FläktGroup GL Series Technical & Service Manual
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FläktGroup GL Series Technical & Service Manual

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Technical Service Manual CA16
GL-SERIES AND HEAMO
FOR INTERNAL USE ONLY

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  • Page 1 Technical Service Manual CA16 GL-SERIES AND HEAMO FOR INTERNAL USE ONLY...

  • Page 2: Table Of Contents

    Technical Manual CA16 GL-Series & HeaMo Contents USER INTERFACE ....................3 Menu structure ......................4 Switching the unit on and off ..................6 Setting the operating mode ................... 8 Setting adjustment methods ..................10 1.4.1 Proportional step adjustment on inlet probe ...............

  • Page 3: User Interface

    GL-Series & HeaMo Technical Manual CA16 USER INTERFACE There are three types of user interface: W3000 W3000 compact W3000 base Depending on the type of user interface installed, there are more or less keys available for controlling the unit and for accessing system information. Description W3000, W3000...

  • Page 4: Menu Structure

    Technical Manual CA16 GL-Series & HeaMo 1.1. Menu structure The tree structures for moving around the various menus are shown below. Tasto Tasto Tasto Power On Menu Setpoint Alarm Menù Setpoint Alarm    Esc /  Display Termoregolatore Visual.
  • Page 5 GL-Series & HeaMo Technical Manual CA16 The menus are briefly described below: • The “Unit Menu” displays information such as temperature, pressure and circuit states. • The “Setpoint menu” is used to set the setpoints for the various available functions. Different setpoints can be set depending on the available operating modes (chiller, heat pump and recovery).

  • Page 6: Switching The Unit On And Off

    Technical Manual CA16 GL-Series & HeaMo 1.2. Switching the unit on and off Caution: connect the unit to the power supply at least 8 hours before starting it; if this is not done, the guarantee will become null and void. There are different procedures for starting or stopping the unit: using the user interface keys or selecting from the display.
  • Page 7 GL-Series & HeaMo Technical Manual CA16 In the W3000 base the following procedure is used: press [MENU] / select the “User” menu using the [UP] or [DOWN] keys / press [ENTER] to access the menu / press enter to type in the password / press [UP] or [DOWN] to choose the password and [ENTER] to confirm / use the [UP] or [DOWN] keys to choose the “dI 0”...

  • Page 8: Setting The Operating Mode

    Technical Manual CA16 GL-Series & HeaMo 1.3. Setting the operating mode Caution: Do not switch from chiller to heat pump unless the inlet temperature is above 15°C. Do not switch from heat pump to chiller unless the inlet water temperature is below 30°C. There are various ways of setting the operating mode of the unit.
  • Page 9 GL-Series & HeaMo Technical Manual CA16 Using the recovery from digital input command: Only for “chiller plus recovery” units and only if the digital input is present. This mode is not present in the W3000 base. Proceed as follows: check that the “Recovery control enable from digital input” parameter in the “Recovery menu”...

  • Page 10: Setting Adjustment Methods

    Technical Manual CA16 GL-Series & HeaMo 1.4. Setting adjustment methods Depending on the type of compressor used, various adjustment methods may be selected. Compressor Unit Adjustment method Water/water heat pump Water/water chiller • Quick Mind on outlet probe • Quick Mind on inlet probe Evaporating units •...

  • Page 11: Proportional Step Adjustment On Inlet Probe

    GL-Series & HeaMo Technical Manual CA16 1.4.1. Proportional step adjustment on inlet probe Some examples of proportional “step” adjustment on the inlet temperature probe: Chiller (n° steps =2) proportional band Figure 1.4: T is the inlet variable, P is the percentage of delivered power (chiller). ▄...
  • Page 12 Technical Manual CA16 GL-Series & HeaMo The following tables show some typical values for the parameters in question. The theoretical maximum and minimum outlet temperature values refer to operation at nominal flow rates ( with a thermal head at the evaporator of 5 °C and sufficient water in the system to ensure a litre / KW ratio equal to or greater than 7).

  • Page 13: Proportional Step Adjustment On Inlet Probe + Integral On Inlet Probe

    GL-Series & HeaMo Technical Manual CA16 1.4.2. Proportional step adjustment on inlet probe + integral on inlet probe This adjustment method is based on the sum of two components: proportional and integral. The proportional component generates the percentage demand for activating/deactivating the steps, as illustrated in the previous paragraph “Proportional step adjustment on inlet probe”.

  • Page 14: Quick Mind Adjustment

    Technical Manual CA16 GL-Series & HeaMo 1.4.3. Quick mind adjustment Users only need set the required setpoint as the other parameters are adapted to the system by the Quick Mind algorithm. The values normally used are: SETPOINT Chiller on inlet 11.0 °C SETPOINT Chiller on outlet 7.0 °C...
  • Page 15 GL-Series & HeaMo Technical Manual CA16 2 compressors - with maximum permitted number of start-ups per hour 8 Litres/kW 10.5  out 2 compressors - with maximum permitted number of start-ups per hour 12 Litres/kW 10.5  out 4 compressors - with maximum permitted number of start-ups per hour 8 Litres/kW 10.5 ...

