Galletti HiWarm 012 Installation, Use And Maintenance Manual Download Page 49

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All copying, even partial, of this manual is strictly forbidden

RG66007967 - Rev 02

The possible methods of selecting unit operating modes is found below, in priority
order:

1 Via a Digital Input.
2 Via Keypad or Supervision.

When the unit is started-up, the control logic will display the information regarding the
mode on the initial screen (correspondence between the symbol used on the display
and the mode can be confi gured via

User menu

Set-points and Parameters

6.3.6

OPERATION MODE

077

SUPERNODE SLAVE BOARD ALARM

With Frecon-APY inverter:

- heat-sink over temperature

- overcurrent during acceleration

- overcurrent

- overcurrent during deceleration

- DC Bus undervoltage

- DC Bus overvoltage

- faulty PFC converter

- overload

- serial communication timeout

- heat-sink temperature probe error

- general alarm

WITH CAREL POWER+ INVERTER:

- Overcurrent

- Motor Overcurrent

- Overvoltage

- Undervoltage

- Over temperature

- Undertemperature

- Overcurrent HW

- Motor Over temperature

- Drive fault

- Cpu error

- Default parameters

- DC bus ripple

- Serial communication timeout

- Thermistor error

- Autotuning error

- Disabled drive

- Missing motor phase

- Faulty fan

- Stalled motor

- Drive fault

EVD-EVO VALVE DRIVER ALARM

08:00 28/09/2011

14.0˚C

DHW

12.5˚C

Summary of Contents for HiWarm 012

Page 1: ...R410A eco 12 kW 22 kW 33 kW MULTIFUNCTION UNIT AIR WATER HEAT PUMP INSTALLATION USE AND MAINTENANCE MANUAL GB ...

Page 2: ......

Page 3: ...for optimal use of our product for maximum comfort Please carefully read the recommendations provided in the following pages and place the manual at the disposal of the unit managers and maintenance technicians Our company is at your disposal for any questions you may have both during the unit start up phase or any other time Our Technical Department is at your disposal for any assistance and spar...

Page 4: ...HIWARM 4 All copying even partial of this manual is strictly forbidden RG66007967 Rev 02 ...

Page 5: ...rm found in the unit documentation by fax at least one week in advance Should this form not be found please contact GALLETTI Tel 39 051 8908111 Fax 39 051 8908122 e mail assistenza galletti it 4 OUR APPOINTMENT Galletti will organise this by asking the Authorised Technical Service Centre in your area to contact you 5 OUR TEST All the preliminary checks and unit test will be performed together with...

Page 6: ... 2 3 Operational safety 14 2 2 4 Residual risk areas 14 2 3 LOCATION OF THE SAFETY LABELS 15 2 3 1 Description of the safety labels 15 2 4 GENERAL SAFETY RULES 17 2 4 1 Attention and maintenance 17 2 4 2 Fire extinguisher and first aid 17 2 5 MAINTENANCE PRECAUTIONS 18 2 5 1 Tools 18 2 5 2 Personnel 18 2 5 3 Keeping the unit clean 18 2 5 4 Warning signs 18 3 DESCRIPTION OF THE PRODUCT 19 3 1 THE R...

Page 7: ...AD MANAGEMENT FUNCTION 41 6 3 USER INTERFACE 42 6 3 1 Description of the keypad 42 6 3 2 Main screen 43 6 3 3 Selecting the control mode 43 6 3 4 Selecting the set point 46 6 3 5 Alarms 47 6 3 6 Operating mode 49 7 MAINTENANCE AND AFTER SALES SERVICE 50 7 1 TROUBLESHOOTING 50 8 OPTIONAL STORAGE TANKS 52 9 TECHNICAL DATA 53 10 DECOMMISSIONING THE UNIT 55 10 1 ENVIRONMENTAL PROTECTION 55 11 WATER PR...

