Galletti HWMC 10 EC User manual

HWMC
10 kW - 29 kW
Total heat recovery reversible multi-purpose heat pumps - DC INVERTER
INSTALLATION, USE AND MAINTENANCE MANUAL
GB

HWMC
2All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
1 THE SERIES HWMC ......................................................................................................................................................................................................................5
1.1 Field of application .......................................................................................................................................................................................................................5
1.2 Models and versions.....................................................................................................................................................................................................................6
1.3 Description of components ...........................................................................................................................................................................................................7
1.4 Plumbing diagrams.....................................................................................................................................................................................................................13
2 INSPECTION, HANDLING, DIMENSIONS AND SITING..................................................................................................................................................................16
2.1 Inspection ...................................................................................................................................................................................................................................16
2.2 Handling .....................................................................................................................................................................................................................................16
2.3 Dimensions.................................................................................................................................................................................................................................17
2.4 Siting ..........................................................................................................................................................................................................................................19
2.4.1 Installation clearance requirements...............................................................................................................................................................................................19
2.5 Position of vibration dampers.....................................................................................................................................................................................................21
3 WATER AND ELECTRICAL CONNECTIONS...................................................................................................................................................................................22
3.1 Water connections......................................................................................................................................................................................................................22
3.1.1 Water connections .......................................................................................................................................................................................................................22
3.1.2 Recommended water circuit.........................................................................................................................................................................................................22
3.1.3 Filling the system.........................................................................................................................................................................................................................23
3.1.4 BASE Multi-purpose system DIAGRAM.........................................................................................................................................................................................24
3.2 Electrical connection ..................................................................................................................................................................................................................25
3.3 Electrical specifications..............................................................................................................................................................................................................26
4 STARTING UP..............................................................................................................................................................................................................................27
4.1 Preliminary checks .....................................................................................................................................................................................................................27
5 OPERATING LIMITS.....................................................................................................................................................................................................................28
5.1 Operating limits in chiller mode..................................................................................................................................................................................................28
5.2 Operating limits in heat pump mode...........................................................................................................................................................................................28
5.3 Operating limits in DHW total recovery ......................................................................................................................................................................................29
5.4 Operating limits only in DHW production....................................................................................................................................................................................29
5.5 Thermal carrier fluid...................................................................................................................................................................................................................29
6 CONTROL AND SAFETY DEVICES................................................................................................................................................................................................30
6.1 Control devices...........................................................................................................................................................................................................................30
6.1.1 Service thermostat.......................................................................................................................................................................................................................30
6.1.2 Control device settings.................................................................................................................................................................................................................30
6.2 Safety devices ............................................................................................................................................................................................................................30
6.2.1 High pressure switch ...................................................................................................................................................................................................................30
6.2.2 Low pressure switch ...................................................................................................................................................................................................................30
6.2.3 Anti-recycle timer.........................................................................................................................................................................................................................30
6.2.4 Antifreeze thermostat ...................................................................................................................................................................................................................30
6.2.5 Water differential pressure switch.................................................................................................................................................................................................30
6.2.6 Water safety valve........................................................................................................................................................................................................................30
6.2.7 Safety device settings ..................................................................................................................................................................................................................30
7 ROUTINE MAINTENANCE AND CHECKS ......................................................................................................................................................................................31
7.1 Checks to be performed by the user ...........................................................................................................................................................................................31
7.2 Checks and maintenance to be performed by specialised personnel .........................................................................................................................................31
8 RETIRING THE UNIT....................................................................................................................................................................................................................31
9 TECHNICAL CHARACTERISTICS..................................................................................................................................................................................................32
9.1 Rated technical data of heat pumps ...........................................................................................................................................................................................32
10 COOLING CIRCUIT DIAGRAMS....................................................................................................................................................................................................33
11 TROUBLESHOOTING ...................................................................................................................................................................................................................36
The technical and dimensional data provided herein may undergo changes in
connection with product improvements.
TRANSLATION OF ORIGINAL INSTRUCTIONS
I REFRIGERATORI D'ACQUA E LE POMPE DI CALORE SONO CONFORMI
ALLA DIRETTIVA 97/23/CE (PED) ATTRAVERSO MODULO D1,
APPROVATO DALL'ENTE TERZO NOTIFICATO ICIM N°0425.

