Technical guide Pro-Pac 45 70 90 1 H HY Air/water heat pumps
Comprehensive support Comprehensive engineering support is provided by our experienced and well qualified team. Calorex units are designed, tested and manufactured in the UK, and supported by our comprehensive customer service organisation Calorex reserves the right to modify these specifications at any time. For accurate sizing please contact Calorex.
Contents Calorex model system identification 4 Air/water heat pumps 5 The heat pump cycle 6 Installation 7 1. Siting/positioning 7 2. Air flow 8 3. Plumbing 9 4. Typical installation diagram 9 Electrical 10 Specification of Calorex Pro-Pac 45 70 90 1 BH BHY 12 What is a WRAS approval? 13 Technical data Heat pumps, specialist applications heaters H models 14 Heat pumps, specialist applications heaters HY models 15 Performance graphs 16 Installation drawings 18 Winterising procedure 23 Start up procedure after winterisation 23
Calorex model system identification PP B H Y Heat pump with reverse cycle defrost, operation down to -15 C Heat pump down to 7 C ambient H=water flow up to 70 C M= water flow up to C Electrical supply 0V ~ 3N ~ Hz Model size Product "Pro-Pac" 4
Air/water heat pumps Models covered in this manual The machines detailed in this manual are specifically designed for heating potable water. The heat pumps use R134a as a refrigerant and operate in air temperatures from 7 C to 55 C providing heated water to 68 C. As an option, machines are available with reverse cycle defrost which allows the heat pumps to operate in temperatures down to -15 C. All units are supplied as a package and 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 six minute cycle time delay is incorporated. The units are weatherproof and can be installed either outside or within a ventilated plant-room (as detailed in section 1 of this manual). A 12 hour delay timer is incorporated into machines, which after a power interruption or from initial start up will prevent the machine compressor(s) from starting for a 12 hour period. This feature is to protect the compressors from liquid pumping which can cause internal compressor damage. Health and Safety This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance Important Note Calorex heat pumps Limited is an ISO9001:2000 certified company. All Calorex heat pumps are CE approved. Heat exchangers within the heat pumps are compliant to WRAS (British Water Regulation Authority Standards) and listed under UL standards. 5
The heat pump cycle The Calorex heat pump 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. The COMPRESSOR, where it is compressed, which has the effect of upgrading the gas to a much higher temperature. The electrical energy that is used to drive the compressor is also absorbed by the refrigerant gas. The hot gas now enters: The EVAPORATOR collects the heat from the air. This is either atmospheric air, which has been heated by the sun, or internal air, which has been heated by heat lost from another process. In Calorex heat pumps, high volumes of air are drawn into the unit by the fan and passed across 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 vaporises to a gas. This pre-heated refrigerant gas then passes to: THE HEAT PUMP CYCLE HOT GAS COMPRESSOR COOL GAS WATER OUT AMBIENT AIR HEAT EXCHANGER EVAPORATOR WATER IN CONDENSED REFRIGERANT HIGH PRESSURE SIDE EXPANSION VALVE COLD LIQUID REFRIGERANT LOW PRESSURE SIDE The HEAT EXCHANGER (or CONDENSER), where it is surrounded by the water to be heated in adjacent tubes. The refrigerant vapour, at a higher temperature, gives up its heat to the water which is returned to a storage tank. As the refrigerant cools it returns back to its liquid state, i.e. it condenses, but remains under high pressure from the compressor. The pressure is released by passing the liquid refrigerant through: 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. Thus a heat pump absorbing 1 of electricity, collecting 4 of energy from the air, and delivering 5 of heat to the 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. 6
