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FläktGroup FG Series Operation Manual

Chillers & heat pumps
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FG/GL-Unit Types
FGAC, GLAC, GLWC, FGAH, GLAH, GLFC, GLWH, GLRC
OPERATION MANUAL

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Summary of Contents for FläktGroup FG Series

  • Page 1 FG/GL-Unit Types FGAC, GLAC, GLWC, FGAH, GLAH, GLFC, GLWH, GLRC OPERATION MANUAL...

  • Page 2: Table Of Contents

    Chillers & Heat Pumps FG/GL Series Table of Contents Unit Identification Plate .............. 4 Unit Type Code ................5 Overview of Units and Packaged Content ........ 6 3.1 Series ......................6 3.2 Unit overview ..................... 6 3.3 Packaged content ..................6 3.4 Accessories and special equipment ............
  • Page 3 Chillers & Heat Pumps FG/GL Series Electrical Connection ............... 63 9.1 Requirements ................... 63 9.2 Connect mains electrical supply ............... 64 9.3 Connecting control contacts and controller ..........65 10 Commissioning ................. 69 10.1 Requirements ................... 69 10.2 Commissioning procedure ................ 69 10.3 Warm-up phase before operation .............

  • Page 4: Unit Identification Plate

    Unit Identification Plate Chillers & Heat Pumps FG/GL Series Unit Identification Plate The unit identification plate is secured on the unit and is explained as follows. Enter the data from the unit identification plate in the operation manual. This record establishes the relationship between the unit and the operation manual.

  • Page 5: Unit Type Code

    Unit Type Code Chillers & Heat Pumps FG/GL Series Unit Type Code FläktGroup FG/GL Series FläktGroup chiller FläktGroup heat pumps FläktGroup/Global Large Series FG/GL Air cooled (outdoor installation) Air cooled (indoor installation) Air cooled with free-cooling function (outdoor installation) without condenser (indoor installation) Water cooled (indoor installation) Chillers Heat Pump...

  • Page 6: Overview Of Units And Packaged Content

    Overview of Units and Packaged Content Chillers & Heat Pumps FG/GL Series Overview of Units and Packaged Content Series For detailed technical specifications on individual unit series refer to the Data&Facts catalog or your quotation for the unit. Unit overview For detailed technical description and unit configuration refer to Data&Facts and order- related documentation supplied with the unit.

  • Page 7: Safety And User Instructions

    Safety and User Instructions Chillers & Heat Pumps FG/GL Series Safety and User Instructions FläktGroup FG/GL units are constructed using state-of-the-art technology and accord- ing to recognized safety regulations. Use the FläktGroup units in a technically sound condition for the intended purpose observing the operation manual, taking safety aspects and potential hazards into account.

  • Page 8: Identification Of Safety Information

    Safety and User Instructions Chillers & Heat Pumps FG/GL Series Identification of safety information To designate the safety instructions the following symbols and notices are provided in appropriate places throughout this document: 4.4.1 DANGER - Death/serious irreversible injury Indicates an extremely hazardous situation which will result in death or serious irre- versible injury, if the safety instruction is not followed.

  • Page 9: Used Safety Symbols

    Safety and User Instructions Chillers & Heat Pumps FG/GL Series Examples: ATTENTION Risk of environmental damage! Heavily contaminated filters can have a negative impact on production processes. Depending on the filtered-out materials, contaminated filters are therefore classi- fied as hazardous waste and must be properly disposed of according to the pre- vailing guidelines and laws.

  • Page 10: Safety-Conscious Work Procedures

    Safety and User Instructions Chillers & Heat Pumps FG/GL Series Safety-conscious work procedures Observe the following instructions when carrying out installation, adjustment or repair jobs: • Wear suitable protective clothing during work, such as protective footwear, gloves, safety goggles, etc. •...
  • Page 11 Safety and User Instructions Chillers & Heat Pumps FG/GL Series Warning of high pressure! When working on hydraulic or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. •...
  • Page 12 Safety and User Instructions Chillers & Heat Pumps FG/GL Series 4.6.1 Handling refrigerants According to DIN EN 378 Part 1, the refrigerant R-134a, R-407C and R-410A belong to the A1 group. Refer to the unit identification plate for data and charge volume of a particular refrigerant.

