gelsystem ECOFLOW FCi Series Use And Maintenance Manual

Water economisers

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Gelsystem srl

Industrial refrigeration and air conditioning systems

Registered Office: Viale Parioli 73 Roma 00197

Production Site: strada Teverina Km5,4 Loc. Acquarossa 01100 Viterbo VT

Tel (+39) 0761.17.63.927, Fax (+39) 0761.1871.004, E-mail:

ufficiotecnico@gelsystem.eu

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Page 1 Gelsystem srl Industrial refrigeration and air conditioning systems Registered Office: Viale Parioli 73 Roma 00197 Production Site: strada Teverina Km5,4 Loc. Acquarossa 01100 Viterbo VT Tel (+39) 0761.17.63.927, Fax (+39) 0761.1871.004, E-mail: ufficiotecnico@gelsystem.eu...
Page 2 DIRECTIVE 2014/68/EU on pressure equipment Gelsystem thanks you for choosing this product and recommends you carefully read all the pages that compose this Use and Maintenance Manual; the information within is of fundamental importance for a safe and long-lasting use of the ECOFLOW economiser you have been supplied.
Page 3 Important notes on installation:  The unit needs a mono-propylene glycol solution equal to 30% of the water volume.  Should you decide not to make use of the hot sanitary water production unit (if present), the circulator pump will need to be deactivated: parameter AR06 needs to be set to 0 (zero).
Page 4: Table Of Contents
1. GENERAL RECOMMENDATIONS ………………………………………..…………………………5 2. INTRODUCTORY NOTES ……………………………………………..………………………………7 2.1 N ................7 OTES AND WARNINGS 2.2 T ..............8 RANSPORT AND HANDLING 2.3 U ................... 8 NPACKING 2.4 I ..................8 NSTALLATION 2.5 H ..............14 YDRAULIC CONNECTION 2.6 P ................
Page 5 ATTACHMENTS: nr. 1 SYSTEM DECLARATION OF CE CONFORMITY nr. 2 SYSTEM CIRCUIT DIAGRAM nr. 3 APPLICABILITY OF COMMUNITY DIRECTIVES TO SYSTEM COMPONENTS nr. 4 CONDENSER UNIT, EVAPORATOR, AND CONTROL PANEL CIRCUIT DIAGRAM nr. 5 COOLANT SAFETY DATA SHEET...
Page 6: General Recommendations
GENERAL RECOMMENDATIONS  INSTALLATION AND MAINTENANCE Prior to any work, installation, start-up, use and maintenance of the equipment, the personnel in charge of these operations must understand all the instructions and recommendations detailed in the system’s user guide and the elements of technical practice of the blueprint. The staff in charge of receiving the system must perform visual control to detect any damage the equipment might have sustained during transport: cooling circuit, control panel, casing, and chassis.
Page 7 Any work on the cooling circuit must be performed in compliance with workmanlike manner and security standards: coolant collection, nitrogen brazing, etc. Any brazing work must be performed by qualified personnel. This system contains pressurised equipment. Only use original spare parts listed on the spare parts table, for defective cooling component replacements.
Page 8: Introductory Notes
Any work on the system can only be performed after shutting down the power. The system must be installed, started up, and maintained by qualified personnel provided by GELSYSTEM’s Support Centre, in full compliance with the current norms. The company does not take responsibility for any potential damage to things, people, animals and/or the product in case of: Improper usage of the equipment;...
Page 9: Transport And Handling
Testing of the system on the end-user’s premises must be performed by qualified technical personnel or by a GELSYSTEM expert after placing the equipment correctly and adequately connecting it to a power supply network. The devices have been designed to be level installed, on wheels or resting on the floor, and can’t be installed close to boiler smoke exhaust chutes nor downwind of fats-contaminated air sources, for example large kitchen exhaust fan outlets.
Page 10 Thermal tanks’ capacity and pumps’ range must be endorsed and subscribed by the manufacturing company. For a summary on the minimum clearance to observe when installing Gelsystem systems and remote condensers (if any), please refer to the following tables.
Page 11 Ecoflow Unit with remote condenser Economiser minimum clearance...
Page 12 Front view Side view Gelsystem s.r.l. Ecoflow Unit with remote condenser Condenser minimum clearance...
Page 13 Ecoflow Unit with on-board condenser Ecoflow Unit and condenser minimum clearance...
Page 14: Hydraulic Connection
The system must be connected to the water supply, which must not have a pressure exceeding 0,8 MPa (8 bar). For the Ecoflow installation, only refer to the piping facsimile made by GELSYSTEM. For specific requirements, like outlet relocations for distances exceeding 10 metres from the economiser or height differences between the two, contact GELSYSTEM for information on the piping to be observed and eventual additional pumps to be added to the hydraulic circuit.
