Calorex Pro-Pac 30 Quick start guide

Technical guide
Air/water heat pumps
Pro-Pac 30|45|70|90|140 H|HY

Comprehensive support
Comprehensive engineering support is provided by our experienced and well qualified team.
Calorex units are designed, tested and manufactured in e UK, and supported by our comprehensive customer service organisation
Calorex reserves e right to modify ese specifications at any time. For accurate sizing please contact Calorex.

Calorex model system identification 4
Air/water heat pumps 5
The heat pump cycle 6
Installation 7
1. Siting/positioning 7
2. Air flow 8
3. Plumbing 9
4. Typical installation diagram 9
Electrical 10
Specification of Calorex Pro-Pac 30 | 45 | 70 | 90 | 140 BH | BHY 12
What is a WRAS approval? 13
Technical data
Heat pumps, specialist applications heaters H models 14
Heat pumps, specialist applications heaters HY models 15
Performance graphs 16
Installation drawings 18
Winterising procedure 23
Start up procedure aer winterisation 23
Contents

4
Calorex model system identification
PP 30 B H Y
Heat pump wi reverse cycle
defrost, operation down to -15°C
Heat pump down to 7°C ambient
H=water flow up to 70°C
M= water flow up to 50°C
Electrical supply
400V ~ 3N ~ 50Hz
Model size
Product "Pro-Pac"

5
Air/water heat pumps
Important Note
Calorex heat pumps Limited is an ISO9001:2000 certified company.
All Calorex heat pumps are CE approved. Heat exchangers wiin e heat pumps are compliant to WRAS (British Water
Regulation Auority Standards) and listed under UL standards.
Models covered in is manual
The machines detailed in is manual are specifically designed
for heating potable water. The heat pumps use R134a as a
refrigerant and operate in air temperatures from 7°C to 55°C
providing heated water to 68°C.
As an option, machines are available wi reverse cycle defrost
which allows e heat pumps to operate in temperatures down
to -15°C.
All units are supplied as a package and have integral safety
devices to protect e heat pump from internal and external
faults. Indicator lamps indicate operating mode. An adjustable
ermostat controls water temperature. Also a six minute cycle
time delay is incorporated. The units are weaerproof and can
be installed eier outside or wiin a ventilated plant-room (as
detailed in section 1 of is manual).
A 12 hour delay timer is incorporated into machines, which
aer a power interruption or from initial start up will prevent e
machine compressor(s) from starting for a 12 hour period. This
feature is to protect e compressors from liquid pumping which
can cause internal compressor damage.
Heal and Safety
This appliance is not intended for use by persons
(including children) wi reduced physical,
sensory or mental capabilities, or lack of
experience and knowledge, unless ey have
been given supervision or instruction concerning
use of e appliance by a person responsible for
eir safety.
Children should be supervised to ensure at
ey do not play wi e appliance

6
The heat pump cycle
The Calorex heat pump provides ermodynamic heating by means of a vapour
compression cycle, (similar to at employed in a conventional refrigerator), in addition to
operating as an active solar collector.
Coecient of Performance
The eciency of a heat pump is usually called its ‘Coecient of Performance’ – (C.O.P.) which is simply a ratio of heat output
to energy input, bo being expressed in kW. Thus a heat pump absorbing 1 kW of electricity, collecting 4 kW of energy from
e air, and delivering 5 kW of heat to e water is said to have a C.O.P. of 5:1. Naturally is ratio will vary according to e
temperature of e ambient air.
COOL GAS
HOT GAS
HEAT
EXCHANGER
EVAPORATOR
COLD LIQUID
REFRIGERANT
HIGH PRESSURE SIDE
CONDENSED
REFRIGERANT
COMPRESSOR
EXPANSION
VALVE
AMBIENT
AIR
LOW PRESSURE SIDE
WATER OUT
WATER IN
THE HEAT PUMP CYCLE
The EVAPORATOR collects e heat from e air. This is eier atmospheric
air, which has been heated by e sun, or internal air, which has been
heated by heat lost from anoer process. In Calorex heat pumps, high
volumes of air are drawn into e unit by e fan and passed across e
evaporator fins. The evaporator has liquid refrigerant passing rough
it, which is at a considerably lower temperature an e ambient air.
Therefore e air gives up its heat to e refrigerant which en vaporises
to a gas. This pre-heated refrigerant gas en passes to:
The COMPRESSOR, where it is compressed,
which has e effect of upgrading e gas to a
much higher temperature. The electrical energy
at is used to drive e compressor is also
absorbed by e refrigerant gas. The hot gas
now enters:
The HEAT EXCHANGER (or CONDENSER), where it is surrounded
by e water to be heated in adjacent tubes. The refrigerant
vapour, at a higher temperature, gives up its heat to e water
which is returned to a storage tank. As e refrigerant cools it
returns back to its liquid state, i.e. it condenses, but remains under
high pressure from e compressor. The pressure is released by
passing e liquid refrigerant rough:
The EXPANSION DEVICE, and from ere, now at
normal pressure, it is returned to e evaporator and
e cycle starts again.

