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InstallatIon, use and maIntenance manual
PLP
air chillers and heat pumps with R290 refrigerant
37 - 63 k W
R-290
Propane
R-290
A3 gas leak
R-290
Axial fan
Cooling only
Heating/
EC scroll
detection
Refrigerant
Cooling
compressor
PLUS
» R290 refrigerant (GWP=3)
» Inverter driven variable speed scroll compressor
» Very low refrigerant charge (< 5 kg)
» Production of hot water up to 80°C
» Full load operation down to -20°C air (60°C water)
» Very high seasonal efficiency values
» Power output and COP monitoring (option)
» Availability of silenced setups
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Summary of Contents for Galletti PLP
- Page 1 InstallatIon, use and maIntenance manual air chillers and heat pumps with R290 refrigerant 37 - 63 k W R-290 Propane R-290 A3 gas leak R-290 Axial fan Cooling only Heating/ EC scroll detection Refrigerant Cooling compressor PLUS » R290 refrigerant (GWP=3) »...
- Page 2 Dear Customer, Thank you for placing your trust in one of the products of Galletti S.p.a This product is the result of our work and our commitment to design, research, and production and has been made from the finest materials, employing state-of-the-art components and production technology.
- Page 3 For more information, contact Ū Galletti S.p.A. shall not accept any liability for injury your installer or local authority. or damage resultingcfrom improper use of the equip-...
- Page 4 � � � � � � � � � � � � � � � � � � � � p� 20 5�1 RATED TECHNICAL DATA FOR PLP C � � � � � � � � � � p� 20 5�2 RATED TECHNICAL DATA FOR PLP H�...
- Page 5 Do not in- the units in the PLP range state of the art in terms of efficiency, stall the unit near sources of ignition (sparks, high-tempera- reliability, and operating limits.
- Page 6 MODELS AND VERSIONS P Plate exchanger and pump S For plate exchanger, pump and tank The PLP range consists of 5 models with cooling capacities from T For plate exchanger and tank 36 to 57 kW for cooling-only versions and heating capacities Acoustic insulation and attenuation from 37 to 63 kW for reversible heat pump versions.
- Page 7 Use of environmentally-friendly refrigerant R290. R290 is the A3 refrigerant with a GWP of only 3, one of the lowest on the mar- ket. This GWP value ensures that the PLP range complies with the gradual reduction of quotas of greenhouse refrigerants in the European market required by the latest version of the F-GAS regulation.
- Page 8 Should you detect any signs of damage, immediately report YES! them to the carrier and note them on the delivery slip. Galletti S.p.A. Must be notified of the entity of the damage with- in 8 days of the delivery date. Check that the following items are present: Ū...
- Page 9 WARNING Use all available lifting points! Ū Avoid the possible reverberation of sound waves; do not in- stall the unit in narrow or cramped spaces; Ū Ensure adequate accessibility for maintenance or repairs SITING AND DAMPERS (see section on 2.4 p. 10). When installing the vibration dampers follow the instructions It is important to bear in mind the following aspects when below:...
- Page 10 INSTALLATION CLEARANCE REQUIREMENTS AND DIMENSIONAL To guarantee the proper functioning of the unit and access for maintenance purposes, it is necessary to comply with the mini- mum installation clearance requirements shown in dimensional drawings. Verify that there are no obstacoles in front of the fans air outlet. Ū...
- Page 11 » PLP 037-057 RG66028508 All copying, even partial, of this manual is strictly forbidden...
- Page 12 » PLP 062 INSTALLATION, USE AND MAINTENANCE MANUAL...
- Page 13 2.4.1 Condensate discharge from unit During normal operation of the unit as a heat pump, condensate is produced due to the dehumidification of the air in contact with the finned block heat exchanger. In order to hold the condensate that the unit normally produces during operation in winter mode (and during defrosting), it is advisable to prepare a technical tank below the base of the unit, with sufficient capacity to collect and discharge the water pro-...
- Page 14 INSTALLATION SITE FEATURES The units of the PLP range are designed for outdoor installation, in a context where the natural dilution of the refrigerant that could escape as the result of a leak guarantees a degree of safety. Each installation site must provide a safe area around the unit with the following characteristics.
