32
Owner Installation Manual for AW631, 831, 1231, 1531 AIR/WATER HEAT PUMPS (SD526750 Issue 10) 04/11/08
Page 1
Owner InstallationManual for
AW631, 831, 1231, 1531AIR/WATER HEAT PUMPS
(SD526750 Issue 10)04/11/08
Page 2
Contents
AIR/WATER HEAT PUMPS FOR SWIMMING POOLS .................................................................................... 3
HOW THE HEAT PUMP WORKS .................................................................................................................... 4
INSTALLATION ............................................................................................................................................... 5
1.SITING ......................................................................................................................................................... 5
2.AIR FLOW .................................................................................................................................................... 6
3.PLUMBING ................................................................................................................................................... 7
RECOMMENDED PLUMBING SCHEMATIC .................................................................................................... 9
4. DETERMINING WATER FLOW ...................................................................................................................10
5.ELECTRICAL (MACHINE WIRING AND SUPPLY). ..................................................................................... 11
ELECTRICAL CIRCUIT DIAGRAMS ...............................................................................................................17
CONTROLS AND INDICATION LAMPS .........................................................................................................19
HEAT PUMP MALFUNCTION .........................................................................................................................20
DATA SHEET ..................................................................................................................................................21
INSTALLATION DRAWINGS ..........................................................................................................................23
WINTERISING PROCEDURE .........................................................................................................................27
START UP PROCEDURE AFTER WINTERISATION.......................................................................................28
WARRANTY CONDITIONS. ............................................................................................................................29
CONTACTING CALOREX ...............................................................................................................................30
Page 3
AIR/WATER HEAT PUMPS FOR SWIMMING POOLS
MODELS AW631, 831,1231, 1531
The Calorex ‘31’ range of air/water heat pumps is for swimming pool applications and consistsof 4 models. Heat pumps in this manual are designed to heat pool water and spas within therange of 10°C to 40°C. Standard units are suitable for outdoor pools operating in ambienttemperatures from 7°C to 40°C. Reverse Cycle Defrost models are available with operationdown to -15ºC, these machines are suitable for heating indoor pools or spas all year round.The water heat exchanger is a full flow type, manufactured from titanium, which is a highlycorrosion resistant material. The heat pumps are suitable for use in fresh water and saltwater pools.The compressors fitted in the heat pumps are the scroll type and are known forquiet 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 externalfaults. Indicator lamps indicate operating mode. An adjustable digital thermostat controlswater temperature. Also a 6 minute cycle time delay is incorporated.
Page 4
HOW THE HEAT PUMP WORKS
The CALOREX Swimming Pool Heat Pump provides thermodynamic heating by means of a vapourcompression cycle (similar to that employed in a conventional refrigerator), in addition to operating as an activesolar collector.
Cooled Air Exhaust Compressor
ExpansionDevice
Outside Air Evaporator(Heat Collector)
Pool Filter
SwimmingPool
Condenser Heat Tranferedto Pool Water
Pool WaterPump
Pool Water
The EVAPORATOR collects heat fromthe outside ambient air, pre-heated by thesun. With Calorex, swimming pool heatpumps high volumes of outside air aredrawn into the unit by the fan and expelledthrough the evaporator fins. The evaporatorhas liquid refrigerant passing through it,which is at a considerably lowertemperature than the ambient air, thereforethe air gives up its heat to the refrigerant,which then vaporizes.This pre-heated vapour now travels to-
The COMPRESSORwhere it is compressed andupgraded to a much highertemperature.The hot vapour now enters -
The CONDENSER where it issurrounded by the pool water. The heatis given up to the cooler pool water andthe now cooler refrigerant returns to itsformer liquid state but still under highpressure from the compressor.This pressure is released by passingthe liquid through -
The EXPANSION DEVICEand from there, now at lowpressure, it is returned to theevaporator and the cycle startsagain.
Coefficient of Performance
The efficiency of a Heat Pump is usually called its 'Coefficient of Performance' - (C.O.P.) which issimply a ratio of heat output to energy input, both being expressed in kW. Thus a Heat Pumpabsorbing 1 kW of electricity, collecting 4 kW of energy from the air, and delivering 5 kW of heat tothe pool water is said to have a C.O.P. of 5:1.
Naturally this ratio will vary according to the temperature of the water and the ambient air.
Page 5
INSTALLATION
1. SITING
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 inpresence of the 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 if mounted on timberfloor.
e Ensure water cannot collect under unit, it is recommend that units are installed on plinths 100mm abovefinished floor level. This also aids condensate drainage.
f Allow adequate clearance to service panels on unit; recommend 500mm minimum.
g All Calorex heat pumps are by design as quiet as is practical, however due consideration should be givento siting the heat pump in order to minimise the noise coming from the machine, for example by positioningthe machine so that the inlet/outlets are parallel to occupied premises.
h Ensure loose debris such as leaves, grass cuttings, etc will not block air inlet grilles.
i Consider protection from extreme weather conditions if installed externally, i.e. lean-to-cover or building.
Page 6
2. AIR FLOW
Due consideration must be given to air flow, i.e. do not obstruct inlet or outlet and ensure discharge air cannotre-circulate to inlet. (See figure 1)
Suitable openingSuitable opening
> 50 cm
PLANT ROOMWALL WALL
FIG 1 POSSIBLE POSITIONS OF A CALOREX 31 UNIT
SWIMMING POOL/SPA
CALOREX 31
CALO
REX
31
CALOREX 31
CALOREX 31
CALOREX 31
Note: If multiple units are installed in an enclosed area then the inlet free areas required for each unit can beadded together to form one inlet aperture. BUT discharge from each unit must be kept separate and must notbe incorporated into one common duct system.
