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Owner InstallationManual for
AW320, 620, 820, 1220, 1520AIR/WATER HEAT PUMPS
& AW834,1234,1534BH, AW1222HC, WA1222C
(SD331850 Issue 13)
CONTENTS
SWIMMING POOL .......................................................................................................................................... 1AIR/WATER HEAT PUMPS ............................................................................................................................. 1HOW THE HEAT PUMPS WORKS ................................................................................................................. 1INSTALLATION ............................................................................................................................................... 2SITING ............................................................................................................................................................ 2AIR FLOW ....................................................................................................................................................... 2PLUMBING...................................................................................................................................................... 3DETERMINING WATER FLOW ...................................................................................................................... 4ELECTRICAL ................................................................................................................................................... 8ELECTRICAL CIRCUIT DIAGRAMS ................................................................................................................ 11CONTROLS AND INDICATION LAMPS ...........................................................................................................15HEAT PUMP MALFUNCTION..........................................................................................................................16USER CHECK LIST ........................................................................................................................................16INSTALLATION DRAWINGS ............................................................................................................................19WINTERISING PROCEDURE..........................................................................................................................23START UP PROCEDURE AFTER WINTERISATION ........................................................................................23WARRANTY CONDITIONS .............................................................................................................................24
Page 1
SWIMMING POOLAIR/WATER HEAT PUMPS
MODELS AW320, 620, 820,1220, 1520The Calorex '20' range of air/water heat pumps for swimming pool application consists of 5 models. The unitsAW1400, 1800 and 4000 are described in a separate manual. Heat pumps in this manual are designed for heatingpool waters and spas within the range of 10°C to 55°C with low water flow rate. The water heat exchanger issuitable for fresh water and salt water pools. Standard units are suitable for outdoor pools operating in ambients7°C to 40°C. Models 320, 620, 820, 1220 and 1520 can also be used for hot water generation up to 55°C.
All units have integral safety devices to protect heat pump from internal and external faults. Indicator lamps indi-cate operating mode. An adjustable thermostat controls water temperature. Also 6 min cycle time delay incorpo-rated.
HOW THE HEAT PUMP WORKSThe CALOREX Swimming Pool Heat Pumps pmvides thermodynamic heating by means of a vapour compressioncycle, (similar to that employed in a conventional refrigerator), in addition to operating as an active solar collector.
The EVAPORATOR collects the heat from the outside ambient air, pre-heated by the sun. In the Calorex swimmingpool heat pumps, high volumes of outside air are drawn into the unit by the fan expelled through the evaporatorfins. The evaporator has liquid refrigerant passing through it which is at a considerably lower temperature than theambient air. Therefore the air gives up its heat to the refrigerant which then vaporizes. This pre-heated vapour nowtravels to -
The COMPRESSOR where it is compressed and upgraded to a much higher temperature. The hot vapour nowenters -
The CONDENSER where it is surrounded by the pool water. the heat is given up to the cooler pool water and thenow cold refrigerant returns to its former liquid state but still under high pressure from the compressor.
This pressure is released by passing the liquid through -
The EXPANSION DEVICE and from there, now at normal pressure, it is returned to the evaporator and the cyclestarts again.
Coefficient of Performance
The efficiency of a Heat Pump is usually called its 'Coefficient of Performance' - (C.O.P.) which is simply a ratio ofheat 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.
Naturally this ratio will vary according to the temperature of the water and the ambient air.
Cooled Air Exhaust Compressor
ExpansionDevice
Outside Air Evaporator(Heat Collector)
Pool Filter
SwimmingPool
Condenser Heat Tranferedto Pool Water
Pool WaterPump
Pool Water
Page 2
INSTALLATION
1. SITINGa 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 on timber floor.
e Ensure water cannot collect under unit - recommend units are installed on plinths 100mm above finishedfloor level and to also aid condensate drainage.
f Allow adequate clearance to service panels on unit; recommend 500mm minimum (see installationdrawings).
g All Calorex heat pumps are by design as quiet as is practical, however due consideration should be givento siting in order to fully exploit this feature, i.e. orientate inlet/outlet 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.
2. AIR FLOWDue consideration must be given to air flow, i.e. do not obstruct inlet or outlet and ensure discharge air cannot re-circulate to inlet. (See figures 1 and 2)
Figure 1
TYPICAL OUTSIDE INSTALLATION
WALL, FENCE OR HEDGE
WRONG WRONG RIGHT
TYPICAL INSIDE OR PLANTROOM INSTALLATION
Figure 2
Grill or Apertures MUST comply with Figures (see Table 1)
TABLE 1
Required Free Areas to provide air flow to and from heat pumps when installed in an enclosed area orwhere required to pass air through a wall, etc.
Free area is the available area through which air can pass through a grille or louvres.
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 not be incorporated into one common duct system.