  • Page 16: Modulating Adjustment Of Screw Compressors

    Technical Manual CA16 GL-Series & HeaMo 1.4.4. Modulating adjustment of screw compressors With screw compressors, modulating adjustment is performed on the outlet probe. Modulating adjustment is only available on “Bitzer” screw compressors. Reference is made to the figure to the left: Tout [°C] The setpoint remains within a dead area.

  • Page 17: Adjustment Method For Centrifuge Compressors

    GL-Series & HeaMo Technical Manual CA16 1.4.5. Adjustment method for centrifuge compressors Adjustment is combined on the inlet temperature and integral on the outlet temperature. Some diagrams outlining how this works are shown below. Suppose we have a single compressor unit. Absorbed power [Kw]...
  • Page 18 Technical Manual CA16 GL-Series & HeaMo set point Tin [°C] proportional band start compressor 1 set point t [min] Pass [Kw] Figure 1.11 c) Suppose we have a unit with more than one compressor. Potenza Absorbed assorbita power [Kw] [Kw] 2x Min Potenza Thermoregulator power...
  • Page 19 GL-Series & HeaMo Technical Manual CA16 Let us take a close look at how the compressor is activated. The amplitude of zone A coincides with the temperature difference at the evaporator, with all the compressors running at minimum power. Zone A is the sum of the zones of each single compressor (A1+A2+…). When the temperature lies in one of the An zones, the power of the active compressors is modulated according to system requirements.
  • Page 20 Technical Manual CA16 GL-Series & HeaMo The following figure, instead, gives an example of the integral contribution of the adjustment method. Set point 100 % P. band Example Start 1-compressor unit compressor Band: 6°C (P09.43) Integral limit: 20% Integral time: 90 s Set point Pass [KW]...

  • Page 21: Alarms

    GL-Series & HeaMo Technical Manual CA16 2. ALARMS Press the [ALARM] key once to enter the “alarms menu” and view the alarm message along with its code. If there is more than one alarm, scroll the menu using the [UP] and [DOWN] keys. In the W3000 base, “NO A”...
  • Page 22 Technical Manual CA16 GL-Series & HeaMo ALARM DESCRIPTION details RESET Condenser pump overheated (only for Condenser pump thermal switch water/water units with freon reversal) Recuperator pump thermal protection Recuperator pump overheated Glycol pump overheated (in units with Glycol pump thermal switch freecooling).
  • Page 23 GL-Series & HeaMo Technical Manual CA16 Circuit 1 low pressure Low pressure detected by the PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 24 Technical Manual CA16 GL-Series & HeaMo ALARM DESCRIPTION details RESET transducer/pressure switch on circuit 1 “as above, for circuit 2” Circuit 2 low pressure “as above, for circuit 3” Circuit 3 low pressure “as above, for circuit 4” Circuit 4 low pressure High pressure detected by the Transducer 1 high pressure transducer/pressure switch on cooling circuit 1...
  • Page 25 GL-Series & HeaMo Technical Manual CA16 Compressor 1 bearings Compressor 1 bearings faulty (only for units with PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 26 Technical Manual CA16 GL-Series & HeaMo ALARM DESCRIPTION details RESET centrifuge compressors) “as above, for compressor 2” Compressor 2 bearings “as above, for compressor 3” Compressor 3 bearings “as above, for compressor 4” Compressor 4 bearings Compressor 1 SCR temperature over max. (only Compressor 1 SCR temperature for units with centrifuge compressors) “as above, for compressor 2”...
  • Page 27 GL-Series & HeaMo Technical Manual CA16 ALARM DESCRIPTION details RESET “analogue, as above” Exp 2 Probe 5 error slave “analogue, as above” Exp 2 Probe 6 error slave “analogue, as above” Exp 2 Probe 7 error slave “analogue, as above” Exp 2 Probe 8 error slave “analogue, as above”...

