air/water heat pumps chillers and heater chillers · saline water except ppt22 8000ppm chlorine -...

SD331852 issue 5

Air/water heat pumps Chillers and heater chillersOwner installation manual (SD331852 issue 7)

2 SD331852 ISSUE 7

OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC

CONTENTS

HEATH AND SAFETY WARNING ..............................................4

AIR/WATER HEAT PUMPS .........................................................5

NOTE THAT WHEN A HEAT PUMP IS CHILLING THE CYCLE IS REVERSED .........................................................6

THE HEAT PUMP CYCLE ............................................................6

INSTALLATION ............................................................................7

1 SITING .......................................................................................7

2 AIR FLOW .................................................................................8

3. PLUMBING ..............................................................................9

4. DETERMINING WATER FLOW ............................................ 11

5. WATER SCHEMATICS.......................................................... 14

ELECTROLYTIC CORROSION IN SWIMMING POOLS ......... 16

ELECTRICAL (MACHINE WIRING AND SUPPLY) ................ 17

CHANGING THE POSITION OF THE DIGITAL THERMOSTAT ON A PP22BC CHILLER ................................ 21

POOL PUMP SYNCHRONISING A POOL PUMP WITH A PP22BC CHILLER ...................................................... 25

ELECTRICAL CIRCUIT DIAGRAMS ........................................ 26

CONTROLS AND INDICATION LAMPS ................................ 34

HEAT PUMP MALFUNCTION ................................................. 36

DATASHEETS ............................................................................ 39

INSTALLATION DRAWINGS .................................................... 41

WINTERISING PROCEDURE ................................................... 47

START UP PROCEDURE AFTER WINTERISATION .............. 47

WARRANTY CONDITIONS. ..................................................... 48

MACHINE RECORD LOG ......................................................... 49

HEALTH AND SAFETY WARNING

As the dehumidifier embodies electrical and rotational equipment, ONLY competent persons should carry out any work on this type of machine.

(SEE GUARANTEE)

3SD331852 ISSUE 7

HEALTH AND SAFETY WARNING

This appliance can be used by children from eight years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been

given supervision or instruction concerning the use of the appliance in a safe way and understand the hazards involved. Children should not play with the appliance. Cleaning and maintenance shall

not be made by children without supervision.

Disconnect from the mains supply and wait three minutes before removing panels and commencing work on this machine.

HEATH AND SAFETY WARNING

4 SD331852 ISSUE 7


AIR/WATER HEAT PUMPS

MODELS COVERED IN THIS MANUAL

HC HEAT PUMPS

These heat pumps are heater chillers, designed for areas of the world where the ambient temperature can vary from 7ºC to 50°C. The pool water is heated when the ambient temperature is low and cooled when the ambient temperature is high, enabling the user to enjoy the pool throughout the year. The units are designed for swimming pools, using R134a as a refrigerant and are ideally suited for operation in a tough climate.

CL, CH AND C HEAT PUMPS

These heat pumps are chillers and are designed to chill either pools or domestic water. These chillers are capable of operating in various conditions and come in three different types. The limits of operation are stated below:

WA634ACH and WA1234BC chillers operate in ambiant air temperatures between 10ºC and 50ºC.

WA634ACL chillers operate in ambient air temperatures between 10ºC and 35ºC.

WA1222AC chillers operate is ambient air temperatures between10ºC and 40ºC.

WA 1834 chillers operate is ambient air temperatures between10ºC and 50ºC.

PP22BC chillers operate in ambient air temperatures between 10ºC and 50ºC.

All units have integral safety devices to protect the heat pump from internal and external faults. Indicator lamps indicate operating mode. An adjustable thermostat controls water temperature. Also a 6 minute cycle time delay is incorporated.

5SD331852 ISSUE 7

COOL GASHOT GAS

HEATEXCHANGER

EVAPORATOR

COLD LIQUIDREFRIGERANT

HIGH PRESSURE SIDE

CONDENSEDREFRIGERANT

AMBIENTAIR

LOW PRESSURE SIDE

WATER OUT

WATER IN

1

2

3

4

COMPRESSOR

EXPANSIONVALVE

THE HEAT PUMP CYCLE

The CALOREX Swimming Pool Heat Pumps provides thermodynamic heating by means of a vapour compression cycle, (similar to that employed in a conventional refrigerator), in addition to operating as an active solar collector.

2 The COMPRESSOR where it is compressed and upgraded to a much higher temperature. The hot vapour now enters -

1 The EVAPORATOR collects the heat from the outside ambient air, pre-heated by the sun. In the Calorex swimming pool heat pumps, high volumes of outside air are drawn into the unit by the fan 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 vaporizes. This pre-heated vapour now travels to -

3 The CONDENSER where it is surrounded by the pool water. the heat is given up to the cooler pool water and the now 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 -

4 The EXPANSION DEVICE and from there, now at normal pressure, it is returned to the evaporator and the cycle starts 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 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.

Naturally this ratio will vary according to the temperature of the ambient air.

NOTE THAT WHEN A HEAT PUMP IS CHILLING THE CYCLE IS REVERSED

6 SD331852 ISSUE 7


INSTALLATION

1 SITING

1. Ensure heat pump on site is as ordered, i.e. model, electrical supply and factory fitted options.

2. Inspect unit for damage, in particular inspect the evaporator (finned side) to ensure that it is undamaged. (Minor indentations in the fins do not affect performance). If severely damaged, endorse delivery note in presence of driver and send a recorded delivery letter to the transport company giving details.

3. Provide a firm level base capable of supporting operational weight of unit; spread load on timber floor.

4. Ensure water cannot collect under unit - recommend units are installed on plinths 100mm above finished floor level and to also aid condensate drainage.

5. Allow adequate clearance to service panels on unit; recommend 500mm minimum (see installation drawings).

6. All Calorex heat pumps are by design as quiet as is practical, however due consideration should be given to siting in order to fully exploit this feature, i.e. orientate inlet/outlet parallel to occupied premises.

7. Ensure loose debris such as leaves, grass cuttings, etc will not block air inlet grilles.

8. Consider protection from extreme weather conditions if installed externally, i.e. lean-to-cover or building.

7SD331852 ISSUE 7

TABLE 1

MODEL MINIMUM FREE AREA m2

INLET DISCHARGE

634 0.28 0.06

834 0.46 0.07

1234 0.39 0.12

1834 0.39 0.12

PP22 0.32 0.17

WRONG RIGHT

TYPICAL OUTSIDE INSTALLATIONFIGURE 1

WALL, FENCE OR HEDGE

TYPICAL INSIDE OR PLANTROOM INSTALLATIONFIGURE 2

WRONG RIGHT

Grill or apertures MUST comply wi figures (see Table 1)

SPACE COOLING/HEATING INSTALLATIONS

MINIMUM DISTANCE TO BE 3m

MINIMUM DISTANCE TO BE 500mm

HEAT PUMP

IDEALPOSITION

ALTERNATIVE POSITIONCOLD

WARM

IDEALPOSITION

2 AIR FLOW

Due 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).

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.