TABLE 1
MODEL Minimum Free Area m²Inlet Discharge
AW 320 0·28 0·023AW 620 0·28 0·06AW 820 0·46 0·06AW 1220 0·46 0·07AW 1520 0·54 0·10
Page 3
3. PLUMBINGa. Calorex '20' range Heat Pumps have water inlet/outlet connections as follows:
b. The Calorex Pool Heat Pump must be connected in bypass after the filter in the return pipe to the pool. Ifan existing heater is being retained, then the Calorex Heat Pump should be connected between the filterand the other heater.(See Figure 3 ).
All models ¾ " BSP parallel, male.(with ¾" BSPF x 1½" ABS male adaptors supplied loose)
c. Suitable breakable couplings should be installed local to heat pump.
d. If heat pump installed at lower level than pool water then isolation valves should be fitted.
e. Drain valve or plug should be fitted to lower pipe to facilitate drain down in winter period.
f. Connections on all models are by parallel female fittings sealed by silicone mastic these should be handtightened only, otherwise damage may result to the threads of 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 using connector supplied. It is thereforenecessary to ensure that the Calorex unit is placed on a level plinth so that the condensate water can runaway with adequate fall to waste ie.½" per foot min and must incorporate a 'u' trap as to not overflow theedges of the drip-tray inside the machine.
h. When the pipework installation is complete the pool pump should be switched on and the system testedfor leaks. 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 requiredby heat pump (see data sheet).
j. All pipework must be adequately supported with allowance for expansion/contraction especially withplastic pipework.
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.
THIS TYPE OF INSTALLATION
SHOULD BE AVOIDED INCORRECT DRAINAGEFOR CONDENSATE
CORRECT DRAINAGEFOR CONDENSATE
ELBOW
'U' TRAP
ADEQUATE FALL
.
IMPORTANT
1. All Pool Purifying Devices and Chemical Injection Systems to be fitted down stream of heat pump unlessinstallation is as per Filter dosing (See Figure 3). This includes the practice of dosing chemicals direct intoSkimmer Basket, which results in concentrated corrosive liquids passing over metal components.
2. Water quality must be maintained as follows:
pH: 7.4 ± 0.4Total Alkalinity: 80 - 120 ppm as CaCo3Total Hardness: 100 - 500 ppm as CaCo3Total dissolved solids: Max. 3000 ppmSaline Water Maximum concentration 6% wt/wtChlorine - free Cl range 1.0 - 3.0 ppm
Superchlorination Max 30ppm for max 24 hrsOzone 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 4
WINDOW
16 l/m
POOL WATER IN
POOL WATER OUT
MACHINE SIDE, MODEL AW32016 LITRES PER MINUTE
33 l/m
WINDOW
POOL WATER IN
POOL WATER OUT
33 LITRES PER MINUTE
MACHINE SIDE, MODELS AW620 TO AW1520/34
4. DETERMINING WATER FLOW (Models AW320 to AW1520/34)
Plumbing.
Machine must be plumbed in bypass, see diagrams below (Label on side of machine).Adjust gate valve to give required flow rate as indicated through window on side of machine.
Page 5
DETERMINING WATER FLOW (Models AW1222,WA1222)
a) Flow Meter Method (see fig 3.)
Ensure isolation valves A' and 'B' and bypass valve 'C' are fully open. Slowly close down bypass valve 'C' untilcorrect flow rate (see data sheet page 18) is shown on the flow meter. Remove handle and lock off valve 'C'.
b) Differential Pressure Method (See fig 3).
By simply installing two filter pressure indicating gauges, one each on the inlet and outlet of the heat pump,and a locking type gate bypass valve in the bypass line, the flow rate through the heat pump can be accuratelydetermined by the difference in the readings of the gauges.This pressure drop is proportional to flow. Flow rateshould be set at the maximum differential with a clean filter if fitted. this differential pressure will drop as the filterbecomes dirty. Provided the filter is cleaned before the minimum differential is reached (which would normally bethe case with a well managed system) then no problems should be encountered.
Setting up the differential.When the installation is complete, the procedure for setting the flow rate through the heat pump using two gaugesis as follows:
1. With the heat pump switched off, ensure isolation valves 'A, 'B' and bypass valve 'C' are fully open.
2. Switch on water circulating pump.
3. Note the water System Pressure on both gauges - they should read the same, but because ofmanufacturing tolerance they may read different.
For example; with a water system pressure of 5mhd the gauge on the inlet may read 5 and the outletgauge 5.5 therefore there is a STATIC ERROR DIFFERENCE of 0.5mhd.
4. Gradually close the bypass valve 'C' until there is a difference in pressure between the two gauges. It willbe noted that the INLET gauge goes up in pressure.