  • Page 28: Table Of Masks

    Technical Manual CA16 GL-Series & HeaMo 3. TABLE OF MASKS Press [UP] or [DOWN] to move from one mask to another inside the same menu. Press [ENTER] to access the parameter, press [UP] or [DOWN] to change the value of the parameter. Para n°...
  • Page 29 GL-Series & HeaMo Technical Manual CA16 Refrigerant: Sets the type of refrigerant used. 01.13 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 30 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Type : R407c Recovery: Enables recovery. 01.14 Enabled: N Recovery is enabled automatically in the polyvalent units. Freecooling: Enables freecooling control. 01.15 Enabled: N Enable probes: Probe enable mask for enabling the external air temperature probe or optional temperature 01.17 probe (only visible in water-air units) 01.24...
  • Page 31 GL-Series & HeaMo Technical Manual CA16 Subcooling Enables subcooling modulating adjustment (only for units with centrifuge compressors) 05.30 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 32 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description modulating adjustment Enable Subcooling Enables subcooling. 05.16 Enabled This function is only enabled in chillers with recovery mode. Subcooling Sets the delay before subcooling adjustment commences and the delay in the subcooling 05.17 Adjustment start relay.
  • Page 33 GL-Series & HeaMo Technical Manual CA16 Power incr. impulse: Sets the period and duration of the power increase impulse. 09.14 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 34 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Period: 010 s (Only for modulating adjustment of screw compressors) 09.15 Min. dur.: 00.3 s 09.16 Max. dur.: 02.0 s Power decr. impulse: Sets the period and duration of the power decrease impulse. 09.17 Period: 010 s...
  • Page 35 GL-Series & HeaMo Technical Manual CA16 Access mask to valves submenu. Press "Up" or "Down" to scroll the other masks and "Esc" to PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 36 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Valves return to the submenu.   Status configuration Status editor mask. S0 => off Configures the valves (A=valve open, C=valve closed) in each status (S0,S1,… S12). Valves: CCCCCCCCCC => 00 Valve configuration is automatically converted.
  • Page 37 GL-Series & HeaMo Technical Manual CA16 Ext t.-evap. t. (only for auto tuning) 21.13 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 38 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description difference threshold Initial threshold for the difference between external temperature and evaporation temperature for changing defrost for changing the defrost start delay. delay 15.0°C Threshold offset (only for auto tuning) 21.14 Start var.
  • Page 39 GL-Series & HeaMo Technical Manual CA16 Cont. cond. control Sets the setpoint and differential for continuous condensation adjustment in the chiller mode. 17.32 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 40 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Chiller 17.33 Setpoint 14.0 bar Diff. 05.0 bar Cont. cond. control Sets the setpoint and differential for continuous condensation adjustment in the heat pump 17.34 HeatPump mode. 17.35 Setpoint 06.0 bar Diff.
  • Page 41 GL-Series & HeaMo Technical Manual CA16 Recuperator flow Configuration parameters for recuperator flow switch alarm. 23.28 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 42 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description switch alarm: Start delay: minimum time during which the flow must remain constant before the 23.29 Start delay 010 s compressors start running. Running delay 001 s Running delay: minimum time before the flow switch triggers with the compressors running. Condenser flow Configuration parameters for condenser flow switch alarm.
  • Page 43 GL-Series & HeaMo Technical Manual CA16 Dual setpoint Enables selection of a second setpoint via an external contact (only displayed on compatible 55.19 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 44 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Enable units). Setpoint variation Enables setpoint variation through an external input which can be configured at 4-20mA or 0- 55.20 Enabled 4-20 mA 5V. Maximum and minimum variation limits can also be set. If time bands have been enabled 55.21 Min.
  • Page 45 GL-Series & HeaMo Technical Manual CA16 Hour counter Sets the threshold for programmed maintenance on the evaporator pump. PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 46 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Pump: 35.01 Threshold 012x1000 Reset N° 000000 Hour counter Sets the threshold for programmed maintenance on pump 2. (this may be pump 2 of the 35.02 Pump 2: evaporator or the pump on the secondary circuit in the water/water units or the recuperator Threshold 012x1000 pump, depending on unit configuration)
  • Page 47 GL-Series & HeaMo Technical Manual CA16 Antifreeze Mask for setting the offset (with respect to the antifreeze alarm) and differential of the anti- 35.44 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 48 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description pre-alarm freeze pre-alarm on the evaporator (only visible if pre-alarm management is enabled). The 35.45 Offset 00.5 °C anti-freeze alarm setpoint and offset define signal activation, the differential defines deactiva- Diff.
  • Page 49 GL-Series & HeaMo Technical Manual CA16 Master calibration Modifies the probe offsets. (Only present if required by the type of machine configured) 27.03 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 50 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description offset Value The word "master" only appears on units with more than 2 circuits. 27.04 0.0°C 12.3°C 0.0°C 12.3°C Master calibration Modifies the probe offsets. (Only present if required by the type of machine configured) 27.05 offset Value...
  • Page 51 GL-Series & HeaMo Technical Manual CA16 Slave calibr. exp1 Modifies the probe offsets of expansion 1. (Only present if required by the type of machine 31.11 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 52 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description offset Value configured) 31.12 0.0°C 35.6°C 0.0°C 40.5°C Slave calibr. exp1 Modifies the probe offsets of expansion 1. (Only present if required by the type of machine 31.13 offset Value configured) 31.14 0.0°C...
  • Page 53 GL-Series & HeaMo Technical Manual CA16 Enter another Personalises the password by defining one that will replace the default password. PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 54 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description user password 0000 Access mask to unit menu. Press "Up" or "Down" to scroll the other masks and "Esc" to return Unit to the submenu.   Temp. Out. Displays inlet and outlet temperatures of the evaporator, recuperator and condenser (where Evap.
  • Page 55 GL-Series & HeaMo Technical Manual CA16 Analogue outputs: Displays analogue outputs 1 and 2. Shows the percentage of demand of the devices PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 56 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Cond. 1 adj.:000 % connected to it (for non-linear devices correspondence with supplied voltage V does not Cond. 2 adj.:000 % apply). Compares Cond.1-2 adj. with single or dual ventilation adjustment. Analogue outputs: Displays analogue outputs 3 and 4.
  • Page 57 GL-Series & HeaMo Technical Manual CA16 Enable Selects/deselects circuits. 47.01 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 58 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description circuits 47.02 Circ1: Y Circ2: 47.03 Circ3: N Circ4: 47.04 Enable Selects/deselects compressors. 47.05 compressors 47.06 C1:Y C2:Y C3:Y C4:Y 47.07 47.08 W 3000 This mask contains the reference information of the software [Code]. The closed padlock symbol shows that the board is provided with its propriety software;...
  • Page 59 GL-Series & HeaMo Technical Manual CA16 An. Out. master Voltage applied to analogue outputs 1 and 2. PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 60 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description N° Value Master is only specified on units with 3 or 4 circuits. 00.0 V 00.0 V An. Out. master Voltage applied to analogue outputs 3 and 4. N° Value Master is only specified on units with 3 or 4 circuits.
  • Page 61 GL-Series & HeaMo Technical Manual CA16 An. Out. master exp3 Voltage applied to analogue output 1 of expansion 3 (if present). PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 62 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description N° Value Master is only specified on units with 3 or 4 circuits. 00.0 V Dig.In. master exp4 Displays the state of the digital inputs of expansion 4 (if present) and specifies their state. 12345 67890 12345 C: Contact closed CCCCC CCCCC CCCCC...
  • Page 63 GL-Series & HeaMo Technical Manual CA16 An. Out. slave Voltage applied to analogue outputs 5 and 6. PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 64 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description N° Value 00.0 V 00.0 V Slaves required Mask indicating the address for the slave expansion boards. This changes depending on the Exp.1: Exp.2: parameter settings. Exp.3: Exp.4: Master is only specified on units with 3 or 4 circuits. Exp.5: Slaves on-line Mask for checking connection with the slave expansion boards.
  • Page 65 GL-Series & HeaMo Technical Manual CA16 Dig.Out. slave exp4 Displays the state of the digital outputs of expansion 4 (if present) and specifies their state. PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 66 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description 12345 67890 12345 C: Contact closed AAAAA AAAAA AAAAA A: Contact open AAAAA AAAAA AAAA An. In. slave exp4 Displays analogue inputs 1 and 2 of expansion 4 (if present). N°...
  • Page 67 GL-Series & HeaMo Technical Manual CA16 Time band 3A Off Setting band A, third daily time band. 901.13 PR-2015-5341-GB · Subject to modifications · R1-07/2019...