7
Installation
1. Siting/positioning
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 e evaporator
(finned side) to ensure at it is undamaged. (Minor
indentations in e fins do not affect performance). If
severely damaged, endorse delivery note in presence of
e driver and send a recorded delivery letter to transport
company giving details.
c) Protect unit if installation is delayed.
d) Provide a firm level base capable of supporting operational
weight of unit; spread load on timber floor.
e) Ensure water cannot collect under unit – recommend units
are installed on plins 100mm above finished floor level
and to also aid condensate drainage.
f) Allow adequate clearance to service panels on unit;
recommend 500mm minimum (see installation drawings).
g) All Calorex heat pumps are by design as quiet as is practical,
however due consideration should be given to siting in
order to fully exploit is feature, i.e. ensure at e inlet
and outlet grilles face away from occupied property.
h) Ensure loose debris such as leaves, grass cuttings, etc will
not block air inlet grilles.
i) Consider protection from extreme weaer conditions if
installed externally, i.e. lean-to-cover or building.

8
Due consideration must be given to air flow, i.e. do not obstruct inlet or outlet and ensure discharge air cannot recirculate to inlet
(See figures 1 and 2).
Required free areas to provide air flow to and from heat
pumps when installed in an enclosed area or where
required to pass air rough a wall, etc.
Free area is e available area at air can pass rough a grille
or louvres.
1. Note: If multiple units are installed in an enclosed area en
e inlet free areas required for each unit can be added
togeer to form one inlet aperture.
Model Minimum Free Area m²
Inlet Discharge
Pro-Pac 30 0.59 0.25
Pro-Pac 45 0.98 0.42
Pro-Pac 70 1.19 0.52
Pro-Pac 90 1.731 0.84
Pro-Pac 140 2.138 1.04
2. Air flow
Installation cont.
BUT discharge from each unit must be kept separate and
must not be incorporated into one common duct system.
2. If e unit is installed wiin a plant-room, connected to
ductwork, Calorex can supply e unit wi an uprated fan
motor. Please consult Calorex before ordering a unit.
Table 1
Fig. 1
Typical outside installation
Fig. 2
Typical inside or plant-room installation
(not recommended for long duct runs)
Grill or apertures MUST comply wi figures (see table 1)

9
a) Calorex ‘Pro-Pac’ range heat pumps have water inlet/outlet
connections as follows:
f) When e pipework installation is complete e system
should be run and tested for leaks. If everying is en
working normally e water circulating system is ready to
use.
g) Water circuit to and from unit to be capable of maintaining
wiin specified limits e rate of flow required by heat
pump (see data sheet).
h) All pipework must be adequately supported wi allowance
for expansion/contraction especially wi plastic pipework.
i) It is recommended at when installing water system e
last connections to be made in e system should be
breakable couplings to avoid any stresses on to e unit
connections.
Model Water in/out connection size
Pro-Pac 30 1½" BSPM
Pro-Pac 45 1½" BSPM
Pro-Pac 70 1½" BSPM
Pro-Pac 90 1½" BSPM
Pro-Pac 140 2" BSPM
b) If an existing heater is retained, e Calorex heat pump
should be connected in parallel wi it.
c) Suitable breakable couplings, isolating valves and flow
meters should be installed local to e heat pump.
d) Drain valve or plug should be fitted to lower pipe to facilitate
drain down in winter period.
e) The condensate drain at e base of e unit collects
condensation from e evaporator fins. This should be run
away to waste via 1½" domestic waste piping. It is erefore
necessary to ensure at e Calorex heat pump is placed
on a level plin so at e condensate can run away wi
adequate fall to waste i.e. ½" per foot minimum. A U trap
should also be incorporated into e pipework
3. Plumbing
Important note
Maximum pressure of water in heat pump circuit should not exceed 10 bar.
Table 2
4 Typical installation diagram
CALOREX HEAT PUMP
HOT WATER
SUPPLY
HOT WATER
RETURN PUMP
AIR VENT
DRAIN VALVE
STORAGE TANK
CLOSED TYPE
MAKE UP COLD
WATER
Installation cont.

