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Page 1 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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
ENERGY MANAGEMENTCONTROLLER
SOFT START
CALOREXHEATPUMPTHREE PHASE
SINGLEPHASE13AMP SUPPLY 230vFUSEDTO SUITWATERPUMP
INTERLOCK
ENERGY MANAGEMENTCONTROLLER
INTERLOCK
ENERGY MANAGEMENTCONTROLLER
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
ENERGY MANAGEMENT CONTROLLER
SWITCHED FUSE ISOLATORWITHIN 2m OF HEAT PUMP ANDSIZED IN ACCORDANCE WITH DATA SHEET
22 SD331852 ISSUE 7
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
L1
L2
L3
SOFT START SOFT START
INTERLOCK
ENERGY MANAGEMENT CONTROLLER
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
ENERGY MANAGEMENT CONTROLLER
5
6
9
10
N
L
CALOREXHEAT PUMPSINGLE PHASE
CALOREXHEAT PUMPTHREE PHASE5
6
9
10
N
SINGLE PHASE13A SUPPLY 230VFUSED TO SUITWATER PUMP
SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
CALOREXHEAT PUMPSINGLE PHASE
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
SOFT START SOFT START
INTERLOCK
N L
SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
INTERLOCK
5
6
9
10
N
L
CALOREXHEAT PUMPSINGLE PHASE
CALOREXHEAT PUMPTHREE PHASE5
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
SOFT START SOFT START
INTERLOCK
N L
SWITCHED FUSE ISOLATOR WITHIN 2m OF HEAT PUMP AND SIZED IN ACCORDANCE WITH DATA SHEET
INTERLOCK
5
6
9
10
N
L
CALOREXHEAT PUMPSINGLE PHASE
CALOREXHEAT PUMPTHREE PHASE5
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
SMART CLOCKFEED TERMINALS
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
SMART CLOCKFEED TERMINALS
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
SMART CLOCKFEED 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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
MAINS (SWITCH) Red Electrical supply on. Also includes ON/OFF rocker switch.
FAULT Amber Internal or external fault condition
DEFROST Amber 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 condition
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
500
760
116
7059
670
CON
SOLE
92
MA
INS
IN
AT S
IDE
LP R
ESET
BU
TTO
NLP
CH
ILL
LIM
IT
RESE
T BU
TTO
N
ARE
A R
EQU
IRED
FO
R SE
RVIC
E AC
CESS
AIR
ON
ARE
A R
EQU
IRED
FO
R SE
RVIC
E AC
CESS
HP
RESE
T BU
TTO
N
42 SD331852 ISSUE 7
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
1025
705
AIR
ON
ARE
A R
EQU
IRED
FO
R SE
RVIC
E AC
CESS
500
TOP
VIEW
35
3/4
BSPM
ST
UBS
500
REA
R VI
EW
AW12
34
DIM
ENSI
ON
S m
m IS
SUE
2
92807
156
70
793
70
CON
SOLE
HP
RESE
TBU
TTO
N
MA
INS
INAT
SID
E
CON
DEN
SATE
202156
WAT
ER IN
172
244.
533
6.5
SID
E VI
EW
WAT
ER O
UT
FLO
W G
AUG
EVI
EWIN
GW
IND
OW
FRO
NT
VIEW
*67
0
*638
*FIX
ING
CEN
TRES
FO
R SE
CURI
NG
MAC
HIN
E
ARE
A R
EQU
IRED
FO
R SE
RVIC
E AC
CESS
251290
203
332
AIR
OFF
43SD331852 ISSUE 7
1025
705
AIR
ON
A
REA
REQ
UIR
ED F
OR
SERV
ICE
ACCE
SS
500
TOP
VIEW
35
3/4
BSPM
ST
UBS
500
REA
R VI
EW
WA
122/
1234
DIM
ENSI
ON
S m
m IS
SUE
4
92807
156
70
793
70
CON
SOLE
HP
RESE
TBU
TTO
N
MA
INS
INAT
SID
E
CON
DEN
SATE
202156
WAT
ER O
UT
172
244.
533
6.5
SID
E VI
EW
WAT
ER IN
FLO
W G
AUG
EVI
EWIN
GW
IND
OW
FRO
NT
VIEW
*670
*638
*FIX
ING
CEN
TRES
FO
R SE
CURI
NG
MAC
HIN
E
ARE
A R
EQU
IRED
FO
R SE
RVIC
E AC
CESS
256290
203
332
POO
L TE
MP
MA
INS
DEF
ROST
FAU
LT
CHIL
L LI
MIT
RESE
TBU
TTO
N
44 SD331852 ISSUE 7
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
AW 1
834B
HC
650
1435
SERV
ICE
PAN
EL
AIR
IN
LET728
SERV
ICE
PAN
EL
STA
NDA
RD U
NIT
MAC
HIN
ETO
P VI
EW
SERV
ICE
PAN
EL
980
TOP
OU
TLET
O
PTIO
NTO
P VI
EW
SERVICE PANEL
SERV
ICE
PAN
EL
AIR
O
UTL
ET
40 369
279
421
MA
INS
INLE
T100
DRA
IN
WAT
ER O
UT
WAT
ER IN
50
200
146406
90
700
125
TOP
OU
TLET
ON
LY
40
680
980
369 670.50
421
279
AIR
O
UTL
ET
SERV
ICE
PAN
EL
45SD331852 ISSUE 7
WA
TER
IN
165
311
124
4
78
780
92
634
Ø469 320
MA
INS
IN
CON
DEN
SATE
DRA
INW
ATE
RO
UT
464
58
AIR
INLE
T
366
737
550
70
389
490
AIR
OUTL
ET
PP22
BC
WA
TER
IN/O
UT
¾”
BSP
MC
ON
DEN
SATE
¾”
DO
MES
TIC
WA
STE
146 22
6
46
64
844
AIR
OFF
AIR
ON
470
127
5
46 SD331852 ISSUE 7
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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.
Page 47 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
OWNER INSTALLATION MANUAL 634ACH/ACL/AHC /1222AC/1234BC/BHC /1834BHC /PP22BC
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
Page 50 SD331852 issue 5
51SD331852 ISSUE 7
Dantherm Ltd.Unit 12, Galliford RoadMaldon CM9 4XDUnited Kingdom +44 (0)1621 [email protected]
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