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Installation and maintenance manual
WATER HEAT EXCHANGER
English
25 PAW-250W5G PAW-250WP5G
$ PAW-500W5G PAW-500WP5G
71 kW PAW-710W5G PAW-710WP5G
30
$
80 kW
Part number: 373189 REV. C
Supersedes: 373189 REV. B ISO 9001:2008 certi ed management system
Table of Contents
English
1 - FOREWORD 6 - CONTROL
1.1 Introduction ..........................................................................2 6.1 System block diagram ............................................... 21 & 22
1.2 Warranty ..............................................................................2 6.2 Circuit board controls and connettors .................................23
1.3 An introduction to the manual ...............................................2
6.3 Fault indicators and codes ..................................................24
2 - SAFETY 6.4 WHE Wiring Diagram ..........................................................25
2.1 Foreword..............................................................................3 7 - PRODUCT DESCRIPTION
2.2 Definitions ............................................................................4
7.1 General information ............................................................26
2.3 Access to the unit ...............................................................4
7.2 Accessories .......................................................................27
2.4 General precautions..............................................................4
2.5 Precautions against residual risks .........................................4 7.3 Circuit diagram .......................................................... 28 & 29
2.6 Precautions during maintenance operations ..........................5 8 - TECHNICAL DATA
2.7 Safety labels ........................................................................6
8.1 Hydraulic features ..................................................... 30 & 31
2.8 Safety regulations.......................................................... 7 to 9
8.2 Envelope .................................................................. 32 & 33
3 - TRANSPORT, HANDLING AND STORAGE 8.3 Physical data......................................................................34
3.1 Inspection ..........................................................................10 8.4 Electrical data.....................................................................35
3.2 Handling ............................................................................10
8.5 Performance Specifications ....................................... 36 to 41
3.3 Anchoring ..........................................................................11
8.6 Position of center of gravity ................................................42
3.4 Storage ..............................................................................11
8.7 Dimensional drawings - WHE .............................................43
4 - INSTALLATION 8.8 Space requirements ...........................................................44
4.1 Installation site ...................................................................12
9 - MAINTENANCE
4.2 Connection to the outdoor unit ................................... 12 & 13
4.3 Placing units one on an other..............................................14 9.1 General requirements .........................................................45
4.4 External water circuit ................................................ 14 & 15 9.2 Planned maintenance .........................................................45
4.5 Water connections ............................................................16 9.3 Eletronic expansion valve....................................................46
4.6 Drainage ............................................................................16 9.4 Evaporator .........................................................................46
4.7 Power supply .....................................................................17 9.5 Components substitution ....................................................46
4.8 Electrical connections................................................ 17 to 19
10 - SPARE PARTS
5 - START-UP
10.1 Spare parts list .................................................................47
5.1 Preliminary checks .............................................................20
5.2 Start-up .............................................................................20
11 - DISMANTLING, DEMOLITION, SCRAPPING
5.3 Checking the operation .......................................................20 11.1 Generalities .......................................................................48
1
1 - Foreword
1.1 Introduction 1.3 An introduction to the manual
Units, manufactured to state-of-the-art design and implementation For safety reasons, it is imperative to follow the instructions given
standards, ensure top performance, reliability and fitness to any type in this manual. In case of any damage caused by non-compliance
of air-conditioning systems. with these instructions, the warranty will immediately become null
and void.
These units are designed for cooling water or glycoled water and
for water heating and are unfit for any purposes other than those Conventions used throughout the manual:
specified in this manual.
This manual includes all the information required for a proper The DANGER sign recalls your attention to
installation of the units, as well as the relevant operating and a certain procedure or practice which, if not
maintenance instructions. followed, may result in serious damage to
DANGER people and property.
It is therefore recommended to read this manual carefully before
installation or any operation on the machine. The unit installation and
maintenance must be carried out by skilled personnel only (where
possible, by one of Authorised Service Centers). The WARNING sign precedes those procedures
that, if not followed, may result in serious
The manufacturer may not be held liable for any damage to people or
WARNING damage to the appliance.
property caused by improper installation, start-up and/or improper
use of the unit and/or failure to implement the procedures and
instructions included in this manual.
1.2 Warranty
The NOTE contain important observations.
