Galletti MPI DC 10 User manual

MPI DC
INSTALLATION, USE AND MAINTENANCE MANUAL
GB
CHILLER AND HEAT PUMPS
DC-INVERTER
10 kW - 15 kW - 27 kW

MPI DC
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1 THE MPI DC SERIES ..........................................................................................................................................................................................5
1.1 Field of application............................................................................................................................................................................................5
1.2 Models and versions .........................................................................................................................................................................................5
1.3 Components lay-out ..........................................................................................................................................................................................6
1.4 Water circuits....................................................................................................................................................................................................8
2 INSPECTION, CONVEYANCE DIMENSIONAL AND SITING.................................................................................................................................10
2.1 Inspection........................................................................................................................................................................................................10
2.2 Conveyance.....................................................................................................................................................................................................10
2.3 Dimensional ....................................................................................................................................................................................................11
2.4 Siting...............................................................................................................................................................................................................13
2.4.1 Installation clearance requirements ...................................................................................................................................................................13
2.5 Dampers siting................................................................................................................................................................................................15
3 PLUMBING AND ELECTRICAL CONNECTIONS .................................................................................................................................................16
3.1 Plumbing connection.......................................................................................................................................................................................16
3.1.1 Hydraulic connection........................................................................................................................................................................................16
3.1.2 Recommended water circuit .............................................................................................................................................................................16
3.1.3 Filling the system..............................................................................................................................................................................................17
3.2 Electrical connections .....................................................................................................................................................................................17
3.3 Electrical data .................................................................................................................................................................................................18
4 STARTING UP ..................................................................................................................................................................................................20
4.1 Preliminary checks..........................................................................................................................................................................................20
5 MICROPROCESSOR CONTROL ........................................................................................................................................................................21
6 OPERATING LIMITS .........................................................................................................................................................................................21
6.1 Operating limits in chiller mode ......................................................................................................................................................................21
6.2 Operating limits in heat pump mode ...............................................................................................................................................................21
6.3 Thermal carrying fluid.....................................................................................................................................................................................21
7 CONTROL AND SAFETY DEVICES ....................................................................................................................................................................22
7.1 Control devices................................................................................................................................................................................................22
7.1.1 Service thermostat ...........................................................................................................................................................................................22
7.1.2 Control device settings .....................................................................................................................................................................................22
7.2 Safety devices.................................................................................................................................................................................................22
7.2.1 High pressure switch........................................................................................................................................................................................22
7.2.2 Low pressure switch ........................................................................................................................................................................................22
7.2.3 Antifreeze thermostat........................................................................................................................................................................................22
7.2.4 Water differential pressure switch .....................................................................................................................................................................22
7.2.5 Water safety valve ............................................................................................................................................................................................22
7.2.6 Safety device settings.......................................................................................................................................................................................22
8 ROUTINE MAINTENANCE AND CHECKS...........................................................................................................................................................23
8.1 Checks to be performed by the user................................................................................................................................................................23
8.2 Checks and maintenance to be performed by specialised personnel..............................................................................................................23
9 RETIRING THE UNIT ........................................................................................................................................................................................24
10 TECHNICAL FEATURES....................................................................................................................................................................................24
10.1 Water chillers rated technical data .................................................................................................................................................................24
10.2 Heat pumps rated technical data.....................................................................................................................................................................25
11 COOLING CIRCUITS.........................................................................................................................................................................................27
12 TROUBLESHOOTING........................................................................................................................................................................................28
INDEX
The technical and dimensional data reported in this manual may be modified in view
of any product improvement.
TRANSLATION OF ORIGINAL INSTRUCTIONS
WATER CHILLERS AND HEAT PUMPS ARE IN ACORDARCE WITH THE
LAW 97/23/CE (PED) FILLING IN D1 FORM, APPROVED BY THE THIRD
NOTIFIED BODY ICIM N°0425.