Required Free Areas to provide air flow toand from heat pumps when installed in anenclosed area or where required to pass airthrough a wall, etc.
Free area is the available area through which aircan pass through a grille or louvres.
MODEL Inlet Discharge
AW 631 0.1648 0.114AW 831 0.2931 0.114AW 1231 0.2931 0.114AW 1531 0.3489 0.114
Minimum Free Area m²TABLE 1
Page 7
THIS TYPE OF INSTALLATION
SHOULD BE AVOIDED INCORRECT DRAINAGEFOR CONDENSATE
CORRECT DRAINAGEFOR CONDENSATE
ELBOW
'U' TRAP
ADEQUATE FALL
FIGURE 3
3. PLUMBING
a. Calorex '31' range Heat Pumps have water inlet/outlet connections as follows:
All models have 1½ " BSP parallel, male threads.
The machine is supplied with bungs fitted in the water connection fittings. These need to be removed beforethe unit is installed. See Section 4.
b. The Calorex Pool Heat Pump must be connected after the filter in the return pipe to the pool. If an existingheater is being retained, then the Calorex Heat Pump should be connected between the filter and the otherheater. (See figure 4).
c. Suitable breakable couplings should be installed local to heat pump.
d. If the heat pump is installed at a lower level than pool water then isolation valves should be fitted.
e. Drain valve or plug should be fitted to the lower pipe to facilitate drain down in winter period.
f. Connections on all models are by BSP parallel, male threaded fittings. These should be hand tightenedonly, otherwise damage may result to the threads of the plastic fittings.
g. The condensate drain at the base of the unit collects the condensation from the evaporator fins. Thisshould be run away to waste via ¾" domestic waste piping. It is therefore necessary to ensure that theCalorex unit is placed on a level plinth so that the condensate water can run away with adequate fall towaste ie.½" per foot min and must incorporate a 'u' trap as to not overflow the edges of the drip-tray insidethe machine. See figure 3.
Page 8
h. When the pipework installation is complete the pool pump should be switched on and the system tested forleaks. Also check the filter gauge to see that there is not an excessive increase in back pressure. Ifeverything is then working normally the water circulating system is ready to use.
i. Water circuit to and from unit to be capable of maintaining within specified limits the rate of flow required byheat pump (see data sheet).
j. All pipework must be adequately supported with allowance for expansion/contraction especially with plasticpipework.
k. It is recommended that when installing water systems the last connections to be made in the systemshould be the breakable connections to avoid any stresses on to the unit connections.
IMPORTANT
1. All Pool Purifying Devices and Chemical Injection Systems to be fitted down stream of heat pumpunless installation is as per Filter dosing (See figure 4). This includes the practice of dosingchemicals direct into Skimmer Basket, which results in concentrated corrosive liquids passing overmetal components.
2. Water quality must be maintained as follows:
pH: 7.4 ± 0.4Total Alkalinity: 80 - 120 ppm as CaCo3
Total Hardness: 100 - 300 ppm as CaCo3
Total dissolved solids: Max. 3000 ppmSaline Water Maximum concentration 6% wt/wtChlorine - free Cl range 1.0 - 3.0 ppmOzone 0.8 - 1.0 ppmBromine 2 - 3 ppmBaquacil 25 - 50 ppmAquamatic Ionic Purifier Maximum 2 ppm CopperTam Pure Purifier Maximum 2 ppm CopperSherwood Purifier Maximum 2 ppm Copper
3. Maximum pressure of water in heat pump circuit should not exceed 3.5kg/cm2 (50 psi)
Page 9
KEY
ISO
LATI
ON
VA
LVE
B
RE
AKAB
LE C
OU
PLI
NG
N
ON
RET
UR
N V
ALV
E
TH
RE
E W
AY
VA
LVE
N
ON
R
ETU
RN
VA
LVE
C
HE
MIC
AL
DO
SIN
G
SAN
ITIS
ER
OR
DE
VIC
E, I
F FI
TTE
D
AU
X H
EATE
R
IF F
ITTE
D
FILT
ER
PU
MP
TO W
AST
E F
OR
W
INTE
RIS
ING
D
RA
IN D
OW
N
AN
TI R
ETU
RN
LO
OP
TO B
E IN
CO
RP
OR
ATE
D,
MIN
IMU
M H
EIG
HT
100m
m A
BO
VE H
EAT
PU
MP
OU
LET
PO
RT
(IF S
AN
ITIS
ER
FIT
TED
)
100mm
CO
ND
EN
SAT
E W
ATE
R
TO W
ASTE
SPA
RE
PO
RT
FOR
W
INTE
RIS
ING
FL
USH
ING
C
ON
NE
CTI
ON
TO W
AS
TE
CA
LOR
EX
HEA
T P
UM
P
POO
L
RECOMMENDED PLUMBING SCHEMATIC
FIG
UR
E 4
Page 10
=I6 MINS
I=
D436856 ISS 1
=0
=0
=I
6 MINSI=
FLOW LAMP ILLUMINATED,ADEQUATE FLOW
FLOW LAMP NOTILLUMINATED,INADEQUATE FLOW
POOL/SPA
PUMP
FILTER
WATER HEATING AFTER6 MINUTE DELAY
SYMBOL CHART- ALL MACHINES
REMOVE AND DISPOSEOF LABEL
4. DETERMINING WATER FLOWPlumbing.The machine must be plumbed in as shown, see diagrams below (a tear off label is attached to the machine ondelivery).Adjust the flow rate until the flow light is illuminated, giving the correct flow rate. The “adequate flow” symbollooks like this:
MACHINE SIDEAW631 AND AW831 FLOW RATE 115 LITRES PER MINUTE
AW1231 AND AW1531 FLOW RATE 160 LITRES PER MINUTE
POOLWATER IN
(REMOVE BUNGBEFORE
INSTALLINGMACHINE)
POOLWATER OUT
CONDENSATEDRAIN
MACHINE LABEL
(REMOVE BUNGSBEFORE INSTALLING
MACHINE)
Page 11
5. ELECTRICAL (MACHINE WIRING AND SUPPLY).SEE FIGURES 5,6,7 AND 8 FOR PREFERRED METHOD
Use of the Calorex Energy Management Controller will enable greater savings to be made because thecirculating pump need only run when required and this can be at a time preferred by the customer, i.e. in theEconomy 7 period.
