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Galletti LCP Series, Installation, Use And Maintenance Manual

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Galletti LCP Series Installation, Use And Maintenance Manual Download Page 31

LCP

 

RG66006889-Rev.01 

                   31 

 

 

 

12 TROUBLESHOOTING 

 
On the next pages you will find a list of the most common causes that may cause the chilling unit to fail or 
malfunction. These causes are broken down according to easily identifiable symptoms. 
 

You should be extremely careful when attempting to implement any of the possible 
remedies suggested: overconfidence can result in injuries, even serious ones, to 
inexpert individuals. Therefore, once the cause has been identified, you are advised to 
contact the manufacturer or a qualified technician for help. 
 

 

 

      

 

 
 

Dryer filter 

Lamination 
valves

Hydronic unit 
one pump per 
circuit 

Plate heat 
exchanger 

Hot water 
inlet 

Hot water 
outlet 

Cold water 
outlet 

Cold water 
inlet 

Summary of Contents for LCP Series

Page 1: ...GB Installation use and maintenance MULTI PURPOSE VERSION ...

Page 2: ...LCP RG66006889 Rev 01 2 ...

Page 3: ...NS OF WATER VANE OPERATED FLOW SWITCH 19 6 3 ELECTRIC CONNECTIONS OF THE CIRCULATION PUMP 19 6 4 REMOTE CONTROLS 19 6 5 REMOTE SUMMER WINTER SWITCHING 19 7 STARTING UP 20 7 1 PRELIMINARY CHECKS 20 7 2 STARTING OPERATION 21 7 3 CHECKS DURING OPERATION 22 7 4 CHECKING THE REFRIGERANT LEVEL 22 7 5 EXPANSION VALVE OPTIONAL 23 7 6 STOPPING THE UNIT 24 8 OPERATING LIMITS 24 8 1 WATER FLOW TO EVAPORATOR ...

Page 4: ... 10 5 HARD VACUUM AND DRYING OF THE COOLING CIRCUIT 29 10 6 CHARGING WITH R410A REFRIGERANT 29 10 7 ENVIRONMENTAL PROTECTION 30 11 RETIRING THE UNIT 30 12 TROUBLESHOOTING 31 13 WATER PRESSURE DROPS 34 13 1 PRESSURE DROPS IN EVAPORATOR 34 13 2 PRESSURE DROPS IN HEAT RECUPERATOR 34 14 SUMMARY TECHNICAL DATA 35 14 1 STANDARD VERSION 35 14 2 LOW NOISE VERSION 37 15 SUMMARY TABLE OF WEIGHTS 39 15 1 PUM...

Page 5: ...LCP RG66006889 Rev 01 5 Declaration of conformity The declaration of conformity is individually appended to the documents accompanying the unit normally placed inside the electrical enclosure ...

Page 6: ...ncy Packs Efficiency pack 1 2 compressors 2 refrigerant circuits Efficiency pack 4 4 compressors 2 refrigerant circuits Below is a list of all possible models broken down by efficiency pack efficiency pack 1 efficiency pack 4 Approximate cooling capacity in vers kW LCP041HS PS 51 4 LCP041HL PL 49 4 LCP051HS PS 56 5 LCP051HL PL 53 7 LCP061HS PS 66 4 LCP061HL PL 64 0 LCP071HS PS 74 1 LCP071HL PL 70 ...

Page 7: ...uit 1 production of cold water summer hot water winter Circuit 2 production of hot water for example for domestic hot water The machine is equipped with 3 distinct heat exchangers Finned pack coil S3 with both evaporating and condensing function for heat exchanger with the thermal source outdoor air Plate heat exchanger S1 intended for utility circuit with evaporating function in summer mode and c...

Page 8: ...ressure Winter Mode d Heat Only represented on following page the system produces hot water on circuit 1 removing heat from outdoor air which together with the power absorbed by the compressors is yielded to the water by means of the plate heat exchanger S1 Ventilation is modulated to vary the air flow depending on evaporation pressure e DHW Only represented on following page the system produces h...

Page 9: ...LCP RG66006889 Rev 01 9 Graphical representation of the operation cycles a b c d e described above ...