Page 8: ...mbols and their meaning Their purpose is to highlight specific information such as The operating rules described in this manual are an integral part of the unit supply These rules are also intended for the previously trained operator specifically to operate this type of unit and contain all the necessary and important information for operating safety and optimal proper use of the unit Hurried and ...

Page 9: ...se take all the precautions necessary The pressurised fluids in the cooling circuit and the presence of electrical components can cause hazardous situations during installation and maintenance operations Therefore only qualified personnel may perform any work on the unit THE UNIT MUST ONLY BE COMMISSIONED BY QUALIFIED PERSONNEL AUTHORISED BY THE COMPANY PLACING IT ON THE MARKET SEE ATTACHMENT FAIL...

Page 10: ...ght kg 50 Alimentazione Power supply 230 1 50Hz Potenza assorbita Massima Maximum power input kW 0 4 Corrente massima Full load ampere FLA A 1 66 Corrente di spunto Starting Current LRA A 0 0 10 All copying even partial of this manual is strictly forbidden RG66007967 Rev 02 Before performing any work on the unit each operator must be perfectly aware of how the unit and its controls work and must h...

Page 11: ...derstood the user instructions well together with the meaning of any symbols on the unit Potential accidents can be prevented by following these technical instructions with reference to the Machinery Directive 2006 42 EC and subsequent amendments In any case always comply with the national safety regulations Do not remove or damage the safety devices labels and notices especially those imposed by ...

Page 12: ...the Standards in force Apply a WORKS IN PROGRESS sign on all sides of the unit Carefully check the unit according to the list of operations specified in this manual The unit must only be used by qualified personnel who is obliged to be aware of the lay out and function of all the controls instruments indicators warning lights and various labels 2 SAFETY REQUIREMENTS 2 1 GENERAL SAFETY STANDARDS 2 ...

Page 13: ...with the unit off and the power supply disconnected Once the unit is cleaned the operator must make sure there are no worn or damaged parts or others that are not fastened securely otherwise a maintenance technician must be asked to intervene Particular attention must be paid to the integrity of the pressurised pipes or other components subject to wear Also make sure there are no leaking fluids or...

Page 14: ...parts are used has a component that is either modified or replaced without written authorisation from the MANUFACTURER especially when the efficiency of the safety systems is intentionally reduced or eliminated is used beyond the ambient temperature limits allowed 2 2 1 Safety precautions 2 2 2 Accident prevention safety 2 2 3 Operational safety 2 2 4 Residual risk areas It has not been possible t...

Page 15: ...he functions of the unit and the consequent risks b Read the use and maintenance manual carefully before operating the unit Power supply label a Do not use water to extinguish fire b Do not smoke and or use open flames 1 2 3 2 3 LOCATION OF THE SAFETY LABELS 2 3 1 Description of the safety labels ALIMENTAZIONE ELETTRICA POWER SUPPLY SPG VERSORGUNGSTEIL 400V 3 50Hz ...

Page 16: ...ll copying even partial of this manual is strictly forbidden RG66007967 Rev 02 a Electric voltage hazard b Risk of shearing in the finned coil area c Risk of burns Liquid refrigerant Hazard moving mechanical parts 4 5 6 ...

Page 17: ... check that the safety devices are in perfect working condition Make sure that no unqualified or unauthorised persons enter the unit area Verify that the fire extinguisher is in place Periodically verify that the fire extinguishers are loaded and all operators know how to use them It is important to know where the first aid kit is kept Periodically verify that the first aid kit is equipped with di...

Page 18: ... solvents must be used even if weak as they damage the paint and increase the formation of rust If a jet of water penetrates the electrical equipment the contacts oxidise and the unit can malfunction Therefore do not use jets of water or steam on the sensors connectors or any electrical part Switch the unit off before performing any maintenance Serious or fatal injury could be caused if other pers...