10
Electrical (machine wiring and supply)
Electrical
All electrical work to be carried out in accordance wi I.E.E.
standards, latest issue, or local codes of practice as applicable.
The machine should be installed in accordance wi
EMC2004/108/EC.
Protected supply
To incorporate fuses or motor type circuit breakers (Type GU,
FAZC) to specified rating, (see Data Sheet). H.R.C. fuses are
recommended. An isolator which disconnects all poles must be
fitted wiin 2m and in sight of machine.*
All units must be correctly eared-grounded and an ear
leakage trip installed.
Inconsistent electrical supply
The following limits of operation must not be exceeded if
Calorex machines are to be guaranteed eier in performance or
warranty terms.
Note
All machines are fitted wi a phase protection relay and will not run if e phases are not connected in correct order (phase
sequence) or if e supply voltage is 15% less an e nominal voltage. (415V for 3N~ 50Hz) . The lamp on e phase rotation relay,
situated in e electric box, is illuminated when e phases are correctly connected and e voltage is sucient. The under voltage
protection feature is not present in phase protection relays fitted in 220V 3~ 60Hz machines.
Voltage Minimum Maximum
Three-phase machines (UK) 360V 440V
Three phase machines (60Hz) 187V 253V
Three phase machines + N (60Hz) 360V 440V
Cycle frequency (50Hz) 47.5Hz 52.5Hz
Cycle frequency (60Hz) 57.0HZ 63.0Hz
N.B. This voltage must be available at e heat pump whilst
running.
The voltage must not drop below e above figures when
starting e machine.
*Note e isolator must have a minimum of 3mm air gap when
turned off.
Fig. 4
Location of mains input and external interlock terminals
Interlock
These units have an interlock circuit incorporated into e
control circuit, brought out to two terminals. These terminals are
shorted out for factory testing.
On site e shorting loop is to be removed and two wires
taken to a pair of volt free contacts in e water pump starter/
contactor/relay or flow switch so at e heat pump cannot
operate unless e water pump is operating.
(See figures 5 and 6).

11
Fig. 6
Recommended electrical installation for Calorex heat pump wi ree phase water pump
Fig. 5
Recommended electrical installation for Calorex heat pump wi single phase water pump
Electrical (machine wiring and supply)
Electrical