  • Page 68: Sp S 08.0°C W 40.0°C

    Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Time 12:00 / 13:30 901.14 Sp S 08.0°C W 40.0°C 901.15 Sp R 40.0°C 901.16 901.17 901.18 Time band 4A Adj. Setting band A, fourth daily time band. 901.19 Time 13:30 / 19:30 901.20 Sp S 07.0°C W 45.0°C 901.21...

  • Page 69: Time Band 6A Off

    GL-Series & HeaMo Technical Manual CA16 Time band 6B Off Setting band B, sixth daily time band. 902.31 PR-2015-5341-GB · Subject to modifications · R1-07/2019...

  • Page 70: Time 19:30 / 19:30

    Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Time 19:30 / 19:30 902.32 Sp S 09.0°C W 40.0°C 902.33 Sp R 40.0°C 902.34 902.35 902.36 Time band 7B Off Setting band B, seventh daily time band. 902.37 Time 19:30 / 19:30 902.38 Sp S 09.0°C W 40.0°C 902.39...
  • Page 71 GL-Series & HeaMo Technical Manual CA16 Time band 9C Off Setting band C, ninth daily time band. 903.49 PR-2015-5341-GB · Subject to modifications · R1-07/2019...

  • Page 72: Time 00:00 / 06:30 Sp S 09.0°C W 40.0°C Sp R 40.0°C

    Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description Time 19:30 / 19:30 903.50 Sp S 09.0°C W 40.0°C 903.51 Sp R 40.0°C 903.52 903.53 903.54 Time band 10C Off Setting band C, tenth daily time band. 903.55 Time 19:30 / 19:30 903.56 Sp S 09.0°C W 40.0°C 903.57...

  • Page 73: Table Of Masks W3000 Base

    GL-Series & HeaMo Technical Manual CA16 4. TABLE OF MASKS W3000 base Para n° Mask Description level1 | level2 | level3 Main display mask. Indicates the state of the unit ("ON", "OFF"). >MODE The submask displays the operating mode of the unit >...
  • Page 74 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description >LL U The submask is used to set the lower limit of the heat pump setpoint with outlet adjustment > > 0 expressed in degrees centigrade 55.11 >HL U The submask is used to set the upper limit of the heat pump setpoint with outlet adjustment >...
  • Page 75 GL-Series & HeaMo Technical Manual CA16 >FLOU The submask is used to set the adjustment flow type. PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 76 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description > > IN "IN"= inlet flow, "OUT"= outlet type 39.02 >BAND The submask can be used to enable time bands > > N "N"= disabled, "Y"= enabled 39.41 >SER The submask is used to enable the supervisor >...
  • Page 77 GL-Series & HeaMo Technical Manual CA16 >AI 7 Displays analogue input 7 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 78 Technical Manual CA16 GL-Series & HeaMo Para n° Mask Description > > 0 value >AI 8 Displays analogue input 8 > > 0 value >AO 3 Displays analogue output 3 > > 70 value expressed in Volts >AO 4 Displays analogue output 4 >...
  • Page 79 GL-Series & HeaMo Technical Manual CA16 Para n° Mask Description >LH 2 Displays compressor 2 operating hours expressed in units > > 50 e.g.: "50"=50 hours >SEL1 Enables compressor 1 > > Y "N"=deselected, "Y"= selected 47.05 >SEL2 Enables compressor 2 >...

