Calorex aa300 Technical Manual
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Calorex aa300 Technical Manual

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TECHNICAL MANUAL
AA300AVH(F) HEAT PUMP
(SD611260 issue 3)
17/03/11
Health and Safety Warning
As the heat pump includes electrical components it is required that only trained and competent
persons should remove panels giving internal access to the unit.
Page 28
Page 1

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Summary of Contents for Calorex aa300

  • Page 1 TECHNICAL MANUAL AA300AVH(F) HEAT PUMP (SD611260 issue 3) 17/03/11 Health and Safety Warning As the heat pump includes electrical components it is required that only trained and competent persons should remove panels giving internal access to the unit. Page 28 Page 1...

  • Page 3: Table Of Contents

    Contents 1.0 HOW THE CALOREX ‘AA300’ WORKS.......................3 1.1 OPERATION ............................5 1.2 HUMIDITY AND AIR TEMPERATURE CONTROLS ................6 1.3 TIME CLOCK SETTINGS ........................7 2.0 INSTALLATION ..............................8 2.1 PLUMBING ............................11 2.2 WATER CONNECTIONS ........................12 2.3 ELECTRICAL INSTALLATION ......................13 2.4 COMMISSIONING CHECKLIST ......................

  • Page 5: How The Calorex 'Aa300' Works

    (optional) for a swimming pool hall. The Calorex ‘AA300 is designed to be connected into an air distribution system that will provide a uniform flow of air through out the hall. An optional fresh air entry point is available.
  • Page 6 2. Variable speed centrifugal fan. When the AA300 is delivered the fan is set to run at two speeds: medium speed when the machine senses a demand for dehumidification (and air heating) and low speed for when there are no demands.

  • Page 7: Operation

    2.3. The isolator is then energised. The MAINS light on the side of the heat pump will illuminate indicating mains ON. If the AA300 is fitted with an LPHW the time clock will start to run. The time clock has a battery reserve fitted which when charged will run for 100 hours so that isolating the machine for short periods will not affect the time clock settings.

  • Page 8: Humidity And Air Temperature Controls

    1.2. HUMIDITY & AIR TEMPERATURE AND CONTROLS HUMIDITY DIGITAL CONTROLLERS To Program the Set Point. Press down P, SP1 and Set Point value will be displayed alternately. Press the 1 2 3 1 2 3 key to change the value of SP1. Once the desired value is displayed press P to memorise the 1 2 3 1 2 3 1 2 3...

  • Page 9: Time Clock Settings

    The time clock is a quartz 24 hour clock with 100 hours battery reserve used to control the automatic operation on the AA300 unit per 24 hour time cycles. The time clock setting determines the OCCUPIED/UNOCCUPIED periods and is set to match the operators requirements regarding opening and closing times for the pool and possible times where the pool is covered.

  • Page 10: Installation

    UNPACKING DUCT On delivery the console for the AA300 will be inside the machine. To retrieve the console unfasten the removable panel on the heat pump. The console should be in the position shown, protected by bubblewrap. Note: the removable panel is on the opposite face of the heat pump to the water connections.
  • Page 11 SITING, MACHINE LOCATION SERVICE ACCESS TO ELECTRIC BOX FILTER ACCESS PANEL NOTE: If the optional flexible ducting flange is not used, due consideration to resonant noise through the duct work must be made. If little or no ducting is fitted it is possible to lower the top speed of the fan. With the machine isolated move the white/black wire connected to terminal 18 to terminal 17 in the electric box.
  • Page 12 INSTALLATION WITH OPTIONAL FEATURES SERVICE ACCESS TO ELECTRIC BOX OPTIONAL FLEXIBLE DUCTING FLANGE FILTER ACCESS PANEL OPTIONAL FLEXIBLE DUCTING FLANGE Ensure duct work pressure drop does not exceed resistance given in data sheet. If little or no ducting is fitted it is possible to lower the top speed of the fan. With the machine isolated move the white/black wire connected to terminal 18 to terminal 17 in the electric box.

  • Page 13: Plumbing

    2.1 PLUMBING CONDENSATE DRAIN The condensate driptray in the ‘AA300VHF’ unit collects the water removed by the dehumidification process. It is therefore necessary to ensure that the’AA300VHF’ unit is placed on a level plinth so that the condensate can run away and not overflow the edges of the driptray inside the machine. The ‘AA300VHF’...