Installation 1. Siting/positioning a) Ensure heat pump on site is as ordered, i.e. model, electrical supply and factory fitted options. b) Inspect unit for damage, in particular inspect the evaporator (finned side) to ensure that it is undamaged. (Minor indentations in the fins do not affect performance). If severely damaged, endorse delivery note in presence of the driver and send a recorded delivery letter to transport company giving details. c) Protect unit if installation is delayed. d) Provide a firm level base capable of supporting operational weight of unit; spread load on timber floor. e) Ensure water cannot collect under unit recommend units are installed on plinths 100mm above finished floor level and to also aid condensate drainage. f) Allow adequate clearance to service panels on unit; recommend 0mm minimum (see installation drawings). g) 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. ensure that the inlet and outlet grilles face away from occupied property. h) Ensure loose debris such as leaves, grass cuttings, etc will not block air inlet grilles. i) Consider protection from extreme weather conditions if installed externally, i.e. lean-to-cover or building. 7
Installation cont. 2. Air flow Due consideration must be given to air flow, i.e. do not obstruct inlet or outlet and ensure discharge air cannot recirculate to inlet (See figures 1 and 2). Fig. 1 Fig. 2 Typical outside installation Typical inside or plant-room installation (not recommended for long duct runs) Grill or apertures MUST comply with figures (see table 1) 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 that air can pass through a grille or louvres. BUT discharge from each unit must be kept separate and must not be incorporated into one common duct system. 2. If the unit is installed within a plant-room, connected to ductwork, Calorex can supply the unit with an uprated fan motor. Please consult Calorex before ordering a unit. 1. 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. Table 1 Model Minimum Free Area m² Inlet Discharge Pro-Pac 0.59 0.25 Pro-Pac 45 0.98 0.42 Pro-Pac 70 1.19 0.52 Pro-Pac 90 1.731 0.84 Pro-Pac 1 2.138 1.04 8
Installation cont. 3. Plumbing a) Calorex Pro-Pac range heat pumps have water inlet/outlet connections as follows: Table 2 Model Pro-Pac Pro-Pac 45 Pro-Pac 70 Pro-Pac 90 Pro-Pac 1 Water in/out connection size 1½" BSPM 1½" BSPM 1½" BSPM 1½" BSPM 2" BSPM b) If an existing heater is retained, the Calorex heat pump should be connected in parallel with it. c) Suitable breakable couplings, isolating valves and flow meters should be installed local to the heat pump. d) Drain valve or plug should be fitted to lower pipe to facilitate drain down in winter period. e) The condensate drain at the base of the unit collects condensation from the evaporator fins. This should be run away to waste via 1½" domestic waste piping. It is therefore necessary to ensure that the Calorex heat pump is placed on a level plinth so that the condensate can run away with adequate fall to waste i.e. ½" per foot minimum. A U trap should also be incorporated into the pipework f) When the pipework installation is complete the system should be run and tested for leaks. If everything is then working normally the water circulating system is ready to use. g) 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). h) All pipework must be adequately supported with allowance for expansion/contraction especially with plastic pipework. i) It is recommended that when installing water system the last connections to be made in the system should be breakable couplings to avoid any stresses on to the unit connections. 4 Typical installation diagram AIR VENT CALOREX HEAT PUMP STORAGE TANK CLOSED TYPE HOT WATER SUPPLY HOT WATER RETURN PUMP DRAIN VALVE MAKE UP COLD WATER Important note Maximum pressure of water in heat pump circuit should not exceed 10 bar. 9
Electrical Electrical (machine wiring and supply) All electrical work to be carried out in accordance with I.E.E. standards, latest issue, or local codes of practice as applicable. Fig. 4 The machine should be installed in accordance with EMC2004/108/EC. Location of mains input and external interlock terminals Protected supply To incorporate fuses or motor type circuit breakers (Type GU, FAZC) 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 and an earth leakage trip installed. Inconsistent electrical supply The following limits of operation must not be exceeded if Calorex machines are to be guaranteed either in performance or warranty