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Calorex AW629AL, Installation Manual

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Calorex Heat Pumps Ltd. · The Causeway,  Maldon, Essex CM9 4XD, UK · Tel: +44 (0)1621 857 171

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.

Summary of Contents for AW629AL

Page 1: ...allation 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 ...

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Page 3: ...AL Page 2 R 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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Page 5: ... 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 ...

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Page 7: ...ufactured 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 externa...

Page 8: ...ow 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 th...

Page 9: ... 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 shoul...

Page 10: ...tiple 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 R...

Page 11: ... 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...

Page 12: ...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 passin...

Page 13: ...Y 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 ...

Page 14: ...witch 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 ...

Page 15: ...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 oxidatio...

Page 16: ...mended 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 INCONSISTENTELECTRICALSUPPLY The following limits of operation must not be exceeded if Calorex machines are to be guaranteed either in performance or wa...

Page 17: ...ssex CM9 4XD UK Tel 44 0 1621 857 171 Installation Manual AW629 829AL Page 14 R MAINS IN BOTH ENDS REMOVE SCREWS FROM TOP COVER AND LIFT OFF FIGURE 5 E N L N L SINGLE PHASE 230V 1N 50Hz 4 2 Location of Mains Input and External Interlock Terminals ...

Page 18: ...9 4XD UK Tel 44 0 1621 857 171 Installation Manual AW629 829AL R 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 ...

Page 19: ...rmostat 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 ...

Page 20: ...RAL 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 1 2 10 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 4 1 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 ...

Page 21: ...3 Check capacitor tolerances where fitted 4 Check condition of all heat exchangers evaporators 5 Check refrigeration system parameters 6 Check operation of control valves 7 Check for water leaks 8 Check driptrays and internal drain lines for blockages and clear 9 Check operation of controls and calibrate if necessary 10 Check operation of interlocks in use 11 Final check of overall operation of un...

Page 22: ...ller or Calorex If in doubt or if advice is required contact Calorex Service Department Telephone 44 0 1621 857171 or 856611 8 1User Check List ACTION 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 or faulty flow switch DEFROST WHITE OFF WATER FLOW GREEN OFF MAINS RED ON First ch...

Page 23: ... cold ambient condi tions and when the heat pump is carrying out a defrost If the RED mains light is off power is not connected to the unit This light is wired between the incoming live and neutral cables and therefore illuminates when the incoming supply is healthy If the GREEN water flow light is not illuminated check for adequate water flow through the heat pump Ensure the flow rate from the wa...

Page 24: ...l display is off check the 3 amp control fuse single phase units or control circuit breaker three phase units in the electric box b Check external devices connected to the interlock Examples of these devices are an external time clock or volt free terminals on the filter pump contactor which would be wired across the terminals labelled as interlock on the terminal block in the heat pump electric b...

Page 25: ...ool water leaks and repair as necessary General rule of thumb check list After switching on the heat pump will take approx six minutes to start This is due to inbuilt time delays within the heat pump that protect the compressor from short cycling Air leaving the heat pump should be 8 to 10 C colder than its entering temperature Water leaving the heat pump will typically be no more than 3 C warmer ...

Page 26: ... 6 L R A 1 ph N A 66 63 10 R L A 1 ph N A 11 4 14 16 SOFT START AMPS 1 ph N A 18 18 35 MAIN FAN AIR FLOW Anemometer air on grille Dry evaporator m h 2200 3300 F L A 1 ph N A 0 8 0 8 0 9 GENERAL DATA HERMETIC SYSTEM GAS CHARGE R407c kg 1 4 1 95 2 2 PHYSICAL DIMENSIONS WIDTH Unpacked mm 1049 1227 107 DEPTH Unpacked mm 593 593 48 HEIGHT Unpacked mm 720 720 135 WEIGHT Unpacked kg 93 104 14 FOR ACCURAT...

Page 27: ...857 171 Installation Manual AW629 829AL Page 24 R R D562755 321 DIA 528 402 1049 720 363 525 60 169 468 662 194 AW629 WATER IN OUT 1 BSPM CONDENSATE DOMESTIC WASTE CONDENSATE 526 593 129 190 500 245 150 206 WATER IN WATER OUT MAINS IN AIR ON AIR OFF 10 0 Installation Drawings ...

Page 28: ...4XD UK Tel 44 0 1621 857 171 Installation Manual AW629 829AL R 526 593 129 190 500 245 150 206 WATER IN WATER OUT CONDENSATE MAINS IN 206 1227 720 60 168 840 194 526 359 789 R D562755 449 402 528 AIR ON AIR OFF AW829 WATER IN OUT 1 BSPM CONDENSATE DOMESTIC WASTE ...

Page 29: ...re 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 into outlet 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 ov...

Page 30: ...ump 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 an air in 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...

Page 31: ...do so by 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 7 The heat pump has suffered frost damage 8 The electrical supply is insufficient or in anyway incorrect Acidity pH pH 7 2 7 8 Total Alkalinity as CaCO...

Page 32: ... R 13 0 Contacting Calorex Email service calorex com Website http www calorex com Tel 44 0 1621 857171 or 44 0 1621 856611 Please give MODEL NUMBER and SERIAL NUMBER of your heat pump when making technical or service enquiries This will assist in correct diagnosis and ensure service can be provided with the minimum delay ...

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