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Summary of Contents for Galletti LCWC055
- Page 1 Installation use and maintenance manual...
- Page 2 LCW - LCR TABLE OF CONTENTS GENERALITIES INSPECTION, CONVEYANCE, SITING Inspection Lifting and conveyance Unpacking Siting INSTALLATION Installation clearance requirements 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...
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Page 3: Setting Operating Parameters
LCW - LCR TABLE OF CONTENTS OPERATING LIMITS Water flow to evaporator Chilled water temperature External water temperature Operation with water at low temperatures SETTING OPERATING PARAMETERS Generalities Maximum pressure switch Minimum pressure switch Service thermostat Antifreeze thermostat Anti-recycle timer ROUTINE MAINTENANCE AND CHECKS Warnings Generalities... -
Page 4: Dichiarazione Di Conformità
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. RG66001652_REV.02... -
Page 5: General Description
LCW - LCR General Description The Series The LCW series of water-condensing chillers includes a range of models capable of satisfying every need. Water-condensing units – cooling only – of [ 53.9 - 296 kW ] Heat pump reversible water-condensing units of [ 53 - 290 kW ] Motor-driven evaporative units –... -
Page 6: Cooling Circuit
97/23 PED. However, the exchanger serial number and declaration of conformity are recorded during production and constitute an integral part of GALLETTI S.p.A records. Cooling components: Molecular mesh activated-alumina filter dryer Flow indicator with humidity indicator. - Page 7 LCW - LCR Control microprocessor: the microprocessor built into the unit allows the different operating parameters to be controlled from a set of pushbuttons situated on the electric control board; Switching on/off of compressor to maintain the temperature set point of the chiller inlet water temperature Alarm management High / low pressure...
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Page 8: Basic Cooling Circuit
LCW - LCR BASIC COOLING CIRCUIT Cooling only versions – Basic diagram of a single circuit Filter dryer Sight glass Plate heat exchanger Filtro deidratore Spia di flusso Scambiatore a piastre Scroll compressor Compressore scroll Thermostatic valve Liquid receiver Valvola termostatica Ricevitore di liquido Check valve... - Page 9 LCW - LCR Heat pump versions – Basic diagram of a single circuit Filter dryer Sight glass Plate heat exchanger Filtro deidratore Spia di flusso Scambiatore a piastre Scroll compressor Compressore scroll Thermostatic valve Liquid receiver Valvola termostatica Ricevitore di liquido Check valve 4 way valve...
- Page 10 LCW - LCR Cooling only versions with remote condenser – Diagram of a single circuit Filter dryer Sight glass Plate heat exchanger Filtro deidratore Spia di flusso Scambiatore a piastre Scroll compressor Compressore scroll Thermostatic valve Liquid receiver Valvola termostatica Ricevitore di liquido Check valve...
- Page 11 LCW - LCR Heat pump versions with remote condenser – Basic diagram of a single circuit Filter dryer Sight glass Plate heat exchanger Filtro deidratore Spia di flusso Scambiatore a piastre Scroll compressor Compressore scroll Thermostatic valve Liquid receiver Valvola termostatica Ricevitore di liquido Suction Liquid separator...
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Page 12: Installation
Delivery Slip before signing GALLETTI S.p.A. or its Agent must be promptly notified of the entity of the damage. The Customer must submit a written report describing every significant sign of damage. -
Page 13: Installation Clearance Requirements
LCW - LCR Unpacking The packing must be carefully removed to avoid the risk of damaging the unit. Different packing materials are used: wood, cardboard, nylon etc. It is recommended to keep them separately and deliver them to suitable waste disposal or recycling facilities in order to minimise their environmental impact. - Page 14 LCW - LCR General Guidelines for Plumbing Connections When you are getting ready to set up the water circuit for the evaporator you should follow the directions below and in any case make sure you comply with national or local regulations (use the diagrams included in this manual as your reference).
- Page 15 LCW - LCR The compressors work intermittently, since the chilling requirements of the user generally do not coincide with the compressor output. 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 satisfies the condition below: τ...