Valve fully open After adjusting valvegauge pressure is: gauge pressure is:
INLET 5.0 6.7OUTLET 5.5 4.0DIFFERENCE 0.5 2.7
Therefore pressure difference is 2.7 + 0.5 = 3.2 metres hd
5. Lock the bypass valve, or render it tamper proof, when correct setting is acheived.
6. See data sheet (page 18) for correct pool water pressure drop.
POOL WATER SCHEMATIC
FILTER
PRESSURE GAUGES METHOD
PUMP
POOL
NON RETURN VALVE
SANITISER OR CHEMICAL DOSING POSITION AFTER CALOREX
FLOW SETTING
VALVE C
(Models AW1222, WA1222 Standard)
CALOREX
ENSURE POOL FILTRATION PUMP SELECTION ALLOWS FOR ALL SYSTEM RESISTANCE
OR LOOP
METHOD
FLOW SETTING FLOW METER
VALVEVALVEISOLATING
B
ISOLATING
A
BYPASS VALVE(LOCKING GATE VALVE TYPE)
AUX HEATER IF FITTED
Page 6
POOL WATER SCHEMATIC (Models AW1222, WA1222 Filter Dosing)ENSURE POOL FILTRATION PUMP SELECTION ALLOWS FOR ALL SYSTEM RESISTANCE
METHODFLOW SETTINGFLOW METER
CALOREX
PUMP
POOL
NON RETURNVALVEOR LOOP
SANITISER ORCHEMICAL DOSINGPOSITIONBEFORE FILTER
FILTER
PRESSUREGAUGES METHODFLOW SETTING
BYPASS VALVE C(LOCKING GATE VALVE TYPE)
VALVEISOLATING
B
NON RETURNVALVEOR LOOP
AUX HEATERIF FITTED
VALVEISOLATING
A
6. ELECTRICAL (MACHINE WIRING AND SUPPLY) SEE FIG. 4,5,6 and 7 FOR PREFERRED METHODUse of the Calorex Energy Management Controller will enable greater savings to be made because the circulatingpump need only run when required and this can be at a time preferred by the Customer, i.e. in the Economy 7period.
All electrical work to be carried out in accordance with l.E.E. standards, latest issue, or local codes of practice asapplicable
Protected supply to incorporate fuses or motor type circuit breakers (Type GU, FAZC) to specified rating, (seeData Sheet). H.R.C. fuses are recommended. An isolator 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 (100mA) 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 in perform-ance 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.
Page 7
L
N
INTERLOCK
SOFT START
5
6
9
10
MANAGEMENTENERGYCONTROLLER
SOFTSTART
CONTROLLERMANAGEMENTENERGY
INTERLOCK
10
9 6
5
N
L3
L2
L1
1 PHASE 230v ~ 1N 50Hz
3 PHASE 400v ~ 3N 50Hz
ELECTRIC BOXMAINS IN
MAINS INELECTRIC BOX
MAINS INAT SIDE
ELECTRIC BOX ACCESS
REMOVE THE 8 SCREWS FROMTOP COVER AND LIFT OFF
LOCATION OF ELECTRICAL SUPPLY CONNECTIONSIN CALOREX HEAT PUMP
Fig. 4
Page 8
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
SINGLEPHASE13AMP SUPPLY 230vFUSEDTO 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
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
CALOR EXENERGYMANAGEMENT CONTROLLERAVAILABLE FROMCALOREX DISTRIBUTOR
SINGLE PHASESUPPLY TO SUITCAPACITY OFWATER PUMP
L N
L N L
N L
4 POLE N/O STARTER WITHOVERLOAD AND 230v 50Hz COILRATED TO SUIT WATER PUMP
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP OF MAXIMUM ¾ H.P. AND
ENERGY MANAGEMENT CONTROLLER
Fig. 5
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP LARGER THAN ¾ H.P. AND
ENERGY MANAGEMENT CONTROLLER
Fig. 6
INTERLOCK
ENERGY MANAGEMENTCONTROLLER
SOFT START
CALOREXHEATPUMPTHREE PHASE
SINGLEPHASE13AMP SUPPLY 230vFUSEDTO 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
Page 9
L1
L2
L3
N
5
6
9
10
SOFT START
INTERLOCK
CALOREX HEAT PUMP
THREE PHASE
ENERGY MANAGEMENT CONTROLLER
L
N
5
6
9
10
SOFT START
INTERLOCK CALOREX HEAT PUMP
SINGLE PHASE
ENERGY MANAGEMENT CONTROLLER
N L
3 4
5 6
7 8 9 10
L1
L2
SINGLE PHASE 13 AMP SUPPLY 230v FUSED AT 1 AMP
N L
CALOREX ENERGY MANAGEMENT CONTROLLER AVAILABLE FROM CALOREX 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
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
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH THREE PHASE WATER PUMP AND ENERGY MANAGEMENT CONTROLLER
Fig. 7
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP OF MAXIMUM ¾ H. P
Fig. 8
(NOTE: Method shown in Fig 9. is a preferred system due to encoporated starter and interlock)
INTERLOCK RELAY230v 50Hz 15 AMP N/O
Page 10
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
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 SINGLE PHASE WATER PUMP OF LARGER THAN ¾ H.P.