Page 19: ...ioned at a height with simple brackets Outdoor unit for indoor use ductable compact with backward curved blade fans activated by an EC synchronous permanent magnets motor designed for attics Expansion device EEV electronic expansion valve to benefit from the possibility of generating thermodynamic cycles under reduced pressure changes with significant COP advantages Built in pump control on system...

Page 20: ...oor unit side panelling in galvanised sheet metal painted with polyester epoxy powders and polymerised in the oven at 180 C and a front cover that incorporates the Display on two basic levels LCD and a 10 Graphic Touch Screen Windows CE The unit is fully panelled but can be accessed on 3 sides since the panels can be easily removed thereby simplifying maintenance and or inspections All routine mai...

Page 21: ... manual is strictly forbidden RG66007967 Rev 02 3 2 MAIN COMPONENTS OF THE INDOOR UNIT PLATE HEAT EXCHANGERS DISPLAY INVERTER SOLENOID VALVES LIQUID SEPARATOR COMPRESSOR CYCLE INVERSION VALVE LIQUID RECEIVER PUMPS STANDARD USER INTERFACE ...

Page 22: ...s well as the need to minimise the amount of oil entrained into the transients and is a parameter that cannot be modified INTERNALTEMPERATURE C M O D E L W I T H I N V E R T E R STANDARDMODEL TIME Scroll or Twin Rotary R410A Compressors Processing optimisation together with a careful choice of the intrinsic volumetric compression ratio ICR allows for a significant improvement in isentropic compres...

Page 23: ...at of R407C units of the same size 20 operating energy supplied by renewable photovoltaic panels 100 useable kW 80 energy absorbed from the environment renewable clean energy TEWI Total Equivalent Warming Impact This expresses the mass of CO2 that produces the same overall effect as the chiller during its operational life The main feature of this parameter is based on the effects of using a refrig...

Page 24: ... same IN OUT configuration and the user does not notice any change N B the above mentioned selection always considers a heat exchange in countercurrent mode Countercurrent Cocurrent Electronic expansion valve EEV Installed as per standard on all HiWarm units If configured correctly and controlled properly by the software this device helps the cooling circuit be highly efficient and this will there...

Page 25: ...on consists of an electrical current being applied to a coil that creates a magnetic field This is transformed into mechanical energy which opens or closes the valve The principle of operation is very reliable inexpensive and widely used for each type of application with ON OFF utilities Liquid separator The liquid separator is placed on the compressor intake line and has the function of containin...

Page 26: ...iency TheBLDCdoesnotrequireinductioninthestatorwindings there already is a permanent magnet in the rotor There are no relative losses The BLDC has no rotor currents due to the stator induction of the asynchronous motors No rotor loss The BLDC has no sliding contacts No maintenance The position of the rotor is detected by measuring the BEFM back electro motive force caused by the rotor during the n...

Page 27: ...mber of 25 x 21 65 mm expanded pipes 8 mm diameter in an automatic and controlled process in 0 10 mm thick aluminium fins Expansion is a fey factor and important process as it determines the pipe fin contact resistance and it is often ignored in the case of high heat exchange efficiencies FINNED PACK HEAT EXCHANGERS FANS Fans 6 polefansareusedintheoutdoorremoteunit 3polepairs with plastic blades h...

Page 28: ...ing and cooling requirements throughout the year with no fossil fuels Three models can be chosen from classified according to the maximum cooling capacity they can produce Priority production of domestic hot water alternated with environmental heating Domestic hot water Water mains Storage tank Storage tank Fan coil Flooring REMOTE UNIT DOMESTIC HOT WATER HOME ENVIRONMENT HiWarm has four different...

Page 29: ...er Domestic hot water Water mains Water mains Storage tank Storage tank Storage tank Storage tank Fan coil Fan coil Flooring Flooring REMOTE UNIT REMOTE UNIT DOMESTIC HOT WATER DOMESTIC HOT WATER HOME ENVIRONMENT HOME ENVIRONMENT Production of domestic hot water only Cooling and simultaneous production of domestic hot water ...

