Galletti LCR055 Installation, Maintenance, Usage Download Page 1

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Installation use and maintenance manual

Summary of Contents for LCR055

Page 1: ...GB Installation use and maintenance manual ...

Page 2: ...irements General guidelines for plumbing connections Water connection to the evaporator Instructions for the filling up of the rank Safety valve drain pipes Electrical connections Generalities Remote controls Split unit installation STARTING UP Preliminary checks Starting up instructions Starting operation Checks during operation Checking the refrigerant level Stopping the unit ...

Page 3: ...s SETTING OPERATING PARAMETERS Generalities Maximum pressure switch Minimum pressure switch Service thermostat Antifreeze thermostat Anti recycle timer ROUTINE MAINTENANCE AND CHECKS Warnings Generalities Repairing the cooling circuit Tightness test Hard vacuum and drying of cooling circuit Charging with R407C refrigerant Environmental protection RETIRING THE UNIT TROUBLESHOOTING ...

Page 4: ...RG66001652_REV 02 4 LCW LCR Dichiarazione di conformità La dichiarazione di conformità è allegata ad ogni macchina Declaration of conformity The declaration of conformity is attached to each unit sold ...

Page 5: ...tine servicing Field of Application The LCW units are designed to cool heat water and solutions containing up to 30 glycol percentage by weight in civil industrial and technological air conditioning systems In buildings with large surface areas the air conditioning system can be expanded step by step as new floors or areas are sold leased by installing an LCW unit for every floor in a small contro...

Page 6: ...heat exchangers with braze welded AISI 304 austenitic stainless steel plates and connections made of AISI 304 L characterised by a reduced carbon content to facilitate brazing Braze welded plate exchangers represent the state of the art in terms of heat exchange efficiency and make it possible to significantly reduce the refrigerant charge compared to traditional solutions The high turbulence indu...

Page 7: ...perature set point of the chiller inlet water temperature o Alarm management High low pressure Antifreeze Flow switch Pump alarm o Alarm signalling o Display of operating parameters o Antifreeze protection of evaporator o Management of maximum number of compressor start ups o RS232 RS485 serial output management optional o Phase sequence error Not displayed by the mP but prevents the compressor fr...

Page 8: ... circuit Plate heat exchanger Scambiatore a piastre Thermostatic valve Valvola termostatica Filter dryer Filtro deidratore Liquid receiver Ricevitore di liquido Sight glass Spia di flusso Check valve Valvola di non ritorno 4 way valve Valvola inversione di ciclo Scroll compressor Compressore scroll ...

Page 9: ...e heat exchanger Scambiatore a piastre Thermostatic valve Valvola termostatica Filter dryer Filtro deidratore Liquid receiver Ricevitore di liquido Sight glass Spia di flusso Check valve Valvola di non ritorno 4 way valve Valvola inversione di ciclo Scroll compressor Compressore scroll ...

Page 10: ...rcuit Plate heat exchanger Scambiatore a piastre Thermostatic valve Valvola termostatica Filter dryer Filtro deidratore Liquid receiver Ricevitore di liquido Sight glass Spia di flusso Check valve Valvola di non ritorno 4 way valve Valvola inversione di ciclo Scroll compressor Compressore scroll ...

Page 11: ... separator Separatore liquido Plate heat exchanger Scambiatore a piastre Thermostatic valve Valvola termostatica Filter dryer Filtro deidratore Liquid receiver Ricevitore di liquido Sight glass Spia di flusso Check valve Valvola di non ritorno 4 way valve Valvola inversione di ciclo Scroll compressor Compressore scroll ...

Page 12: ...onnected from the power supply Inspection Conveyance Siting Inspection on receipt On receiving the unit check that it is perfectly intact the machine left the factory in perfect conditions immediately report any signs of damage to the carrier and note them on the Delivery Slip before signing it GALLETTI S p A or its Agent must be promptly notified of the entity of the damage The Customer must subm...

Page 13: ... installation As special care has been taken in the sound insulation and sealing of the components and hot parts in general they need not be installed in dedicated rooms It is advisable to place a rigid rubber strip between the base frame and the supporting surface INSTALLATION Installation clearance requirements In the case of units with a remote condenser the plumbing and cooling connections are...

Page 14: ...al mesh filter incoming pipes with a mesh not to exceed 1 mm to protect the exchanger from scale or impurities present in the pipes This prescription is particularly important at first start up air vent valves to be placed at the highest points of the water circuit for the purpose of bleeding air The internal pipes of the unit are fitted with small manual air vent valves for bleeding the unit itse...

Page 15: ...tia of the water is lower it is a good idea to check that the water content in the section delivering to users satisfies the condition below Ns Sh Cc V ΔΤ Δ ρ τ V water content in user section m3 Sh specific heat of the fluid J kg C ρ fluid density kg m3 Dτ minimum time lapse between 2 compressor restarts s DT allowed water T differential C Cc Cooling capacity W Ns N of capacity control steps Tank...

Page 16: ...ks concerning the cavitation of the pump It is of fundamental importance for the installer to follow and check the instructions written below stepwise so as to avoid every kind of risks concerning the implosion of the tank or the cavitation of the pump a Empty the expansion tank until the pressure is 0 5 Bar b Charge the system and pressurize it until about 1 Bar in suction pump side with pump not...