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The unit data are reported on the rating label in this page
The label shows the following data:
- Series and size of the unit
- Date of manufacture
- Main technical data
- Manufacturer
- The label is applied on the unit, usually on the enclosing panels beside the condenser
coil.
IMPORTANT: NEVER REMOVE THE LABEL
- Serial number of the unit
- The serial number permits to identify the technical characteristicsand thecomponents
installed
- Without this datum it will be impossible to identify the unit correctly
Serial number
Code
Date of production
Cooling capacity (W)
Heating capacity (W)
Power supply
Power input (kW)
Weight (kg)
Max power input (kW)
Max running amperage (A)
HP Power input (kW)
Refrigerant
Max refrigerant pressure (bar)
Max refrigerant temperature (°C)
Made in Italy
CATEGORIA 1
Galletti S.p.A. via L.Romagnoli 12/a
40010 Bentivoglio (BO) Italia

MPI DC
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GENERAL CAUTIONARY NOTES
- Keep this manual intact in a safe place for the all life of the unit.
- Carefully read all the information contained in this manual, paying special attention to sections marked "Important" and "Warning"; failure to comply
with the instructions provided could result in injury to persons or damage to the equipment.
- Should a fault occur, consult this manual and if necessary contact the nearest Galletti S.p.A. service centre.
- All installation and maintenance operations must be carried out by qualified personnel, unless otherwise indicated in this manual.
- The first start up must be carried out exclusively by qualified personnel and authorized by Galletti SpA
(see warranty sheet attached).
- Before performing any work on the unit, disconnect it from the power supply.
- Failure to comply with the rules provided in this manual will result in the immediate invalidation of the warranty.
- Galletti S.p.A. shall not accept any liability for injury or damage resulting from improper use of the equipment or failure to comply with the directions
provided in this manual and on the unit itself.
- It is obligatory to install a filter to protect the heat exchangers. Not doing so invalidates the warranty.
SAFETY SYMBOLS
Read the manual carefully WARNING Use personal protective
equipment
USE SUITABLE PPE (GLOVES FOR REFRIGERANT, PROTECTIVE GOGGLES).

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1 THE MPI DC SERIES
1.1 FIELD OF APPLICATION
MPI DC air-condensed water chillers and heat pumps have been designed to cool and heat water for air conditioning and heating systems in residential or
commercial buildings.
The MPI DC range units are intended for outdoor installation (IP24 protection degree), in a position not accessible to the public.
If protection grids are not provided (accessory) and if the machine can be reached by non-specialised personnel, access to the finned coil must be prohibited
using appropriate barriers.
Do not install the unit in environments with gas or flammable dusts.
1.2 MODELS AND VERSIONS
All models are charged with R410A refrigerant.
The choice of some options can prevent the choice of some options or oblige the selection of other fields. To contact the Galletti for verification
Complete Unit Code M P I D C 015H0AAA100C00000002
Version 0
Single compressor 0
Model (size) 1 5
Operation H
Chiller C
Heat pump H
Power Supply 0
Standard 400 - 3N - 50 0
single phase M
Refrigerant A
R410a A
Revision A
initial A
Expansion Valve A
Electronic expansion valve A
Pump and accessories 1
modulating pump - expansion vessel - valve 1
BLDC pump- expansion vessel - valve 2
Buffer tank 0
Not present 0
present + expansion vessel S
Heat Recovery 0
Not present 0
Condensing control C
With modulating air flow C
BLDC fans E
Antifreeze kit 0
Not present 0
Present, standard unit E
Present, unit with pump and vessel P
Present, unit with pump, vessel and tank S
Acoustic insulation 0
Not present 0
Sound proofing insulation for compressor housing 1
Compressor sound jackets 2
Option 1 + option 2 3
Refrigerant circuit accessoires 0
Not present 0
Refrigerant gauge M
Remote control 0
Not present 0
RS485 port (modbus + carel protocol) 2
Simplified (PCDS) S
ADVANCED microprocessor remote control PCOXS X
clock card C
Special coil 0
Standard O
Copper / copper heat exchanger R
Cataphoresis C
“Blygold” B
Hydrophilic I
Protection grille 0
Not present 0
Present G
Additional options 0
Not present 0
coil electric heater (only on heat pump version) 4
Control panel 2
pCOXS 2

