Galletti HiWarm Series Installation, Use And Maintenance Manual
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Galletti HiWarm Series Installation, Use And Maintenance Manual

12 kw - 22 kw - 33 kw, multifunction unit: air-water heat pump
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INSTALLATION, USE AND MAINTENANCE MANUAL
GB
12 kW - 22 kW - 33 kW
MULTIFUNCTION UNIT: AIR-WATER HEAT PUMP
eco
R410A

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  • Page 1 INSTALLATION, USE AND MAINTENANCE MANUAL 12 kW - 22 kW - 33 kW MULTIFUNCTION UNIT: AIR-WATER HEAT PUMP R410A...
  • Page 3 Please find our contact details below for a more rapid service: Galletti S.p.A. Via L.Romagnoli 12/a 40010 Bentivoglio (BO) ITALY Tel + 39 051 8908111 Fax + 39 051 8908122/3 e-mail : info@galletti.it RG66007967 - Rev 02 All copying, even partial, of this manual is strictly forbidden...
  • Page 4 HIWARM All copying, even partial, of this manual is strictly forbidden RG66007967 - Rev 02...
  • Page 5 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 your personnel.

  • Page 6: Table Of Contents

    HIWARM CONTENTS 1 - GENERAL DESCRIPTION 1.1 PRECAUTIONS FOR USE 1.2 PREMISE 1.3 LIABILITY 1.4 INTENDED USE 1.5 UNIT IDENTIFICATION 1.6 GENERAL INSTRUCTIONS 2 - SAFETY REQUIREMENTS 2.1 GENERAL SAFETY STANDARDS 2.1.1 Be familiar with the unit 2.1.2 Wear protective clothing 2.1.3 Use safety equipment 2.1.4 Maintenance and inspection warning signs 2.2 GENERAL PRECAUTIONS...
  • Page 7 CONTENTS 5 - CONNECTIONS 5.1 WATER CONNECTIONS 5.1.1 General guidelines for the water connections 5.1.2 Technical data of the hydraulic pumps 5.2 ELECTRICAL CONNECTIONS 6 - MANAGEMENT AND CONTROL 6.1 GWEB OPERATION 6.2 ELECTRICAL LOAD MANAGEMENT FUNCTION 6.3 USER INTERFACE 6.3.1 Description of the keypad 6.3.2 Main screen 6.3.3 Selecting the control mode...

  • Page 8: General Description

    HIWARM 1 - GENERAL DESCRIPTION PRECAUTIONS FOR USE The operating rules in this manual are solely applicable for the following Models: HiWarm The instructions manual must be read and used as follows: - every unit operator and maintenance technician must carefully read the entire manual and comply with that stipulated therein;...

  • Page 9: Liability

    LIABILITY The MANUFACTURER cannot be held liable for any personal accident or damage to property, which may derive from: - failure to comply with the instructions provided in this manual regarding unit management, use and maintenance; - violent actions or incorrect manoeuvres when performing maintenance on the unit; - alterations made to the unit without prior written authorisation from the MANUFACTURER;...

  • Page 10: Unit Identification

    HIWARM - Before performing any work on the unit, each operator must be perfectly aware of how the ATTENTION unit and its controls work and must have read and understood all the technical information in this manual. - It is forbidden to use the unit in conditions or for purposes other than those stipulated in this manual and the MANUFACTURER cannot be liable for faults, problems or accidents due to non-compliance with this prohibition.

  • Page 11: General Instructions

    GENERAL INSTRUCTIONS - It must be stored carefully in a place that is known by the user of the unit, managers ATTENTION and operators in charge of transport, installation, use, maintenance, repairs and final dismantling. - This manual indicates the intended use of the unit and provides instructions regarding transport, installation, assembly, adjustment and use.

  • Page 12: Safety Requirements

    HIWARM 2 - SAFETY REQUIREMENTS GENERAL SAFETY STANDARDS 2.1.1 Be familiar with the unit 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. 2.1.2 Wear protective clothing Every operator must use personal protective equipment...

  • Page 13: General Precautions

    GENERAL PRECAUTIONS The Machinery Directive provides the following definitions: DANGER ZONE: any zone within and/or around machinery in which a person is subject to a risk to his health or safety. EXPOSED PERSON: any person wholly or partially in a danger zone. OPERATOR: the person or persons installing, operating, adjusting, maintaining, cleaning, repairing or moving machinery.