  • Page 13: Modifications And Changes

    Safety and User Instructions Chillers & Heat Pumps FG/GL Series 4.6.2 Proper use FG/GL units are only used to produce chilled water for air treatment units in comfort air conditioning or to provide chilled water for process cooling in enclosed circuits of man- ufacturing facilities.

  • Page 14: Technical Description

    Technical Description Chillers & Heat Pumps FG/GL Series Technical Description Description of the unit These FläktGroup units are performed as chillers or heat pumps. In the factory units are filled with refrigerator oil and refrigerant and a test run is performed, so that when the units are installed on site only chilled water and electrical connections have to be completed.

  • Page 15: Functional Description

    Technical Description Chillers & Heat Pumps FG/GL Series Functional description 5.2.1 FGAC/GLAC – air cooled chillers designed for outside installation and The refrigeration system generates a refrigeration output in a thermodynamic cycle by Refrigeration circuit means of heat removal, this is used to cool a water circuit (indirect cooling). Fig.
  • Page 16 Technical Description Chillers & Heat Pumps FG/GL Series 5.2.3 GLFC - air cooled chillers with a free-cooling function for outside installation Summer operation: During summer operation a 3-way valve directs water for cooling not through an additional air cooled heat exchanger but directly into the evapo- rator.
  • Page 17 Technical Description Chillers & Heat Pumps FG/GL Series 5.2.4 GLRC - chiller without condenser for inside installation In cooling mode the unit operates as specified in chapter 5.2.1 FGAC/GLAC – air cooled chillers designed for outside installation and. With this configuration the condenser is not located in the unit itself and must be pro- vided by others on site, the corresponding pipework has to be established by others as well.
  • Page 18 Technical Description Chillers & Heat Pumps FG/GL Series 5.2.6 GLWH-#D2 - water cooled heat pumps for inside installation with integrated 4-way valve The refrigeration system generates a refrigeration output in a thermodynamic cycle by Refrigeration circuit means of heat removal, this is used to cool a water circuit (indirect cooling). Fig.

  • Page 19: Technical Specifications

    Technical Description Chillers & Heat Pumps FG/GL Series 5.2.7 GLWH-#A2 - water cooled heat pumps for inside installation The refrigeration system generates a refrigeration output in a thermodynamic cycle by Refrigeration circuit means of heat removal, this is used to cool a water circuit (indirect cooling). Fig.

  • Page 20: Operating Limits

    Technical Description Chillers & Heat Pumps FG/GL Series Operating limits For unit operating limits refer to Data&Facts catalogue of the relevant unit series or web-based unit selection and layout software Aid@ (www.aida.FläktGroup.com) for chillers and heat pumps. Notice! – Protect all water-conducting components from freezing at ambient tempera- tures below 5°C.

  • Page 21: Shipping And Storage

    Shipping and Storage Chillers & Heat Pumps FG/GL Series Shipping and Storage Delivery Upon receipt of the units, inspect the units for damage and verify that the shipment is complete (refer to section 3.2 "Packaged content") according to the freight bill. It is necessary to take photographs of all visible transit damage.
  • Page 22 Shipping and Storage Chillers & Heat Pumps FG/GL Series Danger due to overhead loads! Never stand beneath suspended loads, since there is always a risk that the lifting gear, tackle, ropes or slings are faulty or damaged. Failure to follow safety precau- tions could result in death or serious injury.

  • Page 23: Storage

    Shipping and Storage Chillers & Heat Pumps FG/GL Series Storage Permitted storage conditions / permitted air condition for uninstalled units The storage conditions depend on the type of refrigerant. The used refrigerant can be taken from the unit identification plate: Air temperature: Refrigerant R410A: -15 °C bis +46 °C Refrigerant R134a: -15 °C to +55 °C...

  • Page 24: Assembly

    Assembly Chillers & Heat Pumps FG/GL Series Assembly Note on assembling and installing the unit! Here you will find information on how to mount and install the unit. Placement, installation and assembly must only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recog- nized safety and occupational health codes.
  • Page 25 Assembly Chillers & Heat Pumps FG/GL Series – Check if requirements for the installation site defined by EN 378-3 are fulfilled (refrigerating systems and heat pumps - safety and environmental requirements Part 3: installation site and personal protection). These require- ments especially apply to units for indoor installation.
  • Page 26 Assembly Chillers & Heat Pumps FG/GL Series 7.1.1 Overview of application areas and types of heat exchanger coatings Comfort Climate Control The following tables specifiy the most frequent application areas of units for comfort climate control. Essentially these are urban and suburban areas as well as coastal regions.
  • Page 27 Assembly Chillers & Heat Pumps FG/GL Series Special applications The following table provides and overview about typical installations in industrial environments or rural environments. This applies both for units for comfort air conditioning as well as for process cooling. Even though these applications represent a minority of uses, these operational areas are of enormous importance due to existing air pollution, and should therefore be given special attention.