MPI DC
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MPI DC 10 - 15
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1 THE MPI DC SERIES
1.3 COMPONENTS LAY-OUT
Description
1R410A-air heat-exchanger
2 R410A-water heat-exchanger
3 Fans
4Water differential pressure switch (fan housing)
5Automatic air purge valve
6Expansion vessel (fan housing)
7Water tank (accessory)
84-way valve (MPI DC H)
9Electronic expansion valve
10 Water safety valve
11 Liquid receiver (fan housing)
12 Pump
13 Compressor
14 Refrigerant filter
15 Low pressure switch and charge port
16 High pressure switch and charge port
17 Water gauge
18 Water charge
19 Inverter

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MPI DC
MPI DC 27
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1 THE MPI DC SERIES
1.3 COMPONENTS LAY-OUT
Description
1R410A-air heat-exchanger
2 R410A-water heat-exchanger
3 Fans
4Water differential pressure switch (fan housing)
5Automatic air purge valve
6Expansion vessel (fan housing)
7Water tank (accessory)
84-way valve (MPI DC H)
9Electronic expansion valve
10 Water safety valve
11 Liquid receiver (fan housing)
12 Pump
13 Compressor
14 Refrigerant filter
15 Low pressure switch and charge port
16 High pressure switch and charge port
17 Water gauge
18 Water charge
19 Inverter

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1 THE MPI DC SERIES
1.4 WATER CIRCUITS
LEGEND
VS Safety valve
EV Evaporator
PD Water differential pressure switch
MA Water gauge
VAS Air bleed hole
VE Expansion vessel
P Pump
RS Drain
RC Water charge
VU Check valve
MPI DC (EVAPORATOR AND PUMP)

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MPI DC
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1 THE MPI DC SERIES
1.4 WATER CIRCUITS
LEGEND
VS Safety valve
EV Evaporator
PD Water differential pressure switch
MA Water gauge
VAS Air bleed hole
VE Expansion vessel
P Pump
RS Drain
RC Water charge
VU Check valve
SA Buffer tank
MPI DC (EVAPORATOR, PUMP AND BUFFER TANK)

MPI DC
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2 INSPECTION, CONVEYANCE DIMENSIONAL AND SITING
2.1 INSPECTION
On receiving the unit, check that the packing is intact: the machine left the factory in perfect conditions and after thorough inspection.
Should you detect any signs of damage, immediately report them to the carrier and note them on the delivery slip.
Galletti S.p.A. must be notified of the entity of the damage within 8 days of the delivery date.
Check that the following items are present:
- starting up module,
- wiring diagram,
- warranty certificate
- make sure that this manual is intact (32 pages)
2.2 CONVEYANCE
During handling it is compulsory to check dimensions, weights, centre of gravity and anchorages.
Check as well that lifting and positioning devices conform to the current safety regulations.
The unit leaves the factory screwed onto a wooden pallet, which allows it to be easily conveyed with a forklift truck.
After removing the unit from the pallet, handle it gently, without applying excessive pressure on the side panels, finned coil and fan grille.
You should collect and separate the packing materials (wood, cardboard, nylon etc.) and make them available for recycling in order to minimise their
environmental impact.
Before lifting, remove the screws that fasten the machine base to the wooden pallet.
The unit must be lifted using Ø 1½” GAS steel pipes at least 3mm thick, to be inserted in the round holes on the base side members (see figure) and
identified by means of stickers. Piping must protrude of at least 250-300 mm from each side, be slung with ropes of equal length and secured to the lifting
hook (provide stops at the ends of the pipes to prevent the ropes from slipping off due to the weight).
Use ropes and belts sufficiently long to extend beyond the height of the machine and place spacer bars and boards on the top to prevent damaging the sides
and the top of the unit. In this phase, before the definitive position, vibration damping supports can be installed (optional).
WARNING: In all lifting operations make sure that the unit is securely anchored in order to prevent accidental falls or overturning.

