INSTALLATION - OPERATING - SERVICE MANUAL GB Reverse-cycle air/water heat pumps with domestic hot water production, axial-flow fans and water pump assembly.
U I A INDEX U I A General warnings 3 I A Operating characteristics 25 U I A Waiver of liability 3 I A General technical data 31 U I A Fundamental safety rules 3 A Checking and starting up the unit 33 I A Receiving and handling the product 4 A HSW11 functions 34 I A Description of standard unit 5 A LEDs and display 35 I Dimensioned drawings 6 I A Displaying alarms 47 I Installation 6 A Shutting down for long periods 48 I A Water connections 7 A Routine maintenan
GENERAL INDEX WARNINGS These appliances have been designed to chill and/or heat water and must be used in applications compatible with their performance characteristics; these appliances are designed for residential or similar applications. Incorrect installation, regulation and maintenance or improper use absolve the manufacturer from all liability, whether contractual or otherwise, for damage to people, animals or things.
I A RECEIVING AND HANDLING THE PRODUCT When the items are consigned by the carrier, check that the packaging and the unit are undamaged. If damage or missing components are noted, indicate this on the delivery note. A formal complaint should be sent via fax or registered post to the After Sales Department within eight days from the date of receipt of the items.
I A DESCRIPTION OF STANDARD UNIT These air cooled reverse-cycle chillers with axial-flow fans operate with R410A refrigerant fluid and are suitable for outdoor installation. The units are CE marked, as established by the EU directives, including the latest amendments, and the corresponding approximated national legislation. They are factory tested and on site installation is limited to water and electrical connections.
U I A DIMENSIONAL DRAWINGS W1 = E = 900 C W2 B W3 W4 600 A 400 D 1 - Water connections IN 0011÷0025 Ø1” - 0031÷0061 Ø1”1/4 1 - Water connections OUT 0011 Ø3/4” - 0025÷0061 Ø1”1/4 Dimensions A B C D E Weight distribution AWR W1 lato rear dx W2 lato rear sx W3 front sx W4 front dx tot mm mm mm mm mm 0011 900 940 370 320 580 0025 900 1240 420 370 580 0031 900 1240 420 370 580 0041 900 1240 420 370 580 0051 900 1400 420 370 580 0061 900 1400 420 370 580 kg kg kg kg kg 0011 47 23 13 42 1
I A WATER CONNECTIONS The choice and installation of components is the responsibility of the installer who should follow good working practice and current legislation. Before connecting the pipes, make sure they do not contain stones, sand, rust, dross or other foreign bodies which might damage the unit. Construction of a bypass is recommended to enable the pipes to be washed through without having to disconnect the unit (see drain valves).
The heat pumps must be fitted with a filling/top-up system connected to the return line and a drain valve in the lowest part of the system. Systems containing antifreeze or covered by specific legislation must be fitted with low-loss headers.
FILLING THE SYSTEM - Before starting to fill, place the unit mains switch QF1 in the OFF position. - Before filling, check that the system drain OFF valve is closed. - Open all system and terminal air vents. - Open system shut off valves. - Start filling by slowly opening the system water fill valve outside the unit. - When water begins to leak out of the terminal air vent valves, close them and continue filling until the pressure gauge indicates a pressure of 1.5 bar.
PUMP CHARACTERISTICS 140 130 120 110 B Hp [kPa] 100 90 80 70 60 50 40 30 20 A = AWR 0011 MTD B = AWR 0025÷0061 MTD A 10 2 4 6 Q [m3/h] 10 8 The curves shown above refer to the flow-rates and heads of the pumps only. To calculate the useful values relating to the system or source, subtract the pressure drop of the heat exchangers, see the graph "Heat exchanger pressure drop: system".
DHW storage cylinder, 280 litres 10 9 D 11 5 6 C 7 A B 8 1 1 2 3 4 5 6 7 8 Manual fill and drain valve Adjustable thermostat Probe socket Thermometer Thermostatic valve Pump SXM 32-50 Plate heat exchanger WP 24*40 1”1/4 GAS attachment for optional electric heater 9 Automatic vent valve 3/4” GAS 10 Expansion vessel, 18 litres 11 Flexible polyurethane insulation, 50 mm thick, sky blue finish A B C D Primary outlet; heat pump return 1” GAS Domestic water inlet; mains 3/4” GAS Domestic hot water out
I A OPERATING DIAGRAMS, AWR MTD The heat pump is connected directly to the central heating circuit (the minimum water content required must be ensured).