  • Page 28: Assembling The Unit

    Assembly Chillers & Heat Pumps FG/GL Series Additional notice for FGAH/GLAH units: PERSONAL injury! Frozen surfaces around the unit as a result of random or irregular condensate drain- age during defrosting can lead to personal injuries. • Keep the area around the unit free of ice during cold weather conditions. –...
  • Page 29 Assembly Chillers & Heat Pumps FG/GL Series • Do not install the unit on the supplied rubber pads. These are meant for easy loading and unloading only and are not suitable for the operation of the unit. • The unit must be installed horizontally. •...

  • Page 30: Installing Accessories

    Assembly Chillers & Heat Pumps FG/GL Series To find out if the unit is equipped with one or more evaporators, refer to the unit descrip- tion in the Data&Facts catalog, unit quotation text or order-related dimensional draw- ing. Installing accessories 7.3.1 Rubber anti-vibration isolators For exact type of rubber anti-vibration isolators necessary for each unit refer to the unit- related Data&Facts catalog.
  • Page 31 Assembly Chillers & Heat Pumps FG/GL Series FZ 400-57 12.5 FZ 600-51 17.5 FZ 600-57 17.5 FZ 1000-57 21.5 Tab. 7-4 Fig. 7-7: Installation of anti-vibration isolators FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 32 Assembly Chillers & Heat Pumps FG/GL Series Type ØF ØG ØH AA100N AA200N AA300N 12.5 10.5 AA400N 15.0 12.5 AA1000N AA1500N Tab. 7-5: Size in [mm] Fig. 7-8: Installation of anti-vibration isolators FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 33 Assembly Chillers & Heat Pumps FG/GL Series Type AA600N AA800N Tab. 7-6: Size in [mm] Anti-vibration spring isolator Refer to the order-related unit documentation to select the correct type of spring anti- vibration isolators to be installed below the relevant points W1 to Wn. Ø...

  • Page 34: Installation Of Unit Accessories

    Assembly Chillers & Heat Pumps FG/GL Series Δ ∅ Type A [mm] L [mm] Li [mm] Fz [N] H [mm] Frequency (Hz) SR21-550H-AM/L 180-650 from 25 to 58* 5 - 2.65 SR21-800-AM/L 270-800 from 25 to 58* 5 - 2.95 SR21-1000-AM/L 350-1000 from 25 to 58*...
  • Page 35 Assembly Chillers & Heat Pumps FG/GL Series Number of paddles used: Pipe diameter Paddle 1 " 1 ¼ " 1 ½ " 2 " 1, 2 2 ½ " 1, 2 3 " 1, 2, 3 4 " 1, 2, 3 4 "...
  • Page 36 Assembly Chillers & Heat Pumps FG/GL Series 7.4.2 Accessories FGZ/GLZ#### - external control panel Unit: • Install a T connector in the switch cabinet of the unit. External switch cabinet • Install a T-Connector directly where the additional external control panel is meant to be installed.
  • Page 37 Assembly Chillers & Heat Pumps FG/GL Series Setting the address of the external control panel: • Press the keys [ ], [ ] and [ ] simultaneously for several seconds. Enter the desired address with the key [ ] and [ ] and confirm with [ ].
  • Page 38 Assembly Chillers & Heat Pumps FG/GL Series 7.4.3 Accessories GLZ########.I31 – 3-way valve for cooling water regulation. 3-way valve Servo motor • Remove the plastic caps before installing the 3-way valve. • Install the 3-way valve as described in the following examples: Unit GLWC #### #D2 –...
  • Page 39 Assembly Chillers & Heat Pumps FG/GL Series Unit: GLWH #### #D2 – unit with GLPC pump module Legend: Condensers CD/EV Condenser/evaporator (depending on operating mode) 3-way valve Unit water outlet (to hydraulic network) Unit water inlet (from hydraulic network) Unit water inlet (from hydraulic network) Unit water outlet (to hydraulic network) Tab.

