Galletti LCA 0130, Installation, Use And Maintenance Manual

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

Page 2: ...llation clearance requirements General guidelines for plumbing connections Water connection to the evaporator Safety valve drain pipes Electrical connections Generalities Electrical connections of differential pressure switch flow switch Electrical connections of circulation pump Remote controls STARTING UP Preliminary checks Starting operation Checks during operation Checking the refrigerant leve...

Page 3: ... pressure switch Minimum pressure switch Service thermostat Anti freeze thermostat Anti recycle timer Oil differential pressure switch 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 DRAWINGS SHOWING OVERALL DIMENSION...

Page 4: ...LCA RG66000986 Rev 00 4 ...

Page 5: ...ary 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 Failure to comply with the rules provided in this manual or any modification made to the unit without prior authorisation will result in the immediate invali...

Page 6: ...m to suitable waste disposal or recycling facilities in order to minimise their environmental impact SITING You should bear in mind the following aspects when choosing the best site for installing the unit and the relative connections size and origin of water pipes location of power supply accessibility for maintenance or repairs solidity of the supporting surface ventilation of the air cooled con...

Page 7: ...on on roofs or intermediate storeys the unit and pipes must be insulated from walls and ceilings by placing rigid rubber joints in between and using supports that are not rigidly anchored to the walls If the unit is to be installed in proximity to private offices bedrooms or areas where noise levels must be kept down it is advisable to conduct a thorough analysis of the sound field generated and v...

Page 8: ...this reason it is necessary to guarantee the following clearances see figure on this page rear side plumbing connections min 1 5 metres 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 5 metres to guarantee access for inspection and or maintenance of cooling components coil side ...

Page 9: ... from scale or impurities present in the pipes 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 air vent valves for bleeding the unit itself this operation may only be carried out when the unit is disconnected from the power supply drainage valve and where necessary a drainage tank for empty...

Page 10: ...thermal inertia of the water itself is lower it is a good idea to check that the water content in the section delivering to users satisfies the condition below 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 choking steps Tank Ts Q TW i...

Page 11: ...ge of water cannot harm people This is a standard feature of units equipped with the optional storage reservoir Warning When making the plumbing connections make sure there are no open flames in proximity to or inside the unit SAFETY VALVE DRAIN PIPES Safety valves are fitted in each refrigerant circuit some regulations provide that the refrigerant drained from the valves be conveyed to the outsid...

Page 12: ...tuations exceeding 5 and the unbalance between phases must always be below 2 The above operating conditions must always be complied with failure to ensure said conditions will result in the immediate invalidation of the 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 i...

Page 13: ...selves see annexed wiring diagram All remote controls work with a very low voltage 24 Vac supplied by the insulating transformer on the electric control board REMOTE SUMMER WINTER SWITCHING If you wish to include a remote control for switching the unit between the summer and winter operating modes you must remove the bridge between the contacts indicated in the wiring diagram and connect the remot...

Page 14: ...icating function desired is maintained Check that the plumbing connections have been properly made according to the indications given on the plates to be found on the unit itself proper inlet and outlet connections Make sure that the water circuit is duly bled to completely eliminate the presence of air load the circuit gradually and open the air vent valves on the top part which the installer sho...

Page 15: ...f a few bubbles is however allowed especially in the case of high glide ternary mixtures such as HFC R407C A few minutes after the compressors have started up check that the end of condensation temperature shown on the pressure gauge refer to the pressure gauge scale for the refrigerant R407C marked with the initials B P Bubble Point is about 19 22 C higher than the temperature of the air entering...

Page 16: ...c 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 UNIT To stop the unit press the OFF unit on the front panel Warning do not stop the unit using the main switch the latter device serves to disconnect the unit from the electricity supply when there is no passage of current i e when the unit is already ...

Page 17: ...r temperatures are possible but for such applications the Manufacturer should be consulted at the time the order is placed The maximum temperature of the water entering the evaporator is 20 C To allow higher temperatures specific equipment solutions must be adapted split circuits three way valves bypasses storage reservoirs contact the Manufacturer OUTDOOR AIR TEMPERATURE The units are designed an...

Page 18: ...icroprocessor control and are protected by passwords TABLE II SETTING OF CONTROL DEVICES CONTROL DEVICE SET POINT DIFFERENTIAL Service thermostat C C 12 2 Service thermostat H C 40 2 TABLE III SETTING OF SAFETY CONTROL DEVICES CONTROL DEVICE ACTIVATION DIFFERENTIAL RESETTING Antifreeze thermostat C 4 2 Automatic Safety maximum pressure switch bars 28 4 Manual High pressure relief valve bars 29 Min...

Page 19: ... the pressure falls below the set differential see Table III MINIMUM PRESSURE SWITCH The low pressure switch stops the compressor when the intake pressure falls below the set value for more than 180 seconds The switch is automatically reset when the pressure rises above the set differential see Table III however the unit will not resume operation until the alarm memory on the microprocessor contro...

Page 20: ... control It imposes a minimum time lapse of 300 seconds between two successive starts Never attempt to change the delay set in the factory wrong settings could cause serious damage to the unit OIL DIFFERENTIAL PRESSURE SWITCH LCA units are equipped with spinning scroll compressors these compressors do not have a lubricant pump and therefore no oil differential pressure switch is provided ...