Note: If multiple units are installed in an enclosed area then the inlet free areas required for each unit can be added together to form one inlet aperture.

BUT discharge from each unit must be kept separate and must not be incorporated into one common duct system.

Note: ON AW1834BHC ducting must not be fitted directly to the unit. Inlet duct spigots are available to order.

8 SD331852 ISSUE 7


INCORRECT DRAINAGE FOR CONDENSATE

CORRECT DRAINAGEFOR CONDENSATE

THIS TYPE OFINSTALLATION SHOULD

BE AVOIDEDELBOW

ADEQUATE FALL

U TRAP

a. Calorex ‘34’ range Heat Pumps have water inlet/outlet connections as follows:

634/1234 models ¾ “ BSP parallel, male.(with ¾” BSPF x 1½” ABS male adaptors supplied loose).

1834 models 1½” BSP parallel, male.

PP22BC ¾” BSP parallel, male or 50mm

The machine is supplied with bungs fitted in the water connection fittings. These need to be removed before the unit is installed.

b. The Calorex Pool Heat Pump must be connected in bypass after the filter in the return pipe to the pool. If an existing heater is being retained, then the Calorex Heat Pump should be connected between the filter and the other heater.

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 hand tightened 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. On 634/1234 and PP22 this should be run away to waste via ¾” domestic waste piping using connector supplied. On 1834 models the waste piping needs to be 1½”. It is therefore necessary to ensure that the Calorex unit is placed on a level plinth so that the condensate water can run away with adequate fall to waste ie. ½” per foot min and must incorporate a ‘u’ trap as to not overflow the edges of the drip-tray inside the machine.

h. When the pipework installation is complete the pool pump should be switched on and the system tested for leaks. Also check the filter gauge to see that there is not an excessive increase in back pressure. If everything is then working normally the water circulating system is ready to use.

i. Water circuit to and from unit to be capable of maintaining within specified limits the rate of flow required by heat pump (see data sheet).

j. All pipework must be adequately supported with allowance for expansion/contraction especially with plastic pipework.

k. It is recommended that when installing water systems the last connections to be made in the system should be the breakable connections to avoid any stresses on to the unit connections.

3. PLUMBING

9SD331852 ISSUE 7

pH 7.2-7.8

Total Alkalinity 80-120ppm as CaCO3

Total Hardness 80-250ppm as CaCO3

Total dissolved solids 1000ppm

Saline Water Except PPT22 8000ppm

Chlorine - free Cl Range 1.0-2.0ppm Domestic

Chlorine - free Cl Range 3.0-6.0ppm Commercial

Ozone 0.9ppm Max

Bromine 2-5ppm

Baquacil 25-50ppm

Aquamatic Ionic Purifier Max 2ppm Copper

IMPORTANT

1. Maximum pressure of water in heat pump circuit should not exceed 3.5kg/cm2 (50 psi)

FOR POOL APPLICATIONS THE FOLLOWING ALSO APPLY

2. All Pool Purifying Devices and Chemical Injection Systems to be fitted down stream of heat pump 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 metal components.

3. Water quality must be maintained as follows

10 SD331852 ISSUE 7


33 LITRES PER MINUTE

MACHINE SIDE, MODEL AW634/1234

33 l/m

WINDOW

POOLWATER OUT

MACHINE SIDE, MODEL WA634/WA1234

33 l/m

POOLWATER IN

POOLWATER OUT

POOLWATER IN

33 LITRES PER MINUTE

WINDOW

4. DETERMINING WATER FLOW

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.

MODELS 634/1234

11SD331852 ISSUE 7

DETERMINING WATER FLOW AW1834BHC

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’ until correct flow rate is shown on the flow meter. (See data sheets on pages 39 and 40) Remove handle and lock off valve ‘C’.

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 accurately determined by the difference in the readings of the gauges.This pressure drop is proportional to flow.

Flow rate should be set at the maximum differential.

Setting up the differential.

When the installation is complete, the procedure for setting the flow rate through the heat pump using two gauges is 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 of manufacturing tolerances they may have different readings. For example; with a water system pressure of 5mhd the gauge on the inlet may read 5 and the outlet gauge 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 that is equal to the required pressure drop (see data sheet) observing any static error on the gauges before beginning this process.

5. Lock the bypass valve, or render it tamper proof, when correct setting is achieved.

6. See data sheets on pages 39 and 40 for correct water pressure drop.

12 SD331852 ISSUE 7


WATERIN

WATEROUT

AIR INLET

THERMOSTAT

REMOVE BUNGSBEFORE INSTALLING

HEAT PUMP

PP22BC FLOW RATE 1980L/HOUR

DETERMINING THE WATER FLOW PP22BC

The heat pump is fitted with a water flow switch which inhibits the operation of the heat pump when the water flow is less than the figure shown in the table below.

Adjust the flow rate until the flow rate is adequate. The display on the digital thermostat shows “noF” until adequate flow is reached.

MODEL Flow rates for water pressure switch

Machine starts working when the flow rate rises above L/hour

Machine stops working when the flow rate drops below L/hour

PP22 1200 1200

13SD331852 ISSUE 7

POOL WATER SCHEMATIC (STANDARD)ENSURE POOL FILTRATION PUMP SELECTION ALLOWS FOR ALL SYSTEM RESISTANCE

FILTER

PUMP

POOL

NON RETURN

VALVE OR LOOP

VALVE CBYPASS VALVE(LOCKING GATE VALVE TYPE)

AUXHEATERIF FITTED

SANITISER ORCHEMICAL DOSINGPOSITION AFTERCALOREX

ISOLATINGVALVE

'B'

CALOREX

ISOLATINGVALVE

'A'

CALOREX

RR?›Nfi“fl

RR

cSRUWTQ?hrr?R

MAINS WATERFEED

TO DOMESTIC COLD WATER SERVICES

EXISTING COLD WATER STORAGE TANK (INSULATED)UP TO 500 LITRES CAPACITY

CALOREX WATER CHILLER

CIRCULATINGPUMP

RECOMMENDED INSTALLATION OF CALOREX CHILLER TO COOL DOMESTIC WATER

ALTERNATIVE INSTALLATION OF CALOREX CHILLER TO BE CONSIDERED WHEN EXISTINGSTORAGE TANK IS INADEQUATELY INSULATED OR LARGER THAN 500 LITRES CAPACITY

CALOREX

RR?›Nfi“fl

RR

cSRUWTQ?hrr?R

MAINS WATERFEED

TO DOMESTIC COLD WATER

SERVICES

EXISTING COLD WATER STORAGE TANK

CALOREX WATER CHILLER

CIRCULATINGPUMP

VENT

FILL

BUFFER TANK (DIRECT TYPE)NOMINAL CAPACITY 125-250 LITRES

FLOW SETTING

FLOW METER METHOD

FLOW SETTING

PRESSURE GAUGES METHOD

5. WATER SCHEMATICS

14 SD331852 ISSUE 7


HOT WATER SUPPLY

MAKE UP COLD WATER

HOT WATER RETURN PUMP

CALOREX

CALOREXHEAT PUMP

FLOW SETTINGPRESSUREGAUGESMETHOD

ISOLATINGVALVE B

VALVE CBYPASS VALVE

(LOCKING GATE VALVE TYPE)

ISOLATINGVALVE A

STORAGE TANKCLOSED TYPE

FLOW SETTINGFLOW METER

METHOD

TYPICAL INSTALLATION FOR CALOREX HOT WATER HEAT PUMP (INDUSTRIAL USE)

15SD331852 ISSUE 7

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 handrails. It is highly recommended that bonding be retrofitted to existing pools, which may not be protected by this system.