  • Page 80: Parameters Table

    Technical Manual CA16 GL-Series & HeaMo 5. PARAMETERS TABLE Para n° Description of parameter Default U.M. Min. Max. 01.01 Type of unit (0:chiller - 1:heat pump - 2:multi-use) P 99.01 01.02 Type of compressors (0:centrifuge - 1:hermetic - 2:semi-hermetic - 3:screw) P 99.25 P 99.02 N°...
  • Page 81 GL-Series & HeaMo Technical Manual CA16 09.05 Maximum number of compressor start-ups (with Quick Mind or modulating PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 82 Technical Manual CA16 GL-Series & HeaMo Para n° Description of parameter Default U.M. Min. Max. adjustment of screw compressors) Maximum compressor start-up time (with Quick Mind or modulating 09.06 adjustment of screw compressors) 09.07 Enables 100% screw compressor forcing (0:disabled - 1:enabled) °C 09.08 Minimum separation mode temperature setpoint...
  • Page 83 GL-Series & HeaMo Technical Manual CA16 13.14 Valve 1 release time PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 84 Technical Manual CA16 GL-Series & HeaMo Para n° Description of parameter Default U.M. Min. Max. 13.15 Valve 2 release time 13.16 Valve 3 release time 13.17 Valve 4 release time 13.18 Valve 5 release time 13.19 Valve 6 release time 13.20 Valve 7 release time 13.21...
  • Page 85 GL-Series & HeaMo Technical Manual CA16 21.23 Free defrost enable (0:disabled - 1:enabled) PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 86 Technical Manual CA16 GL-Series & HeaMo Para n° Description of parameter Default U.M. Min. Max. °C 21.24 Minimum external temperature for free defrost operation -10.0 10.0 21.25 Drip mode enable with compressors on (0:disabled - 1:enabled) 23.01 High pressure from transducers alarm 28.0 P 25.07 23.02...
  • Page 87 GL-Series & HeaMo Technical Manual CA16 °C/bar 31.21 Expansion 2 Slave Probe 1 calibration -9.9 PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 88 Technical Manual CA16 GL-Series & HeaMo Para n° Description of parameter Default U.M. Min. Max. °C/bar 31.22 Expansion 2 Slave Probe 2 calibration -9.9 °C/bar 31.23 Expansion 2 Slave Probe 3 calibration -9.9 °C/bar 31.24 Expansion 2 Slave Probe 4 calibration -9.9 °C/bar 31.25...
  • Page 89 GL-Series & HeaMo Technical Manual CA16 39.45 #Set communication protocol with supervisor (1:Standard - 2:ModBus - PR-2015-5341-GB · Subject to modifications · R1-07/2019...
  • Page 90 Technical Manual CA16 GL-Series & HeaMo Para n° Description of parameter Default U.M. Min. Max. 3:LonWorks - 4:Trend - 5:Bacnet) #Speed of communication with supervisor setting (0:1200 baud - 1:2400 39.46 baud - 2:4800 baud - 3:9600 baud - 4:19200 baud) 39.47 #Set unit identification number with supervisor 39.48...
  • Page 91 GL-Series & HeaMo Technical Manual CA16 Para n° Description of parameter Default U.M. Min. Max. Evaporator pump operating mode (0:automatic - 1:pump 1 only - 2:pump 2 55.28 only) 55.29 Minimum delay between pump start-up and compressor start-up 55.30 Pump shutdown delay 55.31 Enable limit demand (0:No - 1:Yes) 55.32...

  • Page 92: Table Of Parameter Limits (Depending On Unit Configuration)

    Technical Manual CA16 GL-Series & HeaMo 5.1. Table of parameter limits (depending on unit configuration) Para n° Description of parameter 99.01 Maximum settable limit for configuring the machine type (depends on the type of hardware and the type of compressor): - with hardware L and centrifuge compressors (0:chiller) - with hardware B (1:chiller and heat pump) - other cases (2:chiller, heat pump, all-in-one)
  • Page 93 GL-Series & HeaMo Technical Manual CA16 Para n° Description of parameter 99.25 Minimum settable limit for choosing the compressor type (depends on the type of board installed): - with hardware B (1:hermetic) - with hardware L (0:centrifuge or hermetic) - with hardware XL (2:alternative or screw) 99.26 Possible ventilation type, depends on the number of cooling circuits: - unit with 4 circuits (2: separate, single or dual ventilation)

  • Page 94: Diagrams

    Technical Manual CA16 GL-Series & HeaMo 6. DIAGRAMS This section explains how some operating algorithms work. Most of the configuration parameters are con- tained in the manufacturer and service menus; the tree diagram for navigation is shown below. Enter the manufacturer menu (not present in W3000 base) by pressing [Menu] / selecting the manufacturer menu by pressing [UP] / entering the password.
  • Page 95 GL-Series & HeaMo Technical Manual CA16 Enter the service menu (only partly present in W3000 base) by pressing [Menu] / selecting the service menu by pressing [UP] / entering the password. The tree diagram of the service menu is shown in figure 6.0b. Select assistance Assistance menu menu...