Fig. 9
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP(1Ø or 3Ø)WITH THREE PHASE WATER PUMP
Fig. 10
Page 11
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
AW320, 620, 820, 1220 AM. AW834, 1234AH SINGLE PHASE (230v ~ 1 N 50Hz)
AW 620, 820, 1220 BM. AW834, 1234BH THREE PHASE ( 400v ~ 3 N 50Hz)
CO
MPR
ESSOR
C
S(A)
R(P)
DELAY
TIM
ER
HP SW
ITCH
CO
NTRO
L FUSE
FAULT LIG
HT
MAINS LIG
HT
RUN C
AP
START C
AP
DEFRO
ST
FAN
SOFT
START
LIVE
CO
NTACTO
R
SOFT
START
THERMAL
OVER
LOAD
& FAULT LIG
HT IF FITTED
RELAY/HAR
D
IF FITTED
IF FITTED
LP SW
ITCH
INTERLO
CK
TERM
INALS 5 6
DEFR
OST
STAT LIG
HT
FEED TER
MINALS
SMAR
T CLO
CK
9
10
N L
TERMINAL
BLOCK
CR
ANKCASE HEATER
(IF FITTED)
HOUR
SR
UN METER
IF FITTEDSENSO
R
462
111
10PO
OL STAT
CO
MPR
ESSOR
C
S R
DELAY
TIM
ER
HP SW
ITCH
CO
NTRO
L FUSE
FAULT LIG
HT MAINS LIG
HT
POO
L STAT
DEFR
OST
FAN
SOFT
START
L1 NEUTR
AL
CO
NTACTO
R
SOFT STAR
T THER
MAL
OVER
LOAD
& FAULT LIG
HT
IF FITTED
IF FITTED
LP SW
ITCH
INTERLOC
K TERM
INALS 5 6
DEFR
OST
STAT LIG
HT
SMART C
LOCK
FEED TERM
INALS
9
10
N L
TERM
INAL BLO
CK
L2 L3
CRANKCASE
HEATER
(IF FITTED)
FAN CAPAC
ITOR
HOUR
SR
UN METER
IF FITTEDSEN
SOR
462
111
10
WATER
PRESSURE SWITC
H(IF FITTED
)
WATER
PRESSU
RE SWITC
H(IF FITTED)
Page 12
ELECTRICAL CIRCUIT DIAGRAM AW1520BM/1534BH THREE PHASE (400v ~ 3 N 50Hz)
CO
MPR
ESSOR
C
S R
DELAY
TIMER
HP
SWITC
H
CO
NTR
OL FU
SE
FAULT
LIGH
T MAIN
S LIGH
T
DEFR
OST
FAN
SOFT
START
L1 N
EUTR
AL
CO
NTAC
TOR
SOFT STAR
T TH
ERM
AL O
VERLO
AD
& FAULT
LIGH
T
IF FITTED
IF FITTED
LP SW
ITCH
INTER
LOC
K TER
MIN
ALS
5 6
DEFR
OST
STAT LIG
HT
SMAR
T CLO
CK
FEED TER
MIN
ALS
9
10
N L
TERM
INAL
BLOC
K
L2 L3
CR
ANKC
ASE HEATER
(IF FITTED
)
CO
NTAC
TOR
U1
V1
W1
HO
UR
SR
UN
METER
IF FITTEDSEN
SOR
462
111
10PO
OL STAT
Page 13
CO
MP
RESSO
R
HP
SWITC
H
CO
NTR
OL FU
SE
MAIN
S SWITC
H/LIG
HT
REVER
SING
VALVE
INTER
LOC
K TER
MIN
ALS
SMAR
T C
LOC
K
NE
UTR
AL
CO
NTAC
TOR
SOFT
START
THER
MAL
OVER
LOAD
& FAU
LT LIG
HT
L1
CR
ANKC
ASE
FEED
TERM
INALS
5 6 9
10
N
L
FAN
FAN
CAP
LP SW
ITCH
DEFR
OST
STAT D
EFRO
ST LIGH
T
3 2
6 5
1 4
A B
7
1 4
SHU
T OFF
VALVE
A B 7
4
9
6
PR
ESSUR
E LIM
IT VALVE
HEATER
CO
MPR
ESSOR
AU
X N/O
EVAP PRESSU
RE
LIMIT SW
ITCH
RELAY
2
RELAY
1
CH
ILL LIMIT
LP SWITC
H
DELAY
TIMER
B A
POO
L/WATER
2 STAG
E STAT
RU
N
CAP
RELAY/H
ARD
STAR
T CAP
C
S R
9
3 6 FAU
LT LIG
HT
SOFT STAR
T IF FITTED
ELECTRICAL CIRCUIT DIAGRAMAW1222AHC SINGLE PHASE (230v ~ 1 N 50Hz)
(CH
ILL LIMIT FAU
LT)
(IF FITTED)
CO
MPR
ESSO
R
HP
SWITC
H
CO
NTR
OL FU
SE
MAIN