Page 30: ... the pipes to use to connect the indoor and the outdoor units according to the different sizes of the HiWarm and the length of the line Model 012 022 033 Refrigerant R410A Pipe length m 0 5 6 10 11 15 16 20 21 25 0 5 6 10 11 15 16 20 21 25 0 5 6 10 11 15 16 20 21 25 Compressor frequency Hz 30 120 30 120 30 120 30 120 30 120 20 120 20 120 20 120 20 120 20 120 20 120 20 120 20 120 20 120 20 120 Inta...

Page 31: ...ricting the availability of oxygen Once evacuated the area must be ventilated with fans or blowers in order to circulate the air at floor level FLAMMABILITY according to the 34 ASHRAE Standard R 410A is classified in safety group A1 i e it is not flammable at 1 atm of pressure 101 3 kPa and 18 C CATEGORY the refrigerant is a non hazardous category II fluid WARNING Allthetemperaturesontheperimetero...

Page 32: ...al of this manual is strictly forbidden RG66007967 Rev 02 HiWarm 12 operating limits for the following produced water and outdoor air temperature HiWarm 22 operating limits for the following produced water and outdoor air temperature ...

Page 33: ...ture differential of 8 C lower flow rates could cause excessively low evaporation temperatures which could trigger the safety devices and stop the unit or cause incorrect distribution and risk of heat transfer with non turbulent or not fully turbulent motion conditions HiWarm 33 operating limits for the following produced water and outdoor air temperature Water flow to evaporator Heat transfer flu...

Page 34: ...sign of damage Commissioning report wiring diagram warranty certificate and list of service centres check the integrity of the documents accompanying the unit and of this manual While the unit is being unloaded and positioned utmost care must be taken to avoid abrupt or violent manoeuvres The internal movement must be implemented carefully and gently do not use the unit components as anchors 4 INS...

Page 35: ...rol on the water side allows the correct functionality of the expansion tank to be verified and any water leaks in the system to be detected in advance sumps on inlet and outlet piping for temperature detection for a direct view of operating temperatures They can also be viewed on the display on board the unit if pCO shut off valves gate valves to isolate the unit from the water circuit for mainte...

Page 36: ...l useful head of the hydraulic pumps in cooling conditions water 12 7 C and air 35 C Inverter driven pumps can run within the limited range over the characteristic range of the pump 012 Absorbed power kW 0 1 Absorbed current A 0 6 It is extremely important that the installer follows and verifies the following procedure step by step in order to prevent the risk of tank implosion or pump cavitation ...

Page 37: ...37 All copying even partial of this manual is strictly forbidden RG66007967 Rev 02 022 Absorbed power kW 0 3 Absorbed current A 1 3 033 Absorbed power kW 0 3 Absorbed current A 1 3 ...

Page 38: ...nit Lastly it is possible to find the minimum recommended protection For the correct sizing of the cable it is necessary to take into account standard reference IEC EN60204 1 1 The selected upstream protection 2 Installation conditions 3 Type of cable 4 Maximum cable length The following table provides an example of sizing in the following hypothetical situations 1 Maximum ambient temperature of 4...

Page 39: ... the internal and external unit for a maximum distance of 30m When connecting units with EC fans the power and signal cables must be separate and sized as indicated in the table The 0 10V signal cable must be shielded For any reference as to which terminals must be used refer to the electrical diagram in the details for POWER BOARD and CUSTOMER CONNECTIONS terminal block X2 and X3 HWO HWD FANS TYP...

Page 40: ...can be set downloading all the data records from a web browser or via FTP editing the main parameters in case of an alarm sending an e mail to 5 different recipients GWeb also allows for monitoring to be performed via the following protocols with SNMP v1 v2c protocol with BACnet Ethernet or BACnet IP protocol The parameters relative to SNMP and BACnet protocol management are set from the Administr...