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MPI DC 10 - 15
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2 INSPECTION, CONVEYANCE DIMENSIONAL AND SITING
2.3 DIMENSIONAL
Legend:
1 Water in 1" 1/4female
2 Water out 1" 1/4female
3 Safetyvalve dischargeoutlet providedwith rubberring
holder
4 Water supply 1/2" male (optional tap)
5 Drain manifold 1/2" female
6Power supply ∅28 mm
7 Electric control board
8 Dampers fastening points (accessory)

MPI DC
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MPI DC 27
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2 INSPECTION, CONVEYANCE DIMENSIONAL AND SITING
2.3 DIMENSIONAL
Legend:
1 Water in 1" 1/4female
2 Water out 1" 1/4female
3 Safetyvalve dischargeoutlet providedwith rubberring
holder
4 Water supply 1/2" male (optional tap)
5 Drain manifold 1/2" female
6Power supply ∅28 mm
7 Electric control board
8 Dampers fastening points (accessory)

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2 INSPECTION, CONVEYANCE DIMENSIONAL AND SITING
2.4 SITING
It is important to bear in mind the following aspects when choosing the best site for installing the unit:
- size and origin of water pipes;
- location of the power supply;
- solidity of the supporting surface;
- avoid obstacles to the outflow of air from the fan which could cause back suction (see section on "installation clearance requirements");
- Direction of prevalent winds: (position the unit so as to prevent prevalent winds from interfering with the fan air flow)
Prevalent winds opposing the fan air flow will result in a maximum air temperature below the value indicated in the operating limits;
Wind flowing in the same direction as the fan flow will result in a minimum air temperature above the value indicated in the operating limits.
Even when the chiller is running in the heat pump mode, wind may have the effect of reducing the range of operation"
- avoid the possible reverberation of sound waves; do not install the unit in narrow or cramped spaces;
- ensure adequate accessibility for maintenance or repairs (see section on "installation clearance requirements").
This appliance is not intended to be used by children or persons with physical, sensorial or mental problems, inexpert or unprepared, without
supervision. Be careful that children do not approach the appliance.
2.4.1 INSTALLATION CLEARANCE REQUIREMENTS
To guarantee the proper functioning of the unit and access for maintenance purposes, it is necessary to comply with the minimum installation clearance
requirements shown in figures 1, 2 and 3.
Verify that there are no obstacoles in front of the fans air outlet.
Avoid any and all situations of backflow of hot air between air outlet and inlet of the unit.
If even only one of the above conditions is not fulfilled, please contact the manufacturer to check for feasibility.
In the design of the MPI series, special care has been taken to minimise noise and vibrations transmitted to the ground.
Even greater insulation may be obtained, however, by using vibration damping base supports (available as optional accessories).
If vibration damping base supports are adopted, it is strongly recommended also to use vibration damping couplings on the water pipes.
Whenever the unit is to be sited on unstable ground (various types of soil, gardens, etc.) it is a good idea to provide a supporting base of adequate di-
mensions.
Warning heat pump units produce condensation while operating in the heating mode.

MPI DC
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MPI DC 10 - 15
MPI DC 27
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2 INSPECTION, CONVEYANCE DIMENSIONAL AND SITING
2.4 SITING
2.4.1 INSTALLATION CLEARANCE REQUIREMENTS
HEAT EXCHANGER WATER CONNECTION SIDE
ELECTRICAL BOX
EXCHANGER SIDE
HEAT EXCHANGER WATER CONNECTION SIDE
EXCHANGER SIDE
ELECTRICAL BOX

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2 INSPECTION, CONVEYANCE DIMENSIONAL AND SITING
2.5 DAMPERS SITING (ACCESSORY)
MPI DC n° dampers
10 - 15 4
27 4
Dampers