16 SD331852 ISSUE 7


ELECTRICAL

ELECTRICAL (MACHINE WIRING AND SUPPLY)

SEE FIG. 4,5,6 AND 7 FOR PREFERRED METHOD

Use of the Dantherm Ltd. Energy Management Controller will enable greater savings to be made because the circulating pump need only run when required and this can be at a time preferred by the Customer, i.e. in the Economy 7 period.

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 accordance 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 this heat pump and any associated equipment. When fitting recommended earth leakage trip, to avoid nuisance tripping, the machine should be connected to its own 30mA trip separate from any other associated equipment.

INCONSISTENT ELECTRICAL SUPPLY

The following limits of operation must not be exceeded if Dantherm Ltd. machines are to be guaranteed either in performance or warranty terms:

NOTE: 1234BC/1834BHC and PP22BC units are fitted with phase protection and will not run if the phases are not connected in correct order (phase sequence) or if the supply voltage is 15% less than the nominal voltage. (415V for 3~N 50Hz) . The lamp on the phase rotation relay, situated in the electric box, is illuminated when the phases are correctly connected and the voltage is sufficient.

Minimum Maximum

Voltage

Single phase machines 207V 253V

Three-phase machines 360V 440V

Cycle 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.

17SD331852 ISSUE 7

SOFTSTART

ENERGYMANAGEMENTCONTROLLER

INTERLOCK

10

9 6

5

N

L3

L2

L1

3 PHASE 400V ~ 3N 50Hz

L

N

INTERLOCK

SOFT START

5

6

9

10

ENERGYMANAGEMENTCONTROLLER

1 PHASE 230V ~ 1N 50Hz

ELECTRIC BOXMAINS IN

ELECTRIC BOX ACCESS

CALOREX HEAT PUMPAW634, WA634ACL/ACH, AW1234BHC, WA1222AC/BC

Fig. 4A

LOOSEN THE 8 SCREWS AND LIFT OFF TOP COVER.

(COVER IS RETAINED WITH CAPTIVE FASTENERS)

MAINS IN AT SIDE

ELECTRIC BOXMAINS IN

LOCATION OF ELECTRICAL SUPPLY CONNECTIONS

18 SD331852 ISSUE 7


INTERLOCK

All units have an interlock incorporated innt othe control circuit, brought out to two terminals. These terminals are shorted out for factory testing.

On site the shorting loop is removed and two wires taken out to a pair of voltage free contacts in the water pump starter/contactor/relay or flow switch so that the heatopump cannot operate unless the water pump is operating. (See fig 5).

FIG 5

1. REMOVE LINK BETWEEN TERMINALS 8 AND 9 IF SOFT START FITTED2. REMOVE LINK BETWEEN TERMINALS 6 AND 7 IF VOLT FREE CONTACTS USED

METHOD OF WIRING EXTERNAL INTERLOCK1834 BHCS

SOFT START

POOL PUMP

MAINS SUPPLY

VOLTAGE FREE

CONTACTS NORMALLY

OPEN(RATED 10A AT 250V)

WHITE WIRES TO SOFT START

(IF FITTED)

FACTORY FITTED LINKS

8 96 7

Remove front service panel

1/4 turn fasteners)

Mains supply in

1834 mains terminal block and ear�ing point(also external interlock)

1 2 3 4 5 6 7

NL1

L2

L3

Pool pump interlock

flow switchor so� start

CALOREX HEAT PUMP AW1834BHC

Fig. 4B

19SD331852 ISSUE 7

PP22BC CALOREX CHILLER

THREE PHASE 400V ~3N 50Hz

MAKE MAINS IN EARTH CONNECTION HERE

1213

1415

56

78

916

1718

1910

11

N

L2L1

L3 CABLE ENTRY POINT

ELEC. BOX EARTH STUD

INTERLOCKS

1213

1415

56

78

9

'Y' VRSNONLY

1617

1819

1011

N

L2L1

L3

1411

L1 L

2 L3

REMOTE ON/OFF

VOLT FREE POOL PUMP RUN TERMINALS

LIFT COVER OFF

ELECTRIC BOX

STAT

LOOSEN CAPTIVE SCREWS (2)AT THIS END

BRACKET RIVETTED TO COVER AT THIS END FITS THROUGH

SLOT IN PANELTO REMOVE INNER COVER

FROM TOP OFELECTRIC BOX UNDO THE 2

SCREWS AND SLIDE

TABS.CHECK THAT THE CONNECTORS IN THE BACK

OF THE DIGITAL THERMOSTAT ARE SECURE.

(SEE SECTION 5.1)

BACKWARDS TO DISENGAGE

MAINS IN

WATERIN

WATEROUT

AIR INLET

20 SD331852 ISSUE 7


CHANGING THE POSITION OF THE DIGITAL THERMOSTAT ON A PP22BC CHILLER

If the thermostat is not easily visible when the machine is installed, the position of the thermostat and the “dummy thermostat” can be exchanged. This can be done in easy stages, but should be done by a competent person.

1. Isolate the heat pump from the electricity supply.

2. Remove the lid of the heat pump (see “Location of Electrical Supply connections in a PP22BC Calorex Chiller).

3. Remove the plugs connecting the wiring from the back of the thermostat.

4. Undo the white plastic clips securing the heat pump to the panel. This is done by pressing the clips in at the sides.

5. Remove the thermostat through the panel.

6. Remove the dummy thermostat from its position following the same method described in point 4.

7. Put the thermostat and dummy thermostat in their new positions and secure with white clips.

8. Re connect the connectors to the thermostat taking care that the red markers in the plugs and sockets are correctly aligned.

