Compac 6 Service manual

Page 1
Installation Manual Compac 6/8
OWNER AND INSTALLATION MANUAL
FOR
COMPAC 6/8
SWIMMING POOL HEAT PUMPS
(SD636650 Iss.2 23/12/10)
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.

Page 2
Installation Manual Compac 6/8
Thank you for choosing a Compac Heat Pump!
Your Compac heat pump has been specially designed for pool
heating using high quality components, carefully chosen to provide
maximum efficiency and reliability. Please read this manual
carefully as it provides useful operation and maintenance
information that will maximise the benefits your Compac heat pump
can offer.
To register your product and for further useful information please
visit www.compacheatpumps.co.uk

Page 3
Installation Manual Compac 6/8
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 ................................................................................... 14
4.3 Pool Pump Synchronisation .......................................................................... 15
5.0 Controls and indication lamps ................................................................................. 16
6.0 Circuit Diagram ....................................................................................................... 17
7.0 Regular planned maintenance ................................................................................. 18
8.0 Heat Pump Malfunction ............................................................................................ 19
8.1 User Check List .............................................................................................. 19
9.0 Datasheet ............................................................................................................... 20
10.0 Installation Drawings .............................................................................................. 21
11.0 Winterisation Procedure................................................................................ 22
11.1 Start up Procedure After Winterisation ........................................................... 23
12.0 Warranty Conditions .............................................................................................. 24
12.1 Service Contact ............................................................................................ 24

Page 4
Installation Manual Compac 6/8
The Compac range of air/water heat pump is designed for swimming pool
heating. The heat pumps are designed to heat pool water and spas within
the range of 15°C to 35°C, suitable for outdoor pools operating in ambient
temperatures above 5ºC.
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 known for quiet running.
A 3 minute cycle time delay is incorporated for compressor protection. 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 controlsthe water temperature.
1.0 Introduction

Page 5
Installation Manual Compac 6/8
1.1 Function Swimming pool heat pumps provide 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.
THE HEAT PUMP CYCLE
HEATED
WATER TO
POOL
WATER
FROM POOL
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
1. THE EVAPORATOR collects the heat from the
outside ambient air, pre-heated by the sun. In the
swimming pool heat pumps, high volumes of outside
air are drawn into the unit by the fan and 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 -
2. THE COMPRESSOR
where it is compressed
and upgraded to a much
higher temperature. The
hot vapour now enters -
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
-
4. THE EXPANSION DEVICE
and from there, now at normal
pressure, it is returned to the
evaporator and the cycle
starts again.

Page 6
Installation Manual Compac 6/8
a) Ensure that the heat pump on site is as ordered, i.e. model, electrical
supply and factory fitted options.
b) Inspect the 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 the delivery note in the
presence of the driver and send a recorded delivery letter to the transport
company giving details.
c) Protect the unit if installation is delayed.
a) Provide a firm level base capable of supporting the weight of the unit;
spread the load if mounted on timber floor.
b) Ensure that water cannot collect under the unit, it is recommended that
units are installed on plinths 100mm above finished floor level. This also aids
condensate drainage.
c) Please allow adequate clearance to service panels on the unit;
recommended 500mm minimum.
d) The 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 effect of 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.
g) Use the antivibration feet provided, not only does this help to reduce noise
but it also will help prevent corrosion to the base of the heat pump. Use of
stainless steel fixings is recommended.
2.0 Installation
2.1 Siting

Page 7
Installation Manual Compac 6/8
2.2 Air flow
Suitable opening
Suitable opening
> 50 cm
PLANT ROOM
WALL WALL
POSSIBLE POSITIONS OF A HEAT PUMP
SWIMMING POOL/SP
A
HEAT PUMP
HEAT PUMP
HEAT PUMP
HEAT PUMP
HEAT PUMP
Inlet Discharge
0.21 0.145
Minimum Free Area m²
TABLE 1
IMPORTANT
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 the 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 either the
inlet or outlet and ensure that the 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
enclosed area or where required to pass air
through a wall etc.
Free area is the available area through which
air can pass through a grille or louvres.