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HWMC
All copying, even partial, of this manual is strictly forbiddenRG66008809 - Rev 00
Serial number
Code
Date of production
Cooling capacity (W)
Heating capacity (W)
Power supply
Power input (kW)
Weight (kg)
Max power input (kW)
Max running amperage (A)
HP Power input (kW)
Refrigerant
Max refrigerant pressure (bar)
Max refrigerant temperature (°C)
Made in Italy
CATEGORIA 2
Galletti S.p.A. via L.Romagnoli 12/a
40010 Bentivoglio (BO) Italia
The unit data are reported on the rating label in this page.
THE LABEL SHOWS THE FOLLOWING DATA:
- Series and size of the unit
- Date of manufacture
- Main technical data
- Manufacturer
- The label is applied on the unit, usually on the enclosing panels beside
the condenser coil
IMPORTANT: NEVER REMOVE THE LABEL
- Serial number of the unit
- The serial number permits to identify the technical characteristics and
the components installed
- Without this datum it will be impossible to identify the unit correctly

HWMC
4All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
GENERAL CAUTIONARY NOTES
- Please keep this manual complete and in good condition for the entire life of the machine.
- Carefully read all the information contained in this manual, paying special attention to sections marked “Important” and “WARNING”; failure to comply
with the instructions provided could result in injury to persons or damage to the equipment.
- Should a fault occur, consult this manual and if necessary contact the nearest Galletti S.p.A. service centre.
- All installation and maintenance operations must be carried out by qualified personnel, unless otherwise indicated in this manual.
- FIRST START-UP MAY BE CARRIED OUT SOLELY BY QUALIFIED TECHNICIANS DULY AUTHORIZED BY GALLETTI S.P.A. (SEE ENCLOSURE)
- Before performing any work on the unit, disconnect it from the power supply.
- Failure to comply with the rules provided in this manual will result in the immediate invalidation of the warranty.
- Galletti S.p.A. shall not accept any liability for injury or damage resulting from improper use of the equipment or failure to comply with the directions
provided in this manual and on the unit itself.
- It is mandatory to install filters to protect the heat exchangers. Failure to do so will invalidate the warranty.
- For any further information, contact the manufacturer: [email protected]
- To get the weight of the unit, refer to the User Manual, Rated technical data table.
IMPORTANT:
1) (a) Do not use heat transfer fluids other than those specified.
(b) This unit is not suitable for use in Atex environment or with inflammable heat transfer fluids.
(c) Use original factory parts only.
(2) Use appropriate PPE (refrigerant protection gloves, protective goggles).
(3) If protection grilles (accessory) are not provided or if the unit can be reached by unauthorized persons, special protection barriers should be provided
in order to prevent access to the finned coil.
(4) Upstream from the power supply it is necessary to install a differential switch for protection against earth connection failure.
SAFETY SYMBOLS
Carefully read this manual WARNING Use individual protective
devices
USE APPROPRIATE PPE (REFRIGERANT PROTECTION GLOVES, PROTECTIVE GOGGLES).

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HWMC
S3
S2S1
V4 V5
V3
V1 V2
S3
S2S1
V4 V5
V3
V1 V2
S3
S2S1
V4 V5
V3
V1 V2
S3
S2S1
V4 V5
V3
V1 V2
All copying, even partial, of this manual is strictly forbiddenRG66008809 - Rev 00
DHW
HEAT
PUMP
DHW
HEAT
PUMP
Winter configuration
DHW / Springtime (operating 365 days a year)
Summer configuration (total heat recovery)
Summer configuration
DHW
HEAT
PUMP
DHW
HEAT
PUMP
1 THE SERIES HWMC
1.1 FIELD OF APPLICATION
The DC INVERTER multi-purpose HWMC units have been designed to cool
and heat water for air conditioning and heating systems and for the production
of DHW for residential or commercial use. The units are “real” multipurpose
units, with 4 water collections, whose operating modes are described below:
1. Cold water production in summertime mode, for the air conditioning
system (air condensing system on the finned exchanger)
2. Cold water production in the summertime mode, for the air conditioning
system,with TOTALCONDENSATION HEATRECOVERY(for the production
of DHW by means of a dedicated plate exchanger)
3. Production of hot water in wintertime mode, for the heating system,
functioning as a traditional heat pump (air evaporation on the heat
exchanger side and water condensation on the dedicated plate heat
exchanger on the system side)
4. Domestic hot water production in wintertime mode, temporarily stopping
hot water production for air heating purpose (DHW priority);
5. DHW production only (in particular in mid seasons and in summertime
and wintertime)
Warning When reference is made to the production of domestic
hot water, what is meant is the storage of thermal energy in a tank of
“technical” water. Water for domestic use must be heated by means
of a stainless steel coil contained inside the storage tank, in this way
it is possible to avoid storing domestic water and it is not necessary
to provide for an anti-Legionella cycle (see recommended plumbing
layouts for further details).
Warning HWMCunits are NOT suitable for use as “rapid” heaters."
The HWMC units are designed for outdoor installation (protection rating
IP24), in a position not accessible to the public.
If protection grilles (accessory) are not provided or if the unit can be reached
by unauthorized persons, special protection barriers should be provided in
order to prevent access to the finned coil.
Do not install the unit in places where inflammable gases or powders
are present.