Page 15 In the economizer and, more precisely, in the cold-water stainless-steel tank, glycol water must be inserted so that it does not freeze in the heat exchange with the freon, which could reach the temperature of -15°C. The system operates with glycol solution (mono-propylene glycol) at 30% by volume, the use of the economiser with simple network water is prohibited and proves extremely dangerous for the integrity of Ecoflow.
Page 16: Power Connection
-3-ATTENERSI AI DIAMETRI CONSIGLIATI, I QUALI SONO VALIDI SE LE UTENZE RIMANGONO IN UN RAGGIO DI 10 METRI DALL'ECONOMIZZATORE; PER DISTANZE MAGGIORI E/O QUANDO SI PRESENTASSERO DISLIVELLI TRA ECONOMIZZATORE ED UTENZE, CHIEDERE INFORMAZIONI ALL'UF- FICIO TECNICO GELSYSTEM PRIMA DI PROCEDERE ALLA REALIZZAZIONE DELL'IMPIANTO; ...
Page 17: Resupply
The engine installed on the system has lifetime lubrication; therefore, it does not require any control/replacement or refilling. The amount of gas needed for the circuit to operate is fed in by GELSYSTEM during the post-production testing of the system; in case of a new machine there is no need for refills or filling.
Page 18 For it to be valid, it is necessary to meet all the following conditions: Start-up is to be conducted exclusively by personnel authorised by GELSYSTEM; maintenance of the system is to be performed exclusively by authorised personnel;...
Page 19: Generalities
Use and Maintenance Manual GENERALITIES WARNING PLEASE READ THE INFORMATION CONTAINED IN THIS PARAGRAPH THOROUGHLY. THE FOLLOWING INSTRUCTIONS HAVE THE PURPOSE OF SAFEGUARDING YOUR PHYSICAL INTEGRITY! IN ADDITION TO PROTECTING YOURSELF AND YOUR INVESTMENT, THEY SUGGEST THE APPROPRIATE BEHAVIOUR TO BE MAINTAINED WHILE OPERATING THE SYSTEM. Failure to comply with the instructions and recommendations, such as any unauthorised changes to the system provided, entails the customer forfeiture of the right to warranty and exempts the supplier from any liability.
Page 20: Warranty
Regular maintenance of the system is performed. 3.3 Service centre Gelsystem Technical Support Centre is at the service of the Esteemed Customer for any possible inconvenience and/or technical information. To request the intervention of our specialized staff, please contact our Technical Support by calling 0039 0761.17.63.927.
Page 21: Definitions
SYSTEM USE 4.1 System description Gelsystem water economisers are easily placeable in all those activities that foresee significant water consumption for their production. Thanks to the closed-circuit system, it is possible to reuse network water, mixed with a glycol solution that prevents freezing, several times, avoiding waste and excessive costs.
Page 22: Control Panel
Use and Maintenance Manual The economiser cools the water to a temperature of 8-10 ºC, and is particularly suitable to power terminal air conditioning units (e.g., fan coils). The economiser is in turn cooled by direct or remote external air intakes. 4.2 Control panel The control panel consists of an on/off switch and an electronic control unit for programming the system (Fig.2).
Page 23 Use and Maintenance Manual Economiser’s control panel Detail of LED icons on the control unit  LEDs n°1-2 (With RTC – on-board Real-Time Clock): If on the time is shown in the lower display, the clock icon lights up and LEDs n°1/2 flash; ...
Page 24: Warning Icons
Use and Maintenance Manual 4.3 Warning icons...
Page 25: Key Functions
Use and Maintenance Manual 4.4 Key functions DOWN KEY...
Page 26: Front Leds And Icons
Use and Maintenance Manual 4.4.1 Combined key functions 4.5 Front LEDs and icons 4.6 System start-up Under normal circumstances, the system’s first start-up must be executed by the operator following this procedure: A. Toggle the main switch ON; B. Make sure all the cooling circuit valves are open; C.
Page 27: System Shutdown
In case of prolonged shutdowns (more than a month), some safety procedures must be followed to prevent damage on people and/or the compressor. In this regard, it is recommended to contact Gelsystem’s Service Centre by calling 0039 0761.17.63.927 and let a qualified expert operate the system.
Page 28: Maintenance
No derogation from the prescribed rule. The above avoids unnecessary injuries due to electrocution or mechanical impacts. Gelsystem declines any responsibility for damage to things or people in the event of tampering or unauthorised attempt to repair. 5.2 Simple maintenance...
Page 29: Safety And Environment Protection
It is important to have read and understood the entire content of this manual, before using the refrigeration system and equipment. For any doubt or information please contact the Gelsystem Service Centre. When accessing the engine room or condensing or evaporating batteries, it is mandatory: Not to remove protections and safety devices the system and the equipment are fitted with;...
Page 30: Safety Devices
Use and Maintenance Manual 6.1 Safety devices It is mandatory to use adequate safety devices such as gloves, glasses, earmuffs, shoes, helmets and overalls designed to comply with legal regulations concerning safety and to safeguard one’s own bodily integrity. 6.2 Coolant To reduce risk related to the usage of coolants, please observe the following instructions: Avoid high concentrations of coolant fumes (which may become toxic);...