- Page 16 LCW - LCR A standard feature of LCW units is a device for controlling the flow rate (flow switch or differential pressure switch) in the water circuit in the immediate vicinity of the evaporator. Any tampering with said device will immediately invalidate the warranty. It is OBLIGATORY to install a metal mesh filter on the inlet water pipe.
- Page 17 LCW - LCR Note: 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. RG66001652_REV.02...
- Page 18 LCW - LCR The following table reports the dimensions suggested for piping Unit model Fluid line Thickness (mm) GAS line Thickness (mm) LCRC0502-0672 16 mm LCRC0742-1362 18 mm LCRC1522-2442 22 mm LCRC2582-3042 28 mm Prescriptions for laying Vertical ascending gas lines set a trap every 4 metres Vertical fluid lines: The complete miscibility between oil and refrigerant...
- Page 19 LCW - LCR Evacuation and charging operations for LCR-type units This type of work must be carried out by qualified personnel trained to do their job in observance of current laws and regulations 1. Introduction: The simultaneous presence of liquid and vapour makes it necessary for both to be in a state of saturation [ Gibbs law ], as shown in fig.
- Page 20 LCW - LCR 2. Vacuum and charging machine Tank Charging gun Cock Fig. 2 Solenoid valve Charging machine Charging piston Volumetric Flow Rate Gauge The charging piston compresses the refrigerant to a max P of 20 bar-r, thus favouring the re-condensation of any flash vapour that may have formed during transit through the line between the tank -cylinder: consider fig.
- Page 21 LCW - LCR 3. Vacuum cycle In general it is preferable to apply a “long” rather than “hard” vacuum: reaching low pressures too abruptly may in fact cause any trapped humidity to evaporate instantaneously, thereby freezing part of it. Fig. 3 P [Pa] 200 s Time...
- Page 22 LCW - LCR The best position for charging the air conditioners is the section between the thermostatic valve and the evaporator; care should be taken to avoid fixing the thermostat bulb until the operation is complete. This is important to ensure that the valve orifice remains open so as to allow the passage of refrigerant also toward the condenser/receiver.
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Page 23: Electrical Connections
LCW - LCR ELECTRICAL CONNECTIONS GENERALITIES Before carrying out any job on electrical parts, make sure the power supply is disconnected. Check that the mains electricity supply is compatible with the specifications (voltage, number of phases, frequency) shown on the unit rating plate. The power connection for single-phase loads is to be made with a three-pole cable and “N”... - Page 24 LCW - LCR Remote controls If you wish to include a remote control for switching the unit on and off, you must remove the bridge between the contacts indicated in the wiring diagram and connect the remote ON/OFF control to the terminals themselves [see annexed wiring diagram], then enable the "REMOTE"...
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Page 25: Starting Up For The First Time
LCW - LCR STARTING UP FOR THE FIRST TIME HOW TO START UP THE Chillers OF THE LCW SERIES FOR THE FIRST TIME Water connections Warning: the chiller is charged with HFC R407C – Group I EN 378 refrigerant (non-hazardous •... -
Page 26: Starting Operation
LCW - LCR STARTING OPERATION Before starting the unit, turn the main switch on, select the operating mode desired from the control panel 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... -
Page 27: Stopping The Unit
LCW - LCR 2) read the temperature indicated on the scale of a pressure gauge connected to the liquid inlet at the condenser outlet; refer to the pressure gauge scale for the refrigerant R407C, marked with the initials B.P. (Bubble Point). The degree of undercooling is given by the difference between the temperatures thus determined. -
Page 28: Operating Limits
Operating limits of LCW chillers in relation to the outlet water temperature and water dew point. Applications with water T above the specified limits require the use of R134a refrigerant fluid. For details please contact the local Galletti dealer. Cooling only Units... -
Page 29: Glycol Solutions
LCW - LCR Glycol solutions It is possible to produce water at temperatures below 5°C and as low as -10°C using glycol solutions that lower the freezing point according to the following table: Minimum temperature of water produced 5 °C 2°C -1 °C -5°C... - Page 30 LCW - LCR SETTING OPERATING PARAMETERS GENERALITIES All the control devices are set and tested in the factory before the unit is dispatched. However, after the unit has been in service for a reasonable period of time you can perform a check on the operating and safety devices.