12
Specifications
Calorex Pro-Pac 30 | 45 | 70 | 90 | 140 BH | BHY
Automatic hot water heat pumps
The heat pump shall be a packaged design wi all necessary
refrigeration/control functions fitted wiin e unit as a
hermetically sealed system.
The cabinet shall be weaerproof to IP24. The machine chassis
shall be constructed of 14 gauge hot dipped galvanised steel
and all panels exposed to ambient conditions shall be 20 gauge
steel, phosphate protected and plastisol coated to RAL7038
Agate Grey (fixed panels) or RAL9002 Grey White (service
panels) semi-gloss.
The air-cooled evaporator shall be constructed from rifled
copper tube, aluminium fins and end-plates, all phenolically
coated to prevent corrosion from airborne contaminants and
salt.
The water-cooled condensers shall be of tube in shell type
constructed from copper (tube) and steel (shell). WRAS
approved condensers wi 90/10 marine grade cupro-nickel
(tube) shall be available as an option. The condensers shall be
of seamless construction and e maximum working water
pressure shall be 10 bar.
The Pro-Pac 30 shall utilise a 500mm, 880rpm vertical
discharge axial owlet fan. The Pro-Pac 45 and 90 shall utilise a
710mm, 690rpm, vertical discharge, axial fan (two for e Pro-
Pac 90). The Pro-Pac 70 and 140 shall use an 800mm, 700rpm
vertical discharge, axial fan (two for e Pro-Pac 140). Fans shall
be ERP 2015 compliant FE2 owlet rated to IP 54.
The compressor shall be a fully compliant hermetic, high back
pressure, scroll unit wi built in overload protection. The Pro-
Pac 90 and 140 shall utilise twin scroll compressors.
The refrigeration circuit shall utilise R134a refrigerant and
contain a sight glass, drier and expansion valve control,
reversing valve and pump down valve. Suction accumulators
shall be sized for 100% of e unit refrigerant capacity. The
refrigeration circuit shall be protected by HP, LP, ermal
overloads, MCBs, phase rotation protection and delay timers.
The refrigeration circuit shall be capable of operating in
air temperatures ranging from 10°C to 50°C and water
temperatures up to 68°C. Heating operation shall be controlled
by an integral digital water ermostat wi a 4°C differential.
BH models shall be provided wi a defrost limit ermostat to
provide automatic evaporator defrosting. BHY models shall be
provided wi fully automatic reverse cycle defrost mechanism
to give operation down to -15°C air temperature.
All units are designed, assembled and individually tested in e
UK under ISO 9001:2008 accreditation.
All units are designed, assembled and individually tested
in e UK under ISO 9001:2008 accreditation.
Optional features
The following optional features shall be available on
request:
WRAS approved cupro-nickel condensers
Compressor so-start
High pressure fan
RS485 compatible ermostat

13
What is a WRAS approval?
Any water fitting which, when installed, will carry or receive
water from e public mains water supply in e UK, must
comply wi e Water Supply (Water Fittings) Regulations or
Scottish Byelaws. These require at a water fitting should not
cause waste, misuse, undue consumption or contamination of
e water supply and must be ‘of an appropriate quality and
standard’.
Operational envelope
70
60
50
40
30
20
10
-30 -20 -10 0 10 20 30 40 50 60
Air temperature (°C)
Water off temperature (°C)

14
Technical data
Heat pumps, specialist applications heaters H models
Pro-Pac 30BH Pro-Pac 45BH Pro-Pac 70BH Pro-Pac 90BH Pro-Pac
140BH
Units
Duty - output to water @ 30°C/55°C
Air on @ 30°C, 90%RH
Electrical input
Air on @ 20°C, 65%RH
Electrical input
Air on @ 10°C, 85%RH
Electrical input
kW
kW
kW
kW
kW
kW
24.5/21.6
5.1/8.0
22.0/19.9
4.4/7.0
18.9/16.8
4.2/6.5
30.6/27.0
6.5/10.2
28.0/24.0
5.8/8.9
23.5/20.1
5.5/8.3
46.2/40.7
9.1/14.8
42.0/37.4
8.1/12.8
35.5/31.7
7.6/11.9
61.2/53.9
13.0/20.5
56.0/49.5
11.5/17.7
47.1/42.0
10.9/16.6
92.3/81.4
18.4/30.0
84.0/74.8
16.2/25.5
71.0/63.3
15.2/23.9
Electrical data
Electrical supply (50 Hz, 3PH)
Minimum supply capacity (3PH)
Recommended supply fuse (3PH)
Max starting curent STD (LRA)
Max starting current so start (LRA)
V
amps
amps
amps
amps
400
20
30
80
31
400
22
30
102
34
400
35
50
174
40
400
44
60
102
34
40
70
100
174
40
Air data
Nominal air flow
Fan external resistance
Fan external resistance (F)
m³/h
Pa
Pa
5500
0
n/a
10000
0
60
14000
0
60
20000
0
60
28000
0
60
Water Data
Water flow ±10%
Pressure drop (water)
Water connections
Condensate water connections
l/min
m hd
inch
inch
66
2.1
1½ BSPM
1½ BSPM
66
4.2
1½ BSPM
1½ BSPM
130
3.9
1½ BSPM
1½ BSPM
130
4.2
1½ BSPM
1½ BSPM
260
5.3
2 BSPM
1½ BSPM
General data
Gas charge (R134a) BH
Compressor type
Fan type
Sound pressure level @ 3m AIR ON
Sound level @ 3m AIR OFF
Sound level @ 3m SIDE
kg
dB(A)
dB(A)
dB(A)
5.5
1 x SCROLL
1 x AXIAL
64
60
61
13
1 x SCROLL
1 x AXIAL
66
61
64
22
1 x SCROLL
1 x AXIAL
70
64
65
13 x 2
2 x SCROLL
2 x AXIAL
65
64
61
28 x 2
2 x SCROLL
2 x AXIAL
70
67
65
Dimensions
Wid (unpacked)
Dep (unpacked)
Height (unpacked)
Weight (unpacked)
Wid (export, packed)
Dep (export packed)
Height (export, packed)
Weight (export, packed)
mm
mm
mm
kg
mm
mm
mm
kg
1555
790
1080
247
1775
900
1250
268
1665
1060
1330
329
1845
1170
1500
346
1810
1190
1310
460
2020
1300
1480
571
2065
1190
1350
632
2265
1310
1520
747
2210
1650
1340
858
2470
1770
1505
1078
NOTES:
1) Weight and dimensions nett.
2) Allow 500mm clearance to service panels.
3) Minimum air temperature standard models (BH) 7°C.
4) Calorex reserve e right to change or modify models wiout prior notice.
5) Global warming potential (GWP) R134a 1300.
6) Performance data below 10°C is derated to account for defrost periods.
1 mm WG = 9.8 Pa
1 m hd = 1.4 psi
1 l/min = 0.22 gall/min

