Calorex AW629AL User manual

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
AW629/829AL
R
OWNER/INSTALLATION MANUAL
FOR
AW629/829AL
(SD617652 Iss.A 29/01/10)
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
AW629/829AL
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Thank you for choosing Calorex!
Your Calorex heat pump has been specially designed for pool
heating using high quality components that are carefully chosen to
provide maximum efficiency and reliability. This manual will help
you to get the best out of your heat pump and advise you on how to
maintain it.

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
AW629/829AL
R
Contents
1.0 Introduction ................................................................................................................ 4
1.1 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 Controls and Indication Lamps ................................................................................ 15
5.1 Digital Thermostat ................................................................................................... 16
6.0 Circuit Diagrams ..................................................................................................... 17
7.0 Regular planned maintenance ................................................................................. 18
8.0 Heat Pump Malfunction............................................................................................ 19
8.1User Check List ....................................................................................................... 19
8.2 Outdoor swimming pool heat pump troubleshooting checklist .................................. 20
9.0 Datasheet ............................................................................................................... 23
10.0 Installation Drawings.............................................................................................. 24
11.0 Winterisation Procedure ........................................................................................ 26
11.1 Start up Procedure After Winterisation ................................................................... 27
12.0 Warranty Conditions .............................................................................................. 28
13.0 Contacting Calorex................................................................................................ 29

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
AW629/829AL
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The Calorex ‘Propac’ range of air/water heat pumps are designed for swimming
pool heating and consists of 2 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.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. The heat pumps are
fitted with rotary compressors which 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.
Calorex Heat Pumps Limited is an ISO9001:2000 certified company.
All Calorex heat pumps are CE approved
1.0 Introduction

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
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1.1 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
AW629/829AL
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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.
a) Provide a firm level base capable of supporting operational weight of unit;
spread load if mounted on timber floor.
b) 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.
c) Allow adequate clearance to service panels on unit; recommend 500mm
minimum.
d) 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.
e) Ensure loose debris such as leaves, grass cuttings, etc will not block air
inlet grilles.
f) 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
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2.2 Air flow
Suitable opening
Suitable opening
> 50 cm
PLANT ROOM
WALL WALL
POSSIBLE POSITIONS OF A CALOREX HEAT PUMP
SWIMMING POOL/SP
A
CALOREX
CALOREX
CALOREX
CALOREX
CALOREX
MODEL
Inlet Discharge
AW629 0.157 0.168
AW829 0.264 0.168
AW1229 0.264 0.173
AW1529 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 aper-
ture. 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 below).
Required Free Areas to provide air flow to and
from heat pumps when installed in an en-
closed 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
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a) Calorex Heat Pumps have water inlet/outlet connections as follows:
All models have 1½” BSP parallel, male threads.
b) 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.
c) 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 section 3.1).
d) Suitable breakable couplings should be installed local to the heat pump.
e) If the heat pump is installed at a lower level than the pool then isolation
valves should be fitted.
f) A drain valve or plug should be fitted to the lower pipe to facilitate drain
down in the winter period.
g) 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.
h) 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
below).
THIS TYPE OF
INSTALLATION
SHOULD BE AVOIDED
INCORRECT DRAINAGE
FOR CONDENSATE
CORRECT DRAINAGE
FOR CONDENSATE ELBOW
'U' TRAP
ADEQUATE FALL
3.0 Plumbing

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
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i) 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.
j) 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).
k) All pipework must be adequately supported with allowance expansion/
contraction especially with plastic pipework.
l) 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 (see section 3.1) unless installation is as
per filter dosing . 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
2.5bar (35 psi).
Acidity pH pH 7.2 - 7.8
Total Alkalinity, as CaCO3ppm 80 - 120
Total Hardness, as CaCO3ppm 150 - 250
Total Dissolved Solids ppm 1000 Max
Maximum Salt Content ppm 35000 Max
Free Chlorine Range ppm 1 - 2 Domestic
Free Chlorine Range ppm 3 - 6 Commercial
Superchlorination max 30ppm for 24 hrs
Bromine ppm 2 - 5
Baquacil ppm 25 - 50
Ozone ppm 0.9 Max
Maximum Copper Content ppm 1
Aquamatic Ionic Purifier ppm 2 Max

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
AW629/829AL
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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

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
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3.2 Determining Water
Flow
The heat pump is fitted with a water flow switch which inhibits the operation
of the heat pump when the water flow is below 5000L/h (83.3L/min. Adjust
the flow rate until the flow light (green lamp) is illuminated. This lamp
indicates that the water flow through the heat pump is adequate.
REMOVE BUNGS
BEFORE INSTALLING
HEAT PUMP
HEAP PUMP SIDE
POOL WATER IN
POOL WATER OUT
CONDENSATE DRAIN
FLOW LIGHT
AW629/829 FLOW RATE 115 LITRES PER MINUTE