- Page 31 LCW - LCR MAXIMUM PRESSURE SWITCH The high pressure switch stops the compressor when the outlet pressure exceeds the set value. Warning: do not attempt to change the setting of the maximum pressure switch. Should the latter fail to trip in the event of a pressure increase, the pressure relief valve will open.
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Page 32: Maintenance
LCW - LCR MAINTENANCE The only tasks to be performed by the end user are turning the chillers on and off and switching them between the cooling and heating functions as the seasons change. All other operations are to be considered maintenance work and must thus be carried out by qualified personnel trained to do their job in observance of current laws and regulations. - Page 33 LCW - LCR Generalities To guarantee a constantly satisfactory performance over time, it is advisable to carry out routine maintenance and checks as described below. Operations Frequency Once a year Check the efficiency of all the control and safety devices •...
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Page 34: Tightness Test
LCW - LCR Tightness test Fill the circuit with anhydrous nitrogen supplied from a tank with a pressure-reducing valve until the pressure rises to 22 bars. During the pressurisation phase, do not exceed a pressure of 22 bars-r on the low pressure side The presence of any leaks must be determined using special leak detectors. - Page 35 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...
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Page 36: Troubleshooting
LCW - LCR 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. - Page 37 LCW - LCR FAULT Possible causes Corrective actions Presence of abnormally high Unit overcharged. as revealed by Drain the circuit pressure an undercooling of more than 8 °C. Thermostatic valve and/or filter Check the temperatures upstream obstructed. These symptoms may and downstream from the valve also occur in the presence of an and filter and replace them if...
- Page 38 LCW - LCR Technical data Performance data – cooling models LCW-C Model LCWC055 LCWC060 LCWC070 LCWC080 LCWC090 LCWC105 LCWC115 Refrigerant R407C R407C R407C R407C R407C R407C R407C Cooling capacity at 7°/12° [kW] 53.9 59.8 68.7 81.5 89.8 103.0 121.2 - 15°C...
- Page 39 LCW - LCR Technical data Performance data – cooling models LCW-C Model LCWC130 LCWC150 LCWC180 LCWC205 LCWC235 LCWC250 LCWC275 LCWC300 Refrigerant R407C R407C R407C R407C R407C R407C R407C R407C Cooling capacity at 7°/12° - [kW] 137.3 150.7 172.9 209.6 236.7 253.9 273.5 296.1...
- Page 40 LCW - LCR Technical data Performance data – heat pump models LCW-H Model LCWH055 LCWH060 LCWH070 LCWH080 LCWH090 LCWH105 LCWH115 Refrigerant R407C R407C R407C R407C R407C R407C R407C Cooling capacity (1) [kW] 57.2 65.5 79.4 87.4 100.2 116.8 Heating capacity (2) 58.6 63.4 71.8...
- Page 41 LCW - LCR Technical data Performance data – heat pump models LCW-H Model LCWH130 LCWH150 LCWH180 LCWH205 LCWH235 LCWH250 LCWH275 LCWH300 R407C R407C R407C R407C R407C R407C R407C R407C Refrigerant Cooling capacity (1) [kW] 134.6 147.8 169.4 205.4 231.9 248.9 268.1 290.2 Heating capacity (2)
- Page 42 LCW - LCR Technical data Performance data – models with remote condenser LCR LCR055 LCR060 LCR070 LCR080 LCR090 LCR105 LCR115 Model Refrigerant R407C R407C R407C R407C R407C R407C R407C Cooling capacity (1) [kW] 46.2 51.2 58.8 69.8 76.9 88.2 103.7 Power to unload to the [kW] 59.0...
- Page 43 LCW - LCR Technical data Performance data – models with remote condenser LCR LCR130 LCR150 LCR180 LCR205 LCR235 LCR250 LCR275 LCR300 Model Refrigerant R407C R407C R407C R407C R407C R407C R407C R407C Cooling capacity (1) [kW] 117.6 129.2 148.1 179.6 202.6 217.4 234.1 257.3...
- Page 44 40010 Bentivoglio (BO) Via Romagnoli, 12/a Tel. 051/8908111 Fax 051/8908122 www.galletti.it...
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