I A OPERATING DIAGRAMS, AWR MTD The heat pump is connected directly to the central heating circuit (the minimum water content required must be ensured). The heat pump can also produce domestic hot water by managing a special 3-way valve, connected to a hot water storage cylinder.
I A ELECTRICAL CONNECTIONS The heat pumps must be installed downstream of a main switch (QF1, see wiring diagram), as required by the standards in force in the country where the unit is installed. Connection to the mains power supply and the connection of the flow switch to the corresponding terminals must be performed by authorised personnel in compliance with the standards in force.
I A MAINS POWER SUPPLY CONNECTIONS - Before connecting the unit to the power supply, makes sure that switch QF1 is open, suitably padlocked and marked. - Remove the inspection panel by unscrewing the eight screws (0011) - or ten screws (0025-0061) - Identify the terminals used for electrical connections on the layout drawing shown in this manual.
ELECTRICAL PANEL LAYOUT AWR 0025-0041 MTD-MTD/B SINGLE-PHASE ELECTRICAL PANEL LAYOUT AWR MTD-MTD/B THREE PHASE KA2 KA5 KA2 KA3 KA4 KA3 KA4 A1 A2 A3 A5 C1 C2-3 FU1 FU3 FU4 FU5 TCI KA2 KA3 KA4 KA5 KA6 KA7 KM2-3 QM1 QF1 QF2-3 QS1 16 Radio interference suppresser Fan control module Electronic controller Peak limiter Compressor start capacitor Fan start capacitor System water pump protection fuse Heater protection fuse Transformer protection fuse Auxiliary circuit protection fuse Autotransformer Auxiliar
I A INSTALLER CONNECTIONS All the terminals referred to in the following explanations are to be found on the terminal board located inside the electrical panel and called “installer terminals” (see wiring diagram). REMOTE ON/OFF (SA1) To use a remote on/off device, connect the contact of the device to terminals 14 and 15 on the installer terminal board. Set parameter CL42 = -1. Remote off corresponds to standby status, with the compressor and pump off, yet all the safety features are active.
TERMINAL BLOCK AWR 0011 MTD-MTD/B SINGLE-PHASE 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Gnd Signal+12Vdc Y/G Brown Blue +to Black 1 SA1 SA2 F3 BT4 A4 PE U L N PE YV2 KM4 GN1 RD1 230 VAC 1A max TERMINAL BLOCK AWR 0025-0041 MTD-MTD/B SINGLE-PHASE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Black U N Brown Blue Y/G +to Gnd Signal+12Vdc SA1 SA2 PE U N F3 BT4 A4 L N PE YV2 KM4 GN1 RD1 230 VAC 1A max TERMINAL BLOCK AWR 0031-0061 MTD-MTD/B THR
A1 A2 A3 A4 A5 A6 BP3 BT1 BT2 BT3 BT4 C1 C2 E1 EV1 F1 Radio interference suppresser Fan control module Electronic controller Remote unit control display keypad Compressor start Pump control module Condenser/evaporator control pressure transducer Water heat exchanger inlet temperature sensor Water heat exchanger outlet temperature sensor Outside air temperature sensor Hot water storage temperature sensor Compressor start capacitor Fan start capacitor Water pump Fan High pressure switch F2 F3 F4 FU1 FU2 FU3
A1 A2 A3 A4 A5 A6 BP3 BT1 BT2 BT3 BT4 C1 C2 E1 EV1 F1 Radio interference suppresser Fan control module Electronic controller Remote unit control display keypad Compressor start Pump control module Condenser/evaporator control pressure transducer Water heat exchanger inlet temperature sensor Water heat exchanger outlet temperature sensor Outside air temperature sensor Hot water storage temperature sensor Compressor start capacitor Fan start capacitor Water pump Fan High pressure switch F2 F3 F4 FU1 FU2 FU3
A1 A2 A3 A4 A5 BP3 BT1 BT2 BT3 BT4 C1 C2-3 E1 EV1-2 F1 F2 Radio interference suppresser Fan control module Electronic controller Remote unit control display keypad Compressor start Condenser/evaporator control pressure transducer Water heat exchanger inlet temperature sensor Water heat exchanger outlet temperature sensor Outside air temperature sensor Hot water storage temperature sensor Compressor start capacitor Fan start capacitor Water pump Fan High pressure switch Low pressure switch F3 F4 FU1 FU2 FU