  • Page 96: Freecooling

    Technical Manual CA16 GL-Series & HeaMo 6.1. Freecooling The “freecooling” function is applied to the efficient production of cold water by using external air. The operating principle is illustrated in the following figure External air Text Tout Tfcool FREECOOLING EVAPORATOR COIL "3-way"...
  • Page 97 GL-Series & HeaMo Technical Manual CA16 richiesta Step speed adjustment demand Regolazione velocità a step n. step T. in Setpoint Setpoint Banda dinamica di freecooling Dynamic freecooling band Dynamic Chiller Dinamico Chiller setpoint setpoint Figure 6.2c: fan adjustment in the step mode (example with 8 fans) richiesta demand Regolazione velocità...

  • Page 98: Condensation

    Technical Manual CA16 GL-Series & HeaMo 6.2. Condensation Condensation adjustment depends on how the fans are turned on. Various condensation adjustment types in the “chiller” operating mode are shown below. The fans may be turned on using the on/off system ( “step”) in which the fans are turned on progressively one after the other (figure 6.3a) or mutually excluded (figure 6.3b).

  • Page 99: Hardware

    GL-Series & HeaMo Technical Manual CA16 7. HARDWARE “M” “L” “XL” PR-2015-5341-GB · Subject to modifications · R1-07/2019...

  • Page 100: Hardware "B", Board Configuration With Jumper 5V-24V

    Technical Manual CA16 GL-Series & HeaMo EXPANSION “E” W3000 “B” 7.1. HARDWARE “B”, board configuration with JUMPER 5V-24V A jumper has been added for selecting the input voltage of the pressure probes: As the +V terminals have been shorted together, they will both be at 5V or 24V, depending on the position of the jumper.

  • Page 101: Input/Output Configuration Table

    GL-Series & HeaMo Technical Manual CA16 8. INPUT/OUTPUT CONFIGURATION TABLE 8.1. HARDWARE “L” 8.1.1. Units with hermetic compressors WATER-AIR UNIT with “L” axial fans WATER-AIR UNIT with “L” centrifuge fans Digital inputs Digital inputs ID1 Circuit 1 low pressure switch ID1 Circuit 1 low pressure switch ID2 Compressor 1 thermal protection ID2 Compressor 1 thermal protection...
  • Page 102 Technical Manual CA16 GL-Series & HeaMo “L” WATER-WATER UNIT “L” Digital inputs ID1 Circuit 1 low pressure switch ID2 Compressor 1 thermal protection ID3 Compressor 2 thermal protection ID4 Circuit 2 low pressure switch ID5 Compressor 3 thermal protection ID6 Compressor 4 thermal protection Condenser flow switch (units with freon-side re- versal only) ID9 Evaporator flow switch...
  • Page 103 GL-Series & HeaMo Technical Manual CA16 “L” CONDENSING UNIT “L” EVAPORATING UNIT Digital inputs Digital inputs ID1 Circuit 1 low pressure switch ID1 Circuit 1 low pressure switch ID2 Compressor 1 thermal protection ID2 Compressor 1 thermal protection ID3 Compressor 2 thermal protection ID3 Compressor 2 thermal protection ID4 Circuit 2 low pressure switch ID4 Circuit 2 low pressure switch...

  • Page 104: Units With Centrifuge Compressors

    Technical Manual CA16 GL-Series & HeaMo 8.1.2. Units with centrifuge compressors WATER-WATER UNIT with “L” axial fans “L” WATER-WATER UNIT “L” Digital inputs Digital inputs ID7 Circuit 1 fan thermal protection ID8 Circuit 2 fan thermal protection ID9 Evaporator flow switch ID9 Evaporator flow switch ID10 Remote on/off ID10 Remote on/off...

  • Page 105: Hardware "Xl

    GL-Series & HeaMo Technical Manual CA16 8.2. HARDWARE “XL” WATER-WATER UNIT with “XL” axial fans WATER-WATER UNIT with “XL” centrifuge fans Digital inputs Digital inputs ID1 Circuit 1 low pressure switch ID1 Circuit 1 low pressure switch ID2 Compressor 1 thermal protection ID2 Compressor 1 thermal protection ID3 Compressor 2 thermal protection ID3 Compressor 2 thermal protection...
  • Page 106 Technical Manual CA16 GL-Series & HeaMo “XL” WATER-WATER UNIT “XL” CONDENSING UNIT Digital inputs Digital inputs ID1 Circuit 1 low pressure switch ID1 Circuit 1 low pressure switch ID2 Compressor 1 thermal protection ID2 Compressor 1 thermal protection ID3 Compressor 2 thermal protection ID3 Compressor 2 thermal protection ID4 Circuit 2 low pressure switch ID4 Circuit 2 low pressure switch...
  • Page 107 GL-Series & HeaMo Technical Manual CA16 “XL” EVAPORATING UNIT Digital inputs ID1 Circuit 1 low pressure switch ID2 Compressor 1 thermal protection ID3 Compressor 2 thermal protection ID4 Circuit 2 low pressure switch ID5 Compressor 1 oil ID6 Compressor 2 oil ID7 Circuit 1 fan thermal protection ID8 Circuit 2 fan thermal protection ID9 Evaporator flow switch...