HWMC
6All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
1 THE SERIES HWMC
1.2 MODELS AND VERSIONS
The HWMC series features 5 models of varying capacity, indicatively from
10 to 29 kW in cooling versions (9-32 kW in heating versions) in nominal
conditions (ref. EN14511).
All models are charged with R410Arefrigerant and equipped with compressors
optimised for heat pump applications and domestic hot water production in
all seasons.
N.B. The choice of some options may preclude the choice of others or make
some other fields become mandatory. Contact Galletti S.p.A. for verification
CompleteunitcodeHWMC010H0AAA100CE0000000
Version 0
Single compressor 0
Tandem T
Model (size) 1 0
Operation H
H
Supply voltage 0
Standard 400 - 3N - 50 0
Single-phase M
400 - 3N - 50 + circuit breakers 2
Single-phase + circuit breakers 4
Refrigerant A
R410A high efficiency A
Revision A
Initial A
(Field 1) Expansion valve A
Electronic valve A
(Field 2) Pump and accessories 1
2 Modulating pumps (system+DHW side) 5
2 EC pumps (system+DHW side) 6
(Field 3) Inertial buffer tank 0
Absent 0
Present, system side S
(Field 4) Auxiliary contacts 0
Absent 0
User tank sensor 1
External electric heating element control 2
Opt 1 + Opt 2 3
(Field 5) Fans C
Standard with condensation control C
BLDC with electronic control E
(Field 6) Antifreeze kit E
Base (plate exchangers only) E
Additional protection for 1 pump 1
Additional protection for 1 pump and tank 2
Additional protection for 2 pumps 3
Additional protection for 2 pumps and tank 4
(Field 7) Sound insulation 0
Absent 0
Compressor compartment soundproofing 1
Compressor silencing housings 2
Opt 1 + Opt 2 3
(Field 8) Cooling accessories 0
None 0
Refrigerant pressure gauges M
(Field 9) Remote control 0
Absent 0
MYCHILLER BASE remote control (option 1 - 3 field 13 disabling) B
MYCHILLER PLUS remote control (option 1 - 3 field 13 disabling) P
ADVANCED pGD1 remote control C
(Field 10) Special exchangers 0
Standard O
Copper - copper R
Cataphoresis C
Corrosion-proof B
Hydrophilic GB
(Field 11) Protective grille 0
Absent 0
Present G
(Field 12) Additional options 0
Absent 0
Exchanger heating cable 1
(Field 13) Additional cards 0
Absent 0
RS485 (Carel / Modbus) 1
Clock card 2
LON card 3

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HWMC
HWMC 10 EC PUMPS
All copying, even partial, of this manual is strictly forbiddenRG66008809 - Rev 00
1 THE SERIES HWMC
1.3 DESCRIPTION OF COMPONENTS
Description
12 Circulation pump
HWMC 10 EC PUMPS

HWMC
8
HWMC 10
All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
1 THE SERIES HWMC
1.3 DESCRIPTION OF COMPONENTS
Description
1R410A - air exchanger
2 R410A - water exchanger
3Fan
4Water differential pressure switch (no. 1 fan compartment)
5Automatic air vent valve
6Expansion tank (fan compartment)
7Buffer tank
8Refrigerant solenoid valve
9Electronic thermostatic valve
10 Water safety valve
11 Liquid receiver (fan compartment)
12 Circulation pump
13 Compressor
14 Refrigerant filter
15 Low pressure switch
16 High pressure switch
17 Water pressure gauge
18 Water filling point

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HWMC
HWMC 13 - 18 EC PUMPS
All copying, even partial, of this manual is strictly forbiddenRG66008809 - Rev 00
1 THE SERIES HWMC
1.3 DESCRIPTION OF COMPONENTS
Description
12 Circulation pump

HWMC
10
HWMC 13 - 18
All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
1 THE SERIES HWMC
1.3 DESCRIPTION OF COMPONENTS
Description
1R410A - air exchanger
2 R410A - water exchanger
3Fan
4Water differential pressure switch (no. 1 fan compartment)
5Automatic air vent valve
6Expansion tank (fan compartment)
7Buffer tank
8Refrigerant solenoid valve
9Electronic thermostatic valve
10 Water safety valve
11 Liquid receiver (fan compartment)
12 Circulation pump
13 Compressor
14 Refrigerant filter
15 Low pressure switch
16 High pressure switch
17 Water pressure gauge
18 Water filling point