  • Page 14: Water Connections

    2.2 WATER CONNECTIONS (also see SECTION 2.1) AA300 DRAIN COPPER STUB CUSTOMERS "TUN DISH" AA300 UNIT DRAIN TO WASTE U TRAP BOILER WATER SCHEMATIC INTERNAL 3 WAY MOTORISED VALVE (DIVERTING) CONTROLLED BY VARIHEAT . AW300AVHF CABINET FLOW BALANCE BOILER VALVE...

  • Page 15: Electrical Installation

    The machine should be installed in accordance with EMC2004/108/EC. PROTECTED SUPPLY Whilst not mandatory, Calorex recommend that an R.C.C.B. is always fitted or that the supply is to local electricity authority recommendations, and that all ducting is bonded in accordance with these regulations.
  • Page 16 OPTIONS IF THIS FACILITY IS USED TIME CLOCK (IF FITTED) MUST BE SET TO UNOCCUPIED REMOTE OCC/UNOCCUPIED SEE NOTE 1 SECTION 2.3.2 AA300 WITH LPHW ONLY BOILER DEMAND LOAD SEE NOTE 3 SECTION 2.3.2 OPTIONAL REMOTE SENSOR BOX TERMINALS IN...
  • Page 17 These are voltage free contacts (from terminals 6 & 7) rated at 3(1) Amp at 230 Volts. If the low pressure hot water supply to the unit is to be governed by the Calorex unit then these contacts should be utilised to bring water to the unit via the boiler, motorised valve, boiler pump etc. Remember the maximum inductive load is one amp.

  • Page 18: Commissioning Checklist

    Has the fan speed been set to match the sensors fitted. j) Any sign of abnormal operation such as water dripping should be reported immediately to an installer or Calorex. k) Has fan run amps been recorded against datasheet.
  • Page 19 BLANK PAGE Page 17...

  • Page 20: Circuit Diagrams

    2.5 CIRCUIT DIAGRAMS ELECTRICAL CONTROL & POWER CIRCUIT ‘AA’ VERSION LINK FOR NORMAL RUN (BREAK TO STOP M/C) ON/OFF REMOTE ON/OFF SWITCH F1 2.5A CONTROL MCB F2 1A CONTROL POWER LAMP MAINS LAMP SEE FAN POWER CIRCUIT BELOW SEE FAN POWER CIRCUIT BELOW NOTES 'R' LETTER RELAY'S ARE 12v 'RE' LETTER RELAY'S ARE 230v...
  • Page 21 ELEC CONTROL & POWER CIRCUIT ‘AA’ VERSION CONTINUED LINK IF REMOTE CONTROL FITTED 0-10VDC SUPPLY 12V GRND 0V AIR SENSOR R/H TERMINALS VARY WITH MANUFACTURER DEHUM LAMP OUT2 OUT1 HUMIDITY STAT' RISING RISING HP SWITCH LP SWITCH SOFT START IF FITTED OR LINK DEFROST STAT...
  • Page 22 ELECTRICAL CONTROL & POWER CIRCUIT ‘AA+LPHW’ VERSION LINK FOR NORMAL RUN (BREAK TO STOP M/C) ON/OFF REMOTE ON/OFF SWITCH F1 2.5A CONTROL MCB F2 1A PROBE TIME CLOCK NORTRONICS <PALADIN> D8 P3 <3> CONTROL POWER LAMP AIR STAT' <2> <1> OUT2 OUT1 OUT3...
  • Page 23 ELEC CONTROL & POWER CIRCUIT ‘AA+LPHW’ CONTINUED LINK IF REMOTE CONTROL FITTED 0-10VDC SUPPLY 12V GRND 0V AIR SENSOR R/H TERMINALS VARY WITH MANUFACTURER DEHUM LAMP OUT2 OUT1 HUMIDITY STAT' RISING RISING SWITCH SWITCH SOFT START IF FITTED OR LINK DEFROST STAT TIMER...