MPI DC
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3 PLUMBING AND ELECTRICAL CONNECTIONS
3.1 PLUMBING CONNECTION
All the units belonging to the MPI series are equipped with water differential pressure switch, safety valve, water pressure gauge and automatic filling
device and emptying tap.
Furthermore, depending on the version, MPI units can be supplied complete with pump, expansion vessel and buffer tank:
3.1.1 HYDRAULIC CONNECTION
Warning While connecting the taps, hold the unit's plumbing connections tightly in place using a hexagonal wrench to prevent the pipes inside the
unit from being damaged (see figure).
Percentage by weight Mixture freezing
of ethylene glycol (%) temperature (°C)
0 0
10 -4
15 -8
20 -14
30 -18
Important! If different antifreeze product is to be used, please contact the manufacturer.
Failure to install filters and vibration dampers may cause problems of clogging, breakages and noise, for which the manufacturer may not be
held liable.
3.1.2 RECOMMENDED WATER CIRCUIT
Warning when making the plumbing connections, make sure there are no open flames in proximity to or inside the unit.
When setting up the water circuit, it is advisable to equip it with:
- valves for regulating (VI) the unit on the water pipes, immediately upstream and downstream from the unit itself, to be used in the event maintenance
work is required;
- standard mechanical filter (FM) (OBLIGATORY!) on the pipe feeding the unit, in proximity to the latter;
- standard mechanical filter (FM) (OBLIGATORY!) and check valve (VNR), on the supply line upstream from the filling tap (RC);
- an air vent valve at the highest point of the circuit;
- escape pipe for the safety valve (VS), which, in the event the safety valve opens, diverts the jet of water to an area where it cannot harm persons or
damage property (Important!);
- vibration-damping couplings (GA) on the pipes to prevent vibrations from being transmitted toward the system.
Important! It is advisable to ensure that the pipes connected upstream and downstream from the unit are not smaller in diameter than the
plumbing connections of the unit itself.
Important! During wintertime the water circuit (or the water chiller only) must be emptied to prevent damage caused by freezing; alternatively, the
circuit may be filled with a mixture of water and glycol; the percentage of glycol necessary will depend on the lowest forecast temperature (see
table):

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
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3.1.3 FILLING THE SYSTEM
- Before you start filling, make sure that the system drainage cock is closed.
- Open all the air vent valves of the system and of the indoor units and chiller.
- Open the system regulating devices.
- To fill the circuit open slowly the water tap of the system (optional).
- When water starts coming out of the air vent valves of the indoor units, close them and continue filling until the pressure gauge reading is 1.5 bars.
3 PLUMBING AND ELECTRICAL CONNECTIONS
3.2 ELECTRICAL CONNECTIONS
All operations must be performed by qualified service personnel in accordance with current laws and regulations. For any electrical work on the unit, refer
to the electric diagrams supplied with the unit.
It is recommended to make sure that:
- The characteristics of the mains power supply are adequate for the electrical inputs specified in the table of electrical data.
Warning 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 supply voltage may not undergo fluctuations exceeding ±5% of the rated voltage.
The electrical connections must be made in accordance with the wiring diagram provided with the unit and the regulations in force.
Warning Never attempt to modify internal electrical connections: any undue modifications will immediately invalidate the warranty.
Important! An all-pole circuit breaker must be used on the electric panel upstream, conform to IEC Standards (contacts must be open at least of 3
mm), with suitable interruption capacity and differential protection, according to the electrical data table described below, and installed as close as
possible to the device. For the machine power supply line, use H07RN-F rubber flexible cables, with section as indicated in the table. For the cable
3 PLUMBING AND ELECTRICAL CONNECTIONS
3.1 PLUMBING CONNECTION
3.1.2 RECOMMENDED WATER CIRCUIT
Legend
VS Safety valve
EV Evaporator
PD Water differential pressure switch
MA Water gauge
VAS Air bleed hole
SA Storage tank
VE Expansion vessel
RS Drain
RC Water charge
VI Regulation valve (not supplied)
GA Vibration-damping coupling (not sup
plied)
FM Mechanical filter (OBLIGATORY)
VNR Check valve (not supplied)

