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Table of Contents
Related Manuals for Galletti LCA Series
Summary of Contents for Galletti LCA Series
- Page 1 Installation, use and maintenance...
- Page 2 TABLE OF CONTENTS TECHNICAL DATA Ref. Rating Plate THE SERIES FIELD OF APPLICATION GENERALITIES INSPECTION, CONVEYANCE, SITING Inspection Lifting and conveyance Unpacking Siting INSTALLATION Installation 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...
- Page 3 TABLE OF CONTENTS OPERATING LIMITS Water flow to evaporator Chilled water temperatures Outdoor air temperature Operation with water at low temperatures CONTROL DEVICE SETTINGS Generalities Maximum pressure switch Minimum pressure switch Service thermostat Anti-freeze thermostat Anti-recycle timer Oil differential pressure switch ROUTINE MAINTENANCE AND CHECKS Warnings Generalities...
- Page 4 RG66000986 – Rev.00...
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Page 5: Field Of Application
Luigi Galletti President THE SERIES The LCA series of chillers with fluid heat pumps covers a power range from 44.8 to 234 kW. FIELD OF APPLICATION These machines are designed to cool-heat water and solutions containing up to 30% glycol (percentage by weight) in civil, industrial and technological air-conditioning systems. - Page 6 - possible reverberation of sound waves. All models belonging to the LCA series are designed and built for outdoor installation: avoid covering them with roof structures or positioning them near plants (even if they only partly cover the unit) which may interfere with the regular ventilation of the unit condenser.
- Page 7 It is advisable to place a rigid rubber strip between the base frame and the supporting surface. Whenever more effective insulation is required, it is recommended to use vibrating-damping spring supports. In the case of installation 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.
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Page 8: Installation Clearance Requirements
INSTALLATION INSTALLATION CLEARANCE REQUIREMENTS It is of fundamental importance to ensure an adequate volume of air both on the intake and outlet sides of the condenser coils; it is highly important to prevent the air delivered from being re-aspirated as this may impair the performance of the unit or even cause an interruption in normal operation. - Page 9 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 10 The compressors often 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 itself is lower, it is a good idea to check that the water content in the section delivering to users satisfies the condition below: = water content in user section [m3]...
- Page 11 A standard feature of LCA 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. Frame 3, 4, 5 units include a blade-type flow switch positioned in the ventilation compartment.
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Page 12: Electrical Connections
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 connection to the power supply should be made with a three-pole + neutral cable and earthing wire. -
Page 13: Preliminary Checks
ELECTRIC CONNECTIONS OF FLOW SWITCH OR DIFFERENTIAL WATER PRESSURE SWITCH It is pre-wired in all LCA units. Frame 1, 2, 3 units feature a differential pressure switch that detects pressure drops upstream and downstream from the evaporator (outgoing – returning water in the case of units equipped with a pump system) ;... -
Page 14: Starting Operation
Check that the crankcase heating elements are properly connected to the power supply. The heating elements must be turned on at least 12 hours before the unit is started. Their function is to raise the T of the oil in the sump and limit the quantity of refrigerant dissolved in it. -
Page 15: Checks During Operation
You should not disconnect the unit from the power supply during periods when it is inoperative but only when it is to be taken out of service for a prolonged period (e.g. at the end of the season). To turn off the unit temporarily follow the directions provided in the section "Stopping the Unit"... -
Page 16: Stopping The Unit
The degree of undercooling is given by the difference between the temperatures thus determined. Warning: all LCA units are charged with R407C: any top-ups must be made by specialised personnel using the same type of refrigerant, exclusively in the liquid phase. Warning: the refrigerant R407C requires “POE”... -
Page 17: Operating Limits