15
Technical data cont.
Pro-Pac 30BHY Pro-Pac 45BHY Pro-Pac 70BHY Pro-Pac 90BHY Pro-Pac 140BHY
Units
Duty – output to water @ 30°C/55°C
Air on @ 30°C, 90%RH
Electrical input
Air on @ 20°C, 65%RH
Electrical input
Air on @ 10°C, 85%RH*
Electrical input
Air on @ 0°C, 90%RH
Electrical input
Air on @ -3°C, 99%RH
Electrical input
kW
kW
kW
kW
kW
kW
kW
kW
kW
kW
24.5/21.6
5.1/8.0
22.0/19.9
4.4/7.0
18.9/16.8
4.2/6.5
13.2/11.6
3.6/6.0
12.3/10.47
4.04/6.6
30.6/27.0
6.5/10.2
28.0/24.0
5.8/8.9
23.5/20.1
5.5/8.3
16.4/14.4
5.0/7.6
15.34/13.05
5.25/8.44
46.2/40.7
9.1/14.8
42.0/37.4
8.1/12.8
35.5/31.7
7.6/11.9
24.7/21.7
6.9/10.9
23.14/19.69
7.31/12.13
61.2/53.9
13.0/20.5
56.0/49.5
11.5/17.7
47.1/42.0
10.9/16.6
32.8/28.8
9.9/15.2
30.67/26.1
10.5/16.88
92.3/81.4
18.4/30.0
84.0/74.8
16.2/25.5
71.0/63.3
15.2/23.9
49.5/43.4
13.8/21.8
46.28/39.38
14.62/24.25
Electrical data
Electrical supply (50 Hz, 3PH)
Minimum supply capacity (3PH)
Recommended supply fuse (3PH)
Max starting current STD (LRA)
Max starting current so start (LRA)
V
amps
amps
amps
amps
400
20
30
80
31
400
22
30
102
34
400
35
50
174
40
400
44
60
102
34
400
70
100
174
40
Air data
Nominal air flow
Fan external resistance
Fan external resistance (F)
m³/h
Pa
Pa
5500
0
n/a
10000
0
60
14000
0
60
20000
0
60
28000
0
60
Water Data
Water flow ±10%
Pressure drop (water)
Water connections
Condensate water connections
(optional factory fit)
l/min
m hd
inch
inch
66
2.1
1½ BSPM
1½ BSPM
66
4.2
1½ BSPM
1½ BSPM
130
3.9
1½ BSPM
1½ BSPM
130
4.2
1½ BSPM
1½ BSPM
260
5.3
2 BSPM
1½ BSPM
General data
Gas charge (R134a) BH
Compressor type
Fan type
Sound pressure level @ 3m AIR ON
Sound level @ 3m AIR OFF
Sound level @ 3m SIDE
kg
dB(A)
dB(A)
dB(A)
17
1 x SCROLL
1 x AXIAL
64
60
61
16
1 x SCROLL
1 x AXIAL
66
61
64
30
1 x SCROLL
1 x AXIAL
70
64
65
16 x 2
2 x SCROLL
2 x AXIAL
65
64
61
30 x 2
2 x SCROLL
2 x AXIAL
70
67
65
Dimensions
Wid (unpacked)
Dep (unpacked)
Height (unpacked)
Weight (unpacked)
Wid (export, packed)
Dep (export packed)
Height (export, packed)
Weight (export, packed)
mm
mm
mm
kg
mm
mm
mm
kg
1555
790
1080
TBA
1775
900
1250
TBA
1665
1060
1330
TBA
1845
1170
1500
TBA
1810
1190
1310
TBA
2020
1300
1480
TBA
2065
1190
1350
TBA
2265
1310
1520
TBA
2210
1650
1340
908
2470
1770
1505
1128
NOTES:
1) Weight and dimensions nett.
2) Allow 500mm clearance to service panels.
3) Minimum air temperature standard models (BH) 7°C. Reverse cycle defrost models (BHY) -15°C.
4) Calorex reserve e right to change or modify models wiout prior notice.
5) Global warming potential (GWP) R134a 1300.
6) Performance data below 10°C is derated to account for defrost periods.
* use selection overleaf
1 mm WG = 9.8 Pa
1 m hd = 1.4 psi
1 l/min = 0.22 gall/min
Heat pumps, specialist applications heaters HY models