  • Page 14: Safety Precautions

    HIWARM 2.2.1 Safety precautions The units have been designed and built according to the current state-of-the-art and technical rules in force regarding residential air-water heat pumps that exchanges heat with the external air. Applicable laws, provisions, regulations, decrees and directives to such machinery have been complied with. The materials used and the parts of equipment, as well as production procedures, quality and control assurance comply with the highest standards of safety and reliability.

  • Page 15: Location Of The Safety Labels

    LOCATION OF THE SAFETY LABELS 2.3.1 Description of the safety labels a Warning of danger due to the user not being aware of all the functions of the unit and the consequent risks. b Read the use and maintenance manual carefully before operating the unit. Power supply label.
  • Page 16 HIWARM a Electric voltage hazard. b Risk of shearing in the finned coil area. c Risk of burns. Liquid refrigerant. Hazard: moving mechanical parts. All copying, even partial, of this manual is strictly forbidden RG66007967 - Rev 02...

  • Page 17: General Safety Rules

    GENERAL SAFETY STANDARDS 2.4.1 Attention and maintenance Many accidents and damage are caused due to maintenance errors, such as: - no water in the circuit; - incorrect percentage of refrigerant in the circuit; - inadequate refrigerant; - failure to keep the unit area clean; - circuit inefficiency (pipe connections, loose pipes, screws, etc.).

  • Page 18: Maintenance Precautions

    HIWARM MAINTENANCE PRECAUTIONS 2.5.1 Tools Personal injury is prevented by not using worn or damaged, low quality or makeshift tools. The manufacturer cannot be held liable for damage caused if modified tools are used. ATTENTION 2.5.2 Personnel Routine maintenance specified in this manual must only be performed by authorised and trained personnel. Contact the MANUFACTURER for maintenance or repairs that is not specified in this manual.

  • Page 19: Description Of The Product

    3 - DESCRIPTION OF THE PRODUCT THE SERIES HiWarm is a residential air-water multifunction heat pump that absorbs cold or heat from the external air and simultaneously, with no combustion or fl ame, warms or cools the home and autonomously produces domestic hot water, prioritised or total heat recovery in cooling mode.
  • Page 20 HIWARM Double water circuit: - Air conditioning circuit with reversible cooling circuit side and variable set-point between min/max with potential-free contact or with 0-10V or 4-20 mA signal. - Total heat recovery (for simultaneous cooling) or in any case prioritised DHW circuit. This circuit is separate and does not need long heating/cooling stages of inertial storage, like similar products on the market, which jeopardise energy efficiency especially during summer operation.

  • Page 21: Main Components Of The Indoor Unit

    MAIN COMPONENTS OF THE INDOOR UNIT DISPLAY PLATE INVERTER HEAT EXCHANGERS CYCLE INVERSION SOLENOID VALVES VALVE LIQUID LIQUID RECEIVER SEPARATOR PUMPS COMPRESSOR STANDARD USER INTERFACE RG66007967 - Rev 02 All copying, even partial, of this manual is strictly forbidden...
  • Page 22 HIWARM Scroll or Twin-Rotary R410A Compressors: Scroll Twin Rotary Processing optimisation together with a careful choice of the intrinsic volumetric compression ratio (ICR) allows for a significant improvement in isentropic compression performance and a consequent reduction in energy loss during the process. Low viscosity oils can be used thanks to the scroll and twin rotary compressor, which greatly reduce evaporator thermal resistance, compared to high viscosity oils, with an increase of over 1.5°C in the evaporation...
  • Page 23 R410A refrigerant fl uid: HFC R410A is distinguished by very favourable thermal conductivity of the liquid and negligible Glide, even if this results in a higher GWP than other refrigerants operating energy (Global Warming Potential GWP= 1975 kg (supplied by renewable photovoltaic panels) ), which lead to signifi cantly enhanced energy...
  • Page 24 HIWARM AISI 316 Stainless Steel Plate Heat Exchangers: The thorough study of internal corrugation maximizes turbulence (heat exchange coefficient), thereby minimising the possibility of fouling. In line with the powers involved, it is always recommended to choose the maximum thermal length in order to have the maximum benefits possible from the countercurrent flows.
  • Page 25 Pumps: Energy class A, electronically-controlled, maintenance-free, high efficiency, wet rotor circulation pumps are used with EC motors. The pump body is made of grey cast iron with a cataphoresis KTL finish, which is an excellent protection against corrosion. The thermal insulation is made of polypropylene, the shaft is made of stainless steel, the bearings are made of metal-impregnated carbon, and the impeller with a three-dimensional coil is made of synthetic...