All electrical work to be carried out in accordance with l.E.E. standards, latest issue, or local codes of practiceas applicable.
The machine should be installed in line with EMC2004/108/EC.
Protected supply to incorporate fuses (Type GU, FAZC) or motor (type C) circuit breakers to specified rating,(see Data Sheet). H.R.C. fuses are recommended. An isolator must be fitted within 2m and in sight ofmachine.†
All units must be correctly earthed-grounded. An earth leakage trip of the Current operating type (30mA) isrecommended 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 inperformance or warranty terms:
Minimum MaximumVoltageSingle phase machines 207V 253VThree-phase machines 360V 440VCycle frequency 47.5Hz 52.5Hz
N.B. This voltage must be available at the heat pump whilst running.
† Note the isolator must have a minimum of 3mm air gap when turned off.
IMPORTANT:-
The user should be made aware that on all the installations shown by figures 5, 6, 7 and8 that to work on part of the intallation the supply to all parts of the installation must beisolated.
Three phase units are fitted with a phase protection relay and will not run if phases areconnected incorrectly. A red lamp on the phase rotation relay in the electric box isilluminated when the phases are correctly connected.
Page 12
ELECTRIC BOX ACCESS
REMOVE THE 6 SCREWS FROMTOP COVER AND LIFT OFF
N
L
W ATER PRESSURE
SW ITCH
SO FT START
KIT
FAN L
FAN N
ENERGY MANAGEMENT
CO NTROL LER
WATER FL OW
SW ITCH
INTE
RLO
CKS
REVERSING
VALVE
SW ITCH
REVERSING
VALVE
' Y' VRSN
ONLY
2 4
6
1 3
5
REMOVE THE 6 SCREWS FROMSERVICE PANEL AND LIFT OFF
MAINS INBOTHENDS
1 PHASE 230V ~ 1N 50Hz
N
L
WATER PRESSURESWITCH
SOFT STARTKIT
FAN L
FAN N
ENERGY MANAGEMENTCONTROLLER
WATER FLOW
INTER
LOC
KS
SWITCH
REVERSINGVALVE
'Y' VRSNONLY
3 PHASE 400V ~ 3N 50Hz
N
L
WATER PRESSURESWITCH
SOFT STARTKIT
FAN L
FAN N
ENERGY MANAGEMENTCONTROLLER
WATER FLOWSWITCH
INTE
RLO
CKS
L L
1 3
2
REVERSING
VALVE
'Y' VRSNONLY
LOCATION OF ELECTRICAL SUPPLY CONNECTIONS IN 31 RANGE HEAT PUMP
FIGURE 5
Page 13
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP LARGER THAN ¾ H.P. AND
ENERGY MANAGEMENT CONTROLLER
L1
L2
L3
N
5
6
9
10
L
N
5
6
9
10
N L
3 4
5 6
7 8 9 10
L
N
N L
CALOREX ENERGYMANAGEMENTCONTROLLERAVAILABLE FROMCALOREX DISTRIBUTOR
SINGLE PHASESUPPLY TO SUITCAPACITY OFWATER PUMP
L N
L N L
N L
4 POLE N/O STARTER WITH OVERLOAD AND230v 50Hz COIL RATEDTO SUIT WATER PUMP
SINGLE PHASE13AMP SUPPLY 230vFUSED TO SUITWATERPUMP
SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
INTERLOCK
ENERGY MANAGEMENTCONTROLLER
INTERLOCK
ENERGY MANAGEMENTCONTROLLER
SOFT STARTSOFT START
CALOREXHEAT PUMPSINGLE PHASE
WATER PUMPMAXIMIUM 3/4HPSINGLE PHASE
CALOREXHEATPUMPTHREE PHASE
VOLT FREEAUXILLARYCONTACT N/O
L1
L2
L3
N
5
6
9
10
L
N
5
6
9
10
SOFT START
INTERLOCK
CALOREXHEAT PUMPSINGLE PHASE
ENERGY MANAGEMENTCONTROLLER
N L
3 4
5 6
7 8 9 10
L
N
SINGLE PHASE13AMP SUPPLY 230vFUSED TO SUITWATERPUMP
N L
CALOREX ENERGYMANAGEMENT CONTROLLERAVAILABLE FROMCALOREX DISTRIBUTOR
SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
WATER PUMPMAXIMIUM 3/4HPSINGLE PHASE