Page 10: ... o 25 Cooling 25 DHW o 50 Cooling 100 DHW o 25 Cooling 100 DHW o 100 Cooling 50 DHW o 100 Cooling 25 DHW o 50 Heat 50 DHW o 50 Heat 25 DHW o 25 Heat 50 DHW o 25 Heat 25 DHW o 100 DHW o 75 DHW o 50 DHW o 25 DHW o 100 DHW 5 o 75 DHW o 50 DHW o 25 DHW 1 Summer mode for production of chilled water alone on exchanger S1 12 7 C with outdoor air 35 C 2 Summer mode for simultaneous production of chilled w...

Page 11: ...he directions on the units and take all such precautions as are necessary The fluids under pressure in the cooling circuit and the presence of electrical components may cause hazardous situations during installation and maintenance work Therefore only qualified personnel may perform any kind of work on the unit THE UNIT MUST BE STARTED UP FOR THE FIRST TIME EXCLUSIVELY BY QUALIFIED PERSONNEL AUTHO...

Page 12: ...it is being unloaded and positioned utmost care must be taken to avoid abrupt or violent manoeuvres The unit must be handled carefully and gently avoid using machine components as anchorages when lifting or moving it The unit should be lifted using Ø1 GAS steel pipes at least 3mm thick to be inserted in the round holes provided on the base side members see fig below and identified by means of stic...

Page 13: ...air cooled condenser and necessary clearance direction of prevalent winds avoid positioning the unit in such a way that the prevalent winds favour the backflow of air to the condenser coils a speed of 8 m s 28 8 km h already generates a sufficient stagnation pressure to guarantee approx 60 of the nominal air flow rate possible reverberation of sound waves All models belonging to the LCP series are...

Page 14: ... is necessary to guarantee the following clearances see figure on this page rear side plumbing connections min 1 0 metre to guarantee access to plumbing connections and or for any necessary maintenance on the pumps reservoir expansion tank and flow switch electric control board side min 1 0 metre to guarantee access for inspection and or maintenance of cooling components finned pack heat exchanger...

Page 15: ...ressure indicators for routine maintenance and monitoring of the unit Checking the pressure on the water side will enable you to verify whether the expansion tank is working efficiently and to promptly detect any water leaks within the equipment traps on incoming and outgoing pipes for temperature measurements which can provide a direct reading of the operating temperatures Temperature readings ca...

Page 16: ... the water supplied to the evaporator remains constant 15 in all operating conditions The compressors often work intermittently since the chilling requirements of the user generally do not coincide with the output of LCP unit In systems containing little water where the thermal inertia of the water is lower it is a good idea to check that the water content in the section delivering to users satisf...

Page 17: ...r inside the unit 5 4 SAFETY DEVICES ON THE HIGH PRESSURE SIDE Cooling circuit safety devices are provided on each refrigerant circuit according to the volumetric capacity of the compressors installed as prescribed by Directive 97 23 PED in particular with respect to equipment design this Directive requires manufacturers to abide by the technical standard nearest to the type of object produced in ...

Page 18: ... it with a cable gland Connect the power supply and earthing wire to the terminals of the main switch Open the fuse carriers F1 and F2 or Q1 and Q2 for the motor overload cutouts of the compressors F1 F2 F3 F4 for the fuses or Q1 Q2 Q3 Q4 for the overload cutouts in the case of LCP 4 compressor models to prevent them from starting up in the wrong direction in the event of an incorrect phase sequen...

Page 19: ... installed on board either on the utility side or on the DHW side with OR Standby rotation or AND parallel logic The pump s must be started before the chiller and stopped after the latter minimum recommended delay 60 seconds If included as an option this function is already performed by the microprocessor on the unit 6 4 REMOTE CONTROLS If you wish to include a remote control for switching the uni...

Page 20: ...ard if the sequence is not duly observed it will not enable the machine to start Make sure there are no refrigerant leaks that may have been caused by accidental impacts during transport and or installation Check the power supply to the crankcase heating elements where present The heating elements must be turned on at least 5 10 minutes before the unit is started This function is carried out autom...

Page 21: ...ol panel red button heating green button cooling and press the ON button on the control panel The unit will start up if enabled by the safety devices of the water circulation pump s by the flow switch or differential pressure switch by the T sensor measuring the temperature of the water returning from the system chiller inlet and no alarms have been triggered Starting up Check that all external co...