A1 A2 A3 A4 A5 BP3 BT1 BT2 BT3 BT4 C1 C2-3 E1 EV1-2 F1 F2 Radio interference suppresser Fan control module Electronic controller Remote unit control display keypad Compressor start Condenser/evaporator control pressure transducer Water heat exchanger inlet temperature sensor Water heat exchanger outlet temperature sensor Outside air temperature sensor Hot water storage temperature sensor Compressor start capacitor Fan start capacitor Water pump Fan High pressure switch Low pressure switch F3 F4 FU1 FU2 FU
A1 A2 A3 A4 BP3 BT1 BT2 BT3 BT4 C2-3 E1 EV1-2 F1 F2 F3 F4 Radio interference suppresser Fan control module Electronic controller Remote unit control display keypad Condenser/evaporator control pressure transducer Water heat exchanger inlet temperature sensor Water heat exchanger outlet temperature sensor Outside air temperature sensor Hot water storage temperature sensor Fan start capacitor Water pump Fan High pressure switch Low pressure switch Flow switch Water differential pressure switch FU1 FU2 FU3 F
A1 A2 A3 A4 A5 BP3 BT1 BT2 BT3 BT4 C2-3 E1 EV1-2 F1 F2 F3 Radio interference suppresser Fan control module Electronic controller Remote unit control display keypad Compressor start Condenser/evaporator control pressure transducer Water heat exchanger inlet temperature sensor Water heat exchanger outlet temperature sensor Outside air temperature sensor Hot water storage temperature sensor Fan start capacitor Water pump Fan High pressure switch Low pressure switch Flow switch F4 FU1 FU2 FU3 FU4 FU5 GN1 KA1
I A OPERATING CHARACTERISTICS Temperature control Control is performed based on the system water return temperature. The set points refer to the water return temperature. The water outlet temperature depends on the difference between inlet and outlet, usually 5°C (rated). This temperature difference may change depending on the type of water circuit. For example, if the HEAT set point is set to +30°C, the outlet temperature will be +35°C.
bar Refrigerant circuit pressure The defrost cycle is started if the evaporation pressure falls below the effective start defrost set point, a value that may change, as represented in the graph, in relation to the outside air temperature. A countdown starts, and only at the end is the cycle reversed to cooling mode, if the pressure remains below the effective start defrost set point If the rises back above the effective start defrost set point, the defrost timer is set to zero.
ADDITIONAL HEATER (OUTSIDE THE UNIT) (KM4) The additional heater may be configured as: - DHW storage heater. - Boiler replacing the heat pump. Additional DHW storage heater The additional heater may be a electric heater or a boiler, to be connected as shown in the chapter on “installer connections”.
Heaters as replacement source (factory configuration) Outlet water temperature (°C) The electric heaters are activated to replace the compressor if its operating limits are exceeded, see the graph.
SYSTEM WATER SET POINT COMPENSATION BASED ON THE OUTSIDE TEMPERATURE The unit is fitted with an outside air temperature sensor that is used to optimise the energy efficiency of the unit based on the outside conditions. Set point compensation based on the outside temperature must be enabled by setting a parameter, see the table.
TIME BANDS The HSW11 controller can manage the unit based o the time and the day of the week. The controller features four time bands in three profiles that can be combined, when programming, with the days of the week. The profile defines the behaviour of the unit over a 24 hour period. Time band management must be enabled by parameter tE00 = 1 (tE00 = 0 standard setting). Programming example 1) Define the profile for each time band, as shown in the following table.