S SWITC
H/LIG
HT
REVER
SING
VALVE
INTE
RLO
CK
TERM
INALS
SMAR
T C
LOC
K
CO
NTAC
TOR
SOFT
START
THER
MAL
OVER
LOAD
& FAU
LT LIG
HT
CR
ANKC
ASE
FEED
TERM
INALS
5 6 9
10
N
L
FAN
FAN
CAP
LP SW
ITCH
DEFR
OST
STAT
DEFR
OST
LIGH
T
3 2
6 5
1 4
A B
7
1 4
SHU
T O
FF VALVE
A B 7
4
9
6
PRESSU
RE
LIMIT
VALVE
HEATER
CO
MPR
ESSOR
AU
X N/O
EVAP PR
ESSUR
E LIM
IT SWITC
H
RELAY
2
RELAY
1
CH
ILL LIMIT
LP SW
ITCH
DELAY
TIMER
B A
PO
OL/W
ATER
2 STAGE
STAT
R
S C
9
3 6 FAU
LT LIG
HT
SOFT
START
IF FITTED
ELECTRICAL CIRCUIT DIAGRAMAW1222BHC THREE PHASE (400v ~ 3 N 50Hz)
L1L2
L3N
EUTR
AL
(CH
ILL LIMIT FAU
LT)
(IF FITTED)
Page 14
CO
MPR
ESSOR
C
S R
DELAY
TIMER
HP
SWITC
H
CO
NTR
OL FU
SE
FAULT
LIGH
T
POO
L STAT
RU
N C
AP
INTER
LOC
K TER
MIN
ALS
SOFT
START
CO
NTAC
TOR
SOFT STAR
T TH
ERM
AL O
VERLO
AD
& FAU
LT LAM
P
IF FITTED
SM
ART C
LOC
K FEED
TERM
INALS
5 6 9
10
IF FITTED
N L
CH
ILL LIMIT
FAULT
DE
FRO
ST
CH
ILL LIM
ITLP SW
ITCH
FAN M
OTO
R
EVAP PRESSU
RE
PRESSU
RE LIM
IT
FAN C
AP
MAIN
S
CR
ANKC
ASE H
EATER
SWITC
H/LIG
HT
LIGH
T
LIMIT SW
ITCH
C
OM
PRESSO
R
AUX N
/O
VALVE
ELECTRICAL CIRCUIT DIAGRAMWA1222AC SINGLE PHASE (230v ~ 1 N 50Hv)
L1N
EUTR
AL
(IF FITTED)
CO
MPR
ESSOR
C
S R
DELAY
TIMER
HP
SWITC
H
CO
NTR
OL FU
SE
FAULT
LAMP
POO
L STAT
INTER
LOC
K
TERM
INALS
SOFT STAR
T IF FITTED
C
ON
TACTO
R
SOFT STAR
T TH
ERM
AL O
VERLO
AD
& FAULT
LAMP
SMAR
T CLO
CK
FEED TER
MIN
ALS
5 6 9
10
IF FITTED
N L
CH
ILL LIMIT
FAULT
DEFR
OST
CH
ILL LIMIT
LP SWITC
H
FAN M
OTO
R
EVAP PRESSU
RE
PRESSU
RE LIM
IT
FAN C
AP
MAIN
S
CR
ANKC
ASE H
EATER
SWITC
H/LIG
HT
LIGH
T
LIMIT SW
ITCH
C
OM
PRESSO
R
AUX N
/O
VALVE
ELECTRICAL CIRCUIT DIAGRAMWA1222BC THREE PHASE (400v ~ 3 N 50Hv)
L1L2
L3N
EUTR
AL
(IF FITTED)
Page 15
CONTROLS AND INDICATION LAMPS
THERMOSTATAdjustable digital thermostat controls pool water temperature at 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.OrAdjustable dial thermostat controls & maintains water temperature at required level (red pointer). The black pointerindicates actual water temperature.
INDICATOR LAMPS "AW" POOL HEATERS
MAINS RED Electrical supply onFAULT AMBER Internal or external fault conditionDEFROST WHITE Defrost Mode
INDICATOR LAMPS "AW" HEATER CHILLER
MAINS (SWITCH) RED Electrical supply on.Also includes ON/OFF rocker switch.
FAULT AMBER Internal or external fault conditionDEFROST WHITE Defrost Mode on water heating
Chill Limit Fault on water cooling
INDICATOR LAMPS "WA" CHILLER
MAINS (SWITCH) RED Electrical supply on.Also includes ON/OFF rocker switch.