9. Replace the lid and reconnect the heat pump to the electrical supply.

21SD331852 ISSUE 7

L1

L2

L3

N

5

6

9

10

L

N

5

6

9

10

SOFT START

INTERLOCKCALOREXHEAT PUMPSINGLE PHASE

ENERGY MANAGEMENTCONTROLLER

N L

3 4 5 6 7 8 9 10

L

N

SINGLE PHASE13AMP SUPPLY 230V

FUSED TO SUITWATER PUMP

N L

CALOREX ENERGYMANAGEMENTCONTROLLER AVAILABLEFROM CALOREXDISTRIBUTOR

SWITCHED FUSE ISOLATORWITHIN 2m OF HEAT PUMP ANDSIZED 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

SINGLE PHASESUPPLY TO SUITCAPACITY OFWATER PUMP

L N

L N L

N L

4 POLE N/O STARTERWITH OVERLOAD AND230V 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. 5A

INTERLOCK


SOFT START

CALOREXHEATPUMPTHREE PHASE

SINGLEPHASE13AMP SUPPLY 230vFUSEDTO SUITWATERPUMP

INTERLOCK


INTERLOCK


SOFT STARTSOFT START

CALOREXHEAT PUMPSINGLE PHASE

WATER PUMPMAXIMIUM 3/4HPSINGLE PHASE

CALOREXHEATPUMPTHREE PHASE

CALOREX ENERGYMANAGEMENTCONTROLLER AVAILABLEFROM CALOREXDISTRIBUTOR

Fig. 6A

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP LARGER THAN ¾ H.P. AND


SWITCHED FUSE ISOLATORWITHIN 2m OF HEAT PUMP ANDSIZED IN ACCORDANCE WITH DATA SHEET

22 SD331852 ISSUE 7


L1

L2

L3

SOFT START SOFT START

INTERLOCK


N L

L1

L2

N L

SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET

WATER PUMP THREE PHASE

THREE PHASE SUPPLYTO SUIT CAPACITYOF WATER PUMP

L 4 POLE N/O STARTER WITH OVERLOAD AND 230V 50Hz COIL RATED TO SUIT WATER PUMP

L3

L3 L1 L2

N

L1

L2

L3

N

5

6

9

10

L

SOFT START

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: Me�od shown in Fig 9. is a preferred system due to incoporated starter and interlock)

SINGLE PHASE13A SUPPLY 230VFUSED AT 1 AMP

CALOREX ENERGYMANAGEMENT CONTROLLERAVAILABLE FROM YOURCALOREX DISTRIBUTOR

3 4

5 6

7 8 9 10

L3 L1 L2

INTERLOCK


5

6

9

10

N

L


CALOREXHEAT PUMPTHREE PHASE5

6

9

10

N

SINGLE PHASE13A SUPPLY 230VFUSED TO SUITWATER PUMP



CALOREXHEAT PUMPTHREE PHASE

N L

INTERLOCK

L

NWATER PUMPMAXIMUM 3/4 HPSINGLE PHASE

INTERLOCK RELAY230V 50Hz 15 AMP N/O

SOFT START

INTERLOCK

5

6

9

10

N

23SD331852 ISSUE 7

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH SINGLE PHASE WATER PUMP LARGER THAN 3/4 HP.

Fig. 9

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP (1Ø or 3Ø)WITH THREE PHASE WATER PUMP

Fig. 10

L1

L2

L3


INTERLOCK

N L


INTERLOCK

5

6

9

10

N

L



6

9

10

N

L

NWATER PUMPMORE THAN 3/4 HPSINGLE PHASE

L

4 POLE N/O STARTER WITH OVERLOAD AND 230V 50Hz COIL RATED TO SUIT WATER PUMP

L N

N

L N

SINGLE PHASESUPPLY TO SUITCAPACITY OFWATER PUMP

L1

L2

L3


INTERLOCK

N L


INTERLOCK

5

6

9

10

N

L



6

9

10

N

L1

L2WATER PUMPTHREE PHASE

L

4 POLE N/O STARTER WITH OVERLOAD AND 230V 50Hz COIL RATED TO SUIT WATER PUMP

L3 L2

N

L3 L2

THREE PHASESUPPLY TO SUITCAPACITY OFWATER PUMP

L1

L1

L3

24 SD331852 ISSUE 7


POOL PUMP SYNCHRONISING A POOL PUMP WITH A PP22BC CHILLER

For installations where the filter pump, which also provides water to your chiller, is controlled by a time clock (supplied by the installer) your Calorex chiller can override “pump off” periods set on the time clock so that the filter pump will run if your swimming pool requires chilling. 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 chilling.

This feature operates by overriding the filter pump time clock for three minutes each hour so that water is pumped through the chiller.

If during this sampling period the chiller detects a need for water chilling it will continue to override the time clock until the swimming pool temperature is satisfied. If water chilling 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 filter pump run time and consequently save energy as well as unnecessary filter pump wear and tear.

A pair of volt free terminals (numbered 15 and 16) are available to allow for the chiller to be switched on or off remotely.

CUSTOMERS EXTERNAL PUMP/FILTER TIME CLOCK

N

L

CALOREX CHILLER. EXTERNAL COMPONENTS TO

BE WIRED TO TERMINAL BLOCK LOCATED INSIDE MACHINE ELECTRIC BOX.

15

16

POOL PUMP STARTER

MAX RATING 3A ½ HP AT 250V

25SD331852 ISSUE 7

ELECTRICAL CIRCUIT DIAGRAMS

WA634ACH SINGLE PHASE (230V ~ 1 N 50Hz)

COMPRESSOR

DELAYTIMER6 MINS

CONTROL FUSE

FAULT LIGHT

RUN CAP

START CAP

FAN

SOFTSTART

IFFITTED

LIVE NEUTRAL

CONTACTOR

RELAY/HARD

IF FITTED

SMART CLOCK FEED TERMINALS

TERMINALBLOCK

CRANKCASE HEATER (IF FITTED)

HOURSRUN METER

IF FITTED

SENSOR

FAN CAP

(N/O) L

(N/C) H

BREAKS TO 'H' ONPRESSURE/TEMP FALLING

NOTE!CIRCUIT SHOWS M/C IN UNGASSED/UNENERGIED STATE

BREAKS TO 'L' ONPRESSURE RISING

HP SWITCH

MAINS LIGHT

5

6

10

N

L

FUSE RATINGS

POOL STAT

H (N/C)

C (COM)

C (COM)

L (N/O)

C

S(A)

R(P)

4

62111 10(11)(12)(2) (1)

(9)

(6)

TECNOLOGIC

(NEWASIA)

MODEL FUSE

WA634 5 AMP

21

5 6

(N/O)

(COM)

(N/O)

AUX (N/O)3 4

16

A1

A2 18

15(COM)

(N/C)(N/O)

A2 A1

47

RELAY 2

1(COM)

(N/C)

(N/O)

1

9

74

6

3

(COM)

(COM)

(N/C)

(N/C)

(N/O)

(N/O)

B A B A

D484050

(N/O)

INTERLOCK TERMINALSWATERPRESSURESWITCH(IF FITTED)

9

SOFT STARTTHERMALOVERLOAD& FAULT LIGHT(IF FITTED)

CHILL LIMITSWITCH & LIGHT

RELAY 1

26 SD331852 ISSUE 7


WA1222AC SINGLE PHASE (230V ~ 1 N 50Hz)

NEUTRAL

COMPRESSOR

C

S

R

DELAY TIMER

HP SWITCH

CONTROL FUSE

FAULT LIGHT

POOL STAT

RUN CAP

INTERLOCK

TERMINALS

SOFT START

CONTACTOR

SOFT START THERMAL OVERLOAD & FAULT LAMP

IF FITTED

SMART CLOCK FEED TERMINALS

5

6

9

10

IF FITTED

N

L

CHILL LIMIT FAULT

DEFROST LIGHT

CHILL LIMITLP SWITCH

FAN MOTOR

EVAP PRESSURE LIMIT SWITCH PRESSURE LIMIT

VALVE

FAN CAP

MAINS SWITCH/LIGHT

COMPRESSOR AUX N/O

L1

CRANKCASE HEATER

(IF FITTED)