Page 22: ... R410A marked with the initials D P Dew Point is about 16 22 C depending on the type of unit and charging conditions higher than the temperature of the air entering the condenser with the fans running at top speed Also check that the end of evaporation temperature shown on the pressure gauge refer to the pressure gauge scale for the refrigerant R410A marked with the initials D P Dew Point is about...

Page 23: ...nsion valve is installed as a standard feature on all LCP units If correctly parameterised and controlled by the software this device has the ability to render the operation of the cooling circuit highly efficient and this will have the ultimate effect of decreasing the power intake of the system when a sudden change occurs in the thermal load With a traditional expansion valve there is a transien...

Page 24: ...he unit from the electricity supply the crankcase heating elements will receive no power thereby jeopardising the integrity of the compressor the next time the unit is started 8 OPERATING LIMITS Operating limits of LCP chillers in relation to the outlet water temperature in brackets in cooling mode and outdoor air temperature Min Max Evaporator outlet water temperature C 5 30 12 45 External air te...

Page 25: ...mperatures during wintertime shutdown periods The heating element is activated whenever the temperature of the water leaving the evaporator falls below the temperature set on the antifreeze probe 8 4 OPERATION WITH WATER AT LOW TEMPERATURES The standard units are not designed to work with chilled water temperatures below 5 C at the evaporator outlet In order to work below this limit the unit requi...

Page 26: ...utlet pressure gauge previously installed whether the pressure switch trips i e the compressors stop when the set value is reached Warning during this operation if the safety device fails to trip the second cascade connected pressure switch will step in to shut down the unit in any event however you should be ready to shut off the unit as directed in the section Stopping the Unit see also section ...

Page 27: ...mage to the unit 9 7 OIL DIFFERENTIAL PRESSURE SWITCH LCP units are equipped with spinning scroll compressors these compressors do not have a lubricant pump and therefore no oil differential pressure switch is provided 10 ROUTINE MAINTENANCE AND CHECKS 10 1 WARNINGS All the operations described in this chapter MUST ALWAYS BE PERFORMED BY QUALIFIED PERSONNEL Before carrying out any work on the unit...

Page 28: ...6 months Check that the noise emissions of the unit are regular every 6 months and more specifically that no vibrations and or knocking can be detected Galletti S p A is not responsible for inexact translations of the manual in languages other than English 10 3 REPAIRING THE COOLING CIRCUIT Warning while performing repairs on the cooling circuit or maintenance work on the compressors make sure the...

Page 29: ... the step described above Carry out the step described above for the third time but in this case attempting to reach the hardest vacuum possible Using this procedure you can easily remove up to 99 of pollutants 10 6 CHARGING WITH R410A REFRIGERANT Connect the tank of refrigerant gas to the male 1 4 SAE inlet situated on the liquid line after discharging a little gas to eliminate air in the connect...

Page 30: ...special care should be taken when carrying out maintenance work to minimise refrigerant leaks 11 RETIRING THE UNIT When the unit has reached the end of its working life and needs to removed and replaced a series of operations should be carried out the refrigerant gas it contains should be recovered by specialised personnel and sent to a waste collection facility the lubricating oil in the compress...

Page 31: ... be extremely careful when attempting to implement any of the possible remedies suggested overconfidence can result in injuries even serious ones to inexpert individuals Therefore once the cause has been identified you are advised to contact the manufacturer or a qualified technician for help Dryer filter Lamination valves Hydronic unit one pump per circuit Plate heat exchanger Hot water inlet Hot...

Page 32: ... sure no back suction occurs Check whether the effective RMS voltage to the fans is the maximum If necessary check the pressure transducers via the revolution speed controller where present optional Check the cleanliness of the finned coils Presence of air in the refrigerant circuit as revealed by the presence of bubbles in the flow indicator also with subcooling values exceeding 5 C Drain and pre...

Page 33: ...eplace the filter Low condensation T Check the efficiency of the condensation control device where present Low level of refrigerant Check the refrigerant level by measuring the degree of subcooling if it is below 2 C replenish the charge Coil covered with frost in the case of heat pump operation Check whether the defrost parameters have been properly set Check the efficiency of the 4 way valve Low...

Page 34: ...r Check whether defrosting water is properly drained from the coils Check the uniformity of the refrigerant circuit outlet temperatures at the top and bottom of the coils the maximum temperature differential allowed is 10 C Check the refrigerant level The 4 way valve has failed to work Check whether it is regularly energized and deenergized 13 WATER PRESSURE DROPS 13 1 PRESSURE DROPS IN EVAPORATOR...