Page 8
Installation Manual Compac 6/8
a) The heat pumps have water inlet/outlet connections as follows:
Both models can be connected to either 1 1/2” or 50mm plastic pipe.
b) The Heat Pump must be connected after the filter in the return pipe to the
pool. If an existing heater is being retained, then the Heat Pump should be
connected between the filter and the other heater. (See section 3.1).
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) Adrain valve or plug should be fitted to the lower pipe to facilitate draining
water in the winter period.
f) Connections on all models are via either 1 1/2” or 50mm plastic pipe. The
pipes need to be glued into the water in/out connections with a suitable
adhesive.
g) The condensate drain in the base of the unit collects condensation from
the evaporator fins. This should run away to waste using the flexible
drainage tube provided. It is therefore necessary to ensure that the Heat
Pump is placed on a level plinth so that the condensate water can run
away and not overflow the edges of the drip-tray inside the unit. The
position for fitting the condensate adaptor is in the base of the unit. It will
be easier to fit this and the hose BEFORE the Compac heat pump is
connected to the water supply.
3.0 Plumbing
HOSE CONDENSATE ADAPTOR
FIT IN HOLE IN BASE OF UNIT.
APPROXIMATE POSITION
SHOWN
WATER
OUT
NOTE: FITTINGS SHOWN AT
LARGER SCALE FOR CLARITY
WATER
IN

Page 9
Installation Manual Compac 6/8
h) When the pipework installation is complete the pool circulation 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) The 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 for expansion or
contraction, especially with plastic pipework.
k) It is recommended that when installing water systems, that 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 should 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 the heat pump circuit should not exceed
3kg/cm (50 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

Page 10
Installation Manual Compac 6/8
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
POOL
BYPASS VALVE
NORMALLY SHUT
3.1 Recommended Plumbing Schematic

Page 11
Installation Manual Compac 6/8
3.2 Determining Water
Flow
The heat pump is fitted with a water flow switch which inhibits the
operation of the heat pump.This happens in a Compac 6 when the
water flow rate is below 2500L/hour (41L/min) and in a Compac8
when the water flow is below 3000L/hour (50L/min). Error E3 on the
digital thermostat will be shown until the correct flow rate is
achieved. Once this error has disappeared from the thermostat the
flow rate is adequate.
HEAP PUMP WATER OUT CONNECTIONS
POOL WATER IN
POOL WATER OUT
CONDENSATE DRAIN IN BASE
ECO
Compac 6 Flow rate: 800 to 3000L/hour
Compac 8 Flow rate: 3000 to 5000L/hour

Page 12
Installation Manual Compac 6/8
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 effect.
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 create
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.

Page 13
Installation Manual Compac 6/8
4.1 Electrical
(Machine Wiring
and Supply).
See section 4.2
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 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 OF THE INSTALLATION.

Page 14
Installation Manual Compac 6/8
ECO
4.2 Location of Mains
Input
The Compac heat pump is supplied with 5m of cable
which needs to be hard wired to an appropriate MCB (see
data sheet).

Page 15
Installation Manual Compac 6/8
For installations where the filter pump, which also provides water to your
heat pump, is controlled by a time clock (supplied by the installer) your
heat pump can over-ride “pump off” periods set on the time clock so that
the filter pump will run if your swimming pool requires heating. By doing so
your filter pump will only run when:
a) A block period of pump “running” has been set on the time clock for
filtration purposes.
b) The pool requires heating.
This feature operates by overriding the filter pump time clock for three
minutes each hour so that water is pumped through the heat pump.
If during this sampling period the heat pump detects a need for water
heating it will continue to over-ride the time clock until the swimming pool
temperature is satisfied. If water heating is not required, the filter pump will
turn off after the three minute sampling period and not restart until the next
hourly sampling period or time clock pre set run time. This feature will
reduce the filter pump run time and consequently save energy as well as
unnecessary filter pump wear and tear.
4.3 Pool Pump
Synchronisation
TERMINALS IN
HEAT PUMP
FLOW
SWITCH
POWER SUPPLY
~230N 50Hz
PUMP
CONTACTOR
TIME
CLOCK
LINE VOLTAGE
OUT TO PUMP
CONTACTOR
N
L
AC
FS FS L N
LN
LN
POOL PUMP
LP1LP2

Page 16
Installation Manual Compac 6/8
5.0 Controls and
indication lamps
CONSOLE
FAULT LAMP
ECONOMY
MODE LAMP
DEFROST
LAMP
ECONOMY MODE
INCREASE TEMPERATURE
ON/OFF SWITCH
DECREASE TEMPERATURE
NOT USED
ECO
Using the “ECO” button makes the heat pump more economic to run.
When this lamp is illuminated, ECO mode is on.
When the ECO switch is pressed the heat pump will stop
working when the ambient temperature is below 5ºC and will
restart automatically once the ambient temperature is above
10ºC.

Page 17
Installation Manual Compac 6/8
COMPAC 6/8 SINGLE PHASE 230V~1N 50Hz
6.0 Circuit Diagram