FAULT AMBER Internal or external fault conditionDEFROST WHITE Chill Limit Fault on water cooling
Page 16
HEAT PUMP MALFUNCTION
WARNING: 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 LIST
PMAL NOITCA
ETAREPOTONSEODTINU
SNIAM DER FFO lanretxe-ylppussniamkcehC
TLUAF REBMA FFO .cterotalosi-sesuf
TSORFED ETIHW FFO
SNIAM DER NO pmalsniamnohctiwsFFO/NOtinukcehC
TLUAF REBMA FFO .)ylnoC2221AW,CH2221WA(ylnonoylppussniamnospmaL
TSORFED ETIHW FFO setunim51retfafiesuflortnoclanretnikcehC.gnittestatsomrehtkcehCnurtonseodnaf
SNIAM DER NO .detcirtsertoneraswolfriadnaretawkcehC
TLUAF REBMA NO .dettiffitratStfoSnotuOtuclamrehtkcehC
TSORFED ETIHW FFO teserdnasehctiwstuotuc)C2221AWCH2221WAnoPLdna(PHkcehCerotserot.ctepmupretawkcehC.)tatsomrehtelosnocevobanottubder(
.enihcamhguorhtwolfretaw
FFOROSSERPMOCNONAF
SNIAM DER NO erutarepmetriatahtkcehc)edomgnitaeh(tsorfednotinU
TLUAF REBMA FFO )C2221WAton(C°7wolebtonsi
TSORFED ETIHW NO kcehC.)ylnoC2221AW-CH2221WAedomgnilooc(timilllihcnoffotinU.enihcamhguorhtwolfretawerotserot.ctepmupretaw
YLTNETTIMRETNISETAREPOTINU
SNIAM DER NO .detcirtsertoneraswolfriadnaretawkcehC
TLUAF REBMA FFO/NO etauqedasiylppuslacirtceletahtdna
TSORFED ETIHW FFO
Page 17
For Accurate Application Sizing Consult CALOREX Heat Pumps Ltd.
NOTES:-1) Weight and dimensions nett2) Peformance design Iimitations Ambient = 10°C min, 40°C max Water = 10°C min, 55°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 nght to change or mod/v models wthout pnor notce
1mm WG = 9.8 Pa1m hd = 1.4 psi1L/min = 0.22 gall/min
HEAT PUMPS FOR OUTDOOR POOLSSUMMER SEASON
LEDOM stinU 023 026 028 0221 0251
RETAWLOOPOTTAEH
-:C°42RETAW,C°01TNEIBMA rhWk 6.3 3.7 5.9 6.21 8.51
-:C°42RETAW,C°02TNEIBMA rhWk 6.4 3.9 1.21 1.61 0.12
LACITRCELE
-:DEMUSNOCREWOPLATOT
-:C°42RETAW,C°01TNEIBMA rhWk 68.0 0.2 4.2 4.3 9.3
-:C°42RETAW,C°02TNEIBMA rhWk 9.0 1.2 5.2 6.3 6.4
-:Nhp1).A.L.FxaM(YTICAPACYLPPUSNIM spma 6.6 9.11 7.51 6.12 N
-:Nhp3).A.L.FxaM(YTICAPACYLPPUSNIM spma A/N 0.7 8.7 7.9 5.11
-:Nhp1ESUFYLPPUS'XAM spma 01 91 72 53 A/N
-:Nhp3ESUFYLPPUS'XAM spma A/N 11 31 61 71
CTESWOLFRETAW
-:ETARWOLFRETAWLOOP nim/sertil 61 33 33 33 33
-:)wolFdetaR@(PORDERUSSERPRETAWLOOP dhsertem 75.4 1.2 2.3 9.3 6.4
-:RETAWLOOPERUSSERPGNIKROWXAM rab 5.3 5.3 5.3 5.3 5.3
-:SNOITCENNOCRETAWLOOP sehcni MPSB"4/3 MPSB"4/3 MPSB"4/3 MPSB"4/3 MPSB"4/3
-:SNOITCENNOCNIARDETASNEDNOC sehcni CiTSEMOD"4/3ETSAW
CiTSEMOD"4/3ETSAW
CiTSEMOD"4/3ETSAW
CiTSEMOD"4/3ETSAW
CiTSEMOD"-4/3ETSAW
ROSSERPMOC
-:DEMUSNOCREWOPLANIMON rhWk 8.0 1.2 8.2 4.3 0.4
-:Nhp1-.ARL spma 23 65 67 99 A/N
-:Nhp1-:ALR spma 42.5 1.8 3.11 1.51 A/N
-:Nhp1SPMATRATSTFOS spma 02 72 13 43 A/N
-:Nhp3-:ARL spma A/N 83 24 46 57
--:Nhp3-:ALR spma A/N 0.4 7.4 2.5 4.7
-:Nhp3SPMATRATSTFOS spma A/N 51 61 81 03
NAFNlAM
-:)rotaropaveteW.ellirgnoria@retemomenA(WOLFRIA m3 rh/ 538 0081 0052 0003 0593
-:ERUSSERPCITATSLANRETXEXAM gWmm 0 4 4 4 4
-:Nhp1-:ALF spma 63.0 2.2 2.2 5.3 A/N
-:Nhp3-ALF spma A/N A/N A/N A/N 5.1
ATADLARENEG