- Page 15 » Safety zone Area required for maintenance operations 1.5 m Area required for maintenance operations 1 m Safety zone (see table) » Distance "D" value assigned to each unit Model D (m) PLP037H PLP045H PLP052H PLP057H PLP062H PLP037C PLP045C PLP052C PLP057C PLP062C WARNING: In any case, the above requirements should be...
- Page 16 installation, carried out by a qualified expert, is it possible to accept a reduction of the specified safety zone. In any case, avoid installing the units in locations that could be dangerous during placement, start-up, operation, and mainte- nance operations, such as areas without adequate protection against falls, areas with obstacles that create a danger of trip- ping or falling, and areas with buffer spaces that are not compli- ant with the documentation.
- Page 17 WEIGHTS This drawing shows the points of the machine for which weights » PLP F2 have been calculated, with respect to the basic chiller and heat pump model. The weights are shown in the tables below. » PLP F1 » Lifting center of gravity for transporting unit C version without hydraulic options »...
- Page 18 » Operating weight C version without hydraulic options PLP C Total » Version C weight distribution with empty tank and 1 pump PLP C Total » Version C weight distribution with empty tank and 2 pumps PLP C Total » Version C weight distribution with empty tank + 2 pumps + flow rate measurement + desuperheater...
- Page 19 » Version H weight distribution with empty tank and 1 pump PLP H Total » Version H weight distribution with empty tank and 2 pumps PLP H Total » Version H weight distribution with empty tank + 2 pumps + flow rate measurement + desuperheater...
- Page 20 TECHNICAL FEATURES RATED TECHNICAL DATA FOR PLP C » Rated technical data for the PLP C water chiller PLP C Power supply V-ph-Hz 400-3-50 Cooling capacity (1)(E) 36,0 41,4 46,7 51,2 57,1 Total power input (1)(E) 12,0 14,0 16,4 18,1...
- Page 21 RATED TECHNICAL DATA FOR PLP H » Heat pumps rated technical data PLP H PLP H Power supply V-ph-Hz 400-3-50 Cooling capacity (1)(E) 30,0 35,7 41,6 45,5 50,3 Total power input (1)(E) 12,0 14,4 16,8 18,2 19,3 (1)(E) 2,49 2,48...
- Page 22 MICROPROCESSOR CONTROL Below are specified the microprocessor control functions in the The advanced control instructios are described in service basic version. manual. » pGD DESCRIPTION OF CONTROL PANEL USING THE CONTROL PANEL The unit's control panel allows you to display and set the unit's 6.2.1 Display operating parameters and read the main operating data.
- Page 23 Ū Follow the on-screen instructions to turn the unit on in the preselected operating mode (press PRG when indicated) Switchover mode from cooling to heating is unavailable on cooling only units or motor-driven evaporating units. 6.3.2 Changing the operatining mode (heat pump only) To enable remote ON-OFF switching from the PCDS or via an external switch (not supplied) make connections to terminals...
- Page 24 6.5.2 Restart - Fast restart regulation is switched from the return temperature to the tank temperature. The sensor is optional. When the power supply to the unit is interrupted, the card can store the status it is in (on/off - sum/win - set-point), and when 6.5.9 Antifreeze (heating element) protection power is restored, it starts again in the same mode.
- Page 25 4. POST-DEFROST PHASE with compressors stopped and venti- 6.5.12 LAN lation switched on in order to eliminate water droplets from Local Area Network (LAN) refers to a set of functions that inte- the coils. Switching of the 4-way valve at half of the time grate and optimise the operation of two or more connected WARNING: The following section concerning separate de-...
- Page 26 Mod. Name Description When the unit receives this combination of digital inputs (1,0) (whose external signal remains active for at least 10 minutes according to the SG Ready guidelines), the unit is forced into a forced OFF state. LOCK This state must not last longer than 2 hours. The forced BLOCK state remains active for at least 10 minutes after it is activated.
- Page 27 PLUMBING CONNECTION pressure gauge, manual air vent valve, sludge remover (config- urable) and deaerator (mandatory and configurable). See table PLP units are equipped with a flow switch or water differen- below: tial pressure switch, safety valve (supplied as standard), water »...