  • Page 24: Regular Planned Maintenance

    2.6 REGULAR PLANNED MAINTENANCE Operations to be carried out during a regular planned maintenance visit are as follows: Replace all belts where fitted. Clean or replace filters as applicable. (This action may be required more frequently than regular servicing. Check operation and condition of all fans and compressors. Check capacitor tolerances (where fitted).

  • Page 25: Controls

    STANDARD CONTROL PANEL MODULE (12V) HUMIDITY DISPLAY POWER ON/OFF SWITCH AND 6. DEHUMIDIFICATION LAMP POWER LAMP 4. FAULT LAMP 5. DEFROST LAMP CONSOLE AA300 Power on Power off Power symbol Power lamp Indicates presence of 12V electricity supply to the console. Fault lamp Check that the pool hall air and water flow through the unit are within specified limits.
  • Page 26 ºC AIR TEMPERATURE DISPLAY AND 7. AIR HEATING LAMP = AUTO TIME CLOCK CONSOLE AA300 WHEN FITTED WITH LPHW 8. POOL HALL SYMBOL AUTO SYMBOL 9. MANUAL SYMBOL 10. OCCUPIED SYMBOL (no pool cover) 11. UNOCCUPIED SYMBOL (pool covered) ºC...
  • Page 27 OPTIONAL REMOTE SENSOR BOX Isolate the Low Speed fan circuit breaker when the remote sensor box is fitted. (Marked FAN L). Position in electric box shown below. This stops the fan when there is no demand for humidity or air temperature control. Disconnect wires to sensors at electric box terminals &...

  • Page 28: Data Sheet

    PHYSICAL HEIGHT (Unpacked) DIMENSIONS WEIGHT approx' (AA un-packed no options):- NOISE LEVEL @ 1m For accurate application sizing consult CALOREX Heat Pumps Ltd Boiler not required for AA versions without LPHW. 1 mm WG = 9.8pa 1 mhd = 1.4psi...

  • Page 29: Dimension Drawing

    5.0 DIMENSION DRAWING AA300 Page 27...

  • Page 30: Warranty Conditions

    6.0 WARRANTY CONDITIONS The following exclusions apply to the Warranty given by Calorex Heat Pumps Ltd. No claims will be accepted if :- 1.The heat pump is incorrectly sized for the application. 2.The heat pump is installed in any way that is not in accordance with the current procedures as defined by Calorex Heat Pumps Ltd.

  • Page 31: Contacting Calorex

    7.0 CONTACTING CALOREX Email service@calorex.com Web Site http://www.calorex.com +44 (0)1621 857171 +44 (0)1621 856611 Please give MODEL NUMBER and SERIAL NUMBER of your heat pump when making technical or service enquiries. This will assist in correct diagnosis and ensure service can be provided with the minimum delay.

  • Page 32: Refrigeration Diagrams

    8.0 REFRIGERATION DIAGRAMS Page 30...

  • Page 33: Spare Parts Lists

    9.0 SPARE PARTS LISTS CONSOLE ASSEMBLY AA300AVH(F) SA607701 ITEM PART No. DESCRIPTION QUAN UNITS SD607501 CONSOLE BOX 1.00 SD607651 CONSOLE PANEL 1.00 SD432451 THERMOSTAT HUMIDITY 1.00 SD318650 SWITCH ROCKER 2 POLE 1.00 SD470350 PILOT LIGHT RED 12V AC 2.00 SD470352 PILOT LIGHT YELLOW 12V AC 2.00 A607901...
  • Page 34 CONSOLE ASSY AA300AVHF WITH LPHW FITTED ºC AUTO SA607702 ITEM PART No. DESCRIPTION QUAN UNITS SD607501 CONSOLE BOX 1.00 SD607651 CONSOLE PANEL 1.00 SD432451 THERMOSTAT HUMIDITY 1.00 SD432555 AIR STAT (4 STAGE) 1.00 SD151554 TIME CLOCK 24Hr 12V AC 1.00 SD318650 SWITCH ROCKER 2 POLE 1.00...