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HWMC
HWMC 23 - 29 FANS HWMC 23 - 29 EC PUMPS
All copying, even partial, of this manual is strictly forbiddenRG66008809 - Rev 00
1 THE SERIES HWMC
1.3 DESCRIPTION OF COMPONENTS
Description
12 Circulation pump
HWMC 23 - 29 EC PUMPS

HWMC
12
HWMC 23 - 29
All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
1 THE SERIES HWMC
1.3 DESCRIPTION OF COMPONENTS
Description
1R410A - air exchanger
2 R410A - water exchanger
3Fan
4Water differential pressure switch
5Automatic air vent valve
6Expansion tank (fan compartment)
7Buffer tank
8Refrigerant solenoid valve
9Electronic thermostatic valve
10 Water safety valve
11 Liquid receiver (fan compartment)
12 Circulation pump
13 Compressor
14 Refrigerant filter
15 Low pressure switch
16 High pressure switch
17 Water pressure gauge
18 Water filling point

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HWMC
All copying, even partial, of this manual is strictly forbiddenRG66008809 - Rev 00
1 THE SERIES HWMC
1.4 PLUMBING DIAGRAMS
HWMC (EVAPORATOR AND PUMP)HWMC (EVAPORATOR)
Legend
VR Filling valve
VS Safety valve
EV Evaporator
PD Differential pressure switch
MA Water pressure gauge
VAS Air vent valve
VE Expansion tank
P Pump
RS Drainage valve
RC Water filling cock
VU Check valve
OPTIONAL
OPTIONAL
SYSTEM SIDE
SYSTEM SIDE
DHW SIDE
DHW SIDE

HWMC
14 All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
Legend
VR Filling valve
VS Safety valve
EV Evaporator
PD Differential pressure switch
MA Water pressure gauge
VAS Air vent valve
VE Expansion tank
P Pump
RS Drainage valve
RC Water filling cock
VU Check valve
SA Buffer tank
1 THE SERIES HWMC
1.4 PLUMBING DIAGRAMS
HWMC (EVAPORATOR AND TANK)HWMC (EVAPORATOR, PUMP AND TANK)
OPTIONAL
FRAME 2 ONLY
SYSTEM SIDE
DHW SIDE
OPTIONAL
FRAME 2 ONLY
SYSTEM SIDE
DHW SIDE

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HWMC
All copying, even partial, of this manual is strictly forbiddenRG66008809 - Rev 00
1 THE SERIES HWMC
1.4 PLUMBING DIAGRAMS
HWMC (EVAPORATOR AND DUAL PUMP)HWMC (EVAPORATOR, DUAL PUMP AND TANK)
Legend
VR Filling valve
VS Safety valve
EV Evaporator
PD Differential pressure switch
MA Water pressure gauge
VAS Air vent valve
VE Expansion tank
P Pump
RS Drainage valve
RC Water filling cock
VU Check valve
SA Buffer tank
OPTIONAL
OPTIONAL
DHW SIDE
DHW SIDE
FRAME 2 ONLY
SYSTEM SIDE
SYSTEM SIDE

HWMC
16 All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
2 INSPECTION, HANDLING, DIMENSIONS AND
SITING
2.1 INSPECTION
On receiving the unit, check that the packing is intact: the machine left the
factory in perfect conditions and after thorough inspection.
Should you detect any signs of damage, immediately report them to the
carrier and note them on the delivery slip.
Galletti S.p.A. must be notified of the entity of the damage within 8 days of
the delivery date.
Check that the following items are present:
- putting into service report,
- wiring diagram,
- warranty certificate and list of authorised service centres,
- make sure that this manual is intact (40 pages).
2.2 HANDLING
During handling it is compulsory to check dimensions, weights, centre of
gravity and anchorages. Check as well that lifting and positioning devices
conform to the current safety regulations.
The unit leaves the factory screwed onto a wooden pallet, which allows
it to be easily conveyed with a forklift truck. After removing the unit from
the pallet, handle it gently, without applying excessive pressure on the side
panels, finned coil and fan grille.
You should collect and separate the packing materials (wood, cardboard,
nylon etc.) and make them available for recycling in order to minimise their
environmental impact.
Before lifting, remove the screws fastening the base of the unit to the wood
platform.
The unit should be lifted using Ø1½” GAS steel pipes at least 3mm thick,
to be inserted in the round holes provided on the base side members (see
figure) and identified by means of stickers. The pipes, which should protrude
by at least 250-300mm on every side, must be slung with ropes of equal
length secured to the lifting hook (provide stops at the ends of the pipes to
prevent the ropes from slipping off due to the weight).
Use ropes or belts whose length exceeds the machine height and place
spacer boards and bars on the top of the unit to avoid damaging the sides
and upper part of the unit itself.
At this point, before final positioning, it is possible to install the vibration-
damping supports (optional).
WARNING: In all lifting operations make sure that the unit is securely anchored
in order to prevent accidental falls or overturning.