  • Page 26: Synchronous Motors

    HIWARM Touch Screen Display: Possibility of 10.4” Touch Screen Display with WINDOWS CE® operating system. User interface: The user interface, PGD1, consists of an LCD display (8 rows x 22 columns) and 6 keys. All the program operations can be run, the conditions of the operating unit can be displayed at any time and the parameters can be modified.

  • Page 27: Main Components Of The Outdoor Unit

    MAIN COMPONENTS OF THE OUTDOOR UNIT The outdoor unit has the same components in all three sizes. FINNED PACK The size of the fi nned coil changes together with the number HEAT EXCHANGERS of fans that increase by one unit as the size increases (two fans for the 012, three for the 022 and four for the 033).

  • Page 28: Range And Operation

    HIWARM RANGE AND OPERATION HiWarm is a multifunction residential air-water heat pump that can autonomously satisfy all the heating and cooling requirements throughout the year, with no fossil fuels. Three models can be chosen from, classifi ed according to the maximum cooling capacity they can produce: HiWarm has four diff erent operating modes: Priority production of domestic hot water alternated with environmental heating.
  • Page 29 Production of domestic hot water only. HOME ENVIRONMENT REMOTE UNIT DOMESTIC HOT WATER Fan coil Storage tank Domestic hot Storage tank water Flooring Water mains Cooling and simultaneous production of domestic hot water. HOME ENVIRONMENT REMOTE UNIT DOMESTIC HOT WATER Fan coil Storage tank Domestic hot...

  • Page 30: Piping And Load Design Criteria

    HIWARM Cooling, dehumidification and simultaneous production of domestic hot water, alternated with excess heat dissipation to the coil. HOME ENVIRONMENT REMOTE UNIT DOMESTIC HOT WATER Fan coil Storage tank Domestic hot Storage tank water Flooring Water mains PIPING AND LOAD DESIGN CRITERIA All the copper pipes are made according to our specifications for the construction process to be fully controlled and implicitly improve the quality of our products.

  • Page 31: Operating Limits

    The unit is pre-charged with R410A before leaving the factory, however, the charge must be verified during the start-up phase. Since R410A is a binary blend of R32 and R125, it is advisable to charge with refrigerant in the liquid WARNING phase to ensure the correct percentage of the 2 components.
  • Page 32 HIWARM 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: All copying, even partial, of this manual is strictly forbidden RG66007967 - Rev 02...
  • Page 33 HiWarm 33 operating limits for the following produced water and outdoor air temperature: Heat transfer fluid: water or mixture of water and max 30% glycol anti-freeze Maximum water side pressure: 5 bar Maximum pressure on high pressure side 41.5 bar-r Maximum ambient Temp of the indoor unit 42°C Minimum ambient Temp of the indoor unit -10°C Maximum pressure on low pressure side 29 bar-r (*)

  • Page 34: Inspection, Transport And Positioning

    HIWARM 4 - INSPECTION, TRANSPORT AND POSITIONING INSPECTION Upon receiving the unit, verify its integrity: the unit left the factory in perfect conditions; report any damage to the carrier immediately and write them on the Delivery Note before signing it. In particular, check that the fins of the finned pack heat exchangers are not bent and have not been subject to any impact that could affect the tightness of the pressurised system.

  • Page 35: Connections

    Before starting is required to remove the fixing screws (a) of the compressor which have to ATTENTION block the compressor during transport. 5 - CONNECTIONS WATER CONNECTIONS 5.1.1 General guidelines for the water connections It is mandatory to follow the requirements below when preparing to set up the water circuit for the evaporator and in any case national or local Standards must be complied with (refer to the diagrams attached to this document).

  • Page 36: Technical Data Of The Hydraulic Pumps

    HIWARM It is extremely important that the installer follows and verifi es the following procedure step by step in order to prevent the risk of tank implosion or pump cavitation: - Drain the expansion tank in the system until the pressure reaches 0.5 bar. - Fill the system and pressurise it to approximately + 1 bar in pump suction (pump stopped).
  • Page 37 Absorbed power (kW) Absorbed current Absorbed power (kW) Absorbed current RG66007967 - Rev 02 All copying, even partial, of this manual is strictly forbidden...