- Page 28 Important! During wintertime the water circuit (or the water Ū Silicon may pose a risk of corrosion. Limit: < 1 mg/l. Ū Electrical conductivity: the higher the specific resistivity, the chiller only) must be emptied to prevent damage caused by lower the tendency of corrosion.
- Page 29 Ū Open all the air vent valves of the system and of the indoor door units, close them and continue filling until the pressure units and chiller. gauge reading is 1.5 bars. 7.1.4 Water circuit » PLP (evaporator and pump) LEGEND 10 Cut-off valve Evaporator 11 Hydraulic pump...
- Page 30 » PLP (evaporator and tank) LEGEND 11 - Evaporator 12 Deaerator Water filter (included) 13 Dirt separator for the water system (supplide loose) Flow switch (excluding differential pressure switch 14) 14 Differential pressure switch Air purge valve Pressure gauge 15 Tank drain valve...
- Page 31 » PLP (evaporator, pump and tank) LEGEND 11 Hydraulic pump Evaporator 12 Deaerator Water filter (included) 13 Dirt separator for the water system (supplide loose) Flow switch (excluding differential pressure switch 14) 14 Differential pressure switch Air purge valve Pressure gauge...
- Page 32 » PLP (evaporator, tank and 2 pumps) LEGEND 11 Hydraulic pump Evaporator 12 Deaerator Water filter (included) 13 Dirt separator for the water system (supplide loose) Flow switch (excluding differential pressure switch 14) 14 Differential pressure switch Air purge valve...
- Page 33 7.1.5 Main water circuit devices 3. 3-way valve 4. Y-shaped filter 1. Deaerator with safety valve 5. Safety valve 2. Dirt separator for the water system (supplide loose) Uninsulated sludge Deaerator with safety valve Insulated sludge remover 3-way valve Y-shaped filter Safety valve remover The unit must be installed vertically...
- Page 34 The software can manage the enabling signal of a maximum of 2 supplementary heating elements. 7.1.7 Anti-legionella On the PLP range, anti-legionella control can be used if option 1 In order to use the anti-legionella cycle correctly, the following field 15 is configured.
- Page 35 Ū The supply voltage must not vary by more than ±5% from The PLP units are equipped with a control board with a special the rated value. Electrical connections must be made in ac- section protected by a Plexiglas barrier and identified by special cordance with the wiring diagram provided with the unit adhesive labels with the warning "live even if the door is open",...
- Page 36 100/125A 25 mm² 25 mm² (N)8T4 (N)7L4 100A 16 mm² 16 mm² 5/A1 5/A1 1.5 mm² The electrical control board of the units is physically separat- ed from the technical compartment containing the refrigerant circuit, except for the passage of cables, which is achieved by means of standard cable glands.
- Page 37 » Sensor wiring diagram RG66028508 All copying, even partial, of this manual is strictly forbidden...
- Page 38 7.2.1 Electrical connection of alarm indicator lights alarm status of the unit from a safe remote position. To connect these indicator lights, the customer must use the voltage-free As mentioned in this manual, the two threshold gas alarms must contacts inside the electrical control board as shown in the di- be installed by the customer in a clearly visible location outside agram below.
- Page 39 » Electrical control board diagram BMS card Gate RS485 expansion board Relays available for gas alarm indicator light connection Relays available for SG Ready SMART GRID connection ELECTRICAL DATA » Electrical data PLP Power supply V-ph-Hz 400-3-50 Auxiliary power supply V-ph-Hz 230-1-50...
- Page 40 (refer to the wiring diagram supplied with the units). OPERATING LIMITS The graphs below illustrate the operating limits of PLP units (in following operating limits refer is therefore dependent on the case of continuous operation) in relation to the outlet water the set point/differential combination set on the return line, temperature and outdoor air temperature.
- Page 41 THERMAL CARRYING FLUID glycol and propylene glycol can be tolerated at concentrations of up to 35%. The hydraulic pumps belonging to the PLP series can operate IMPORTANT: observe the minimum water temperature in- with mixtures of water and ethylene glycol, with percentage in- dicated in the operating ranges.