terms. Voltage Minimum Maximum Three-phase machines (UK) 3V 4V Three phase machines (Hz) 187V 253V Three phase machines + N (Hz) 3V 4V Cycle frequency (Hz) 47.5Hz 52.5Hz Cycle frequency (Hz) 57.0HZ 63.0Hz Interlock These units have an interlock circuit incorporated into the control circuit, brought out to two terminals. These terminals are shorted out for factory testing. On site the shorting loop is to be removed and two wires taken to a pair of volt free contacts in the water pump starter/ contactor/relay or flow switch so that the heat pump cannot operate unless the water pump is operating. (See figures 5 and 6). N.B. This voltage must be available at the heat pump whilst running. The voltage must not drop below the above figures when starting the machine. *Note the isolator must have a minimum of 3mm air gap when turned off. Note All machines are fitted with a phase protection relay 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 3N~ Hz). 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. The under voltage protection feature is not present in phase protection relays fitted in 220V 3~ Hz machines. 10
Electrical Electrical (machine wiring and supply) Fig. 5 Recommended electrical installation for Calorex heat pump with single phase water pump Fig. 6 Recommended electrical installation for Calorex heat pump with three phase water pump 11
Specifications Calorex Pro-Pac 45 70 90 1 BH BHY Automatic hot water heat pumps The heat pump shall be a packaged design with all necessary refrigeration / control functions fitted within the unit as a hermetically sealed system. The cabinet shall be weatherproof to IP24. The machine chassis shall be constructed of 14 gauge hot dipped galvanised steel and all panels exposed to ambient conditions shall be 20 gauge steel, phosphate protected and plastisol coated to RAL7038 Agate Grey (fixed panels) or RAL9002 Grey White (service panels) semi-gloss. The air-cooled evaporator shall be constructed from rifled copper tube, aluminium fins and end-plates, all phenolically coated to prevent corrosion from airborne contaminants and salt. The water-cooled condensers shall be of tube in shell type constructed from copper (tube) and steel (shell). WRAS approved condensers with 90/10 marine grade cupro-nickel (tube) shall be available as an option. The condensers shall be of seamless construction and the maximum working water pressure shall be 10 bar. BH models shall be provided with a defrost limit thermostat to provide automatic evaporator defrosting. BHY models shall be provided with fully automatic reverse cycle defrost mechanism to give operation down to -15ºC air temperature. All units are designed, assembled and individually tested in the UK under ISO 9001:2008 accreditation. All units are designed, assembled and individually tested in the UK under ISO 9001:2008 accreditation. Optional features The following optional features shall be available on request: WRAS approved cupro-nickel condensers Compressor soft-start High pressure fan RS485 compatible thermostat The Pro-Pac shall utilise a 0mm, 880rpm vertical discharge axial owlet fan. The Pro-Pac 45 and 90 shall utilise a 710mm, 690rpm, vertical discharge, axial fan (two for the Pro- Pac 90). The Pro-Pac 70 and 1 shall use an 800mm, 700rpm vertical discharge, axial fan (two for the Pro-Pac 1). Fans shall be ERP 2015 compliant FE2 owlet rated to IP 54. The compressor shall be a fully compliant hermetic, high back pressure, scroll unit with built in overload protection. The Pro- Pac 90 and 1 shall utilise twin scroll compressors. The refrigeration circuit shall utilise R134a refrigerant and contain a sight glass, drier and expansion valve control, reversing valve and pump down valve. Suction accumulators shall be sized for 100% of the unit refrigerant capacity. The refrigeration circuit shall be protected by HP, LP, thermal overloads, MCBs, phase rotation protection and delay timers. The refrigeration circuit shall be capable of operating in air temperatures ranging from 10 C to C and water temperatures up to 68 C. Heating operation shall be controlled by an integral digital water thermostat with a 4 C differential. 12