  • Page 38: Electrical Connections

    HIWARM ELECTRICAL CONNECTIONS The electric connections must be set up by qualified staff. All connections must comply with the regulations enforced in the country of installation. A suitable cutting-off device must be set up upstream of the electrical supply for the internal unit, taking into consideration the electrical absorptions indicated in this manual and on the data plate.
  • Page 39 Regarding the differential protection that needs to be installed upstream, it is necessary to use a type B switch that is sensitive to direct currents. It is also preferable for it to have the following features: 1 Calibratable operation threshold. 2 Calibratable operation delay.

  • Page 40: Management And Control

    HIWARM 6 - MANAGEMENT AND CONTROL The software on board the unit is very complex and allows HiWarm operation to be fully controlled. For this reason, many parameters and settings must be managed by the manufacturer in order to make sure the unit runs smoothly according to the set flow temperatures.

  • Page 41: Electrical Load Management Function

    ELECTRICAL LOAD MANAGEMENT FUNCTION LOAD This function allows the electrical loads to be managed and priorities to be assigned to our HiWarm system or other utilities, such as appliances. This function requires a current transformer (CT) set upstream the mains meter. This CT must be of good quality (class I) and the selected ratio must guarantee a constant amperometric signal to the secondary within the 0.5 ÷...

  • Page 42: User Interface

    HIWARM USER INTERFACE 6.3.1 DESCRIPTION OF THE KEYPAD Description ALARM Press the ALARM key to reset the alarms. The button lights up when an alarm is triggered. Press the PRG key to enter the main menu. PROGRAM Press the ESC key to move up one level in the menu. Press the UP key to go to the next screen or increase the value of a parameter.

  • Page 43: Main Screen

    6.3.2 MAIN SCREEN When the unit is started up the control logic will display the mode on the initial screen: 08:00 28/09/2011 14.0 ˚ C 32.5 ˚ C On which the following information is also displayed besides the utility temperature (summer or winter mode) and the domestic hot water temperature: Indicates that the utility pump is active.
  • Page 44 HIWARM Press the DOWN key with the cursor in the top left side on the J1 screen to access the following screen (J2): UNIT CONTROL -› FROM LOCAL KEYPAD PGD1 The type of activation for the unit operating modes can be selected here as follows: - via the display keys;...
  • Page 45 ON-OFF CONTROL VIA BANDS If the clock card option is present, the unit activation On/Off bands can be set. Activation - Clock board installed. UNIT ON/OFF - On-Off activation via bands (User menu Lan and Supervision J1). ENABLE ON/OFF FROM: - BANDS : YES On/Off Bands Configuration...

  • Page 46: Selecting The Set-Point

    HIWARM 6.3.4 SELECTING THE SET-POINT Active Utility Set-point UTILITY SET-POINT (Set-point menu ACTIVE: 12.0 ˚ C - SECONDARY The first screen displayed in the SET-POINT menu indicates the set-point value used in - FROM BAND: the utility regulation logic. This value is the result of the overall set-point management - REMOTE CORRECTION as a result of automatic variations, corrections and restrictions.

  • Page 47: Alarms

    Required conditions for time band management: SET-POINT - clock board present; AUTOMATIC VARIATION - selected "via bands" set-point automatic variation (User menu Set-points and parameters H4). -› VIA TIME BANDS Secondary set-point from a digital input (Set-point menu SETTING THE SECONDARY SET-POINT The summer and winter secondary set-point values, controlled from the digital input ID14, accessible from terminals X3:61-62, can be set from the SET-POINT menu.
  • Page 48 HIWARM All the HiWarm alarms and their meaning are found in the list below: ALARM DESCRIPTION CODE DIGITAL INPUT ALARM UTILITY PUMP CIRCUIT BREAKER ALARM UTILITY FLOW ALARM PROBE FAULT ON ANALOGUE INPUT B1 ALARM PROBE FAULT ON ANALOGUE INPUT B2 ALARM PROBE FAULT ON ANALOGUE INPUT B3 ALARM PROBE FAULT ON ANALOGUE INPUT B4 ALARM PROBE FAULT ON ANALOGUE INPUT B5 ALARM...

  • Page 49: Operating Mode

    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...