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HWMC
HWMC 10 ÷ 13 ÷ 18
All copying, even partial, of this manual is strictly forbiddenRG66008809 - Rev 00
Legend:
1 Water inlet 1" ¼ female
2 Sanitary hot water inlet 1" ¼ female
3 Water outlet 1" ¼ female
2 Sanitary hot water outlet 1" ¼ female
5 Safety valve discharge outlet with rubber ring holder
6 Water supply ½" male (optional tap)
7Water drainage ½" female
8 Sanitary hot water drainage ½" female
9 Power supply Ø 28 mm
10 Electric control board
11 Fastening points for vibration dampers
2 INSPECTION, HANDLING, DIMENSIONS AND
SITING
2.3 DIMENSIONS

HWMC
18
HWMC 23 ÷ 29
All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
Legend:
1 Water inlet 1" ¼ female
2 Sanitary hot water inlet 1" ¼ female
3 Water outlet 1" ¼ female
2 Sanitary hot water outlet 1" ¼ female
5 Safety valve discharge outlet with rubber ring holder
6 Water supply ½" male (optional tap)
7Water drainage ½" female
8 Sanitary hot water drainage ½" female
9 Power supply Ø 28 mm
10 Electric control board
11 Fastening points for vibration dampers
2 INSPECTION, HANDLING, DIMENSIONS AND
SITING
2.3 DIMENSIONS

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2 INSPECTION, HANDLING, DIMENSIONS AND
SITING
2.4 SITING
It is important to bear in mind the following aspects when choosing the best
site for installing the unit:
- size and origin of water pipes;
- location of the power supply;
- solidity of the supporting surface;
- avoid obstacles to the outflow of air from the fan which could cause back
suction (see section on “installation clearance requirements”);
- direction of prevalent winds: (position the unit so that prevalent winds
do not alter the fan air flow). A prevalent wind blowing from a direction
opposite to the fan air flow will reduce the maximum air temperature
to a lower value than specified in the operating limits, a wind blowing
in the same direction as the fan air flow will increase the minimum air
temperature to a higher value than specified in the operating limits. Also
in the heat pump mode, wind may have the effect of reducing the unit's
operating range.
- avoid the possible reverberation of sound waves; do not install the unit
in narrow or cramped spaces;
- ensure adequate accessibility for maintenance or repairs (see section
on “installation clearance requirements”).
This device is not intended to be used by children or by people with
physical, sensory or mental impairments, except under supervision. Make
sure that children do not have access to the device.
2.4.1 INSTALLATION CLEARANCE REQUIREMENTS
To guarantee the proper functioning of the unit and access for maintenance
purposes, it is necessary to comply with the minimum installation clearance
requirements shown in figures 1, 2 and 3.
There must be no obstacles blocking the path of the air flow from the fans.
Avoid any and all situations of backflow of hot air between air outlet and
inlet of the unit.
If even only one of the above conditions is not fulfilled, please contact the
manufacturer to check for feasibility.
In the design of the HWMC series, special care has been taken to minimise
noise and vibrations transmitted to the ground.
Even greater insulation may be obtained, however, by using vibration damping
base supports (available as optional accessories).
If vibration damping base supports are adopted, it is strongly recommended
also to use vibration damping couplings on the water pipes.
Whenever the unit is to be sited on unstable ground (various types of soil,
gardens, etc.) it is a good idea to provide a supporting base of adequate
dimensions.
Warning while operating in heating or DHW mode, the units
produce condensation..

HWMC
20
1
2
HWMC 10 ÷ 18
HWMC 23 ÷ 29
All copying, even partial, of this manual is strictly forbidden RG66008809 - Rev 00
2 INSPECTION, HANDLING, DIMENSIONS AND
SITING
2.4 SITING
2.4.1 INSTALLATION CLEARANCE REQUIREMENTS
COIL PLUMBING CONNECTION SIDE
ELECTRIC CONTROL BOARD
COIL SIDE
COIL PLUMBING CONNECTION SIDE
ELECTRIC CONTROL BOARD
COIL SIDE