27SD331852 ISSUE 7

(R407c UNITS)

WA1234BC THREE PHASE (400V ~ 3 N 50Hz)

SOFT STARTIF FITTED

L1

FAN FUSE

A

COMPRESSOR

POOL STAT

CONTACTOR

10

FAN MOTOR

FAN CAP

DELAYTIMER

RELAYFANCUT OUT

FAULT LAMP

MAINSSWITCH/LIGHT

CRANK CASEHEATER(IF FITTED)

NEUTRALL3 L2 L1

PHASE ROTATION RELAYCONTROLFUSES

L3L2

11

14

HP SWITCH

CHILL LIMITLP SWITCH

CHILL LIMITFAULTDEFROSTLAMP

B

4 7

5

6

9

INTERLOCKTERMINALS

N

L

SMART CLOCKFEED TERMINALS

SOFT STARTTHERMAL OVERLOAD& FAULT LAMPIF FITTED

C

S

R

28 SD331852 ISSUE 7


AW634AHC SINGLE PHASE (230V ~1N 50Hz)

LIVE

CONTROL FUSE

RELAY/HARDSTART CAP(IF FITTED)

SOFTSTART

IFFITTED

CONTACTOR

5

6

9

10

N

L

STANDBY

RUN

TEM

P O

K LI

GH

T

H

3

STANDBYSWITCH

1

4

C

2

6

5

TEM

P

RELAY

1

POOL/WATER2 STAGE STAT

MAKES 1 TO 3 ON TEMP RISINGMAKES 4 TO 5 ON TEMP FALLING

97B

LIQUID

SHUT OFF

FAN CAP

4 1 6A 3

NEUTRAL

MAINS LIGHT

FAULTLIGHT

FAN

RUN CAP

DELAYTIMER

DEFROSTSTAT

DEFROSTLIGHT

CRANKCASE HEATER(IF FITTED)

COMPRESSOR

R(P)S(A)

C

HOURS RUN METER(IF FITTED)

CHILL LIGHTSOFT STARTTHERMAL

OVERLOAD &FAULT LIGHT

IF FITTED

LPSWITCH

HPSWITCH

TERMINALBLOCK


INTERLOCKTERMINALS

WATERPRESSURE

SWITCH(IF FITTED)

HEATLIGHT

REVERSINGVALVE

C L

CHILL LIMIT PRESSURESWITCH & LIGHT

(BREAKS ON TEMP FALLING)

29SD331852 ISSUE 7

WA634ACL SINGLE PHASE (230V ~1N 50Hz)

NOTECIRCUIT SHOWS M/C IN

UNGASSED/UN-ENERGISED STATE

A2 A1

21

5 6

(N/O)

(N/O)

(N/O) L

(N/C) H

(COM)

(N/O)

BREAKS TO 'L' ONPRESSURE RISING

HP SWITCH

CONTROL FUSE

FAULTLIGHT

MAINS LIGHT

LIVE NEUTRAL

SOFT STARTTHERMAL

OVERLOAD& FAULT LIGHT

IF FITTED

LP CHILL LIMITSWITCH AND LIGHTBREAKS TO H ON

PRESSURE/TEMP FALLING

5

6


9

10

N

L

TERMINALBLOCK

SENSOR

4

62111 10

POOL STAT

INTERLOCKTERMINALSWATER

PRESSURE SWITCH(IF FITTED)

(11)(12)(2)(1)

(9)

(6)

TECNOLOGIC(NEWASIA)

H (N/C)

C (COM)

C (COM)

L (N/O)

N/O

COMPRESSORC

S(A)

R(P)

DELAYTIMER

FAN

SOFTSTART

IFFITTED

CONTACTOR

RELAY/HARDSTART CAPIF FITTED

CRANKCASE HEATER

(IF FITTED)

RUN CAP

HOURSRUN METER

IF FITTED

SENSOR

SENSOR1N

L 2 3

FAN SPEEDCONTROLLER

WA634 5 AMP

MODEL FUSE

FUSE RATINGS

30 SD331852 ISSUE 7


CONTROLFANFUSE 16A

MODEL FUSESAW1234BHC 3A

FUSE RATINGS

AW1234BHC THREE PHASE (400V ~3N 50Hz)

ALL OTHER CONTACTS SHOWN IN DE-ENERGISED STATE BUT WITH REFRIGERATIONCIRCUIT FULLY CHARGED.WHERE CONTACTS ARE MARKED (N/O) OR (N/C) ON CIRCUIT DIAGRAM ABOVECONDITIONS APPLY.

HP SWITCH BREAKS TO 'L' ON

INTERLOCK TERMINALS


NEUTRAL

SOFT START THERMAL OVERLOAD & FAULT LIGHT

L3

CRANKCASE

5

6

9

10

N

L

FAN

HEATER

DELAY TIMER

FAULT LIGHT

L2 PHASE ROTATION RELAY

L3L2L1

CONTROL FUSES

3A

16A

FAN FUSE

PRESSURE RISING

L1

12 (N

/C)

11 (COM)

MAINS SWITCH / LIGHT

14 (N

/O)

2

1

(N/O) 3 C (COM)H (N/C)(N/O) L

C (COM)H (N/O)(N/C) LLP SWITCH

BREAKS TO 'H' ONPRESSURE FALLING

A

B

6 (N

/O)

3 (N

/C)

(CO

M) 9

4 (N

/O)

1 (N

/C)

(CO

M) 7

RELAY 2

2 STAGE POOL/WATER THERMOSTAT

(SHOWN IN HEAT MODE)

5 (N

/C)

3 (N

/O)

6 (N

/O)

2 (N

/C)

4 (COM) 1 (COM)

A

BRELAY 1

1 (N

/C)

4 (N

/O)

7 (C

OM

)

3 (N

/C)

6 (N

/O)

9 (C

OM

) DEFROST LIGHT (CHILL LIMIT FAULT)

REVERSING VALVE

C (COM)

H (N/O)

L (N

/C)

CHILL LIMIT SWITCHBREAKS TO 'H' ONPRESSURE/TEMP

C (COM)H (N/O)(N/C) L

DEFROST STAT

SHUT OFF VALVE

531

6 (N/O)4 (N/O)2 (N/O)

CONTACTORA2 A1

STARTSOFT

UVW

COMPRESSOR

FALLING

31SD331852 ISSUE 7

AW1834BHC THREE PHASE (400V ~3N 50Hz)

FUSE SIZES TMBLK No. 12,13,14 15,16,17 18,19,20

OVERLOAD SETTINGS MODEL

AW1834BHC FUSE 3A 5A 20A

COMPRESSOR FAN MODEL 1.4A 12AAW1834BHC

PHASEROTATION

14

11L3

L2

L1

12 (N/O)(N/C)

(COM)