- Page 42 The first start up must be carried out exclusively by qualified this operation for a sufficient time to allow the water to cir- personnel and authorized by Galletti S.p.A. (see warranty culate in the system a few times. sheet attached).
- Page 43 In this scenario, the sec- PLP units are equipped with a safety control unit with highly ond-threshold alarm would intervene by opening switch IG1, sensitive sensors for detecting refrigerant leaks. The sensor is lo- which would cut power to all normal equipment, but keep the cated in the cooling compartment at the base of the unit.
- Page 44 gas detectors and portable ATEX extractor fans before entering pressing and holding down for at least 1 second the reset button the perimeter of the unit to check the status of the unit. located inside the electrical control board. After confirming that the first alarm threshold has been reached, the control unit can be reset by de-energising the gas sensor by »...
- Page 45 10.2.5 Water differential pressure switch or flow be installed outside the occupied zone in accordance with switch UNI EN 378-1. The water differential pressure switch or flow switch stops the IMPORTANT: The water safety valve and deaerator must be unit in the event of an excessive reduction in the water flow, installed on the delivery branch from the unit to protect the thus protecting it from the formation of ice (chiller operation) user in the event of a plate heat exchanger rupture.
- Page 46 11 ROUTINE MAINTENANCE AND CHECKS To keep the unit in good working order and guarantee the ex- It is necessary to periodically test the operation of the extractor pected levels of performance and safety, it is necessary to car- fan to ensure that it is working properly as it is an essential safety ry out some periodic routine checks: some may be performed device.
- Page 47 11.1.1 Microchannels air condenser maintenance closing panels, and ensure that the appropriate "WORK IN For PLP C units, proper cleaning and periodic maintenance of PROGRESS - DO NOT PERFORM ANY OPERATIONS" sign is af- the microchannel heat exchanger is essential in order to main- fixed near the main switch on the unit's control board.
- Page 48 Ū Check the electric control board terminals to ensure that atmosphere, the extent of which depends on the size of the they are securely tightened: the movable and fixed contacts leak. Non-powered instruments can be used without risk of the circuit breakers must be periodically cleaned and re- when working on units containing an A3 refrigerant.
- Page 49 Ū Pressurise the circuit for the first time with inert gas (e.g. NITROGEN) to a pressure of about 20-25 bar (without exceeding the low pressure PS); Ū Evacuate the circuit with an ATEX vacuum pump to a minimum absolute pressure of 0.3 bar. This is es- sential to degas the compressor oil, which normally retains refrigerant;...
- Page 50 12 COOLING CIRCUITS » PLP C legend N° COMPONENT Quantity Microchannel coil Dehydrating filter Air fan Electronic expansion valve Sight glass Gas desuperheater Scroll compressor Water differential pressure switch Electrical heating elements Microplate exchanger High pressure switch Evaporator adhesive heating element...
- Page 51 » PLP H legend N° COMPONENT Quantity Air fan Dehydrating filter Electronic expansion valve Sight glass Gas desuperheater Finned battery 4-way valve Scroll compressor Liquid receiver Check valve Electrical heating elements Microplate exchanger High pressure switch Evaporator adhesive heating element...
- Page 52 Operations marked with the letter "S" may be performed exclusively by specialised personnel. Once the cause has been identified, you are advised to contact a Galletti S.p.A. service centre or a qualified technician for help.
- Page 53 Who can take corrective action SYMPTOM U = User Probable cause Possible remedy S = specialised personnel Pressure switch failure Check and replace Unit completely empty See item G Finned coil obstructed, Remove dirt from the coil insufficient air flow Water circulation pump Release the pump blocked...
- Page 54 14 RETIRING THE UNIT When the unit has reached the end of its working life and needs to be removed and replaced, a series of operations should be carried out: In particular, the disposal of the unit should be car- ried out solely by qualified technicians specifically trained for this type of equipment, in conformity with current regulations.
- Page 56 Romagnoli 12/a 40010 Bentivoglio (BO) - Italy Ph. +39 051/8908111 - Fax +039 051/8908122 Galletti S.p.A Organization has a Management System Certified ac- cording to the UNI EN ISO 9001:2015, UNI EN ISO 14001:2015 and UNI ISO www.galletti.com 45001:2018 standards.
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