-:)dekcap-nU(HTDIW mm 718 028 0601 0601 0121
-:)dekcap-nU(HTPED mm 506 507 507 507 557
-:)dekcap-nU(THGIEH mm 046 067 708 708 708
-:)dekcap-nU(THGIEW gk 97 29 911 031 651
-:SERTEM3TASLEVELERUSSERPDNUOS Abd 55 55 75 95 26
-:)c704R(EGRAHCSAG gK 3.1 2.1 8.1 59.1 53.2
Page 18
For Accurate Application Sizing Consult CALOREX Heat Pumps Ltd
NOTES:-1) Weight and dimensions nett2) Pertormance design limitations - Water heating mode - Ambient = 10°C min 50°C max 1534BH 12°C min 30°C max Water = 10°C min 50°C max 1534BH 15°C min 70°C max Water cooling mode - Ambient = 10°C min 50°C max (1534BH n/a) Water = 10°C min 35°C max (1534BH n/a)3) Pool water to have correct balance. pH 7 4 ± 0.4, Free Chlorine 1.0-3.0 ppm4) Allow 500mm clearance to senvice panels5) Calorex reserve the right to change or modify models without prior notice
1mm WG = 9.8 Pa1m hd = 1.4 psi1L/min = 0.22 gall/min
HEAT PUMPS FOR POOLS. SPECIALIST APPLICATIONSCHILLERS, HEATERS AND HEATER CHILLERS
LEDOM stinU CH2221 C2221 H438 H4321 HB4351
ROSSERPMOC
-:DEMUSNOCREWOPLANIMON rhWk 4.3 4.3 1.2 7.2 0.4
-:Nhpl-ARL spma 09 09 67 99 A/N
-:Nhpl-ALR spma 71 71 2.7 8.8 A/N
-:Nhp1SPMATRATSTFOS spma 33 33 13 43 A/N
-:Nhp3-ARL spma 93 93 24 46 57
-.ALR -:Nhp3 spma 8.5 8.5 2.3 5.3 0.5
-:Nhp3SPMATRATSTFOS spma 12 12 61 81 73
NAFNIAM
-:)rotaropaveyrd,ellirgnoria~retemomenA(WOLFRIA m3 rh/ 0023 0023 0562 0023 0004
-:ERUSSERPCITATSLANRETXEXAM gWmm 0 0 0 0 0
-:Nhpl-ALF spma 6.3 6.3 2.2 2.3 A/N
-:Nhp3-ALF spma A/N A/N A/N A/N 56.1
ECNAMROFREP
-:EDOMGNITAEHRETAW
-:C°03RETAW,C°01TNEIBMA rhWk 31 A/N 4·5 9·6 01
-:C°03RETAW,C°03TNEIBMA rhWk 71 A/N 3·9 9·11 3.71
-:EDOMGNILOOCRETAW
-:C°51RETAW,C°01TNEIBMA rhWk 2.21 2.21 A/N A/N A/N
-:C°51RETAW,C°54TNEIBMA rhWk 6.8 6.8 A/N A/N A/N
CTESWOLFRETAW
-:ETARWOLFRETAWLOOP nim/sertil 33 33 33 33 33
-:)wolFdetaR@(PORDERUSSERPRETAWLOOP dhsertem 9.3 9.3 2.3 9.3 75.4
-:RETAWLOOPERUSSERPGNIKROWXAM rab 5.3 5.3 5.3 5.3 5.3
-:SNOITCENNOCRETAWLOOP sehcni MPSB"4/3 MPSB"4/3 MPSB"4/3 MPSB"4/3 MPSB"4/3
-:SNOITCENNOCNIARDETASNEDNOC sehcni CITSEMOD"4/3ETSAW
CITSEMOD"4/3ETSAW
CiTSEMOD"4/3ETSAW
CiTSEMOD"4/3ETSAW
CITSEMOD"4/3ETSAW
LACIRTCELE
-:DEMUSNOCREWOPLATOT
-:EDOMGNITAEHRETAW
-:C°03RETAW,C°01TNEIBMA rhWk 4.3 A/N 4.2 4.3 0.3
-:C°03RETAW,C°03TNEIBMA rhWk 8.3 A/N 5.2 6.3 5.3
-:EDOMGNILOOCRETAW
-:C°51RETAW,C°01TNEIBMA rhWk 9.2 9.2 A/N A/N A/N
-:C°51RETAW,C°54TNEIBMA rhWk 9.3 9.3 A/N A/N A/N
-:NhpI)ALFxaM(YTICAPACYLPPUSNIM spma 9.32 9.32 8.01 0.41 A/N
-:Nhp3)ALFsaM(YTICAPACYLPPUSNIM spma 5.01 5.01 0.6 4.7 51
-:Nhp1ESUFYLPPUSXAM spma 53 53 51 22 A/N
-:Nhp3ESUFYLPPUSXAM spma 61 61 01 21 52
SNOISNEMIDLACISYHP
-:)dekcap-nU(HTDIW mm 028 0601 0601 0601 0121
-:)dekcap-nU(HTPED mm 507 507 507 507 557
-:)dekcapnU(THGIEH mm 708 708 708 708 708
-:)dekcap-nU(THGIEW gk 751 051 911 031 651
-:SRETEM3TASLEVELERUSSERPDNUOS Abd 17 17 75 95 26
Page 19
AW320DIMENSIONS mmWATER IN/OUT 3/4" BSPM STUBS ISSUE 3
605.
00
787.00
TOP VIEW
AREA REQUIRED FOR SERVICE ACCESS
AIR ON
AIR OFF
500.