Page 35: ...01 90 112 13 131 01 Heating capacity 2 kW 65 22 72 20 79 1 93 76 107 15 130 64 144 33 167 86 Total Input power 2 kW 16 29 18 12 22 0 23 41 26 45 32 59 36 23 45 08 Total COP 2 7 68 7 57 7 79 7 71 7 83 7 69 7 57 6 2 Heating capacity 3 kW 77 81 86 100 44 111 01 124 3 154 24 170 45 199 68 Total Input power 3 kW 18 18 20 21 23 43 26 09 28 96 36 33 40 4 49 82 COP 3 4 28 4 26 4 29 4 25 4 29 4 25 4 22 4 0...

Page 36: ...ty 2 kW 186 26 211 79 252 69 286 12 315 58 345 39 390 66 422 7 Total Input power 2 kW 49 88 55 46 64 14 73 55 79 83 89 04 99 10 109 5 Total COP 2 7 60 7 67 7 79 7 56 7 63 7 62 7 66 7 41 Heating capacity 3 kW 218 11 250 03 291 94 339 2 368 62 408 75 459 56 468 1 Total Input power 3 kW 54 96 61 17 70 72 81 35 89 05 99 49 110 46 121 4 COP 3 3 97 4 09 4 13 4 17 4 14 4 11 4 16 3 85 Winter Mode Heating ...

Page 37: ...1 Heating capacity 2 kW 65 22 72 20 84 47 93 76 107 15 130 64 144 33 167 86 Total Input power 2 kW 15 66 17 49 20 13 22 47 25 21 31 33 34 98 42 80 Total COP 2 7 68 7 57 7 79 7 71 7 83 7 69 7 57 7 71 Heating capacity 3 kW 77 12 85 23 99 12 109 24 123 37 152 21 167 41 193 59 Total Input power 3 kW 17 54 19 57 22 48 25 04 27 91 35 02 39 11 47 48 COP 3 4 40 4 36 4 41 4 36 4 42 4 35 4 28 4 08 Winter Mo...

Page 38: ... kW 186 26 211 79 252 69 286 12 215 58 245 39 390 66 422 71 Total Input power 2 kW 47 60 53 18 61 86 71 27 77 55 86 74 96 80 107 26 Total COP 2 7 60 7 67 7 79 7 56 7 63 7 62 7 66 7 41 Heating capacity 3 kW 214 26 245 93 290 62 339 2 368 62 405 16 459 56 468 18 Total Input power 3 kW 52 67 58 67 68 44 79 07 86 77 97 12 108 16 119 17 COP 3 4 07 4 19 4 25 4 29 4 25 4 17 4 25 3 93 Winter Mode Heating ...

Page 39: ...LE OF WEIGHTS This drawing shows the points of the unit for which the weights for the basic version were calculated multi purpose in configuration without pumps without tank and empty with treated water They are shown on the following table ...

Page 40: ...7 232 254 257 L2 242 242 282 284 291 172 172 227 232 254 257 L3 68 68 81 82 84 102 102 132 135 150 152 L4 68 68 81 82 84 102 102 132 135 150 152 L5 172 172 227 232 254 257 L6 172 172 227 232 254 257 L7 102 102 132 135 150 152 L8 102 102 132 135 150 152 HS HL PS PL HS HL PS PL HS HL PS PL HS HL PS PL HS HL PS PL SIZE 214 244 274 294 324 FRAME 5 5 6 6 6 total kg 1710 1810 2102 2137 2188 L1 269 284 4...

Page 41: ...ndard pump and back up pump uprated pump and back up pump standard pump for combined operation uprated pump for combined operation In the case of pump systems including a back up pump the microprocessor controls the pumps in such a way as to equally divide the hours of operation changing over the pumps in the event of a fault All of these considerations can also be chosen on the DHW side ...

Page 42: ...LCP RG66006889 Rev 01 42 ...

Page 43: ...LCP RG66006889 Rev 01 43 ...

Page 44: ...40010Bentivoglio BO Via Romagnoli 12 a Tel 051 8908111 Fax 051 8908122 www galletti it Company UNI EN ISO 9001 and OHSAS 18001 certified ...

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