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP OF MAXIMUM ¾ H.P. AND
ENERGY MANAGEMENT CONTROLLER
INTERLOCK
ENERGY MANAGEMENTCONTROLLER
SOFT START
CALOREXHEATPUMPTHREE PHASE
FIGURE 6
FIGURE 7
Page 14
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH THREE PHASE WATER PUMP AND ENERGY MANAGEMENT CONTROLLER
L
N
5
6
9
10
SOFT START
INTERLOCK CALOREX HEAT PUMP
SINGLE PHASE
ENERGY MANAGEMENT CONTROLLER
N L
3 4 7 8 9 10
L1
L2
SINGLE PHASE 13 AMP SUPPLY 230v FUSED AT 1 AMP
N L
CALOREX ENERGYMANAGEMENT CONTROLLERAVAILABLE FROMCALOREX DISTRIBUTOR
SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
WATER PUMP THREE PHASE
THREE PHASE SUPPLY TO SUIT CAPACITY OF WATER PUMP L3 L1
L3 L2 L
4 POLE N/O STARTER WITH OVERLOAD AND 230v 50Hz COIL RATED TO SUIT WATER PUMP
L1
L3
L2
N
VOLT FREEAUXILLARYCONTACT N/O
5 6 L1
L2
L3
N
5
6
9
10
SOFT START
INTERLOCK
CALOREX HEAT PUMP
THREE PHASE
ENERGY MANAGEMENT CONTROLLER
FIGURE 8
Page 15
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)
L1
L2
L3
N
5
6
9
10
SOFT START
INTERLOCK
CALOREX HEAT PUMP
THREE PHASE
L
N
5
6
9
10
SOFT START
INTERLOCK CALOREX HEAT PUMP
SINGLE PHASE
L
N
SINGLE PHASE 13 AMP SUPPLY 230v FUSED TO SUIT WATER PUMP
N L
SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
WATER PUMP MAXIMIUM 3/4 HP SINGLE PHASE
WITH SINGLE PHASE WATER PUMP OF MAXIMUM ¾ H. P(NOTE: Method shown in Fig 9. is a preferred system due to incorporated starter and interlock)
L1
L2
L3
N
5
6
9
10
SOFT START
INTERLOCK
CALOREX HEAT PUMP
THREE PHASE
L
N
5
6
9
10
SOFT START
INTERLOCK CALOREX HEAT PUMP
SINGLE PHASE
L
N
N L
SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
WATER PUMP MORE THAN 3/4 HP SINGLE PHASE
SINGLE PHASE SUPPLY TO SUIT CAPACITY OF WATER PUMP
L N
L N L
N L
4 POLE N/O STARTER WITH OVERLOAD AND 230v 50Hz COIL RATED TO SUIT WATER PUMP
N
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP(1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP OF LARGER THAN ¾ H.P.
VOLT FREEAUXILLARY
CONTACT N/O
FIGURE 9
FIGURE 10
Page 16
L1
L2
L3
N
5
6
9
10
SOFT START
INTERLOCK
CALOREX HEAT PUMP
THREE PHASE
L1
N
5
6
9
10
SOFT START
INTERLOCK CALOREX HEAT PUMP
SINGLE PHASE
L1
L2
N L
SWITCHED FUSE ISOLATED WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
WATER PUMP THREE PHASE
THREE PHASE SUPPLY TO SUIT CAPACITY OF WATER PUMP
L3 L3
L3 L2 L
4 POLE N/O STARTER WITH OVERLOAD AND 230v 50Hz COIL RATED TO SUIT WATER PUMP
L1
L3
L2
N
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP(1Ø or 3Ø)WITH THREE PHASE WATER PUMP
VOLT FREEAUXILLARYCONTACT N/O
FIGURE 11
Page 17
AW631, 831, 1231 AL SINGLE PHASE (230V ~ 1 N 50Hz)
AW 631, 831, 1231 1531BL THREE PHASE ( 400V ~ 3 N 50Hz)
LIV
E
NEU
TRAL
WAT
ER
FLO
W
SW
ITC
H
87
CO
MP
RES
SOR
W (C
)
V(S)
U(R
)
DEL
AY
TIM
ER
HP
SW
ITC
H
CO
NTR
OL
FUSE
FAU
LT
LIG
HT
MA
INS
LIG
HT
RU
N C
AP
DEF
RO
ST
FAN
SO
FT
STA
RT
IF
FITT
ED
CO
NTA
CTO
R
SO
FT S
TAR
T TH
ER
MA
L O
VER
LOA
D
& FA
ULT
LI
GH
T
REL
AY/H
ARD
ST
ART
CAP
(IF
FIT
TED
)
IF F
ITTE
D
LP
SW
ITC
H
5 6
DE
FRO
ST
STA
T LI
GH
T
TER
MIN
AL
BLO
CK HO
UR
SR
UN
MET
ERIF
FIT
TED
SEN
SOR
4 62
111
10P
OO
L ST
AT