00
500.
0031
0.00
101.
00
35.00
REAR VIEW
AREA REQUIRED FOR SERVICE ACCESS
231.50 229.00
SIDE VIEW
120.
0015
6.00
164.00210.00
342.00
CONDENSATE
WATER IN
WATER OUT
FLOW GAUGEVIEWING WINDOW
116.0070.00596.0070.00
92.0
0
640.
00
FRONT VIEW
CONSOLE
HP RESETBUTTON
MAIN INAT SIDE
INSTALLATION DRAWINGS
Page 20
AW620 DIMENSIONS mm ISSUE 7
AIR OFF
785
705
AIR ON
TOP VIEW
500
AREA REQUIRED FOR SERVICE ACCESS
REAR VIEW
3/4 BSPM STUBS
258
145 287
192
35
AREA REQUIRED FOR SERVICE ACCESS
500
1025
705
AIR OFF
AIR ON
AREA REQUIRED FOR SERVICE ACCESS
500
TOP VIEW
35
258
225 287
192
3/4 BSPM STUBS
AREA REQUIRED FOR SERVICE ACCESS
500
REAR VIEW
AW820/834 DIMENSIONS mm ISSUE 5
FRONT VIEW
SIDE VIEW
156 20
2
172213
305
WATER OUT
WATER IN
CONDENSATE
FLOW GAUGE VIEWING WINDOW
92
807
15670 79370
CONSOLE
HP RESET BUTTON
MAINS INAT SIDE
FRONT VIEW
760
1167059670
CONSOLE
92
MAINS IN AT SIDE
HP RESET BUTTON
CONDENSATE
202
156
172244.5
336.5
WATER IN
SIDE VIEW
WATER OUT
FLOW GAUGEVIEWING WINDOW
Page 21
1025
705
AIR OFF
AIR ON
AREA REQUIRED FOR SERVICE ACCESS
500
TOP VIEW
35
258
205 327
218
3/4 BSPM STUBS
AREA REQUIRED FOR SERVICE ACCESS
500
REAR VIEW
AW1220/1234 DIMENSIONS mm ISSUE 7
755
500
1175
AIR OFF
TOP VIEW
AREA REQUIRED FOR SERVICE ACCESS
AIR ON
500
288
335
207 393 35
REAR VIEW
AREA REQUIRED FOR SERVICE ACCESS
3/4 BSPMSTUBS
AW1520/1534DIMENSIONS mmISSUE 3
92
807
15670 79370
CONSOLE
HP RESETBUTTON
MAINS IN AT SIDE
CONDENSATE 20
215
6
172244.5
336.5
WATER IN
SIDE VIEW
WATER OUT
FLOWGAUGEVIEWING WINDOW
386
294
172
156 20
2
WATER IN
WATER OUTCONDENSATE
FLOWGAUGEVIEWING WINDOW
SIDE VIEW
807
92
156
944
FRONT VIEW
HP RESETBUTTON
CONSOLE
70
70
MAINS IN AT SIDE
FRONT VIEW
Page 22
1025
705
AIR OFF
AIR ON
AREA REQUIRED FOR SERVICE ACCESS
500
TOP VIEW
35
256
202 332
290
3/4 BSPM STUBS
AREA REQUIRED FOR SERVICE ACCESS
500
REAR VIEW
AW1222/WA1222DIMENSIONS mmISSUE 3
377
202
156
172244.5
336.5
CONDENSATE
WATER IN AW1222WATER OUT WA1222
SIDE VIEW
WATER OUTAW1222
WATER INWA1222
9280
7
15670 79370
MAINS IN
CONSOLE
FRONT VIEW
HP RESET BUTTON
LP RESET BUTTONNOT FITTED TOWA1222 MODELS
LP CHILL LIMITRESET BUTTON
Page 23
WINTERISING PROCEDURE
WARNING. Isolate machine before opening! As the heat pump embodies electrical androtational equipment, it is recommended for your own safety that a competent person
carries out the following procedure
(Drain Down Procedure)ALL MODELS
Object
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 ofheat pump.
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 hoseinto inlet connection - run for 10 minutes minimum; use spray nozzle if available.
6. Allow to drain - fit plastic bags secured by elastic bands over water connections.
7. Uncover electrical enclosure (see page 6 fig.4) 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 useplastic sheet as condensation can occur within unit.
N.B. If this procedure is not adopted and frost or corrosion damage results then the warranty will become invalid.
START UP PROCEDUREAFTER WINTERISATION
1. Replace covers (if not fitted).
2. Remove front grille -- using 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 daily to ensure pool water is at correct pH and has correct chemical balance. See Section 3Plumbing
Page 24
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 100-500Total 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
IF IN ANY DOUBT PLEASE ASKNote:- The Reply Paid Warranty Registration Card must be returned, to ensure that the correct warranty is given. Ifyou do not find a Registration Card with your Heat Pump please contact the Calorex Service Department giving yourname, address and serial number of your heat pump. A card will be sent to you for completion.
01621 857171 01621 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