I A GENERAL TECHNICAL DATA AWR MT Heating capacity (1) Power input (1) C.O.P. Heating capacity (2) Power input (2) C.O.P. Rated water flow (1) Useful pressure head (1) Cooling capacity (3) Power input (3) E.E.R. Cooling capacity (4) Power input (4) E.E.R. Rated water flow (3) Useful pressure head (3) No.
OPERATING LIMITS Heating Outside air temperature (°C) 45 7 -5 -15 30 40 50 55 Outlet water temperature (°C) Outside air temperature (°C) Cooling 48 43 35 10 -12 0 7 Outlet water temperature (°C) Water temperature head min/max= 3/8 °C Water circuit pressure min/max = 1/3 bar Maximum glycol percentage = 40% 32 AWR MTD - AWR MTD/B GB 01/2009 18
A CHECKING AND STARTING UP THE UNIT PREPARING FOR FIRST START UP The unit must be started up for the first time by the Technical Service: Before starting up the units, make sure that: - All safety conditions have been respected; - The unit is adequately fixed to the surface it rests on - Functional distances have been respected; - Water connections have been carried out as indicated in the instruction manual; - The water circuit is filled and vented.
A HSW11 FUNCTIONS esc set DESCRIPTION OF THE BUTTONS AND ASSOCIATED FUNCTIONS Button Description UP DOWN Press once [press and release] - Increases a value - Goes to the next label Associated Press and hold Menu / Notes function [press for about 3 seconds] [Manual defrost activation] Functions menu see Functions chapter (folder FnC) - Decreases a value - Goes to the previous label Esc(ape) Output - Exit without saving new settings (Without saving - Go back to previous level new settings) Set Confir
A LEDS AND DISPLAY 1 2 esc set 3 1 STATUS AND OPERATING MODE LEDS 2 VALUE AND UNIT OF MEASURE LEDS Alarm Clock (RTC) Heating Degrees centigrade Cooling Pressure (Bar) Standby Menu (ABC) Defrost 3 UTILITY LEDS Compressor 1st auxiliary heating element stage activation 2nd auxiliary heating element stage activation Fan System pump Domestic hot water function activation External auxiliary heating element activation GB 01/2009 AWR MTD - AWR MTD/B 35
SETTING THE CLOCK The HSW11 controller is fitted with a clock for managing time bands to control specific events. Follow the procedure shown below to set the hours, minutes and date. To set the clock of the unit, starting from the main display, press the set button. Pressing the set button once displays the various directories. Scroll the menu using the UP and DOWN buttons until reaching the directory CL. To enter menu CL press the set button. Once having entered this menu, HOUr will be shown.
... press the set button. To exit the clock setting menu press the esc button until returning to the main display.
SELECTING THE OPERATING MODE There are three different modes: • Standby mode (StbY); in standby the compressor and pump are off but all the safety features are active • Heating mode (HEAT) • Cooling mode (COOL) For example, to switch operation from StbY to COOL. To change the operating mode, press and hold the mode button for at least 2 seconds. PS: The main display is set as RTC (current time). A scroll menu will start flashing with the values StbY (standby), HEAt (heat) and COOL (cool).
SETTING THE SET POINTS As an example, the Set Point in COOL mode will be changed from 12.0 degrees centigrade to 12.5 degrees centigrade.di. To change the set point, starting from the main display, press the set button. Pressing the set button once displays the various directories. Scroll the menu using the up and down buttons until reaching the SP directory. To enter the SP directory press the set button.
The instrument will display the current set point (in this case 12.0 degrees centigrade). To increase or decrease the value, use the up and down buttons. For example, to change the set point to 12.5 degrees, press the up button until the desired value is displayed. Once having reached the desired set point, press the set button. In this way, the instrument will save the value 12.5. To return to the main display, press esc or wait for the menu timeout to expire (15 seconds).
DISPLAYING INSTALLER PARAMETERS From the main display, press the set button. Example of displaying the analogue inputs. For the other I/Os the procedure is essentially the same***. The display will show label Ai. (Scroll the other labels using the UP and DOWN buttons until reaching the desired label). Press the set button to display the label for the first analogue input (in this case AiL1). Press the set button again to display the value of AiL1.