These units are delivered complete, tested and ready for being NOTE
operated. Any form of warranty will become null and void in the event
that the appliance is modified without manufacturer's preliminary
written authorisation.
In order for this warranty to be valid, the following conditions shall The USEFUL TIPS provide valuable information
be met: that optimises the efficiency of the appliance.
USEFUL TIPS
n The machine must be operated only by skilled personnel from
Authorised After-Sales Service.
This manual and its contents, as well as the documentation which
n Maintenance must be performed only by skilled personnel - from
accompanies the unit, are and remain the property of manufacturer,
one of Authorised After-Sales Centers.
which reserves any and all rights thereon. This manual may not
n Use only original spare parts. be copied, in whole or in part, without manufacturer's written
authorization.
n Carry out all the planned maintenance provided for by this manual
in a timely and proper way.
Failure to comply with any of these conditions will automatically void
the warranty.
2
2 - Safety
English
2.1 Foreword
These units must be installed in conformity with
the provisions of Machinery Directive 2006/42/EC, It is the User's responsibility to ensure that
Electromagnetic Compability Directive 2014/30/EU, as the unit is fit for the conditions of intended use
well as with other regulations applicable in the country of and that both installation and maintenance are
installation. If these provisions are not complied with, the carried out by experienced personnel, capable
of respecting all the recommendations
unit must not be operated.
provided by this manual.
DANGER
It is important that the unit is adequately
The unit must be grounded, and no supported, as detailed in this manual. Non-
installation and/or maintenance operations compliance with these recommendations may
may be carried out before deenergising the create hazardous situations for the personnel.
DANGER electrical panel of the unit.
The unit must rest on a base which meets the
Failure to respect the safety measures mentioned above may result characteristics specified in this manual; a
in electrocution hazard and fire in the presence of any short-circuits. base with inadequate characteristics is likely
DANGER to become a source of serious injury to the
Inside the heat exchangers, the compressors personnel.
and the refrigeration lines, this unit contains
liquid and gaseous refrigerant under
DANGER pressure. The release of this refrigerant may
be dangerous and cause injuries. The packaging material must not be disposed of
in the surrounding environment or burnt.
WARNING
The units are not designed to be operated with
natural refrigerants, such as hydrocarbons.
Manufacturer may not be held liable for any
problems deriving from the replacement
DANGER of original refrigerant or the introduction of
hydrocarbons.
n The used refrigerants are included in group II (non-hazardous
fluids).
n The maximum working pressure values are mentioned on the
unit's data plate.
n Suitable safety devices (pressure switches and safety valves)
must be installed on the refrigerant line when installing the unit.
n Dedicated guards (removable panels with tools) and danger signs
indicate the presence of hot pipes or components (high surface
temperature).
3
2 - Safety
2.2 Definitions
OWNER: means the legal representative of the company, body or n be sure to have removed all tools, electrical cables and any other
individual who owns the plant where unit has been installed; he/she
objects before closing and starting the unit again
has the responsibility of making sure that all the safety regulations
specified in this manual are complied with, along with the national
laws in force. 2.5 Precautions against residual risks
INSTALLER: means the legal representative of the company who has
been given by the owner the job of positioning and performing the Prevention of residual risks caused by the control
hydraulic, electric and other connections of unit to the plant: he/she
is responsible for handling and properly installing the appliance, as system
specified in this manual and according to the national regulations in
force. n be sure to have perfectly understood the operating instructions
before carrying out any operation on the control panel
OPERATOR: means a person authorised by the owner to do on unit
all the regulation and control operations expressly described in this
manual, that must be strictly complied with, without exceeding the n when you have to work on the control panel, keep always the
scope of the tasks entrusted to him. operating instructions within reach
ENGINEER: means a person authorised directly by manufacturer or,
in all EC countries, excluding Italy, under his full responsibility, by n start the unit only after you have checked its perfect connection
the distributor of product, to perform any routine and extraordinary to the plant
maintenance operations, as well as any regulation, control, servicing
operations and the replacement of pieces, as may be necessary n promptly inform the ENGINEER about any alarm involving the unit
during the life of the unit.
n do not reset manual restoration alarms unless you have identified
2.3 Access to the unit
and removed their cause
The unit must be placed in an area which can be accessed also
by OPERATORS and ENGINEERS; otherwise the unit must be
surrounded by a fence at not less than 2 meters from the external Prevention of residual mechanical risks
surface of the machine.
n install the unit according to the instructions provided in this
OPERATORS and ENGINEERS must enter the fenced area only
manual
after wearing suitable clothing (safety shoes, gloves, helmet etc.).