FUSES CONTACTORS OVER

LOADS

FAN

COMPRESSOR

L1

L2

L3

HEA

TER(

S)

DELAY TIMER

DEFROST STAT

DEFROST LIGHT

LP SWITCH

HP SWITCH

FAN OVERLOAD

COMPRESSOR OVERLOAD

CONTROL FUSES

FAU

LT L

IGH

T

MAINS LIGHT L3 L2 L1

STARTER

NEUTRAL

INTE

RLO

CK

TERM

INA

LS

10

11

1 4

7

6

9

3

CHILL LIGHT

RELAY

CHILL LIMIT PRESSURESWITCH & LIGHT

TEM

P O

K LI

GH

T

H

3

HEAT LIGHT

POOL/WATER 2 STAGE STAT

REVERSING VALVE

OR FLOW SWITCH

STANDBY

RUN

STANDBY SWITCH

1

4

C

2

6

5

COMP AUX (NC)

(BREAKS ON PRESSURE RISING)

(BREAKS ON PRESSURE FALLING)

TEM

P

MAKES 1 TO 3 ON TEMP RISINGMAKES 4 TO 5 ON TEMP FALLING

(BREAKS ON TEMP FALLING)

(NO) COMP AUX

VALVE,COIL E (LIQUID LINE

SHUT OFF)

SOFT START THERMAL O/LOAD AND FAULT LIGHT IF FITTED

32 SD331852 ISSUE 7


1

4

12

2

21

20

14

15

COM

COM

COM

COM

OUT2

OUT4

STAT

10

12

OUT1

L1 NEUTRAL

10

COMPRESSOR

R

S

C

SOFTSTART

IFFITTED

SOFT STARTTHERMALOVERLOAD& FAULTLIGHTIF FITTED

HP SWITCH

LP SWITCHBREAKS ONPRESSURE

FALLING

BREAKS ONPRESSURE

RISING

C

L

C

L

SENSOR

A1A2

FAN

VOLT

FRE

EPU

MP

RUN

MA

X 3A

MPS

15

COMPRESSOR

4

2

CONTACTOR1

4

2

5

24(N)

22

DIG

ITA

L IN

PUTS

COMPRESSOR

11

FLOW SWITCH

CHILLLIMIT

SWITCH

FALLING

HC

L2

13

5

2

4

6

L1 L2 L3

11COM

14N/O

PHASEROTATION

RELAYCONTROLCIRCUITBREAKER

14

CRANK CASE HEATER

66

di3

3

com

9

di4

di1

di2

(WATER TEMP)

O/LOAD ALARM

BREAKS ONPRESSURE

OUT3

SUPPLY

N/O

N/O

N/O

N/C

3

13

O/LOAD

O/LOAD ALARM96

95N/C

9

N/O

N/C

N/C

N/C

13

9897

N/O

N/O

REMOTE ON/OFFINTERLOCK

13

18

19

23(L)

N/C

N/O

16

16

17

L3

PP22BC THREE PHASE (400V ~3N 50Hz)

MCB

OVERLOAD SETTINGS

MODEL PP22BC

CONTROL2.5A

COMPRESSOR MODEL

12APP22BC

33SD331852 ISSUE 7

U

P

NOT USED

INCREASE SET POINT

DECREASE SET POINT

ACCESS SET POINT

INDICATOR LAMP "AW" 634 HEATER CHILLER

MAINS (SWITCH) Red Electrical supply on. Also includes ON/OFF rocker switch.

FAULT Amber Internal or external fault condition

DEFROST White Defrost Mode on water heating Chill Limit Fault on water cooling

INDICATOR LAMPS "AW"1234/1834 HEATER CHILLER

In addition to the lamps already mentioned these heater chillers have the following indicator lamps:

CHILL Red Chill mode

HEAT Red Heating mode

TEMP OK Green Temp OK on

CHILL LIMIT Amber Chill Limit fault

INDICATOR LAMPS "WA634ACH"/ACL



DEFROST Amber Chill Limit Fault on water cooling

INDICATOR LAMPS "WA" CHILLER



DEFROST White Chill Limit Fault on water cooling

Adjustable 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 down symbols. After 5 seconds display will revert to actual water temperature.

Or

Adjustable dial thermostat controls & maintains water temperature at required level (red pointer). The black pointer indicates actual water temperature.

CONTROLS AND INDICATION LAMPS THERMOSTAT

The thermostat will be marked TLZ11 (WA634ACH and WA634ACL)

34 SD331852 ISSUE 7


DIGITAL THERMOSTAT IN THE PP22BC

An adjustable digital thermostat controls and maintains the water temperature and incorporates the indicator lamps.

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.

AUX

T CNOLOGiC

X31SX

U

P

DEFROST LAMP (NOT USED)

WATER HEATING (NOT USED)

FAN LAMP

ALARM LAMP - FAULT

AUX LAMP - POOL PUMPAUX

CHILLING LAMP

Increase Set Point(Also starts and stopsmanual defrost)

Decrease Set Point

Access Set Point

Set Lamp

Not Used

35SD331852 ISSUE 7

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.

Any sign of abnormal operation such as water dripping should be reported immediately to an installer or Dantherm Ltd.

If in doubt or if advice required contact the Dantherm Group UK Service Department.

Telephone (01621) 856 611 (option 4).

LAMP ACTION

UNIT DOES NOT OPERATE

MAINS RED OFF Check mains supply - external

FAULT AMBER OFF fuses - isolator

DEFROST WHITE/AMBER OFF

MAINS RED ON Check unit ON/OFF. switch on mains lamp.

FAULT AMBER OFF Lamps on mains supply on only (WA1222C only).

DEFROST WHITE/ AMBER OFF Check thermostat setting. Check internal control fuse if after 15 minutes fan does not run.

MAINS RED ON Check water and air flows are not restricted.

FAULT AMBER ON Check thermal cut out on Soft Start if fitted.

DEFROST WHITE/ AMBER OFF Check HP (and LP on WA1222C,AW634AHC), cut out switches and reset (red button above console thermostat). Check water pump etc. to restore water flow through machine.

FAN ON COMPRESSOR OFF

MAINS RED ON Unit on defrost (heating mode) check air temperature is not below 7°C.

FAULT AMBER OFF

DEFROST WHITE/ AMBER ON Unit off on chill limit (cooling mode WA1222C, AW634AHC only) Check water pump etc. to restore water flow through machine.

UNIT OPERATES INTERMITTENTLY

MAINS RED ON Check water and air flows are not restricted

FAULT AMBER ON/OFF

and that electrical supply is adequate.