Page 41: ...ads and the branch point of the power supply for the power factor correction panel the installed CT must measure all the absorbed currents of the system inductive motors or similar as well as capacitive condensers Any condensers for the fixed power factor correction must be installed downstream the CT unless they are used for the power factor correction of the system power supply transformer Profe...

Page 42: ...Press the PRG key to enter the main menu ESC Press the ESC key to move up one level in the menu UP Press the UP key to go to the next screen or increase the value of a parameter ENTER PresstheENTERkeytogototheparameterfieldtobeeditedandtoconfirmanychange DOWN Press the DOWN key to go to the previous screen or decrease the value of a parameter 6 3 USER INTERFACE 6 3 1 DESCRIPTION OF THE KEYPAD ...

Page 43: ...ter the main menu use the UP and DOWN keys to scroll the menu to select USER press ENTER and enter the password default 100 using the UP and DOWN keys press ENTER to confirm the password and access the user menu use the UP and DOWN keys to select Lan and Supervision press the ENTER key to access the following screen J1 Enable one or more unit start up options on this screen The options are from th...

Page 44: ...unication board is installed pCOWeb or RS485 that acts as an interface between the main unit control and the supervision system The type of protocol and main communication configuration parameters can be set in the User menu Lan and Supervision J6 Besides all the previous controls on off utility and DHW activation the supervision system also allows the status of all the alarms to be read the alarm...

Page 45: ... hours Band 3 F3 the unit is always on Band 4 F4 the unit is always off Weekly program configuration Once the On Off bands are set they must be used to define the logic of the different days of the week User menu Clock L3 N B the On Off control via bands is simply consent to operate which involves unit start up solely if all the activated On Off options via User menu Lan and Supervision give conse...

Page 46: ... screen Time band set point solely for the utility A time band for each day of the week can be set from the SET POINT menu to control the variation of the set point during the intervals of the day when the unit is ON Set point menu F7 The summer and winter set points to be used during the time bands and not must be set together with these Set point menu F5 F6 UTILITY SET POINT F0 ACTIVE 12 0 C SEC...

Page 47: ...y lights up Press the ALARM key once to access the list of active alarms then use the UP and DOWN keys to scroll the list Each alarm is identified by a code and a brief description the complete list is found in the software manual Press the ALARM key again to reset the alarms provided the cause that triggered them has been resolved If the specific function is enabled all the alarms besides the hig...

Page 48: ... ALARM 013 LOW PRESSURE ALARM 015 PRESSURE SWITCH OR COMPRESSOR CIRCUIT BREAKER HIGH PRESSURE ALARM 017 LOW PRESSURE PROBE ALARM 019 HIGH PRESSURE PROBE ALARM 023 FAN CIRCUIT BREAKER ALARM 025 PUMP 1 EXCEEDED OPERATING HOURS 026 PUMP 2 EXCEEDED OPERATING HOURS 027 PHASE DIRECTION OR MISSING PHASE ALARM 028 ANTI FREEZE ALARM 030 COMPRESSOR EXCEEDED OPERATING HOURS THRESHOLD 038 CLOCK BOARD FAULT 04...

Page 49: ...AVE BOARD ALARM With Frecon APY inverter heat sink over temperature overcurrent during acceleration overcurrent overcurrent during deceleration DC Bus undervoltage DC Bus overvoltage faulty PFC converter overload serial communication timeout heat sink temperature probe error general alarm WITH CAREL POWER INVERTER Overcurrent Motor Overcurrent Overvoltage Undervoltage Over temperature Undertempera...

Page 50: ... unit Faulty high pressure Insufficient air flow rate to the condenser Check that all fans turn correctly Check the condenser air inlet T and prevent any recirculation Check that the maximum RMS voltage reaches the fans If necessary check the pressure transducers that control the revolution controller optional Make sure the finned coils are clean Air in the circuit detected by air bubbles on the f...

