do not affect
performance). If severely damaged, endorse delivery note in presence of the
driver and send a recorded delivery letter to transport company giving details.
Protect unit if installation is delayed.
c Provide a firm level base capable of supporting operational weight of unit;
spread load if mounted on timber floor.
d Ensure water cannot collect under unit, it is recommend that units are
installed on plinths 100mm above finished floor level. This also aids
condensate drainage.
e Allow adequate clearance to service panels on unit; recommend 500mm
minimum.
f All Calorex heat pumps are by design as quiet as is practical, however due
consideration should be given to siting the heat pump in order to minimise
the noise coming from the machine, for example by positioning the machine
so that the inlet/outlets are parallel to occupied premises.
g Ensure loose debris such as leaves, grass cuttings, etc will not block air
inlet grilles.
h Consider protection from extreme weather conditions if installed externally,
i.e. lean-to-cover or building
2.0 Installation
2.1 Siting

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY R
2.2 Air flow
Suitable opening
Suitable opening
> 50 cm
PLANT ROOM
WALL WALL
FIG 1 POSSIBLE POSITIONS OF A CALOREX HEAT PUMP
SWIMMING POOL/SP
A
CALOREX
CALOREX
CALOREX
CALOREX
CALOREX
MODEL
Inlet Discharge
PPT8 0.157 0.168
PPT12 0.264 0.168
PPT16 0.264 0.173
PPT22 0.308 0.173
Minimum Free Area m²
TABLE 1
Note if multiple units are installed in an enclosed area then the inlet free
areas required for each unit can be added together to form one inlet
aperture. BUT discharge from each unit must be kept separate and must
not be incorporated into one common duct system.
Due consideration must be given to air flow i.e. do not obstruct inlet or outlet
and ensure discharge to air cannot recirculate to inlet. (See figure 1).
Required Free Areas to provide air flow to
and from heat pumps when installed in an
enclosed area or where required to pass air
through a wall etc.
Free areas is the available area through
which air can pass through a grille or
louvres.

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY
Page 8
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a) Calorex Heat Pumps have water inlet/outlet connections as follows:
All models have 1½” BSP parallel, male threads.
The heat pump is supplied with bungs fitted in the water connection fittings.
These need to be removed before the heat pump is installed. See section
3.2.
b) The Calorex Heat Pump must be connected after the filter in the return
pipe to the pool. If an existing heater is being retained, then the Calorex
Heat Pump should be connected between the filter and the other heater.
(See figure 4).
c) Suitable breakable couplings should be installed local to the heat pump.
d) If the heat pump is installed at a lower level than the pool then isolation
valves should be fitted.
e) A drain valve or plug should be fitted to the lower pipe to facilitate drain
down in the winter period.
f) Connections on all models are by BSP parallel male threaded fittings.
These should be hand tightened only, otherwise damage may result to the
threads of the plastic fittings.
g) The condensate drain at the base of the unit collects condensation from
the evaporator fins. This should run away to waste via ¾” domestic waste
piping. It is therefore necessary to ensure that the Calorex Heat Pump is
placed on a level plinth so that the condensate water can run away with
adequate fall to waste i.e. ½” per foot minimum and must incorporate a “u”
trap as to not overflow the edges of the drip tray inside the heat pump. See
figure 3.
THIS TYPE OF
INSTALLATION
SHOULD BE AVOIDED
INCORRECT DRAINAGE
FOR CONDENSATE
CORRECT DRAINAGE
FOR CONDENSATE ELBOW
'U' TRAP
ADEQUATE FALL
3.0 Plumbing
FIG 3

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY R
h. When the pipework installation is complete the pool pump should be
switched on and the system tested for leaks. Also check the filter gauge to
see that there is not an excessive increase in back pressure. If everything is
then working normally the water circulating system is ready for use.
i. Water circuit to and from the unit is to be capable of maintaining within
specified limits the rate of flow required by the heat pump. (See section 10).
j. All pipework must be adequately supported with allowance expansion/
contraction especially with plastic pipework.
k. It is recommended that when installing water systems the last connections
to be made in the system should be breakable connections to avoid any
stresses on the unit connections.
IMPORTANT
1. All Pool Purifying Devices and Chemical Injection Systems to be fitted
down stream of the heat pump unless installation is as per filter dosing
(see figure 4). This includes the practice of dosing chemicals direct into
skimmer basket, which results in concentrated corrosive liquids passing
over vulnerable metal components.
2. Water quality must be maintained as follows:
3. Maximum pressure of water in heat pump circuit should not exceed
3kg/cm2(50 psi)
pH 7.2 - 7.8
Total Alkalinity 80 - 120 ppm as CaCO3
Total Hardness 150 - 250 ppm as CaCO3
Total dissolved solids Max 1000 ppm
Saline Water Max 35,000 ppm
Chlorine - free Cl Range 1.0 - 2.0 ppm Domestic
Chlorine - free Cl Range 3.0 - 6.0 ppm Commercial
Ozone 0.9 Max ppm
Bromine 2 - 5 ppm
Baquacil 25 - 50 ppm
Aquamatic Ionic Purifier Max 2 ppm Copper

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
PPT8/12/16/22L/LY
Page 10
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KEY ISOLATION VALVE BREAKABLE COUPLING NON RETURN VALVE THREE WAY VALVE
NON RETURN VALVE CHEMICAL DOSING
SANITISER OR
DEVICE, IF FITTED
AUX HEATER IF FITTED
FILTER
PUMP
TO WASTE FOR
WINTERISING
DRAIN DOWN
ANTI RETURN LOOP
TO BE INCORPORATED,
MINIMUM HEIGHT
100mm ABOVE HEAT PUMP
OUTLET PORT
(IF SANITISER FITTED)
100mm
CONDENSATE WATER
TO WASTE
SPARE PORT FOR
WINTERISING
FLUSHING
CONNECTION
TO WASTE
CALOREX HEAT PUMP
POOL
3.1 Recommended Plumbing Schematic
FIG 4