  • Page 50: Maintenance And After Sales Service

    HIWARM 7 - MAINTENANCE AND AFTER SALES SERVICE TROUBLESHOOTING The most common causes that can block the heat pump or cause a malfunction are listed in the following pages. They are listed according to the easily identifiable symptoms. Be very careful when carrying out the various recommended problem-solving operations: WARNING over-confidence can cause serious injuries for unskilled persons.
  • Page 51 FAULT ANALYSIS OF POSSIBLE CAUSES CORRECTIVE ACTION Low condensation pressure. Fault in the transducers. Check the transducers and verify that the depressor on the Schrader valves that they are connected to works correctly. Outdoor T too low and/or presence of Mount the condensation control and/ strong wind.

  • Page 52: Optional Storage Tanks

    HIWARM 8 - OPTIONAL STORAGE TANKS HiWarm can heat technical water for domestic hot water production. Domestic hot water production always requires a water storage tank (preferably technical) on the circuit used for this function. The storage tank is used to meet demand peaks without installing thermal powers that are too high.

  • Page 53: Technical Data

    9 - TECHNICAL DATA Compressor status [Hz] ESEER Eurovent radiant panels (utility @ 23-18°C) 8.61 6.69 6.52 ESEER Eurovent fan-coils (utility @ 12-7°C) 5.65 5.30 5.24 Cooling Capacity [kW] 11.2 20.4 31.9 Compressor Absorbed Power [kW] 11.0 Compressor Absorbed Current 11.1 12.6 16.6...
  • Page 54 HIWARM Compressor status [Hz] ESEER Eurovent radiant panels (utility @ 23-18°C) 8.61 6.69 6.52 ESEER Eurovent fan-coils (utility @ 12-7°C) 5.65 5.30 5.24 Heating Capacity [kW] 11.7 22.7 34.9 Compressor Absorbed Power [kW] 10.8 Compressor Absorbed Current 12.3 12.7 18.9 19.6 Fan Absorbed Power [kW]...

  • Page 55: Decommissioning The Unit

    10 - DECOMMISSIONING THE UNIT When the unit has reached the end of its working life and must be removed and replaced, a number of measures must be followed: - the refrigerant gas it contains must be collected by qualified personnel and sent to a waste collection facility; - the compressor lubricating oil must also be collected and sent to a waste collection facility;...

  • Page 56: R410A Refrigerant Safety Data Sheet

    HIWARM 12 - R410A REFRIGERANT SAFETY DATA SHEET COMPOSITION/INFORMATION REGARDING THE INGREDIENTS CHEMICAL NATURE OF THE PRODUCT MIXTURE OF: FORANE 32 (DIFLUOROMETHANE): CAS: 75-10-5 EINECS: 200-839-4 F+ R_12. FORANE 125 (PENTAFLUOROETHANE): CAS: 354-33-6 EINECS: 206-557-8. EINECS Compliant. IDENTIFICATION OF RISKS MAJOR RISKS PHYSICAL AND CHEMICAL RISKS Thermal decomposition in toxic and corrosive products.
  • Page 57 PHYSICAL AND CHEMICAL PROPERTIES PHYSICAL STATE (20°C) Liquefied gas. COLOUR Colourless. ODOUR Slightly similar to ether. Not applicable. BOILING POINT -52.6°C. FLAMMABILITY POINT It does not ignite under test conditions. VAPOUR PRESSURE (25°C): 1.68 MPa (16.8 bar). (50°C): 3.11 MPa (31.1 bar). (65°C): 4.31 MPa (43.1 bar).
  • Page 58 HIWARM ECOLOGICAL INFORMATION Due to its composition: Not easily biodegradable - Not bioaccumulative. SUBSTANCE FORANE 125. Mobility In an aqueous environment: Fast evaporation: t½ life= 3.2 h (estimate). In soils and sediments: Weak adsorption: log Koc= 1.3 - 1.7. Persistence/degradability In water Not easily biodegradable - 5% after 28d.

  • Page 59: Rg66007967 - Rev 02 All Copying, Even Partial, Of This Manual Is Strictly Forbidden

    NOTES RG66007967 - Rev 02 All copying, even partial, of this manual is strictly forbidden...
  • Page 60 40010 Bentivoglio (BO) Via Romagnoli 12/a Tel. 051/8908111 - Fax. 051/8908122 Company UNI EN ISO 9001 and OHSAS 18001 certified...

This manual is also suitable for:

Hiwarm 012Hiwarm 033Hiwarm 022

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