INTE
RLO
CK
TE
RM
INAL
S
74
AB
9 10
WAT
ER
PRES
SUR
E
SWIT
CH
(IF F
ITTE
D)
N L
SM
ART
CLO
CK
FEED
TER
MIN
ALS
FAN
CAP
ACIT
OR
WAT
ER F
LOW
LI
GH
T
R1
WAT
ER
FLO
W
LIG
HT
WAT
ER F
LOW
SWIT
CH
CO
NTR
OL
MO
TOR
STA
RTE
RPH
ASE
RO
TATI
ON
REL
AY
L1L2L3
1114
7 8
6 4
5 3 12
R1 74
AB
CO
MPR
ESSO
R
DE
LAY
TIM
ER
HP
SWIT
CH
FAU
LTLI
GH
T MAI
NS
LIG
HT
PO
OL
STAT
FAN
L1
NEU
TRAL
CO
NTA
CTO
R
SO
FT S
TAR
T TH
ERM
AL
OVE
RLO
AD &
FA
ULT
LIG
HT
IF F
ITTE
D
SOFT
S
TAR
T IF
FI
TTE
D
LP
SWIT
CH
INTE
RLO
CK
TE
RM
INAL
S
DE
FRO
ST
STA
T D
EFR
OST
LI
GH
T
TER
MIN
AL
BLO
CK
L2
L3
FAN
CAP
AC
ITO
R
HO
UR
SR
UN
ME
TER
IF F
ITTE
D
SE
NSO
R
4 62
111
10
5 6 9 10
N L
SMAR
T C
LOC
KFE
ED
TE
RM
INA
LS
WAT
ERP
RES
SUR
E SW
ITC
H(IF
FIT
TED
)
U(R
)
V(S)W
(C)
ELECTRICAL CIRCUIT DIAGRAMS
Page 18
AW631, 831, 1231 ALY SINGLE PHASE (230V ~ 1 N 50Hz)
AW 631, 831, 1231 1531BLY THREE PHASE ( 400V ~ 3 N 50Hz)
LIV
E
DEF
RO
ST
CO
NTR
OL
STA
T
1 4
2 3
NEU
TRAL
WAT
ER F
LOW
LI
GH
T
WAT
ER
FLO
W
SW
ITC
H
87
CO
MP
RES
SO
R
C[W
]
S [V
] R
[U]
DEL
AY
TIM
ER
HP
S
WIT
CH
CO
NTR
OL
FUS
E
FAU
LT
LIG
HT
MAI
NS
LIG
HT R
UN
CAP
STA
RT
CAP
DEF
RO
ST FA
N
SOFT
ST
ART
CO
NTA
CTO
R
SOFT
STA
RT
THER
MA
L O
VER
LOAD
&
FAU
LT
LIG
HT
REL
AY/H
ARD
(IF F
ITTE
D)
IF
FITT
ED
IF F
ITTE
D
LP
SW
ITC
H
5 6
LIG
HT
TER
MIN
AL
BLO
CK HO
UR
SR
UN
MET
ER
IF F
ITTE
D
SE
NS
OR
4 62
111
10PO
OL
STA
T
INTE
RLO
CK
TE
RM
INA
LS
R1
74
AB
9 10
WA
TER
PR
ES
SUR
E S
WIT
CH
(IF F
ITTE
D)
N L
SM
AR
T C
LOC
KFE
ED
TE
RM
INA
LS
REV
ER
SIN
G V
ALVE
DE
FRO
ST
CO
NTR
OL
STAT
1 4
2 3
LIG
HT
WAT
ER F
LOW
WAT
ER
FLO
WSW
ITC
H
CO
NTR
OL
MO
TOR
STAR
TER
PHA
SE R
OTA
TIO
N
R
ELA
Y
L1L2L3
1114
7 8
56
34
12
R1
74
ABCO
MPR
ESS
OR
C(W
)
S(V)
R(U
)
DE
LAY
TIM
ER
HP
SW
ITC
H
FAU
LT
LIG
HT M
AIN
S L
IGH
T
POO
L ST
AT
FAN
SOFT
ST
ART
L1
NEU
TRAL
CO
NTA
CTO
R
SOFT
STA
RT
THER
MAL
O
VER
LOAD
&
FAU
LT
LIG
HT
IF
FITT
ED
IF F
ITTE
D
LP
SW
ITC
H
INTE
RLO
CK
TER
MIN
ALS
5 6
TER
MIN
AL
BLO
CK
L2
L3
FAN
CAP
ACIT
OR
HO
UR
SR
UN
M
ETE
RIF
FIT
TED
SEN
SO
R
4 62
111
10
POO
L PU
MP
9 10
N L
SM
ART
CLO
CK
FEE
D T
ER
MIN
ALS
DE
FRO
ST
LIG
HT
RE
VER
SIN
G V
ALV
E
Page 19
U
P
CONTROLS AND INDICATION LAMPS
THERMOSTATAdjustable digital thermostat, controls pool water temperature at the required level.
Press and release key ‘P’ to display required temperature, to alter required temperature press up or downsymbols. After 5 seconds display will revert to actual water temperature.
INDICATOR LAMPS "AW" POOL HEATERS
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 LABEL
NON FUNCTIONAL ON THIS APPLICATION
INCREASE SET POINT
DECREASE SET POINT
ACCESS SET POINT
Page 20
HEAT PUMP MALFUNCTIONWARNING: Isolate machine electrically before entering machine or removing panels.
The user check list should be carried out before initiating a service call.
Do not attempt to interfere with any internal control settings as these have been factory calibrated and sealed.
If in doubt or if advice required contact Calorex Service Department.
Telephone (01621) 857171 or 856611
USER CHECK LISTACTION
MAINS RED OFF
FAULT AMBER OFF Check mains supply- external fuses - isolator etc.