Page 17: ...te Only qualified personnel may choose and install the piping and carry out the final braze welding operations as per current laws and regulations Said personnel must issue a new declaration of conformity for units assembled on site ...

Page 18: ...he fact that in the case of rising lines the pressure drop due to the travel height reduces the undercooling of the liquid resulting in the possible formation of flash vapours in this case choose a larger sized remote condenser and charge until you obtain 2 C of additional undercooling for every 10 m of height The table below shows the classification of piping according to EEC directive 97 23 PED ...

Page 19: ...um the pressure in the tank corresponds to the T of the surrounding environment a withdrawal of refrigerant charge will cause pressure drops which will be associated with withdrawal of refrigerant charge pressure drop in tank pressure drop in tank T drop change of state T drop change of state evaporation of part of the liquid causing the liquid itself to cool cooling of liquid thermal exchange wit...

Page 20: ...olenoid valve of the charging machine allows the passage of refrigerant liquid toward the charging gun and flow is measured by the volumetric flow rate gauge the quantity in weight is calculated by measuring the T of the liquid calculating its density tables and multiplying this value by the volumetric flow rate Given the constant pressure in the charging machine cylinder the flow rate of the refr...

Page 21: ...ering the refrigerant Refrigerants all tend to dissolve in oil compressor sump in percentages that are directly proportional to increases in pressure and decreases in the T of the oil itself Charles Law The release of refrigerant tends to cool the oil and thus actually serves to oppose the release itself for this reason it is advisable to switch on the crankcase heating elements if available durin...

Page 22: ...on of the lubricant in any case first check the compatibility between the crankcase capacity and the required charge volumes Safety valve drain pipes A safety valve is present on the refrigerant circuit Some regulations provide that the refrigerant drained from the valves be conveyed to the outside by means of a suitable pipe with a diameter at least matching that of the valve drainage outlet the ...

Page 23: ... warranty The electrical connections must be made in accordance with the information shown in the wiring diagram provided with the unit and current regulations An earth connection is mandatory The installer must connect the earthing wire using the earthing terminal situated on the electric control board yellow and green wire The power supply to the control circuit is shunted from the power line th...

Page 24: ...able 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 12 hours before the unit is started This function is carried out automatically when the main switch is off Their function is to r...

Page 25: ... running in the wrong direction in the case of a phase sequence error Position the Local Remote selector SLR situated at the top middle of the electric board on LOCAL and switch on the power by turning the main switch IG to ON Check the phase sequence relay situated in the middle of the electric control board to make sure the phases are in the right sequence R S T the green indicator light should ...

Page 26: ...the service thermostat CHECKING THE REFRIGERANT LEVEL After a few hours of operation check whether the liquid level indicator has a green crown a yellow colour indicates the presence of humidity in the circuit In such a case the circuit must be dehumidified by qualified personnel Large quantities of bubbles should not appear through the liquid level indicator A constant passage of numerous bubbles...

Page 27: ...er oil of the type and viscosity indicated on the compressor rating plate For no reason should oil of a different type be introduced into the oil circuit The difference between the Dew Point and Bubble Point is known as GLIDE and this is a characteristic property of refrigerant mixtures If pure fluids are used the phase change occurs at a constant T and thus the glide is equal to zero STOPPING THE...

Page 28: ...25 45 Below 25 C the condensation pressure control is required Evaporator inlet heating mode 25 45 Without antifreeze products Condenser inlet heating mode 12 25 in heat pump operation heat exchangers work on reverse function Cooling only units with remote condenser Water temperature Minimum Maximum Notes Evaporator inlet 10 25 Without antifreeze products Dew Point C 40 65 Below 40 C the condensat...

Page 29: ...C Maximum operating T indoor environment 50 C Minimum operating T 10 C Maximum operating P Low pressure side 22 6 bar r Supply voltage 10 of rating plate voltage Maximum stocking T 50 C Minimum stocking T 10 C limit imposed by the built in electronic components this value can be reached only in storage conditions and determines the refrigerant saturation pressure of 22 bar r on the low pressure si...

Page 30: ...parameters and control system settings configurable by means of the microprocessor control are password protected if they have a potential impact on the integrity of the unit TABLE II SETTING OF CONTROL DEVICES CONTROL DEVICE SET POINT DIFFERENTIAL Service thermostat Cooling C 12 2 Service thermostat H C 40 2 TABLE III SETTING OF SAFETY CONTROL DEVICES CONTROL DEVICE ACTIVATION DIFFERENTIAL RESETT...

Page 31: ...mpressors operation as a function of the reading of the inlet water temperature of the chilling unit return from the system For further details refer to the microprocessor control section in the manual ANTIFREEZE THERMOSTAT The antifreeze probe is located at the evaporator outlet and stops the compressor when the temperature goes below the set limit value Together with the flow switch and low pres...