  • Page 40: Medium Connections

    Medium Connections Chillers & Heat Pumps FG/GL Series Medium Connections Medium connections must only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant acci- dent prevention regulations, as well as other generally recognized safety and occupational health codes (also refer to section 4.10 „Personnel selection and qualification“).
  • Page 41 Medium Connections Chillers & Heat Pumps FG/GL Series • Use only ethylene or propylene glycols that are suitable for closed chilled water systems and used materials. Observe the manufacturer's information regarding safe handling of glycols as well as information on their application and disposal. •...
  • Page 42 Medium Connections Chillers & Heat Pumps FG/GL Series 8.1.2 Water quality recommendations A good water quality – e.g. salt and lime free drinking water – considerably increases the service life and efficiency of the unit and the connected secondary system. Check the limit values in the table once a year to avoid damage to the hydraulic system components.

  • Page 43: Connecting Water Circuit (Chilled And Warm Water)

    Medium Connections Chillers & Heat Pumps FG/GL Series Connecting water circuit (chilled and warm water) Check the following before commencing medium connections of the unit: • The entire chilled water system must be designed and implemented in accordance with the current standards and guidelines. •...

  • Page 44: Check And Adjust Inlet Pressure In Expansion Tank (For Units With Installed Hydraulic Or Pump Module With Expansion Tank)

    Medium Connections Chillers & Heat Pumps FG/GL Series • Connect the piping system by others to the chilled water inlet and outlet. • For exact positions of the water inlet and outlet refer to the order-related documentation and compare these positions with data on the unit stickers. •...
  • Page 45 Medium Connections Chillers & Heat Pumps FG/GL Series Inlet pressure (estimated): 0 3 , ------------- 10 2 , 0 3 , Plant filling pressure min. (estimated): Psv 0 3 , – Plant filling pressure max.: : Initial pressure [bar], measured at pressure connection of expansion tank Minimum setting 0.5 bar : Height of water column over expansion tank : Minimum plant filling pressure [bar], measured at unit...

  • Page 46: Charging Water Circuit

    Medium Connections Chillers & Heat Pumps FG/GL Series D. 1 Height of water column over expansion tank H [m] Charging water circuit • Connect the water supply or the pre-mixed water-glycol to the filling valve. • Open shut off valves. •...
  • Page 47 Medium Connections Chillers & Heat Pumps FG/GL Series 8.4.1 Schematic representation of various hydraulic circuits (examples) The following components must be installed in every cold or warm water circuit in com- pliance with the correct order. – Pressure gauge on the water inlet and outlet of the unit –...
  • Page 48 Medium Connections Chillers & Heat Pumps FG/GL Series With a single circuit buffer tank, the buffer tank serves primarily to increase the volume Purpose: in the hydraulic system in order to guarantee the compressor's minimum runtime and to prevent the unit from being repeatedly switched on and off unnecessarily. With small to medium-sized air-conditioning systems, a single circuit buffer tank sys- Application: tem is used, wherever possible, with identical consumers requiring the same volume...
  • Page 49 Medium Connections Chillers & Heat Pumps FG/GL Series 8.4.3 Dual circuit buffer tank with multiple pumps for the entire system Fig. 8-2: Hydraulic circuit of twin-circuit buffer tank Pressure gauge Expansion tank Stop cock Filling valve Automatic venting Flow switch Vibration damping connection Balancing valve/Double regulating valve Unit-independent pipeline fixing point...

  • Page 50: Connecting Cooling Water Circuit (Only Glwc And Glwh Units)