DEFROST WHITE OFF
WATER FLOW GREEN OFF
MAINS RED ON
FAULT AMBER OFF Water flow inadequate
DEFROST WHITE OFF
WATER FLOW GREEN OFF
MAINS RED ONFirst check water flow, then
FAULT AMBER OFF Check unit control fuse on single phase machine. Check MCB on three phase machine.
DEFROST WHITE OFF
WATER FLOW GREEN OFF
MAINS RED ON Check water and air flows are not restricted.
FAULT AMBER ON Check thermal cut out on Soft Start if fitted and that air flow is not restricted. Check unit control fuse on
DEFROST WHITE OFF single phase machine. Check MCB on three phase machine.
WATER FLOW GREEN OFF
MAINS RED ON Unit on defrost (heating mode) check that air temperature is not below 7°C.
FAULT AMBER OFF Check evaporator is clean.
DEFROST WHITE ON
WATER FLOW GREEN ON
MAINS RED ON Check water and air flows are not restricted, and that electrical supply is adequate.
FAULT AMBER ON/OFF Check gas charge and airflow to machine.
DEFROST WHITE OFF
WATER FLOW GREEN OFF
UNIT DOES NOT OPERATE
FAN ON COMPRESSOR OFF
UNIT OPERATES INTERMITTENTLY
LAMP
Page 21
For Accurate Application Sizing Consult CALOREX Heat Pumps Ltd.
NOTES:-1) Weight and dimensions nett2) Performance design Iimitations Ambient = 7°C min, 40°C max Water = 10°C min, 40°C max3) Pool water to have correct balance, pH 7.4 ± 0.4 Free Chlorine 1.0 - 3.0 ppm4) Allow 500mm clearance to service panels5) Calorex reserve the right to change or modify models without prior notice.6) R407c Global warming potential (GWP) 1700.1mm WG = 9.8 Pa1m hd = 1.4 psi1L/min = 0.22 gall/min
HEAT PUMPS FOR OUTDOOR POOLSSUMMER SEASON (AL, BL)
MODEL Units AW631 AW831 AW1231 AW1531
HEAT TO POOL WATERAMBIENT 10°C, WATER 24°C kWhr 7.2 9.9 12.4 17.7AMBIENT 20°C, WATER 24°C kWhr 9.2 12.5 15.6 22.4
ELECTRICITYELECTRICAL SUPPLY 1 PHASE 230V/~1N/ 50HzELECTRICAL SUPPLY 3 PHASETOTAL POWER CONSUMEDAMBIENT 10°C, WATER 24°C kWhr 1.8 2.3 3.1 4.2AMBIENT 20°C, WATER 24°C kWhr 2.0 2.5 3.3 4.3MIN SUPPLY CAPACITY (Max F.L.A.) 1 ph N:- A 14.3 17.4 19.0 N/AMIN SUPPLY CAPACITY (Max F.L.A.) 3 ph N:- A 6.0 6.2 8.0 13.0MAX SUPPLY FUSE 1 ph N:- A 20.0 25.0 30.0 N/AMAX SUPPLY FUSE 3 ph N:- A 10.0 10.0 15.0 18.0
WATER FLOWS ETCPOOL WATER FLOW RATE:- l/mn 115 115 160 160POOL WATER PRESSURE DROP (@ Rated Flow):- m hd 1.1 1.1 2.9 2.9MAX WORKING PRESSURE POOL WATER:- bar 3.5 3.5 3.5 3.5POOL WATER CONNECTIONS:- inches 1 1/2" BSPM 1 1/2" BSPM 1 1/2" BSPM 1 1/2" BSPMCONDENSATE DRAIN CONNECTIONS:- inches 3/4"BSPM STUD 3/4"BSPM STUD 3/4"BSPM STUD 3/4"BSPM STUD
COMPRESSORNOMINAL POWER CONSUMED kWhr 1.8 2.14 2.6 3.8L.R.A. 1 ph N:- A 66 63 100 N/AR.L.A. 1 ph N:- A 11.4 14 16.6 N/ASOFT START AMPS 1 ph N:- A 29 31 35 N/A L.R.A. 3 ph N:- A 32 30 48 48R.L.A. 3 ph N:- A 4 4.7 7.3 10SOFT START AMPS 3 ph N:- A 14 14 17 25
MAIN FANAIR FLOW (Anemometer @ air on grille. Wet evaporator):- m³/hr 1800 2700 3000 4700MAX EXTERNAL STATIC PRESSURE:- mm Wg 0 0 0 0F.L.A. 1 ph N:- A 0.7 0.7 0.97 2
GENERAL DATAHERMETIC SYSTEMGAS CHARGE R407c kg 1.6 2.05 2.2 2.45
PHYSICAL DIMENSIONSWIDTH (Unpacked):- mm 1076 1076 1076 1200DEPTH (Unpacked):- mm 485 485 485 485HEIGHT (Unpacked):- mm 1255 1255 1355 1355WEIGHT (Unpacked):- kg 126 134 144 158