DISPLAYING AUTHORISED TECHNICIAN PARAMETERS Accessing the PASS directory (from the main display, pressing the esc and set buttons together [esc+set] and scrolling to the directory with up / down) and setting the PASS accesses the parameters visible for the password entered. To access the PASS directory from the main display, press esc and set together [esc+set]. Pressing the two buttons accesses the menu listing the directories. Scroll using the up and down buttons to the PASS directory.
For parameter CF00, the value displayed will be 2. To change the value of the parameter, press the up or down button. When having selected the value, press the set button. ** To exit the display and return to the previous level, press esc. **NOTE: pressing the set button confirms the new value; pressing the esc button returns to the previous level without changing the existing value. DISPLAYING AND RESETTING COMPRESSOR/PUMP HOURS Example of displaying and resetting (tens) the operating hours for Pump 2.
MUTING AND MANUALLY RESETTING THE ALARMS The alarm signals are displayed flashing. The following procedure describes how to mute an alarm. The various errors will be displayed in directory AL (see Status menu) The errors will be displayed by alternating the error message... ... with the main display. The ALARM LED is on steady. MUTE The alarm is muted by pressing any button once. Once any button has been pressed, the alarm LED starts flashing.
DISPLAYING ALARMS The alarm signals are displayed flashing. The following procedure describes how to mute an alarm. The various errors will be displayed in directory AL (see Status menu) From the main display, press the set button The display will show label Ai. Scroll the other labels using the UP and DOWN buttons until reaching label AL. Press the set button to display the label for the first active alarm (if this exists). In this case, the first alarm is Er01.
RESET ALARM LOG Below are the instructions on how to reset the alarm log if the alarm signal Er90 is shown. To access directory FnC from the main display, press esc and set together. [esc+set]. the first directory displayed is PAr. Use the UP and DOWN buttons to scroll to the directory FnC. Press the set button to access the Functions menu. The first label displayed is dEF. Use the UP and DOWN buttons to select directory EUr. Press the set button for 3 seconds.
Pump Fan Pump Electric heaters Directory label CL Cr CF Ui tr St CP PI FI FE PE HI HE HA br dF dS Ad AF AS HP PL tE AL LIST OF ACCESSIBLE PARAMETERS Meaning of the code (label) Parameters Parameters for: ConFiguration CL00... CL97 Analogue input/output configuration ConFiguration Cr00... Cr50 Analogue input configuration ConFiguration CF01... CF61 Serial configuration User interface UI00... UI36 User interface thermoregulation tr00... Tr44 Temperature control Stati (Modi di funzionamento) St00...
FAULT CAUSE SOLUTION Values display indication Er35 High water outlet temperature Alarm with automatic reset Check water outlet temperature Check water flow Check water temperature Set Point Check correct positioning of sensor BT2 Values display indication Er47 HSW11 communication error with remote keypad (only if remote keypad featured) Check electrical connection Values display indication Er 48 Anti-Legionella cycle not completed Contact the authorised service centre Values display indication
A ROUTINE MAINTENANCE Never perform any cleaning operations before having disconnected the unit from the mains power supply. Terminals 6, 7, 8 and 9 may be live even when the unit has been disconnected. Check for voltage before proceeding. Regular maintenance is fundamental to maintain the efficiency of the unit both in terms of operation and energy consumption.
I A TROUBLESHOOTING FAULT CAUSE SOLUTION No voltage Check presence of voltage Check safety systems upstream of the appliance Switch QF1 in OFF position Remote switch (if featured) in OFF position Control panel set to OFF Main switch QS1 in OFF Compressor thermal overload switch OFF Switch ON Supply voltage too low Check power line Contactor coil faulty HSW11 controller fault Start-up capacitor faulty (if featured) Compressor faulty Reversed phases (three-phase units only) Replace the component I
FAULT High discharge pressure (greater than 23 bars)* CAUSE SOLUTION High outside water temperature High utility water inlet temperature Check Insufficient water flow-rate in outside heat exchanger (cooling mode) Insufficient water flow-rate in utility heat exchanger (heating mode) Check pump operation Faulty operation of outside heat exchanger control (pressure regulating valves) Check Air in water circuit (heating mode) Vent Excessive refrigerant content Check Low utility water inlet temperat
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