OPERATING LIMITS Operating limits of LCA chillers in relation to the outlet water temperature and outdoor air temperature: Min. Max. Temperature of water leaving evaporator [°C]: 5 (30) 12 (45) Outdoor air temperature [°C]: WATER FLOW TO EVAPORATOR The nominal flow rate is based on a thermal differential of 5° C between inlet and outlet water, in relation to the cooling capacity provided at the nominal water (12/7 °C) and air (35°C) temperatures. -
Page 18: Control Device Settings
CONTROL DEVICE SETTINGS 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 19: Antifreeze Thermostat
MAXIMUM PRESSURE SWITCH The high pressure switch is of the manually reset type and classifiable as category IV under EEC 97/23. It directly stops the compressor when the discharge pressure exceeds the set value. Warning: do not attempt to change the setting of the pressure switch: should the latter fail to trip in the event of a pressure increase, the pressure relief valve will open! To verify its efficiency, while the compressors are running, close off the passage of air into the condensers and check by referring to the compressor outlet pressure gauge (previously installed) -
Page 20: Anti-Recycle Timer
ANTI-RECYCLE TIMER The function of the timer is to prevent excessively frequent compressor starts and stops. This device is a function included in the microprocessor 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. -
Page 21: Routine Maintenance And Checks
ROUTINE MAINTENANCE AND CHECKS WARNINGS All the operations described in this chapter 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 outlet pipe of the compressor may reach temperatures as high as 110°C. - Page 22 GENERALITIES It is a good idea to carry out periodic checks to ensure that the unit is working properly: • Check the efficiency of all the control and safety devices as previously described. • Check the terminals on the electric control board and compressor terminal boards to ensure that they are securely tightened.
- Page 23 TIGHTNESS TEST Fill the circuit with anhydrous nitrogen supplied from a tank with a pressure-reducing valve until the pressure rises to 10 bars. During the pressurisation phase, do not exceed the pressure setting of the safety valves; otherwise you will cause the latter to open. The presence of any leaks must be determined using special leak detectors.
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Page 24: Environmental Protection
CHARGING WITH R407C REFRIGERANT - Connect the cylinder 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 connection pipe. - Carry out the charging operation with the refrigerant in liquid form until you reach 75% of the total charge. -
Page 25: Retiring The Unit
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;... - Page 26 FAULT Possible causes Corrective actions The unit does not start No power supply Check that power is being supplied both to the primary and auxiliary circuits. The electronic card is cut off from Check the fuses the power supply Alarms have been triggered Check whether any alarms are signalled on the microprocessor control panel, eliminate the causes...
- Page 27 FAULT Possible causes Corrective actions Low condensation pressure Transducer fault Check the transducers and the efficiency of the needle pusher on schrader valves they connected to Outdoor T too low and/or presence Install the condensation control of strong winds device and/or protect the unit from prevalent winds Low water T, in the case of heat Check whether the thermal load is...
- Page 28 FAULT Possible causes Corrective actions High evaporation pressure Water T too high Check the thermal load and/or efficiency thermostat function. Check efficiency thermostatic valve Defrosting absent or incomplete 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...
- Page 29 13 DRAWINGS SHOWING OVERALL DIMENSIONS LCA 045 - 050 RG66000986 – Rev.00...
- Page 30 LCA 060 – 070 - 080 RG66000986 – Rev.00...
- Page 31 LCA 090 - 105 RG66000986 – Rev.00...
- Page 32 LCA 115 - 130 - 150 - 180 RG66000986 – Rev.00...
- Page 33 LCA 205 – 220 – 235 LCA 180 CL RG66000986 – Rev.00...
- Page 34 14 – WATER PRESSURE DROPS 14.1 EVAPORATOR PRESSURE 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 10°C 130 - 150 220 - 235 (kPa) 10.000 20.000...
- Page 35 14.3 WATER PUMPING AND STORAGE SYSTEMS LCA units may be equipped with 4 types of pumping systems, complete with expansion tank, and inertial storage reservoirs: - single standard pump - single uprated pump - standard pump and back-up pump - uprated pump and back-up pump. 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.
- Page 36 40010 Bentivoglio (BO) Via Romagnoli, 12/a Tel. 051/8908111 Fax 051/8908122 www.galletti.it...
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