16
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
-5 0 5 10 15 20 25 30 35
Heat output to water (kW)
Air temperature (°C)
PP45BHY
Performance graphs
0.00
5.00
10.00
15.00
20.00
25.00
30.00
-5 0 5 10 15 20 25 30 35
Heat output to water (kW)
Air temperature (°C)
PP30BHY
Water temperature (°C)
Heat output (kW)
Heat output (kW)
Power input (kW)
Power input (kW)
30
30
35
35
40
40
45
45
50
50
55
55
60
60
65
65
Water temperature (°C)
Water temperature (°C)
30
30
35
35
40
40
45
45
50
50
55
55
60
60
65
65
Water temperature (°C)

17
0.00
10.00
20.00
30.00
40.00
50.00
60.00
-5 0 5 10 15 20 25 30 35
Heat output to water (kW)
Air temperature (°C)
PP70BHY
Water temperature (°C)
30
30
35
35
40
40
45
45
50
50
55
55
60
60
65
65
Water temperature (°C)
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
-5 0 5 10 15 20 25 30 35
Heat output to water (kW)
Air temperature (°C)
PP90BHY
Water temperature (°C)
30
30
35
35
40
40
45
45
50
50
55
55
60
60
65
65
Water temperature (°C)
0.00
20.00
40.00
60.00
80.00
100.00
120.00
-5 0 5 10 15 20 25 30 35
Heat output to water (kW)
Air temperature (°C)
PP140BHY
Water temperature (°C)
30
30
35
35
40
40
45
45
50
50
55
55
60
60
65
65
Water temperature (°C)
Heat output (kW)
Heat output (kW)
Heat output (kW)
Power input (kW)
Power input (kW)
Power input (kW)

18
Propac 30 Dimensions in mm Allow 500mm for access to service panels Allow 1000mm clearance in front of evaporator Allow 3000mm clearance above machine Water connections 1½" BSPM Condensate 1½"
Installation drawings
Pro-Pac 30 Dimensions in mm Allow 500mm for access to service panels Allow 1000mm clearance in front of evaporator Allow 3000mm clearance above machine Water connections 1½" BSPM Condensate 1½"

19
Installation drawings cont.
Pro-Pac 45 Dimensions in mm Allow 500mm for access to service panels Allow 1000mm clearance in front of evaporator Allow 3000mm clearance above machine Water connections 1½" BSPM Condensate 1½"

20
Installation drawings cont.
Pro-Pac 70 Dimensions in mm Allow 500mm for access to service panels Allow 1000mm clearance in front of evaporator Allow 3000mm clearance above machine Water connections 1½" BSPM Condensate 1½"