    Medium Connections Chillers & Heat Pumps FG/GL Series A constant water volume flow across the unit must be ensured in the primary circuit. The water volume flow on the secondary side, i.e. at the consumers, can vary due to hydraulic separation, thus enabling the use of speed-regulated pumps. With a dual-cir- cuit buffer tank, individual consumer circuits can also be switched off and on depending on demand.
  • Page 51 Medium Connections Chillers & Heat Pumps FG/GL Series Fig. 8-3: Heat rejection circuit with cooling water pump with speed control and/or speed control of the heat rejection unit Fig. 8-4: Heat rejection circuit with a 3-way valve and/or fan speed control of the heat rejection unit Pressure gauge Safety valve Stop cock...
  • Page 52 Medium Connections Chillers & Heat Pumps FG/GL Series ATTENTION Damage to the unit! Consider to install a water filter directly before the water inlet of the evaporator and condenser. The water filter (mesh width from 0.5 to 1 mm) prevents formation of dirt and scale on the coils.The water filter is a requirement for safe and trouble-free operation of the unit and in therefore is covered by the warranty.
  • Page 53 Medium Connections Chillers & Heat Pumps FG/GL Series Notice! For additional information regarding installation of different cold, hot and cooling water circuits refer to our manual on hydraulic systems for chillers and heat pumps. Please contact your FläktGroup sales office. 8.5.1 Operation of a 3-way valve (by others) Ensure a minimum cooling water outlet temperature after compressor start.

  • Page 54: Connecting Refrigeration Circuit To An External Condenser (By Others, Only Glrc)

    Medium Connections Chillers & Heat Pumps FG/GL Series Connecting refrigeration circuit to an external condenser (by others, only GLRC) Warning of high pressure! When working on hydraulic or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. •...
  • Page 55 Medium Connections Chillers & Heat Pumps FG/GL Series Refer to the relevant documentation provided by the manufacturer for further details on layout and installation of air cooled condensers. Refrigerant lines Only copper refrigerant lines meeting DIN EN12735-1 standards may be used. The relevant requirements especially apply to: –...
  • Page 56 Medium Connections Chillers & Heat Pumps FG/GL Series 8.6.2 Placement and installation examples Example 1 GLRC chiller and condenser at the same vertical level with horizontal pipe routing GLRC chiller Discharge line Condensers  1 % slope (1 cm/m) Liquid Line Circuit 2 Fig.
  • Page 57 Medium Connections Chillers & Heat Pumps FG/GL Series Example 3 GLRC chiller below the condenser at different vertical levels. Condensers Discharge line  1 % slope (1 cm/m)   GLRC chiller Hot Gas Line 1 % slope (1 cm/m) ...
  • Page 58 Medium Connections Chillers & Heat Pumps FG/GL Series Routing refrigerant lines Notice! When routing the pipes, always make sure that the pipe ends are sealed. Even if the unit setup is incomplete, seal all pipe ends after the job is finished. Only this way can penetration of dirt and humidity be prevented.
  • Page 59 Medium Connections Chillers & Heat Pumps FG/GL Series Drying systems Notice! When replacing components within the refrigeration circuit, the drier must always be replaced too! The drier must always be replaced last. The new drier is vacuum-packed. After opening the vacuum packing, commence with brazing as soon as possible. Evac- uation must be performed within 2 hours.
  • Page 60 Medium Connections Chillers & Heat Pumps FG/GL Series 8.6.5 Evacuation Before charging the system with a refrigerant, the refrigeration circuit must be evacu- Reasons for evacuation ated using a vacuum pump in order to remove air and humidity. Air in the refrigeration circuit has the following effects: –...
  • Page 61 Medium Connections Chillers & Heat Pumps FG/GL Series Pressure rise after evacuation 0,018 0,016 Humid and leaking 0,014 0,012 Humid and leak-free at Ta = +10 °C 0,01 0,008 0,006 0,004 0,002 Dry and leak-free Time [h] Fig. 8-9: Pressure rise after evacuation 8.6.6 Charging Warning of high pressure! When working on hydraulic or in case of damage to the components or piping, there...

  • Page 62: Connect Desuperheater/Heat Recovery Circuit

    Medium Connections Chillers & Heat Pumps FG/GL Series Connect Desuperheater/Heat Recovery Circuit Refer to the unit identification plate to see if the unit is equipped with a desuperheater/ heat recovery circuit. Compare unit identification plate with chapter 2 unit type code. For connecting desuperheater/heat recovery circuit the points specified in chapter 8.2 also apply: –...

  • Page 63: Electrical Connection

    Electrical Connection Chillers & Heat Pumps FG/GL Series Electrical Connection Electrical connections may only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant acci- dent prevention regulations, as well as other generally recognized safety and occupational health codes.