  • Page 108: Hardware "B

    Technical Manual CA16 GL-Series & HeaMo 8.3. HARDWARE “B” Water/air chiller with “B” axial fans Water/air chiller with “B” centrifuge fans Digital inputs Digital inputs ID1 Circuit 1 high pressure switch ID1 Circuit 1 high pressure switch High pressure transducer circuit 2 / Low pressure High pressure transducer circuit 2 / Low pressure transducer circuit 1 transducer circuit 1...
  • Page 109 GL-Series & HeaMo Technical Manual CA16 WATER-WATER UNIT “B” Digital inputs ID1 Circuit 1 high pressure switch ID2 Circuit 2 high pressure switch ID3 Remote on/off ID4 Chiller/Heat pump from external contact ID5 Evaporator flow switch ID6 Circuit 1 low pressure switch ID7 Circuit 2 low pressure switch ID8 Compressor 1 thermal protection ID9 Compressor 2 thermal protection...

  • Page 110: Expansions

    Technical Manual CA16 GL-Series & HeaMo 8.4. EXPANSIONS 8.4.1. Units with hermetic compressors “E” expansion for chiller with recovery. Expansion "E" - address 1 Digital inputs Digital inputs Recovery flow switch Recovery remote enable Analogue inputs Circuit 1 liquid temperature Circuit 2 liquid temperature Recovery inlet temperature ID10...
  • Page 111 GL-Series & HeaMo Technical Manual CA16 “E” Expansion Heat pumps for low external air temperatures Expansion “E” - address 1 Digital inputs Digital inputs Analogue inputs Compressor 1 outlet temperature Compressor 2 outlet temperature Compressor 3 outlet temperature ID10 Compressor 4 outlet temperature ID11 ID12 Digital outputs...
  • Page 112 Technical Manual CA16 GL-Series & HeaMo “M” expansion for hermetic compressors. Air-cooled polyvalent units and heat pumps with total recovery. Expansion "M" - address 2 Digital inputs Digital inputs Recovery flow switch ID10 ID10 ID11 ID11 ID12 ID12 ID13 ID13 ID14 ID14 ID15...
  • Page 113 GL-Series & HeaMo Technical Manual CA16 “M” expansion for hermetic compressors. Water-cooled polyvalent units and heat pumps with total recovery. Expansion "M" - address 2 Digital inputs Digital inputs Recovery flow switch Condenser flow switch Condenser pump thermal switch ID10 ID10 ID11 ID11...
  • Page 114 Technical Manual CA16 GL-Series & HeaMo “E” expansion for hermetic compressors. Chiller with freecooling. Expansion "E" - address 3 Digital inputs Digital inputs Glycol pump thermal switch Analogue inputs Circuit 1 low pressure transducer Circuit 2 low pressure transducer Freecooling inlet temperature ID10 ID11 ID12...

  • Page 115: Units With Alternative And Screw Compressors

    GL-Series & HeaMo Technical Manual CA16 8.4.2. Units with alternative and screw compressors “E” expansions for chillers with heat pumps or two pumps. Expansion "E" - address 5 Digital inputs Digital inputs Chiller/Heat pump from external contact Pump 1 thermal switch Pump 2 thermal switch Analogue inputs Evap.
  • Page 116 Technical Manual CA16 GL-Series & HeaMo “E” expansions for chillers with external signal setpoint variation or dual setpoint. Expansion "E" - address 3 Digital inputs Digital inputs Glycol pump thermal switch Dual setpoint Analogue inputs Setpoint var. from ext. signal (4-20mA) Recovery setpoint var.
  • Page 117 GL-Series & HeaMo Technical Manual CA16 “E” expansions for chillers with recovery. Expansion "E" - address 1 Digital inputs Digital inputs Recovery flow switch Recovery remote enable Analogue inputs Circuit 1 liquid temperature Circuit 2 liquid temperature Recovery inlet temperature ID10 Recovery outlet temperature ID11...
  • Page 118 Technical Manual CA16 GL-Series & HeaMo “M” expansion for alternative and screw compressors. Air-cooled polyvalent units and heat pumps with total recovery. Expansion "M" - address 2 Digital inputs Digital inputs Recovery flow switch ID10 ID10 ID11 ID11 ID12 ID12 ID13 ID13 ID14...
  • Page 119 GL-Series & HeaMo Technical Manual CA16 “M” expansion for alternative and screw compressors. Water-cooled polyvalent units and heat pumps with total recovery. Expansion "M" - address 2 Digital inputs Digital inputs Recovery flow switch Condenser flow switch Condenser pump thermal switch Not used ID10 ID10...
  • Page 120 Technical Manual CA16 GL-Series & HeaMo “E” expansion for alternative and screw compressors. Chiller with freecooling. Expansion "E" - address 3 Digital inputs Digital inputs Glycol pump thermal switch Dual setpoint from external contact Analogue inputs Setpoint var. from ext. signal (4-20mA) Recovery setpoint var.
  • Page 121 GL-Series & HeaMo Technical Manual CA16 “E” expansions for semi-hermetic compressors. Condensing unit or for alternative compressors. Unit with four compressors on two circuits. Expansion "E" - address 4 Digital inputs Digital inputs Compressor 3 thermal protection Compressor 4 thermal protection Compressor 3 oil Compressor 4 oil Analogue inputs...

  • Page 122: Units With Centrifuge Compressors

    Technical Manual CA16 GL-Series & HeaMo 8.4.3. Units with centrifuge compressors Expansion “E” Chiller with bypass valves. Expansion "E" - address 1 Digital inputs Digital inputs Analogue inputs ID10 ID11 ID12 Digital outputs ID13 Injection 1 ID14 Injection 2 ID15 Injection 3 ID16 Injection 4...