Page 32: ... MUST ALWAYS BE PERFORMED BY QUALIFIED PERSONNEL Before carrying out any work on the unit or accessing internal parts make sure you have disconnected it from the mains electricity supply The upper part and the outlet pipe of the compressor reach high temperatures Be especially careful when working in the surrounding area with the panels off Be especially careful when working in proximity to finned...

Page 33: ...ted to fall below the freezing point of the fluid used Every 6 months Check whether the water in the circuit needs to be replenished Every 6 months Check the efficiency of the flow switch or differential pressure switch Every 6 months Clean the metal mesh filters mounted externally on the water pipes First start up Check the humidity indicator green dry yellow humid on the liquid level indicator i...

Page 34: ...e 150 Pa of absolute pressure with a capacity of approximately 10 m3 h If such a pump is available one evacuation will normally suffice to achieve an absolute pressure of 150 Pa If there is no such vacuum pump available or whenever the circuit has remained open for long periods of time you are strongly recommended to adopt the triple evacuation method This method is also recommended when there is ...

Page 35: ...ree constituents Introduce refrigerant through the inlet in the liquid line A unit that was originally charged with R407C in the factory cannot be charged with R22 or other refrigerants without the written authorisation of GALLETTI S p A Environmental protection The law implementing the regulations reg EEC 2037 00 which govern the use of ozone depleting substances and greenhouse gases bans the dis...

Page 36: ...ve been triggered Check whether any alarms are signalled on the microprocessor control panel eliminate the causes and restart the unit The phase sequence is wrong Invert two phases in the primary power line after disconnecting them upstream from the unit The compressor is noisy The compressor is rotating in the wrong direction Check the phase sequence relay Invert the phases on the terminal board ...

Page 37: ... opens and adjust it if necessary If it does not respond replace it Filter clogged Pressure drops upstream and downstream from the filter should not exceed 2 C If they do replace 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 undercooling if it is below 2 C replenish...

Page 38: ... 9282 10295 11810 14015 15441 17715 20841 Pressure drop evaporator side kPa 48 4 48 4 48 4 47 1 41 7 32 3 39 0 Condenser water flow rate 1 l h 3588 5 4049 2 4587 5 5430 1 6098 5 6984 4 8236 2 Pressure drop condenser side kPa 20 25 13 18 23 22 25 Additional pressure drop for condensation control optional kPa 14 18 24 20 24 12 15 Compressor type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Numbe...

Page 39: ...40708 43670 47046 50931 Pressure drop evaporator side kPa 41 7 43 1 53 8 37 7 35 0 36 3 40 4 40 4 Condenser water flow rate 1 l h 9331 8 10251 6 11803 7 14313 4 16128 3 17359 8 18633 9 20174 9 Pressure drop condenser side kPa 19 23 28 15 17 21 25 25 Additional pressure drop for condensation control optional kPa 17 21 18 21 12 15 17 17 Compressor type Scroll Scroll Scroll Scroll Scroll Scroll Scrol...

Page 40: ... drop evaporator side kPa 48 4 48 4 48 4 47 1 41 7 32 3 39 Condenser water flow rate 1 l h 5307 1 5855 3 6608 2 7988 5 8953 0 10263 7 20101 Pressure drop condenser side kPa 45 56 25 29 25 40 5 51 75 49 5 56 25 Additional pressure drop for condensation control optional kPa 31 5 40 5 54 45 54 27 33 75 Compressor type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Number of cooling circuits 2 2 2 2...

Page 41: ... side kPa 41 7 43 1 53 8 37 7 35 36 3 40 4 40 4 Condenser water flow rate 1 l h 13810 15183 17492 21193 23907 25722 27617 29886 Pressure drop condenser side kPa 41 6 50 4 61 5 32 9 37 4 46 1 54 9 54 9 Additional pressure drop for condensation control optional kPa 37 2 46 1 39 5 46 0 26 4 32 9 37 3 37 3 Compressor type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Number of cooling circui...

Page 42: ... 2 2 Oil charge compressor dm3 3 3 3 3 4 1 4 1 6 5 8 8 Evaporator type BPHE BPHE BPHE BPHE BPHE BPHE BPHE Number of evaporators 2 2 2 2 2 1 1 Water content dm3 5 5 6 1 6 6 7 1 7 9 32 33 5 Type of refrigerating circuit connections RTK RTK RTK RTK RTK RTK RTK Type of water connections GAS GAS GAS GAS GAS GAS GAS Size of water connections 2 2 2 2 2 2 2 Remote condenser Standard model SHVN 61 V SHVN 7...

Page 43: ...8 8 Evaporator type BPHE BPHE BPHE BPHE BPHE BPHE BPHE BPHE Number of evaporators 1 1 1 1 1 1 1 1 Water content dm3 34 1 36 2 38 1 67 8 70 6 73 5 73 5 73 5 Type of refrigerating circuit connections RTK RTK RTK RTK RTK RTK RTK RTK Type of water connections Victaulic Victaulic Victaulic Victaulic Victaulic Victaulic Victaulic Victaulic Size of water connections 3 3 3 4 4 4 4 4 Remote condenser Stand...

Page 44: ...40010 Bentivoglio BO Via Romagnoli 12 a Tel 051 8908111 Fax 051 8908122 www galletti it ...

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