  • Page 64: Connect Mains Electrical Supply

    Electrical Connection Chillers & Heat Pumps FG/GL Series EXAMPLE Input data Result Rated voltage 400 V/50 Hz/3 phases Requirements Calculate and determine specific in- L1/L2 = 409 V; L2/L3 = 398 V; L1/L3 = 396 V Voltage between put data and measurements before- phases hand.

  • Page 65: Connecting Control Contacts And Controller

    Electrical Connection Chillers & Heat Pumps FG/GL Series Fig. 9-2: Connection of mains isolator for unit with L1 L2 L3 PE supply-voltage code 2 1 Q S1 L1 L2 L3 PE 400 V / 3 / 50 Hz Connecting control contacts and controller NOTICE! Run the power supply cable of unit separately from the internal unit cabling and on- site provided supply lines of the unit.
  • Page 66 Electrical Connection Chillers & Heat Pumps FG/GL Series 9.3.2 Integrating common fault signal ATTENTION Damage to the unit! Do not open the remote on/off contact, e.g. via the changeover contact of the on-site relay, if the system is faulty. – As a result, the fault can be reset, –...
  • Page 67 Electrical Connection Chillers & Heat Pumps FG/GL Series Notice! Only for water-cooled, reversible heat pumps (GLWH-BD unit series): Install a flow switch in each water outlet of unit and connect to terminals A-B (for chilled-water circuit in cooling mode) and terminals A1-B1 (for warm-water circuit in cooling mode).
  • Page 68 Electrical Connection Chillers & Heat Pumps FG/GL Series seconds of the pump lead time. Upon opening the external enabling contact (contact E-F) the compressors are con- secutively switched off and the contact P1-P2 (pump enabling contact) opens 60 sec- onds later. The request of the pump (by others) is removed. As long as the external enabling contact is closed and the unit is activated using the display - the pump is oper- ated in order to measure water temperatures in the hydraulic system.

  • Page 69: Commissioning

    Commissioning Chillers & Heat Pumps FG/GL Series 10 Commissioning This information applies to initial commissioning of the FläktGroup units as well as re-commissioning after an extended shut-down period. All commissioning work must be entrusted only to qualified licensed staff or other individuals with proper professional training and experience in the relevant regula- tions and codes of practice! 10.1 Requirements...
  • Page 70 Commissioning Chillers & Heat Pumps FG/GL Series • Contact your system manufacturer to request the filled-in report „Technical requirements for client witness test or maintenance of chillers/heat pumps” (refer to Appendix I). • Keep the operation manual as well as order-related documentation for the unit at hand.
  • Page 71 Commissioning Chillers & Heat Pumps FG/GL Series • Check if a pump contact (terminals C-D) in units with screw compressors without an integrated hydraulic module is wired according to the wiring diagram (refer to section 9.2.4 „Pump enabling“) ATTENTION Damage to the unit! The pump can be damaged, if the unit is operated without water flowing through a water cooled heat exchanger, e.g.

  • Page 72: Warm-Up Phase Before Operation

    Commissioning Chillers & Heat Pumps FG/GL Series • Disconnect the unit from the power supply. Re-tighten all electrical connections in the switch cabinet and in the terminal boards of the consumers. Check that all connections are tight. • Check that the earth conductors are connected correctly and that the earth terminals are securely tightened.
  • Page 73 Commissioning Chillers & Heat Pumps FG/GL Series • Check supply voltage. The voltage must match the details on the plate/identification or the unit-specific documentation. • Check the phase tolerance. • Check if the clockwise rotating field is applied. It is important that the rotating direction is correct for proper unit operation: clockwise rotating field! •...
  • Page 74 Commissioning Chillers & Heat Pumps FG/GL Series Calibration 8 hours of uninterrupted oil heater operation will ensure that there is no more refriger- ant in the oil. The unit can now be put into operation and calibrated. Contact with unit surfaces can lead to injuries! The surfaces of the unit and the pipework can be both very cold and hot.
  • Page 75 Commissioning Chillers & Heat Pumps FG/GL Series In the table below you will find typical temperature and pressure values of the unit. Compare the values below with your measured readings. Operating limits may vary depending on the unit series. Refer to Data&Facts catalogue of the relevant unit series, quotations for the unit or web-based unit selection and layout software Aid@ (www.aida.FläktGroup.com) for specific unit data.

