Galletti LEP Quick start guide

GB
Installation use and maintenance
LEP
Multifunction heat pumps
40 – 420 kW

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CONTENTS
Page
1. GENERAL DESCRIPTION 6
1.1 The series 6
1.2 Structure 6
1.3 Field of application 6
1.4 Cooling circuit 7
2. PRELIMINARY PROCEDURES 12
2.1 Inspection upon reception 12
2.2 Lifting and conveyance 12
2.3 Unpacking 13
2.4 Positioning 13
3. INSTALLATION 13
3.1 Installation clearance requirements 13
3.2 General recommendations for hydraulic connections 14
3.3 Hydraulic connection to evaporator 14
3.4 Filling tank and/or pumps (if foreseen by the system) 16
4. ELECTRICAL CONNECTIONS 16
4.1 General Information 16
4.2 Electric connections of the circulation pump 17
4.3 Remote controls 17
4.4 Remote Summer-Winter changeover [Heat pump versions] 17
5. STARTING UP 17
5.1 Preliminary checks 17
5.2 Commissioning instructions for LEP series chillers 18
5.3 Starting operation 19
5.4 Checks during operation 19
5.5 Checking refrigerant load 19
5.6 Stopping the unit 20

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CONTENTS
Page
6. OPERATING LIMITS 20
6.1 Use of glycol solutions 21
6.2 Working limits 21
6.3 Water flow to evaporator 22
7. SETTING CONTROL DEVICES 22
7.1 General Information 22
7.2 Maximum pressure switch 23
7.3 Minimum pressure switch 23
7.4 Service thermostat function 23
7.5 Antifreeze thermostat function 23
7.6 Anti-recycle timer function 23
8. MAINTENANCE 24
8.1 Warnings 24
8.2 General Information 24
8.3 Repairing the cooling circuit 25
8.4 Tightness test 25
8.5 Emptying and drying of the cooling circuit 25
8.6 Restoring R410A refrigerant load 26
8.7 Environmental protection 26
9. TROUBLESHOOTING 27

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RG66007652– Rev.01
Declaration of conformity
The declaration of conformity is attached to each unit

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1. GENERAL DESCRIPTION
1.1 The Series
The LEP series of water-cooled water chillers consists in a range of models which meet all different
system requirements:
LEP C water chillers - cold water only - R410A refrigerant
LEP H chillers and water-to-water heat pump - R410A refrigerant
1.2 Structure
All of the LEP series units are constructed with a support base and panelling made of galvanised sheet
metal painted with black polyester epoxy powders oven-polymerised at 180°C. The unit has an exclusive
design enhancing the overall assembly with a smart outward appearance. Moreover the closed unit
makes the components inaccessible: this aspect together with the wide use of soundproof material inside
the compartment, optional for low-noise version, reduces the emitted sound output to exceptionally low
levels (Lp < 66 dB-A @1 metre). The hydraulic/chiller connections are envisioned at the top, to reduce the
technical space required for installation. All the panels are removable making the unit fully accessible
even though routine maintenance only needs accessing from the front.
1.3 Field of application
LEP units are intended for cooling-heating water and glycol solutions up to a maximum of 30% the
weight, in civil, industrial and technological air conditioning environments. For large buildings, air
conditioning can be implemented as the floors/zones are sold or rented, by installing a LEP unit for each
floor in a small size technical room, thus dividing the investment in time. The possibility of keeping the
evaporator on the inside allows you not to add glycol to the water in the system. It also makes it possible
for all the components requiring maintenance to be installed in an easily accessible space. The
advantages of these products are summarised in the following table:
Water-cooled versions LEP C-H
oLess space taken up in plan
oPossibility of using water without glycol in the utility circuit
oHigh COP [Coefficient of performance] of thermodynamic cycle
oNo noise on the outside
oLess charging with refrigerant.
oInnovative aesthetical features and full safety since units are completely closed
oPossibility of combining an external Dry Cooler when disposable water cannot be
used to cool the condenser
oHeat pump mode with chiller side cycle inversion
oPossibility of even heat pump versions using condensation control
The use of LEP C-H units is recommended within the functioning limits carried in this manual, or else the
warranty attached to the sales contract would cease.
Do not install the unit in environments with gas or flammable dusts.
1.4 Cooling circuit
The cooling circuit is fully implemented in the Factory exclusively using prime brand components and
procedures in compliance with Directive 97/23 for all the brazing operations. The units are made with
single and double cooling circuit, using exclusively prime International brand components.

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Compressors: only prime international brand Scroll compressors are used on the LEP units.
The Scroll compressor is the best solution today in terms of reliability and efficiency in the
range of power outputs up to 182 kW for each circuit and the best solution in terms of emitted
sound output. N.B.: Scroll compressors, just like all air-tight compressors, are classified as
pressure recipients in compliance with PED for that which regards the low pressure section to
which the PS indicated on the data plate refers.
Heat exchangers: only brazed plate heat exchangers are used, made of austenitic stainless
steel AISI 304 with AISI 304 L connections, featured by a reduced carbon content to simplify
brazing operations. The solution of the brazed plate heat exchanger represents the state-of-
the-art in terms of thermal exchange efficiency and allows a strong reduction of refrigerant
load compared to standard solutions. The high degree of turbulence induced by the internal
corrugation of the plates together with their perfect smoothing features, makes it difficult for
filth to deposit or for limestone to build up on the condenser side. N.B.: due to thermal
insulation, the data plate in compliance with 97/23 PED is not legible, but the serial number of
the heat exchanger and the declaration of conformity are detected during production and are
an integral part of the HiRef archive.
Chiller components:
oMolecular and alumina sieve filter dryer activated
oSight glass with humidity indicator. The key is directly on the sight glass.
oMechanical thermostatic valve + external equalisation and built-in MOP function
oElectric thermostatic valve with step motor and specific electronic driver for the
maximum efficiency of the cooling circuit and to optimise operating parameters.
oCycle inversion valve (only heat pumps)
oOne-way valves (only heat pump)
oHigh and low pressure switches
oSchrader valves for control, access and/or maintenance
oRefrigerant-side safety valve
Electrical control board: the electrical control board is implemented and wired in compliance
with the directives EEC 73/23 and EEC 89/336 and to related standards. The board can be
accessed through the small door after having activated the main switch. All the remote
controls are implemented with signals at 24 V, powered by an isolation transformer positioned
inside the control board. A T control kit composed of thermostat and auxiliary fan is available
on demand. The unit is rated IP 43. N.B.: the mechanical safety devices such as the high
pressure switch have characteristic direct intervention and any microprocessor control circuit
failure cannot affect its efficiency in compliance with 97/23 PED.
Control microprocessor: the microprocessor on-board the unit controls the various operating
parameters by means of a keyboard set-up on the electrical control board:
oCompressor connection/disconnection to maintain the set-point of the chiller inlet
water T;
oAlarm management
High/ low pressure
Antifreeze
Flow switch
Pump alarm
oAlarm signals
oDisplay of operation parameters
oAntifreeze protection of evaporator
oControl of maximum number of compressor starts
oSerial output control (optional) RS232, RS485
oIncorrect sequence phases [not viewed on µP, but keeps compressor from starting]
[ref. Microprocessor control manual for further details]

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STANDARD COOLING CIRCUITS
Cooling only versions (NB: standard layout; refer to the layout attached to the unit)

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Heat pump versions (NB: standard layout; refer to the layout attached to the unit)