  • Page 35: Thermostat Control

    THERMOSTAT CONTROL PARAMETER SETTING INSTRUCTIONS AA300AVH(F) HUMIDITY SETTING INSTRUCTIONS (THERMOSTATS MARKED TLK38) NOTE : These parameter settings are programmed by the supplier to the figures shown below and should not need altering. 1. To Program the Set Point. Press down P: SP (Set Point) and current set point value will be displayed alternately. 1 2 3 1 2 3 1 2 3...
  • Page 36 THERMOSTAT CONTROL PARAMETER SETTING INSTRUCTIONS AA300AVH(F) AIR SETTING INSTRUCTIONS (THERMOSTATS MARKED TLK31) NOTE : These parameter settings are programmed by the supplier to the figures shown below and should not need altering. 1. To Program the Set Point. Press down P: SP (Set Point) and current set point value will be displayed alternately. 1 2 3 1 2 3 Press the...
  • Page 37 ERROR CODES AA300AVHF WITH LPHW DISPLAY ERROR ACTION VERIFY CORRECT CONNECTION BETWEEN PROBE LIMIT UNDER/OVER uuuu OR oooo PROBE AND STAT, THEN VERIFY CORRECT RANGE FUNCTIONING OF PROBE. CHECK WORKING OF PROBE AND ACTUATOR LOOP CONTROL INTERRUPTED AND SWAP INSTRUMENT TO rEG CONTROL POSSIBLE ANOMALY OF ErEP PUSH "P"...
  • Page 38 BLANK PAGE Page 36...
  • Page 39 AA300AVH(F) ELECTRIC BOX ASSEMBLY 2, WIRING DIAGRAM D604450 TERMINALS 12 TO 31 4 5 6 7 8 9 Page 37...
  • Page 40 ASSY No A609301 AT ISS 1 (01/06/2009). ELECTRIC BOX ASSEMBLY AA300AVHF ITEM NO. PART No. DESCRIPTION QUAN UNITS SD316557 MINIATURE CIRC BREAKER 16A SD316552 CIRCUIT BREAKER MINIATURE 6A SD316551 CIRCUIT BREAKER MINIATURE 4A SD316550 CIRCUIT BREAKER MINIATURE 2A SD611352 CONTACTOR 18A 3+1NC Aux SD409551 TERM BLOCK EARTH (SL10) SD403650...
  • Page 41 AA300AVH(F) WITH LPHW ELECTRIC BOX ASSEMBLY 2, WIRING DIAGRAM D604450 TERMINALS 12 TO 35 4 5 6 7 8 9 Page 39...
  • Page 42 ASSY No A609302 AT ISS 1 (01/06/2009). ELECTRIC BOX ASSEMBLY AA300AVH WITH LPHW ITEM NO. PART No. DESCRIPTION QUAN UNITS SD316557 MINIATURE CIRC BREAKER 16A SD316552 CIRCUIT BREAKER MINIATURE 6A SD316551 CIRCUIT BREAKER MINIATURE 4A SD316550 CIRCUIT BREAKER MINIATURE 2A SD611352 CONTACTOR 18A 3+1NC Aux SD409551...
  • Page 43 AA300AVH(F) MAIN ASSEMBLY Page 41...
  • Page 44 ASSY No A609201 AT ISS 1 (22/06/2009). MAIN ASSEMBLY AA300AVH ITEM NO. PART No. DESCRIPTION QUAN UNITS SD557850 SERVICE PANEL SD557650 TOP COVER SD595950 FILTER COVER SD611250 MANUAL O/I SD596450 COVER PLATE SA609301 ELECTRIC BOX ASSEMBLY SA607701 CONSOLE ASSY. SD434051 FLYING LEAD 25 WAY D CONNECTOR SD416603 EVAPORATOR COIL...
  • Page 45 AA300AVH(F) WITH LPHW MAIN ASSEMBLY Page 43...
  • Page 46 ASSY No A609202 AT ISS 1 (22/06/2009). MAIN ASSY AA300AVH WITH LPHW ITEM NO. PART No. DESCRIPTION QUAN UNITS SD557850 SERVICE PANEL SD557650 TOP COVER SD595950 FILTER COVER SD611250 MANUAL O/I SD596450 COVER PLATE SA609302 ELECTRIC BOX ASSEMBLY SA607702 CONSOLE ASSY SD434051 FLYING LEAD 25 WAY D CONNECTOR SD416603...

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