  • Page 123: Connecting Several Boards

    GL-Series & HeaMo Technical Manual CA16 9. CONNECTING SEVERAL BOARDS Caution: , perform the following operations before touching the boards in order to prevent electrostatic discharge: • wear the bracelet (connected to the earth circuit) and the heel strap • the board should be closed inside an antistatic bag protecting it from electrostatic discharge: remove it from the bag and place it on the light-blue mat with the yellow edge or on the dark-blue mat.
  • Page 124 Technical Manual CA16 GL-Series & HeaMo EXPANSIONS FOR HERMETIC COMPRESSORS Additional function Function, chiller type Expansion Expansion address type Recovery enable Chiller with heat recovery Low external air temperature kit Heat pump for low external air tem- peratures Recovery enable Multi-purpose Heat pump with total heat recovery Freecooling enable...

  • Page 125: Master-Slave" Connection

    GL-Series & HeaMo Technical Manual CA16 9.2. “MASTER-SLAVE” connection Intelligence is distributed instead in the “master-slave” connections. Suppose we have a unit with 4 cooling circuits: t . In this he master board manages circuits 1 and 2 while the slave board manages circuits 3 and 4 case, the additional board is not simply an input/output expansion, but is fully involved managing part of the unit.

  • Page 126: Mixed" Connection

    Technical Manual CA16 GL-Series & HeaMo 9.3. “Mixed” connection The “mixed” connection is used in units with 3/4 cooling circuits where an increase in inputs/outputs is required. The master board manages circuits 1 and 2 while the slave board manages circuits 3 and 4. Additionally, depending on the required functions or the type of machine, boards used as expansions can be connected.
  • Page 127 GL-Series & HeaMo Technical Manual CA16 Master Expansion M Expansion E Slave Expansion M Figure 9.3b: “mixed” connection PR-2015-5341-GB · Subject to modifications · R1-07/2019...

  • Page 128: Terminal Configuration

    Technical Manual CA16 GL-Series & HeaMo 10. Terminal configuration The first thing to do when connecting the boards of several units in a network in order to have a remote keypad or replace a board, is to configure the terminals. This cannot be achieved with the basic W3000 keypad.

  • Page 129: Setting The Board Address

    GL-Series & HeaMo Technical Manual CA16 10.2. Setting the board address The board address is set by the software using the keypad. Proceed as follows: Display address Make sure the keypad address is set to 0 (see keypad address settings Setting..:00 para) I/O Board address:...

  • Page 130: Plan Network Configuration

    Technical Manual CA16 GL-Series & HeaMo 10.3. Plan network configuration 10.3.1. Plan network connection (local) For each unit with an on-board keyboard, perform the following procedure to create a “local” plan network: Make sure the board has been addressed (as described in the previous pLan address: increase paragraph).

  • Page 131: Configuring The Plan Network (Global)

    GL-Series & HeaMo Technical Manual CA16 10.3.2. Configuring the plan network (global) It is easy to install a PLAN network (global). Just a few but essential operations are required. If just one of these is not performed correctly, the entire system will not work. The remote keyboard will work problem-free if the following operations are performed one after the other.

  • Page 132: Connecting The Remote Keypad

    Technical Manual CA16 GL-Series & HeaMo 10.4. Connecting the remote keypad Usually, just the keyboard on the chiller is used. This is connected directly to connector J10. It is possible to connect a remote keyboard to the chillers and choose between various configurations. Unit 10.4.1.

  • Page 133: Remote Keyboard Up To 200 Metres

    GL-Series & HeaMo Technical Manual CA16 10.4.2. Remote keyboard up to 200 metres To connect a remote keyboard two “T” shunt boards must be used, one near the controller and one near the remote keyboard. If a remote keyboard monitors just one unit, the correct configuration is: Shielded and twisted Unit...

  • Page 134: Remote Keyboard From 200 Metres Up To 500 Metres

    Technical Manual CA16 GL-Series & HeaMo 10.4.3. Remote keyboard from 200 metres up to 500 metres If the remote keyboard must be installed over 200m away from the plan network, a power unit must be installed near the remote keyboard. The remote keyboard cannot be installed more than 500 m away.

  • Page 135: Remote Keypad For More Than One Unit

    GL-Series & HeaMo Technical Manual CA16 10.4.4. Remote keypad for more than one unit To connect more than one chiller to the same remote keyboard, connect the two boards together by jumpering connectors J11. A configuration similar to the two shown above should only be used on the last board in the network (the one nearest the remote keyboard).
  • Page 136 Technical Manual CA16 GL-Series & HeaMo SYMBOLS The following symbols are used in the W3000 and W3000 compact masks. Flashing items Description on main mask Bands Time bands active Fcool Unit in free-cooling mode Limit Power limit active (demand limit) Freeze Outlet temperature approaching anti-freeze setpoint Unit...
  • Page 137 WWW.FLAKTGROUP.COM SERVICE MANUAL CA16 FläktGroup is the European market leader for smart and energy efficient Indoor Air and Critical Air solutions to support every application area. We offer our customers innovative technologies, high quality and outstanding performance supported by more than a century of accumulated industry experience.

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