Page 51: ... the filter must not exceed 2 C saturation temperature Should it happen replace the filters Low condensation T Make sure the condensation control works properly if present Low refrigerant charge Check the charge by measuring the sub cooling if it is below 2 C charge with refrigerant Frosted coil if in heat pump mode Check the correct defrost parameter settings Make sure the 4 way valve works prope...

Page 52: ...ers that are too high This leads to regular and continuous system operation and therefore better thermal performance The water heated by the unit is stored inside the tank and the energy stored this way allows the tank to be used with an instantaneous preparer The manufacturer proposes this solution as it prevents unnecessary anti legionella cycles and allows for good thermal efficiency by heating...

Page 53: ... 4 41 6 34 3 46 6 80 3 47 UTILITYWater Flow Rate kg h 714 2696 1458 4834 1472 7565 UTILITYWater Pressure Drops kPa 3 0 37 0 4 0 49 0 11 1 44 0 DISSIPATIONWater Flow Rate m3 h 3500 7000 5250 10500 7000 14000 DHW 50 55 C and 30 C outdoor air Heating Capacity kW 3 3 16 6 7 6 32 3 11 8 51 7 Compressor Absorbed Power kW 0 9 4 3 2 1 9 5 3 2 14 2 Compressor Absorbed Current A 12 8 18 4 15 2 23 7 20 2 25 ...

Page 54: ... 0 30 0 45 0 45 0 60 0 60 Fan Absorbed Current A 1 40 1 40 0 80 0 80 1 10 1 10 COP 3 48 4 03 3 69 3 65 3 91 3 71 UTILITYWater Flow Rate kg h 527 2093 1050 4034 1687 6147 UTILITYWater Pressure Drops kPa 2 0 22 0 4 0 34 0 4 0 29 0 DISSIPATIONWater Flow Rate m3 h 7000 7000 10500 10500 14000 14000 Power absorption Power supply single phase 230 1 50 three phase 400 3 50 three phase 400 3 50 FLA with fa...

Page 55: ...tatetheworkcarriedoutinthewastecollection disposalandrecyclingfacilitiesandminimisetheenvironmental impact of such processes The law EC 2037 00 that regulates the use of stratospheric ozone depleting substances and greenhouse gases bans disposal of refrigerant gases in the environment and requires whoever is in their possession to collect them and at the end of their useful life return them to the...

Page 56: ... not smoke SPECIAL PROTECTION SYSTEMS FOR THE FIRST AIDERS Wear breathing apparatus and protective clothing MEASURES IN CASE OF ACCIDENTAL DISPERSION PERSONAL PRECAUTIONS Avoid contact with your skin eyes and inhalation of vapours Use personal protective equipment In an enclosed area ventilate the area or use breathing apparatus risk of anoxia No smoking ENVIRONMENTAL PROTECTION PRECAUTIONS Minimi...

Page 57: ...tic components the product can cause the following due to vapour accumulation and or inhalation of large quantities Loss of consciousness and cardiac disorders aggravated by stress and lack of oxygen Life threatening Experimental in animals studies on the constituents of the product Practically not harmful if inhaled No death occurred in rats given 500 000 ppm 4h LOCAL EFFECTS Contact with skin Po...

Page 58: ...Packaging group Classification code 2A Labels 2 2 ADN ADNR Substance identification number 3163 Hazard identification number 20 Class 2 Number and letter 2nd A Labels 2 IMDG ONU No IMDG 3163 Class 2 2 Subsidiary risks Packaging group Labels 2 2 Marine Pollutant MP NO IATA ONU No IATA or ID No 3163 Class 2 2 Subsidiary risks Packaging group Labels 2 2 Refer to ARKEMA s safety services for further i...

Page 59: ...59 All copying even partial of this manual is strictly forbidden RG66007967 Rev 02 NOTES ...

Page 60: ...www galletti it 40010 Bentivoglio BO Via Romagnoli 12 a Tel 051 8908111 Fax 051 8908122 Company UNI EN ISO 9001 and OHSAS 18001 certified ...

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