What is a WRAS approval? Any water fitting which, when installed, will carry or receive water from the public mains water supply in the UK, must comply with the Water Supply (Water Fittings) Regulations or Scottish Byelaws. These require that a water fitting should not cause waste, misuse, undue consumption or contamination of the water supply and must be of an appropriate quality and standard. Operational envelope 80 70 Water off temperature ( C) 20 - -20-10 0 10 20 Air temperature ( C) 13
Technical data Heat pumps, specialist applications heaters H models Pro-Pac BH Pro-Pac 45BH Pro-Pac 70BH Pro-Pac 90BH Pro-Pac 1BH Units Duty - output to water @ C/55 C Air on @ C, 90%RH Electrical input Air on @ 20 C, %RH Electrical input Air on @ 10 C, 85%RH Electrical input 24.5/21.6 5.1/8.0 22.0/19.9 4.4/7.0 18.9/16.8 4.2/6.5.6/27.0 6.5/10.2 28.0/24.0 5.8/8.9 23.5/20.1 5.5/8.3 46.2/.7 9.1/14.8 42.0/37.4 8.1/12.8 35.5/31.7 7.6/11.9 61.2/53.9 13.0/20.5 56.0/49.5 11.5/17.7 47.1/42.0 10.9/16.6 92.3/81.4 18.4/.0 84.0/74.8 16.2/25.5 71.0/63.3 15.2/23.9 Electrical data Electrical supply ( Hz, 3PH) Minimum supply capacity (3PH) Recommended supply fuse (3PH) Max starting curent STD (LRA) Max starting current soft start (LRA) V amps amps amps amps 0 20 80 31 0 22 102 34 0 35 174 0 44 102 34 70 100 174 Air data Nominal air flow Fan external resistance Fan external resistance (F) m³/h Pa Pa 50 0 n/a 10000 0 100 0 20000 0 28000 0 Water Data Water flow ±10% Pressure drop (water) Water connections Condensate water connections l/min m hd inch inch 66 2.1 66 4.2 1 3.9 1 4.2 2 5.3 2 BSPM General data Gas charge (R134a) BH Compressor type Fan type Sound pressure level @ 3m AIR ON Sound level @ 3m AIR OFF Sound level @ 3m SIDE kg db(a) db(a) db(a) 5.5 1 x SCROLL 1 x AXIAL 64 61 13 1 x SCROLL 1 x AXIAL 66 61 64 22 1 x SCROLL 1 x AXIAL 70 64 13 x 2 2 x SCROLL 2 x AXIAL 64 61 28 x 2 2 x SCROLL 2 x AXIAL 70 67 Dimensions Width (unpacked) Depth (unpacked) Height (unpacked) Weight (unpacked) mm mm mm kg 1555 790 1080 247 16 10 13 329 1810 1190 1310 4 20 1190 13 632 2210 10 13 858 Width (export, packed) Depth (export packed) Height (export, packed) Weight (export, packed) mm mm mm kg 1775 900 12 268 1845 1170 10 346 2020 10 1480 571 22 1310 1520 747 2470 1770 15 1078 NOTES: 1) Weight and dimensions nett. 2) Allow 0mm clearance to service panels. 3) Minimum air temperature standard models (BH) 7 C. 4) Calorex reserve the right to change or modify models without prior notice. 5) Global warming potential (GWP) R134a 10. 6) Performance data below 10 C is derated to account for defrost periods. 1 mm WG = 9.8 Pa 1 m hd = 1.4 psi 1 l/min = 0.22 gall/min 14
Technical data cont. Heat pumps, specialist applications heaters HY models Pro-Pac BHY Pro-Pac 45BHY Pro-Pac 70BHY Pro-Pac 90BHY Pro-Pac 1BHY Units Duty output to water @ C/55 C Air on @ C, 90%RH Electrical input Air on @ 20 C, %RH Electrical input Air on @ 10 C, 85%RH* Electrical input Air on @ 0 C, 90%RH Electrical input Air on @ -3 C, 99%RH Electrical input 24.5/21.6 5.1/8.0 22.0/19.9 4.4/7.0 18.9/16.8 4.2/6.5 13.2/11.6 3.6/6.0 12.3/10.47 4.04/6.6.6/27.0 6.5/10.2 28.0/24.0 5.8/8.9 23.5/20.1 5.5/8.3 16.4/14.4 5.0/7.6 15.34/13.05 5.25/8.44 46.2/.7 9.1/14.8 42.0/37.4 8.1/12.8 35.5/31.7 7.6/11.9 24.7/21.7 6.9/10.9 23.14/19.69 7.31/12.13 61.2/53.9 13.0/20.5 56.0/49.5 11.5/17.7 47.1/42.0 10.9/16.6 32.8/28.8 9.9/15.2.67/26.1 10.5/16.88 92.3/81.4 18.4/.0 84.0/74.8 16.2/25.5 71.0/63.3 15.2/23.9 49.5/43.4 13.8/21.8 46.28/39.38 14.62/24.25 Electrical data Electrical supply ( Hz, 3PH) Minimum supply capacity (3PH) Recommended supply fuse (3PH) Max starting current STD (LRA) Max starting current soft start (LRA) V amps amps amps amps 0 20 80 31 0 22 102 34 0 35 174 0 44 102 34 0 70 100 174 Air data Nominal air flow Fan external resistance Fan external resistance (F) m³/h Pa Pa 50 0 n/a 10000 0 100 0 20000 0 28000 0 Water Data Water flow ±10% Pressure drop (water) Water connections Condensate water connections (optional factory fit) l/min m hd inch inch 66 2.1 66 4.2 1 3.9 1 4.2 2 5.3 2 BSPM General data Gas charge (R134a) BH Compressor type Fan type Sound pressure level @ 3m AIR ON Sound level @ 3m AIR OFF Sound level @ 3m SIDE kg db(a) db(a) db(a) 17 1 x SCROLL 1 x AXIAL 64 61 16 1 x SCROLL 1 x AXIAL 66 61 64 1 x SCROLL 1 x AXIAL 70 64 16 x 2 2 x SCROLL 2 x AXIAL 64 61 x 2 2 x SCROLL 2 x AXIAL 70 67 Dimensions Width (unpacked) Depth (unpacked) Height (unpacked) Weight (unpacked) mm mm mm kg 1555 790 1080 TBA 16 10 13 TBA 1810 1190 1310 TBA 20 1190 13 TBA 2210 10 13 908 Width (export, packed) Depth (export packed) Height (export, packed) Weight (export, packed) mm mm mm kg 1775 900 12 TBA 1845 1170 10 TBA 2020 10 1480 TBA 22 1310 1520 TBA 2470 1770 15 1128 NOTES: 1) Weight and dimensions nett. 2) Allow 0mm clearance to service panels. 