Page 31: Residual Risks
Use and Maintenance Manual You must ensure the environmental temperature does not exceed 65°C and adhere strictly to the instructions listed within the present manual. Such precautions, especially when the system is at a standstill, would prevent the opening of the safety release valve and, subsequently, the loss of coolant filling.
Page 32: First Aid Notions
Use and Maintenance Manual FIRST AID NOTIONS 7.1 General notions NEVER TRY TO REPLACE THE DOCTOR. First aid is help given to those who have experienced an accident of any nature. Related injuries can be minor, serious, or urgent:  Minor: escorting the injured person to the hospital is enough. ...
Page 33: Accidental Contact With Coolant
Use and Maintenance Manual Proceed with more rescue breathing (5 insufflations at a time), eventually alternated with Cardiopulmonary Resuscitation (CPR) (5 compressions at a time, only if there is no detectable heart rate) and with vital function control; Remember: help is on the way. It is extremely important to contact 112/999.
Page 34 Use and Maintenance Manual 8.1 Solving most common issues ISSUE PROBABLE CAUSE RIMEDIO POSSIBILE System does not start Power supply; Check power supply; Tripping protection Reset protections. system. Internal temperature is not Equipment close to heat source; Move heat source away; low enough Clogged condenser.
Page 35 Use and Maintenance Manual -AP 8 - Probe 8 failure (Ptc - Wrong reading; - Check probe reading with a discharge Comp. 5) out-of-range comparison probe; Check proper detection wiring; Replacement -AP 9 - Probe 9 failure (Ntc - Wrong reading; - Check probe reading with a hot H2O) out-of-range...
Page 36 Use and Maintenance Manual -noL Remote terminal - Incorrect connection - Check Electrical connection; error between remote terminal configuration terminal controller terminals configured with same address -Atr1 Remote terminal - Remote terminal not - Check the wiring connection disconnected connected ALARM RESET 1) PRESS “MENÙ”...
Page 37 Use and Maintenance Manual 6) REPEAT STEP 5 IN CASE OF MULTIPLE COMPRESSOR THERMAL ALARMS TO BE RESET 7) PRESS “MENÙ” TO GO BACK TO MAIN SCREEN AC Inverter alarms Inverter alarms Warning: When an overcurrent alarm occurs, it is necessary to reset only after Overcurrent eliminating the cause, otherwise you risk damaging the IGBT inside the inverter.
Page 38 Use and Maintenance Manual Failure of the cooling system.  check for foreign matter in the heat sink Inverter An old cooling fan has not been  Replace fan with a new one overheating replaced with a new one.  maintain room temperature Room temperature is too high.
Page 39 Use and Maintenance Manual...
Page 40 Use and Maintenance Manual NOTES……………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… …………………………………………………………………………………………………………...
Page 41: System Log
Use and Maintenance Manual ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… SYSTEM LOG 9.1 Maintenance Defectiveness found: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Intervention description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 2. Defectiveness found: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Intervention description:...
Page 42 Use and Maintenance Manual ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:……………………………...
Page 43: Coolant And Oil
Use and Maintenance Manual 9.2 Coolant and oil Type of intervention Fluid Brand Q.ty Replacement ………………….………... kg:………... Refill ………………….………… kg:………... Notes ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… Type of intervention Fluid Brand Q.ty Replacement ………………….………... kg:………... Refill ………………….………… kg:………... Notes ………………………………………………………………………………..
Page 44: Prolonged Shutdowns
Use and Maintenance Manual 9.3 Prolonged shutdowns Shutdown on……………………. Stamp:…………………………… Rebooted on……………………. Stamp:…………………………… Total days……………………. Notes:…….………………………… ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Shutdown on……………………. Stamp:…………………………… Rebooted on……………………. Stamp:…………………………… Total days……………………. Notes:…….………………………… ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Shutdown on……………………. Stamp:…………………………… Rebooted on……………………. Stamp:…………………………… Total days……………………. Notes:…….………………………… ………………………………………………………………………………..
Page 45: Component Replacement
Use and Maintenance Manual 9.4 Component replacements Component:………………………………………………………………… Manufacturer:….………………………………………………………………. Model:….…………………………………………………………………. Serial number:….………………………………………………………………… Date:……………………. Stamp:…………………………… Component:………………………………………………………………… Manufacturer:….………………………………………………………………. Model:….…………………………………………………………………. Serial number:….………………………………………………………………… Date:……………………. Stamp:…………………………… Component:………………………………………………………………… Manufacturer:….………………………………………………………………. Model:….…………………………………………………………………. Serial number:….………………………………………………………………… Date:……………………. Stamp:……………………………...