MPI DC
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4 5
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- The maximum input power is the mains power that must be available in order for the unit to work.
- The maximum current absorption refers to the current that will trigger the internal safety devices of the unit. It is the maximum current allowed
in the unit.This value may never be exceeded; it must be used as a reference for determining the size of the power supply line and the related safety devices
(refer to the wiring diagram supplied with the units).
MPI DC 010 015 027
Power cables mm2 46 10
Safety fuse F A 20 25 32
Circuit breaker IL A 20 25 40
3.3 ELECTRICAL DATA
MPI DC 010 015 027
Maximum power input kW 5,4 9,1 16,1
Maximum current absorption A 16 20,3 34,6
Starting absorbed current A 10 10 10
Fan motor rated power kW 0,14 0,14 0,14
Fan motor rated current A 0,64 0,64 0,64
Pump motor rated power kW 0,48 0,65 0,65
Pump motor rated current A 2,7 3,0 3,0
Power supply V/f/Hz 230-1-50 400-3N-50
Auxiliary power supply V/f/Hz 230-1-50
Power cables mm2 4 6 10
PCD connecting cables mm2 AWG22 AWG22 AWG22
PCDS connecting cables mm2 1 1 1
Safety fuse F A 20 25 32
Circuit breaker IL A 20 25 40
passage, use sheaths and channels suitable for outdoor installation. Provide a line switch and delayed-type fuses with features as indicated in the table.
To access the electric control board it is necessary to remove the inspection panel (figure 4) by taking out the screws; introduce the power cable into the
unit through the bushing on the side panel; then bring it to the electric control board through the cable holder provided.
Important! Tighten the wires securely to the terminals and clamp the cable in place with the cable holder (figure 5).
Important! To preserve the protection degree of the machine, use a cable gland compatible with the sheath or power cable diameter, in correspondence
to the unit side panel hole.
Important! An earth connection is mandatory: connect the earth cable to the appropriate terminal of the electric panel (refer to the electric panel layout
provided with the unit) and marked with:
Important! If you wish to include:
- a remote on/off switch
- a remote switch for changing over between the cooling and heating mode (MPI H only),
- a remote alarm indicator
it is a good idea to do so at this stage of the installation procedure, by connecting the switches or PCDS remote control (accessory) to the
electric control board terminals as directed in section 3.3 and using the unit wiring diagram as your reference.

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3 PLUMBING AND ELECTRICAL CONNECTIONS
3.3 ELECTRICAL DATA
DIAGRAM SHOWING ELECTRICAL CONNECTIONS BETWEEN MPI DC AND PCDS REMOTE CONTROL PANEL
Note: On the terminal block of the
electric control panel a voltage of
24V will be present at the 50/24V
terminals in the event of an alarm;
if it is desired to interface with a
voltage-free contact, a relay must
be applied for this purpose by the
installer.
ELECTRIC BOARD TERMINAL
DIAGRAM SHOWING ELECTRICAL CONNECTIONS MPI DC WITH
MYCHILLER REMOTE CONTROL
MAIN ELECTRICAL CONNECTION OF THE ONE-PHASE AND
THREE-PHASE UNITS
GENERAL ALARM SIGNAL COOLING/HEATING REMOTE SELECTION ON/OFF (STAND-BY) SWITCH PCDS POWER SUPPLY

MPI DC
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4 STARTING UP
THE FIRST START UP MUST BE CARRIED OUT EXCLUSIVELY BY QUALIFIED PERSONNEL AND AUTHORIZED BY GALLETTI SPA (SEE WARRANTY
SHEET ATTACHED).
At first start-up of the installation make sure to comply with current national regulations.
4.1 PRELIMINARY CHECKS
When starting up the unit for the first time or after a seasonal period of quiescence, it is advisable to have the following checks performed by specialised
personnel:
- Check that the electrical connections have been made properly and that all the terminals are securely tightened.
- Check that the external power supply is within +-5 % tolerance from the power supply reported on the unit identification label.
If the power supply is subject to frequent voltage fluctuations, contact Galletti S.p.A. for advice on choosing suitable protections.
- Check for refrigerant leaks, with the aid of a leak detector if necessary.
- Check that the plumbing connections have been properly made according to the indications given on the plates to be found on the unit itself (water
inlet, water outlet etc.).
- Make sure that the pump is not blocked.
- 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, which
the installer should have set in place.
Warning before starting the unit, make sure all the covering panels are in place and secured with the fastening screws provided.
To start the unit, move the main switch to on. Use the keypad of the electronic control as directed in section 3.3 to select the cooling or heating mode.
Warning 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 section 3.3.
Warning do not cut off power 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 turned
OFF.