3) Minimum air temperature standard models (BH) 7 C. Reverse cycle defrost models (BHY) -15 C. 4) Calorex reserve the right to change or modify models without prior notice. 5) Global warming potential (GWP) R134a 10. 6) Performance data below 10 C is derated to account for defrost periods. * use selection overleaf 1 mm WG = 9.8 Pa 1 m hd = 1.4 psi 1 l/min = 0.22 gall/min 15
Performance graphs.00 PPBHY Water temperature ( C) 25.00 35 45 55 Heat output () 20.00 Heat output to water () 15.00 10.00 5.00 Water temperature ( C) 55 45 35 Power input () 0.00-5 0 5 10 15 20 25 35 Air temperature ( C) PP45BHY 35.00.00 Water temperature ( C) 35 45 55 Heat output () 25.00 Heat output to water () 20.00 15.00 10.00 5.00 Water temperature ( C) 55 45 35 Power input () 0.00-5 0 5 10 15 20 25 35 Air temperature ( C) 16
.00 PP70BHY Heat output to water ().00.00.00 20.00 10.00 Water temperature ( C) 35 45 55 Water temperature ( C) 55 45 35 Heat output () Power input () 0.00-5 0 5 10 15 20 25 35 Air temperature ( C) PP90BHY 70.00.00 Water temperature ( C) 35 45 55 Heat output ().00 Heat output to water ().00.00 20.00 10.00 Water temperature ( C) 55 45 35 Power input () 0.00-5 0 5 10 15 20 25 35 Air temperature ( C) 120.00 PP1BHY Heat output to water () 100.00 80.00.00.00 20.00 Water temperature ( C) 35 45 55 Water temperature ( C) 55 45 35 Heat output () Power input () 0.00-5 0 5 10 15 20 25 35 Air temperature ( C) 17
Installation drawings Propac Pro-Pac Dimensions in in mm Allow 0mm for access to to service panels Allow 1000mm clearance in in front of of evaporator Allow 00mm clearance above machine Water connections 1½" BSPM Condensate 1½" 18
Installation drawings cont. Pro-Pac 45 Dimensions in mm Allow 0mm for access to service panels Allow 1000mm clearance in front of evaporator Allow 00mm clearance above machine Water connections 1½" BSPM Condensate 1½" 19
Installation drawings cont. Pro-Pac 70 Dimensions in mm Allow 0mm for access to service panels Allow 1000mm clearance in front of evaporator Allow 00mm clearance above machine Water connections 1½" BSPM Condensate 1½" 20
Installation drawings cont. Pro-Pac 90 Dimensions in mm Allow 0mm for access to service panels Allow 1000mm clearance in front of evaporator Allow 00mm clearance above machine Water connections 1½" BSPM Condensate 1½" 21
Installation drawings cont. Pro-Pac 1 Dimensions in mm Allow 0mm for access to service panels Allow 1000mm clearance in front of evaporator Allow 00mm clearance above machine Water connections 2" BSPM Condensate 1½" 22
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 Objective 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. c note that on units fitted with more than one condenser, there are also multiple drain down points. Each condenser water circuit will need to be drained when the winterisation process is carried out. 5. Flush through water circuit in heat pump by using CLEAN TAP WATER via hose into outlet connection run for 10 minutes minimum; use spray nozzle if available. 6. Allow to drain, after draining fit plastic bags secured by elastic bands over water connections. 7. Uncover electrical enclosure (see page 10) and liberally spray interior of unit with moisture-repellant aerosol WD or similar; reseal enclosure. 8. If heat pump located outside, protect from weather by covering with VENTILATED cover. Do not use plastic sheet as condensation can occur within unit. 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 water is at correct ph (if applicable) and has correct chemical balance. See warranty conditions. N.B. If this procedure is not adopted and frost or corrosion damage results then the warranty will become invalid. 23
Technical support and service Comprehensive technical support is provided by our experienced and well qualified team Calorex Heat Pumps Ltd The Causeway Maldon Essex CM9 4XD United Kingdom t. +44 (0)1621 856611 e. sales@calorex.com w. calorex.com Pro-Pac technical guide v1.1 24