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
AW629/829AL
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4.0 Electrolytic
Corrosion in Swimming
Pools
Electrolytic corrosion will occur when dissimilar metals that are in
contact with each other create a potential difference between
themselves. Sometimes separated by a conductive substance
known as an electrolyte, the dissimilar metals will create a small
voltage (potential difference) that allows the ions of one material to
pass to the other.
Just like a battery, ions will pass from the most positive material to
the more negative material.
Anything more than 0.3 volts can cause the most positive material to
degrade.
A swimming pool with its associated equipment can create this ef-
fect. The pool water being an ideal electrolyte and components of
the filtration circuit, heating system, steps, lights etc providing the
dissimilar metals needed to complete the circuit.
Whilst these small voltages are rarely a safety threat, they can cre-
ate premature failure through corrosion. Not dissimilar to corrosion
through oxidation, electrolytic corrosion can cause complete failure
of a metallic material in a very short period of time.
In order to prevent this type of corrosion all metallic components in
contact with swimming pool water should be bonded together using
10mm² bonding cable. This includes non-electrical items such as
metal filters, pump strainer boxes, heat exchangers, steps and hand-
rails. It is highly recommended that bonding be retrofitted to existing
pools, which may not be protected by this system.

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
AW629/829AL
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4.1 Electrical (Machine
Wiring and Supply).
SEE FIGURES 5,6,7 AND 8 FOR PREFERRED METHOD
All electrical work to be carried out in accordance with l.E.E. standards,
latest issue, or local codes of practice as applicable.
The machine should be installed in line with EMC2004/108/EC.
Protected supply to incorporate fuses or motor type circuit breakers (Type
C) to specified rating, (see Data Sheet). H.R.C. fuses are recommended.
An isolator which disconnects all poles must be fitted within 2m and in
sight of machine.†
All units must be correctly earthed-grounded. An earth leakage trip of the
Current operating type (30mA) is recommended to be fitted to all pool
electrics.
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:
Minimum Maximum
Voltage single phase 207V 253V
Frequency - Hz 47,5 52,5
This voltage must be made available at the heat pump while running.
† Note the Isolator must have a minimum of 3mm air gap when turned off.
IMPORTANT
The user should be made aware that THE WHOLE installation should be
isolated when working on ANY PART.

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
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MAINS IN
BOTH ENDS
REMOVE SCREWS FROM TOP
COVER AND LIFT OFF
FIGURE 5
ENL
N
L
SINGLE PHASE 230V ~1N 50Hz
4.2 Location of Mains Input and External Interlock Terminals

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
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5.0 Controls and
Indication Lamps
MAINS RED Electrical supply on
FAULT AMBER Internal or external fault condition
DEFROST WHITE Defrost Mode
WATER FLOW GREEN Water flowing at adequate rate
CONSOLE

Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
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5.1 Digital Thermostat
Not used
Increase Set Point
Decrease Set Point
Access Set Point
An adjustabe single stage digital thermostat controls and maintains the
water temperature.
Press and release the P key to display required temperature, to alter
required temperature press the up or down keys. After 5 seconds the
display reverts to actual water temperature.

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Calorex Heat Pumps Ltd. · The Causeway, Maldon, Essex CM9 4XD, UK · Tel: [phone]
Installation Manual
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A1
A2
MODEL
FUSE RATINGS
FUSE
AW629AL
AW829AL
3A
3A
T1
(6 MINS)
LIVE NEUTRAL
WATER FLOW
LIGHT
WATER FLOW
SWITCH
COMPRESSOR
C
S(A)
R(P)
DELAY
TIMER
CONTROL FUSE
FAULT
LIGHT
MAINS LIGHT
RUN CAP
DEFROST
FAN
CONTACTOR
LIGHT
SENSOR
POOL
STAT
A
B
6
4
1210 11
(N/O)
(COM)
HP
SWITCH
LP
SWITCH
BREAKS ON
PRESSURE FALLING
BREAKS ON
PRESSURE RISING
L
C
H
C
(N/O)
L
C
DEFROST
STAT (N/C)
R1
7
41
(N/C) (N/O)
(COM)
(N/C)
(N/O)
5
1
6
2
(N/O)
(N/O)
AW629/829AL SINGLE PHASE (230V ~1N 50Hz)6.0 Circuit Diagrams