The INSTALLER personnel or any other visitor must always be
accompanied by an OPERATOR. n carry out all the periodical maintenance operations prescribed by
this manual
For no reason shall any unauthorised personnel be left alone in
contact with the unit.
n before opening any panelling of the machine, make sure that it is
2.4 General precautions secured to it by hinges
The OPERATOR must simply use the controls of the unit; he must not
open any panel, other than the one providing access to the control Prevention of residual electrical risks
module.
n connect the unit to the mains according to the instructions
When you approach or work on the unit, follow the precautions listed
provided in this manual
below:
n do not wear loose clothing or jewellery or any other accessory tat n periodically carry out all the maintenance operations specified by
may be caught in moving parts
this manual
n wear suitable personal protective equipment (gloves, goggles
etc.) when you have to work in the presence of free flames n disconnect the unit from the mains by the external disconnecting
(welding operations) or with compressed air switch before opening the electrical board
n cut off connecting pipes, drain them in order to balance the
pressure to the atmospheric value before disconnecting them, n check the proper grounding of the unit before start-up
disassemble connections, filters, joints or other line items
n check all the electrical connections, the connecting cables, and in
n do not use your hands to check for any pressure drops
particular the insulation; replace worn or damaged cables
n use tools in a good state of repair; be sure to have understood the
instructions before using them
4
2 - Safety
English
n periodically check the board's internal wiring The following precautions must be always adopted:
n do not use cables having an inadequate section or flying n do not scatter the fluids of the refrigeration circuit in the
connections, even for limited periods of time or in an emergency surrounding environment
Prevention of other residual risks n when replacing an eprom or electronic cards, use always suitable
devices (extractor, antistatic bracelet, etc.)
n make sure that the connections to the unit conform to the
instructions provided in this manual and on the unit's panelling n to replace the pump, the evaporator or any other weighty element,
make sure that the lifting equipment is consistent with the weight
n if you have to disassemble a piece, make sure that it has been to be lifted
properly mounted again before restarting the unit
n contact manufacturer for any modifications to the refrigeration,
n do not touch the delivery pipes from the compressor and any hydraulic or wiring diagram of the unit, as well as to its control
other piping or component inside the machine before wearing logics
protective gloves
n contact manufacturer if it is necessary to perform very difficult
n keep a fire extinguisher fir for electrical appliances near the disassembly and assembly operations
machine
n use only original spare parts purchased directly from manufacturer
n Install safety valves on the refrigeration circuis to a piping network or the official retailers of the companies on the recommended
that can channel any overflowing refrigerant outside spare parts list
n remove and leak of fluid inside and outside the unit n contact manufacturer if it is necessary to handle the unit one year
after its positioning on site or if you wish to dismantle it.
n collect the waste liquids and dry any oil spillage
n do not store flammable liquids near the unit
n do not disperse the refrigerant and the lubricating oil into the
environment
n weld only empty pipes; do not approach flames or other sources
of heat to refrigerant pipes
n do not bend/hit pipes containing fluids under pressure
2.6 Precautions during maintenance operations
Maintenance operations can be carried out by authorised technicians
only.
Before performing any maintenance operations:
n disconnect the unit from the mains with the external disconnecting
switch
n place a warning sign "do not turn on - maintenance in progress"
on the external disconnecting switch
n make sure that on-off remote controls are inhibited
n wear suitable personal protective equipment (helmet, safety
gloves, goggles and shoes etc.)
To carry out any measurements or checks which require the
activation of the machine:
n work with the electrical board open only for the necessary time
n close the electrical board as soon as the measurement or check
has been completed
5
2 - Safety
2.7 Safety labels
Identification of the refrigerant - Outside, on the external panel Factory adjusted flow switch
RECUPERARE FLUIDO - NON DISPERDERE NELL'AMBIENTE - REGOLAMENTO CEE N