400V/~3N/ 50Hz
DATA SHEET
Page 22
HEAT PUMPS FOR OUTDOOR POOLSREVERSE CYCLE DEFROST (ALY, BLY)
MODEL Units AW631 AW831 AW1231 AW1531
HEAT TO POOL WATERAMBIENT 10°C, WATER 24°C :- kWhr 7.2 9.9 12.4 17.7
ELECTRICALELECTRICAL SUPPLY 1 PHASEELECTRICAL SUPPLY 3 PHASETOTAL POWER CONSUMED:-AMBIENT 10°C, WATER 24°C :- kWhr 1.8 2.3 3.1 4.2AMBIENT 20°C, WATER 24°C :- kWhr 2.0 2.5 3.3 4.3MIN SUPPLY CAPACITY (Max F.L.A.) 1 ph N:- amps 14.3 17.4 19.0 N/AMIN SUPPLY CAPACITY (Max F.L.A.) 3 ph N:- amps 6.0 6.2 8.0 13.0MAX' SUPPLY FUSE 1 ph N:- amps 20.0 25.0 30.0 N/AMAX' SUPPLY FUSE 3 ph N:- amps 10.0 10.0 15.0 18.0
WATER FLOWS ETCPOOL WATER FLOW RATE:- litres/min 115 115 160 160POOL WATER PRESSURE DROP (@ Rated Flow):- metres hd 1.0 1.0 2.0 2.0MAX WORKING PRESSURE POOL WATER:- bar 3.5 3.5 3.5 3.5POOL WATER CONNECTIONS:- inches 1 1/2" BSPM 1 1/2" BSPM 1 1/2" BSPM 1 1/2" BSPMCONDENSATE DRAIN CONNECTIONS:- inches 3/4" BSPM STUD 3/4" BSPM STUD 3/4" BSPM STUD 3/4" BSPM STUD
COMPRESSORNOMINAL POWER CONSUMED:- kWhr 1.8 2.14 2.6 3.8LRA.- 1 ph N:- amps 66 63 100 N/ARLA:- 1 ph N:- amps 11.4 14 16.6 N/ASOFT START AMPS 1 ph N:- amps 29 31 35 N/A LRA:- 3ph N:- amps 32 30 48 48RLA: -3 ph N:- amps 4 4.65 7.3 10SOFT START AMPS 3 ph N:- amps 14 14 17 25
MAlN FANAIR FLOW (Anemometer @ air on grille. Wet evaporator):- m³/hr 1800 2700 3000 4700MAX EXTERNAL STATIC PRESSURE :- mm Wg 0 0 0 0FLA:- 1 ph N:- amps 0.7 0.7 0.97 2
GENERAL DATAHERMETIC SYSTEMGAS CHARGE R407c kg 2.31 3.0 4.5 4.5
PHYSICAL DIMENSIONSWIDTH (Un-packed):- mm 1076 1076 1076 1200DEPTH (Un-packed):- mm 485 485 485 485HEIGHT (Un-packed):- mm 1255 1255 1355 1355WEIGHT (Un-packed) :- kg 133 142 157 170
230V/~1N/50Hz400V/~3N/50Hz
For Accurate Application Sizing Consult CALOREX Heat Pumps Ltd.
NOTES:1) Weight and dimensions nett2) Performance design IimitationsAmbient = -15°C min, 35°C maxWater = 10°C min, 40°C max3) Pool water to have correct balance, pH 7.4 ± 0.4 Free Chlorine 1.0 - 3.0 ppm4) Allow 500mm clearance to service panels5) Calorex reserve the right to change or modify models without prior notice.6) R407c Global Warming Potential (GWP) 1700.1mm WG = 9.8 Pa1m hd = 1.4 psi1L/min = 0.22 gall/min
Page 23
INSTALLATION DRAWINGS
1025
.00
1245.00
603.
00
954.00
DIA
472
.00
AIR
ON
AIR
OFF
485.
00
719.00
184.00479.00
110.
00
350.
00
400.
00
WA
TER
OU
T
WA
TER
INC
ON
DE
NS
ATE
MAI
NS
IN
PO
SIT
ION
CO
NS
OLE
191.
0050
5.00
716.00501.00
65.0
0
ALT
ER
NA
TIV
E
MAI
NS
IN
PO
SITI
ON
4 H
OLE
S Ø
8,6
TO
SE
CU
RE
U
NIT
TO
TH
E G
RO
UN
D19
0.00
816.
00
30.00
450.00
*
**
*
AW
631
WAT
ER IN
/OU
T 1
1/2”
BSP
M S
TUBS
CO
ND
ENSA
TE 3
/4” B
SPM
Page 24
1025
.00
1245.00
603.
00
954.00
DIA
472
.00
AIR
ON
AIR
OFF
485.
00
719.00
184.00479.00
110.
00
350.
00
400.
00
WA
TER
OU
T
WAT
ER
IN
CO
ND
EN
SATE
MA
INS
IN
POS
ITIO
N
CO
NS
OLE
4 H
OLE
S D
IA 8
.6 T
O S
EC
UR
E
MAC
HIN
E T
O T
HE
GR
OU
ND
.19
0.00
816.
00
30.00
450.00
*
**
*
95.0
0
807.
00
665.00552.00
65.0
0
ALT
ERN
ATIV
EM
AIN
S IN
P
OSI
TIO
N
AW
831
WAT
ER IN
/OU
T 1
1/2”
BSP
M S
TUBS
CO
ND
ENSA
TE 3
/4” B
SPM
Page 25
1025
.00
1345.00
1028.89
558.
90
472.
00
AIR
ON
AIR
OFF
ALT
ER
NAT
IVE
M
AIN
S IN
PO
SIT
ION
65.0
0 95.0
0
820.