Page 21: ...ains electricity supply The upper part and outlet pipe of the compressor may reach temperatures as high as 110 C Be especially careful when working in the surrounding area while the unit is running Be especially careful when working in proximity to finned coils since the 0 11 mm thick aluminium fins can cause superficial injuries due to cuts After completing maintenance jobs always replace the pan...

Page 22: ...to be replenished Check the efficiency of the flow switch or differential pressure switch Check the heating elements where present of the compressor crankcases Clean the metal mesh filters mounted externally on the water pipes Check the humidity indicator on the liquid level indicator green dry yellow humid if the indicator is not green as shown on the indicator sticker replace the filter every 6 ...

Page 23: ...IT To achieve a hard vacuum in the cooling circuit it is necessary to use a pump capable of generating a high degree of vacuum i e 15 Pa of absolute pressure If there is no suitable 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 a presence of hu...

Page 24: ...ure the correct percentages of the three 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 ENVIRONMENTAL PROTECTION The law implementing the regulations reg EEC 2037 00 which govern the use of ozone depleting substances and greenhouse gases bans the dispersal of refri...

Page 25: ...ecially for the considerable quantities of copper and aluminium present in the unit This will make the job of waste collection disposal and recycling facilities easier and minimise the environmental impact of such processes 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 ...

Page 26: ... no back suction occurs Check whether the effective RMS voltage to the fans is the maximum If necessary check the pressure transducers controlling the revolution regulator 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 undercooling values exceeding 5 C Drain and press...

Page 27: ...lace 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 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 28: ...mplete Error in parameter settings Check the setting of the start and end defrost parameters on the microprocessor 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 thermal differential allowed is 10 C Check the refrigerant level The 4 way valve has failed to work Chec...

Page 29: ...6 9 Vista dall alto Top view 1960 265 1164 1 Water inlet 2 gas 2 Water outlet 2 gas 3 Power supply input 4 Electric control board 5 Refrigerant pressure gauges optional 6 Advanced control microprocessor optional 7 pump system optional 8 Inertial storage reservoir optional 9 Condenser protection grilles optional Center of gravity with empty tank 13 DRAWINGS SHOWING OVERALL DIMENSIONS LCA 045 050 ...

Page 30: ... 158 936 158 870 466 Vista dall alto Top view 2360 265 9 Center of gravity with empty tank 1 Water inlet 2 gas 2 Water outlet 2 gas 3 Power supply input 4 Electric control board 5 Refrigerant pressure gauges optional 6 Advanced control microprocessor optional 7 pump system optional 8 Inertial storage reservoir optional 9 Condenser protection grilles optional LCA 060 070 080 ...

Page 31: ...all alto Top view 3140 407 870 5 9 1 2 5 6 7 37 5 1197 1493 5 85 Center of gravity with empty tank 1 Water inlet 2 gas 2 Water outlet 2 gas 3 Power supply input 4 Electric control board 5 Refrigerant pressure gauges optional 6 Advanced control microprocessor optional 7 pump system optional 8 Inertial storage reservoir optional 9 Condenser protection grilles optional LCA 090 105 ...

Page 32: ... alto Top view Frontale Front view Laterale Side view Retro Rear view 3 9 Center of gravity with empty tank 1 Water inlet 2 gas 2 Water outlet 2 gas 3 Power supply input 4 Electric control board 5 Refrigerant pressure gauges optional 6 Advanced control microprocessor optional 7 pump system optional 8 Inertial storage reservoir optional 9 Condenser protection grilles optional ...

Page 33: ...Retro Rear view 1 2 Vista dall alto Top view 3 Center of gravity with empty tank 1 Water inlet 2 gas 2 Water outlet 2 gas 3 Power supply input 4 Electric control board 5 Refrigerant pressure gauges optional 6 Advanced control microprocessor optional 7 pump system optional 8 Inertial storage reservoir optional 9 Condenser protection grilles optional LCA 205 220 235 LCA 180 CL ...

Page 34: ...SSURE DROPS The diagram shows the pressure drops on the water side Dpw as a function of the water flow rate Qw assuming an average water temperature of 42 5 C 0 0 20 40 60 80 100 120 Qw l h 20 000 140 30 000 40 000 Dpw kPa 10 000 50 000 60 000 060 070 080 090 105 115 180 205 220 235 045 050 130 150 0 0 10 20 30 40 50 60 Qw l h 10 000 70 20 000 Dpw kPa 30 000 045 050 060 070 080 090 105 115 180 80 ...

Page 35: ...A B B B C Available head LCA with standard pump nominal flow rate kPa 79 74 123 117 116 159 Rated electrical output standard pump kW 0 55 0 55 0 75 0 75 0 75 1 50 Operating current standard pump A 1 7 1 7 2 3 2 3 2 3 4 3 Uprated pump type kW C C D D D E Available head LCA with uprated pump nominal flow rate kPa 183 178 138 224 221 229 Rated electrical output uprated pump kW 1 50 1 50 2 20 2 20 2 2...

Page 36: ...40010 Bentivoglio BO Via Romagnoli 12 a Tel 051 8908111 Fax 051 8908122 www galletti it ...