DEFROST WHITE/ AMBER OFF

USER CHECK LIST FOR WA634ACH, WA634ACL, AW634AHC, WA1222AC AND WA1234BC

36 SD331852 ISSUE 7


USER CHECKLIST FOR AW1234/1834HC

LAMP COLOUR ACTIONMODE

HEAT COOL

UNIT DOES NOT OPERATE

ALL LAMPS OFF Check Mains supply - external fuses

- isolator etc. - check internal control

fuse

MAINS RED ON Check thermostat setting

TEMP O.K. ON Check compressor/fan fuses

OTHER LAMPS OFF Standby' switch is 'ON' (if fitted)

MAINS RED ON Check water and air flows are not

HEAT RED ON restricted

FAULT AMBER ON Check interlock if fitted

OTHER LAMPS OFF Check fan and compressor overloads and, if fitted, soft start reset button

FAN RUNS, COMPRESSOR OFF

MAINS RED ON

CHILL RED ON Check water flow not restricted

CHILL LIMIT AMBER ON Check thermostat not set too low

OTHER LAMPS OFF

MAINS RED ON Unit on defrost - check air flow not

HEAT RED ON restricted

DEFROST WHITE ON Ensure air temperature is above 9°C for

OTHER LAMPS OFF standard model.

UNIT OPERATES INTERMITTENTLY

MAINS RED ON

HEAT RED ON Check air and water flows not

FAULT AMBER ON/OFF restricted

OTHER LAMPS OFF

MAINS RED ON Check water flow not restricted

CHILL RED ON Check thermostat not set too low

CHILL LIMIT AMBER ON/OFF

37SD331852 ISSUE 7

USER CHECKLIST FOR PP22BC

ERRORS ASSOCIATED WITH THE DIGITAL THERMOSTAT

SYMBOL DESCRIPTION LAMP ON ACTION

E1-E1/E2-E2 Probe error Probe interrupted, short circuit or outside range

Check connection between probes and thermostat

EPr Probe error Internal EEPROM memory error

Switch off heat pump supply for five minutes then switch back on. If fault persists contact installer

SYMBOL DESCRIPTION LAMP ON LAMP FLASHING LAMP OFF

Water chilling Demand for water chilling

Water chilling demand. Compressor delay timer not timed out

No demand for water chilling/ demand satisfied

FanFan running Fan not running. Compressor delay

timer not timed out.Fan not running

AUX Pool pump Pool pump running Pool pump not running

OFF Off lampHeat pump off

If an error occurs any of the following lamps or messagses will be displayed

SYMBOL DESCRIPTION LAMP ON LAMP FLASHING LAMP OFF

Alarm - fault Illuminates with “to” - -

noF Water flow lamp Water flow off or inadequate

Water flow off or inadequate Check water pump running and any external bypass valves are closed

to Thermal overload Internal thermal overload trip

- Contact a competent electrician to reset thermal overload. If problem persists check site voltage

PrA Pressure switch alarm

HP/LP fault - Consult installer

38 SD331852 ISSUE 7


HEAT PUMPS FOR POOLS. SPECIALIST APPLICATIONS - CHILLERS, HEATERS AND HEATER CHILLERS

DATASHEETS

Model Units AW634AHC WA634ACH/ACL WA1222AC/ WA1234BC

AW1234BHC AW1834BHC

Performance

Water heating modeAmbient 10°C, water 30°C kW 3.39 n/a n/a 8.7 12.0Ambient 30°C, water 30°C kW 6.6 n/a n/a 13.0 16.0Water cooling modeAmbient 10°C, water 15°C kW 5.3 5.3 9.0 9.0 11.4Ambient 45°C, water 15°C kW 3.4 3.4 7.0 7.0 8.8

ElectricalTotal power consumed

Water heating modeAmbient 10°C, water 30°C kW 1.31 n/a n/a 2.0 2.7Ambient 30°C, water 30°C kW 1.46 n/a n/a 2.3 3.1

Water cooling mode

Ambient 10°C, water 15°C kW 1.5 1.5 1.7 1.7 2.2

Ambient 45°C, water 15°C kW 1.8 1.8 2.6 2.6 3.5

Min supply capacity (Max F L A) I ph N A 12 12 23.9 n/a n/a

Min supply capacity (Max F L A) 3 ph N A n/a n/a 10.5 17.1 9.2

Max supply fuse 1 ph N A 20 20 35 n/a n/a

Max supply fuse 3 ph N A n/a n/a 16 25 16

Water flows etc.

Water flow rate L/minute 33 33 33 33 42

Water pressure drop at rated flow metres hd 1.4 1.4 7.0 7.0 3.5

Max working pressure water bar 3.5 3.5 3.5 3.5 3.5

Water connections inches 3/4 BSPM 1.5” BSPM

Condensate drain connections inches 3/4 domestic waste 1.5” BSPM

Compressor

Nominal power consumed kW 1.4 1.4 3.4 3.4 3.2

LRA- 1phN A 42 42 100 N/A N/A

RLA- 1phN A 9 9 16.6 N/A N/A

Soft start amps 1 ph N A 23 23 34 N/A N/ALRA- 3phN A n/a n/a 48 48 48RLA.-3phN A n/a n/a 7.3 7.9 10Soft start amps 3 ph N A n/a n/a 17 25 25

Main fan

Air flow Anemometer ~ air on grille, dry evaporator m³/h 2400 2400 3200 3200 4300

Max external static pressure mmWg 0 0 0 0 4

FLA- 1ph N A 2.2 2.2 3.8 3.8 N/A

FLA- 3ph N A N/A N/A N/A N/A 1.65

Physical dimensions

Width un-packed mm 820 820 1060 1060 980

Depth un-packed mm 702 702 705 705 700

Height un packed mm 762 762 807 807 1490

Weight un-packed kg 111 111 150 157 230

Sound pressure levels at 3 metres dbA 63 63 71 71 61

For Accurate Application Sizing Consult Dantherm Ltd 1mm WG = 9.8 Pa

NOTES 1) Weight and dimensions nett 1mm WG = 9.8 Pa

2) Performance design limitations 1m hd =1.4 psi

Water heating mode: Ambient = 10°C min 50°C max. Note: WA634ACL 0ºC min 35ºC max 1L/min = 0.22 gall/min

Water = 10°C min 50°C max

Water cooling mode: Ambient = 10°C min 50°C max. Note: WA1222AC 10ºC min 40ºC max

Water = 10°C min 35°C max

3) Pool water to have correct balance, pH 7.2 - 7.8. Free Chlorine 1.0 - 2.0 ppm domestic, 3.0 - 6.0 commercial.