00
762.00553.00
4 H
OLE
S D
IA 8
.6 T
O S
EC
UR
E
MA
CH
INE
TO
TH
E G
RO
UN
D
190.
00
816.
00
30.00
450.00
*
**
*
CO
ND
ENS
ATE
WA
TER
INWA
TER
OU
T
CO
NS
OLE
MAI
NS
INP
OSI
TIO
N
485.
00
816.00
662.00496.00
181.00
110.
0035
5.00
401.
00
AW
1231
WAT
ER IN
/OU
T 1
1/2”
BSP
M S
TUBS
CO
ND
ENSA
TE 3
/4” B
SPM
Page 26
CO
ND
EN
SA
TE
4 H
OLE
S D
IA 8
.6 T
O S
EC
UR
E M
ACH
INE
TO
TH
E G
RO
UN
D
240.
00**
30.00
450.00
880.
00
**
1033.00
567.
00
DIA
472
.00
1115
.00
1345.00
ALT
ER
NAT
IVE
M
AIN
S IN
PO
SIT
ION
AIR
ON
AIR
OFF
65.0
0 104.
0090
9.00
762.00553.00
WAT
ER
IN
WAT
ER
O
UT
CO
NS
OLE
MA
INS
INP
OS
ITIO
N
485.
00
816.00
662.00496.00
181.00
110.
0035
5.00
401.
00
AW
1531
WAT
ER IN
/OU
T 1½
” BSP
M S
TUBS
CO
ND
ENSA
TE 3
/4” B
SPM
STU
B
Page 27
WINTERISING PROCEDURE
ALL MODELS
Objective
To provide frost protectionTo eliminate corrosion problemsTo inhibit electrical components
1. Switch off electric supply to heat pump.
2. Remove external fuses and keep in safe place away from heat pump to prevent accidental operation of heatpump.
3. Ensure water circulation pump is switched off.
4. Drain water from heat pump by:
a. drain valve if fitted
b. disconnecting pipework to and from heat pump
5. Flush through water circuit in heat pump by using CLEAN TAP WATER (NOT POOL WATER) via hose intooutlet connection - run the hose for 10 minutes minimum; use spray nozzle if available.
6. Allow to drain - when drained, fit plastic bags secured by elastic bands over water connections.
7. Uncover electrical enclosure (see page 12) and liberally spray interior of unit, with moisture-repellantaerosol WD40 or similar; reseal enclosure.
8. If heat pump located outside, protect from weather by covering with VENTILATED cover. Do not use plasticsheet as condensation could occur within unit.
WARNING. Isolate machine before removing covers! The heat pumpembodies electrical and rotational equipment, it is recommended for your
own safety that a competent person carries out the following procedure
N.B. If this procedure is not adopted and frost or corrosion damage results then thewarranty will become invalid.
Page 28
START UP PROCEDURE AFTER WINTERISATION
1. Replace covers (if not fitted).
2. Remove front grille .Using a soft brush clean finned surfaces of heat pump. Replace panel.
3. Remove plastic covers on water connections and reconnect water piping or close drain valve.
4. Start up water circulating pump and leave running for at least 1/4 hour to establish flow and enable any airin piping to escape.
5. Replace fuses to heat pump circuit.
6. Switch on heat pump.
7. Check control thermostat is set to required pool temperature.
8. Check pool water daily to ensure it is at correct pH and has correct chemical balance. See Section 3Plumbing.
Page 29
WARRANTY CONDITIONS.The following exclusions apply to the Warranty given by Calorex Heat Pumps Ltd. No claims will be accepted if : -
1. The heat pump is incorrectly sized for the application.
2. The heat pump is installed in any way that is not in accordance with the current procedures as defined byCalorex Heat Pumps Ltd.
3. The heat pump has been worked upon or is adjusted by anyone other than a person authorised to do soby Calorex Heat Pumps Ltd.
4. The air flow to and from the machine is outside the specified limits.
5. The water flow through the machine is outside the specified limits.
6. The water pH level and/or chemical balance is outside the following limits:-
Acidity pH: 7.4 ± 0.4Total Alkalinity, as CaCo3 ppm 80 -120Total Hardness, as CaCo3 ppm 100-300Total Dissolved Solids: ppm MAX 3000Maximum Salt Content: wt/wt 6%Free Chlorine Range: ppm 1.0 - 3.0
Superchlorination: ppm MAX 30 for MAX 24hrsBromine: ppm 2-3Baquacil: ppm 25 - 50Ozone: ppm 0.8 - 1.0*Maximum Copper Content: ppm MAX 2*Aquamatic Ionic Purifier: ppm MAX 2*Tarn Pure Purifier: ppm MAX 2*Sherwood Purifier: ppm MAX 2
7. The heat pump has suffered frost damage.
8. The electrical supply is insufficient or in anyway incorrect.
Page 30
IF IN ANY DOUBT PLEASE ASK
Note:- The Reply Paid Warranty Registration Card must be returned, to ensure that the correct warranty is given.If you do not find a Registration Card with your Heat Pump please contact the Calorex Service Department givingyour name, address and serial number of your heat pump. A card will be sent to you for completion.
Email: [email protected] Website: http//www.calorex.com
01621 857171 01621 856611
Please give MODEL NUMBER and SERIAL NUMBER of your heat pump when making technical or serviceenquiries. This will assist in correct diagnosis and ensure service can be provided with the minimumdelay
CONTACTING CALOREX