4) Allow 500mm clearance to service panels

5) Dantherm Ltd. reserves the right to change or modify models without prior notice

6) Global warming potential (GWP) R407c 1774, R134a 143039SD331852 ISSUE 7

Model Units PP22BC

Cooling to pool waterCooling modeAmbient 45°C, 50% RH, water 32°C COOLINGCooling of water from 32°C kW 13Electrical input kW 5.5

ElectricityElectrical supply 3 phaseTotal power consumedMin supply capacity (Max F.L.A.) 3 ph N A 13.8Recommended supply fuse 3 ph N A 20.0

Water flows etcPool water flow rate L/min 33Pool water pressure drop at rated flow) m hd 4.2Max working pressure pool water bar 3.5Pool water connections inches ¾” BSPMCondensate drain connections inches ¾" domestic waste

CompressorNominal power consumed kWh 3.8L.R.A. 3 ph N:- A 48R.L.A. 3 ph N:- A 10Soft start amps 3 ph N:- A 25

Main fanAir flow (Anemometer at air on grille. Dry evaporator) m³/h 5000F.L.A. 1 ph N:- A 1.75

General dataHermetic systemGas charge R134a kg 9.5Sound pressure level at 3m Air on dbA 54Sound pressure level at 3m Air off dbA 56Sound pressure level at 3m Side dbA 52Sound power dbA 67.8

*Physical dimensions*Width (unpacked) mm 1275*Depth (unpacked) mm 550*Height (unpacked) mm 737Weight (unpacked) kg 145

For Accurate Application Sizing Consult Dantherm Ltd 1mm WG = 9.8 PaNOTES 1) Weight and dimensions nett 1m hd =1.4 psi

2) Performance design limitations 1L/min = 0.22 gall/minWater heating mode: Ambient = 10°C min 50°C max. Note: WA634ACL 0ºC min 35ºC max

Water = 10°C min 50°C maxWater cooling mode: Ambient = 10°C min 50°C max. Note: WA1222AC 10ºC min 40ºC max

Water = 10°C min 35°C max3) Pool water to have correct balance, pH 7.2 - 7.8. Free Chlorine 1.0 - 2.0 ppm domestic, 3.0 - 6.0 commercial.4) Allow 500mm clearance to service panels5) Dantherm Ltd. reserves the right to change or modify models without prior notice6) Global warming potential (GWP) R407c 1774, R134a 1430

40 SD331852 ISSUE 7


INSTALLATION DRAWINGSW

A63

4ACH

/ACL

DIM

ENSI

ON

S m

m

ISSU

E 8

TOP

VIEW

SID

E VI

EW

REA

R VI

EW

FRO

NT

VIEW

AIR

OFF

785

705 500

156202

CON

DEN

SATE

172

213

305

FLO

W

GAU

GE

VIEW

ING

W

IND

OW

WAT

ER O

UT

WAT

ER IN

3/4

BSPM

ST

UBS

258

145

287

192

35

500

760

116

7059

670

CON

SOLE

92

MA

INS

IN

AT S

IDE

HP

RESE

T BU

TTO

N

LP C

HIL

L LI

MIT

RE

SET

BUTT

ON

AIR

ON

ARE

A R

EQU

IRED

FO

RSE

RVIC

E AC

CESS

A

REA

REQ

UIR

ED F

OR

SERV

ICE

ACCE

SS

41SD331852 ISSUE 7

AW63

4AH

C

DIM

ENSI

ON

S m

m IS

SUE

1

TOP

VIEW

SID

E VI

EW

REA

R VI

EW

FRO

NT

VIEW

AIR

OFF

785

705 500

156202CO

ND

ENSA

TE

172

213

305

FLO

W

GAU

GE

VIEW

ING

W

IND

OW

WAT

ER IN

WAT

ER O

UT

3/4

BSPM

ST

UBS

258

145

287

192

35

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46 SD331852 ISSUE 7


WINTERISING PROCEDURE

WARNING. Isolate machine before opening! As the heat pump embodies electrical and rotational 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 protection

To eliminate corrosion problems

To 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 heat 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 hose into outlet 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 pages 18 to 20) and liberally spray interior of unit, with moisture-repellant aerosol WD40 or similar; reseal enclosure.

8. If the heat pump located outside, protect from weather by covering with VENTILATED cover. Do not use plastic 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

START UP PROCEDURE AFTER 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 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 daily to ensure pool water is at correct pH and has correct chemical balance. See Section 3 Plumbing.

SD331852 issue 5

WARRANTY CONDITIONS.

for Pool water applications

pH 7.2 - 7.8

Total Alkalinity 80 - 120 ppm as CaCO3

Total Hardness 150 - 250 ppm as CaCO3

Total dissolved solids 1000 ppm

Saline Water 8000 ppm

Chlorine - free Cl Range 1.0 - 2.0 ppm Domestic

Chlorine - free Cl Range 3.0 - 6.0 ppm Commercial

Ozone 0.9 Max ppm

Bromine 2 - 5 ppm

Baquacil 25 - 50 ppm

Aquamatic Ionic Purifier Max 2 ppm Copper

for Potable water applications

TEST RECOMMENDED LEVELS

Appearance Clear to slight haze, no debris

pH 6.6-8.5

Conductivity μS/cm More than supply mains water

Chloride ppm Less than 125

Excess Chloride ppm Less than 50

Total hardness as CaCO3 ppm 50 to 200

Hardness deposition % Less than 30

M alkalinity as CaCO3 ppm 300 more than supply mains

Sodium ppm 50 less than supply mains water

Potassium ppm Less than 60

Aluminium ppm Less than 3

Iron ppm Less than 50

Copper ppm Less than 3

Phosphorus ppm Less than 80

Boron ppm More than 150

Molybdenum ppm More than 20

The following exclusions apply to the Warranty given by Dantherm 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 by Dantherm Ltd.

3. The heat pump has been worked upon or is adjusted by anyone other than a person authorised to do so by Dantherm 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 any way incorrect.

9. The fan amps and duct pressure are outside the specified limits.

10. The heat pump has not been maintained in accordance with service requirements in section 4.1.

If in doubt or if advice is required please contact the Dantherm Group UK Service Department by calling 01621 856 611 (option 4) or emailing [email protected]

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 Dantherm Service Department giving your name, address and serial number of your heat pump. A card will be sent to you for completion.

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.

48 SD331852 ISSUE 7


MACHINE RECORD LOG

In order to comply with European F-Gas regulations, it is necessary for hermetically sealed systems with more than 6kg refrigerant to be leak tested annually. The operator of the unit is responsible for seeing that the test is carried out. For machines affected see datasheet. A sample log sheet can be seen below. Dantherm Ltd. is an F-Gas registered company. Certificate number REF1011570.

General Information

Plant Name Serial Number

Location of Plant

Plant Operator1

Operator Contact2

Refrigerant Type Refrigerant Quantity installed (kg)

Plant manufacturer Dantherm Ltd Year of installation

Refrigerant Additions

Date Engineer3 Amount added kg Reason for addition

Company Name

Refrigerant Removals

Date Engineer Amount removed kg Reason for removal What done with recovered refrigerantCompany Name

Name and Address of Recycling or reclamation facility Certificate number if applicable

Leak Tests

Date Engineer Test Result Follow up action required

Company Name

Follow up Actions

Date Engineer Related to test on Actions taken

Company Name

Testing of Automatic Leak Detection System (if fitted)

Date Engineer Test Result Comments

Company Name

1Name and address of company operating plant.2Contact details of operator’s nominated person responsible for FGas compliance.3Company and technician carrying out work, with details to provide evidence of compliance.IMPORTANT The company carrying out refrigerant checking and removals, and the owner of the equipment need to keep records for FIVE YEARS.When this machine is decommissioned the refrigerant gas is to be recovered in accordance with current environmental legislation.

49SD331852 ISSUE 7

SD331852 issue 5

51SD331852 ISSUE 7

Dantherm Ltd.Unit 12, Galliford RoadMaldon CM9 4XDUnited Kingdom +44 (0)1621 [email protected]

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