  • Page 76: Operating Unit

    Operating Unit Chillers & Heat Pumps FG/GL Series 11 Operating Unit ATTENTION Damage to the unit! The unit must not be operated unless proper function test has been carried out. Ensure that all steps specified in chapter 10 "Commissioning" have been carried out.
  • Page 77 Operating Unit Chillers & Heat Pumps FG/GL Series 11.2.1 Switching on Notice! Before switching the unit on, make sure you are aware of the operating mode HEATING or COOLING (only for GLAH and GLWH) Contacts G-H open = HEATING Contacts G-H open = COOLING •...

  • Page 78: Operating Controller

    Operating Unit Chillers & Heat Pumps FG/GL Series 11.3 Operating controller 11.3.1 External remote ON/OFF via digital input [ON/OFF] The unit can only be switched on and off via the digital contact (terminals E/F), if the contact is enabled in the user menu (USER) and connected in the unit’s switch cabinet in accordance with the wiring diagram.
  • Page 79 Operating Unit Chillers & Heat Pumps FG/GL Series • Select the “Setpoint” menu with the arrow keys. • Press the “Enter” key to confirm.  Use the arrow keys to adjust the parameter “Chiller setpoint”. • Press the “Enter” key to confirm. •...

  • Page 80: Overview Of Operator Elements

    Operating Unit Chillers & Heat Pumps FG/GL Series 11.4 Overview of operator elements Operator and display elements FläktGroup HVAC systems - Step III and units of the GLFC series: Operator ele- Description ment Enables unit switching on and off. Serves to display and reset alarms. Provides access to the main menu.

  • Page 81: Operating Controller

    Operating Unit Chillers & Heat Pumps FG/GL Series 11.5.1 Switching on • If "Com.: off" is not displayed, press the "Esc" key until "Com.: off" appears in the display. • Use „On/Off“ to switch the unit.  If “On” remains on the display, the unit is switched on. 11.5.2 Switching off •...
  • Page 82 Operating Unit Chillers & Heat Pumps FG/GL Series • Press the "Esc" key to return to the start screen. • Activate unit (refer to „Switching on“). Notice! Changing the setpoint downwards may trigger a frost protection malfunction warn- ing (AL 010: frost protection for evaporator; standard switching value of +4°C at evaporator water outlet).
  • Page 83 Operating Unit Chillers & Heat Pumps FG/GL Series reduced to 50 %. Therefore the temperature difference across the evaporator goes down as well by 50 % to 2.5 K. As a result, the water outlet temperature rises at water inlet temperature of 10.75 °C from 5.75 °C with two active compressors to 8.25 °C with only one active compressor.
  • Page 84 Operating Unit Chillers & Heat Pumps FG/GL Series ture control and assuming continuous operation, the water outlet temperature will fluc- tuate between 5.75 °C and 8.25 °C. Proportional control via chilled water inlet temperature - unit with 2 capacity stages Power Example heating: Water inlet...
  • Page 85 Operating Unit Chillers & Heat Pumps FG/GL Series Proportional control via chilled water inlet temperature - unit with 4 capacity stages Capacity Example heating: Water inlet Setpoint Setpoint Proportional band 5 K Fig. 11-6: Proportional control 4 speeds In the following example it is assumed that the temperature difference across the heat exchanger amounts to 5 K at 100 % heating capacity of the unit and that the water con- tent of the unit is sufficient.

  • Page 86: Disconnecting From Power Supply

    Operating Unit Chillers & Heat Pumps FG/GL Series Auto-adaptive control with neutral range via water outlet or inlet temperature Capacity reduced Capacity increased Setpoint cooling/heating Power ↑ Power ↓ Neutral zone Temperature Variable zone Fig. 11-7: Auto-adaptive control With this type of control system the chilled water inlet or outlet temperature is used as the control variable.

  • Page 87: Draining Water Circuit

    Operating Unit Chillers & Heat Pumps FG/GL Series Danger due to electrical hazard which leads to serious injuries or death! • Check that all electrical control cables provided on-site are disconnected from the power supply. Depending on the contact, on-site potential may be necessary. •...

  • Page 88: What To Do In Case Of Alarm And Error Messages

    Operating Unit Chillers & Heat Pumps FG/GL Series ATTENTION Damage to the unit! – Residual water can freeze and destroy the unit. – If the unit is equipped with a pump enabling function (see chapter 9.3.4 pump enabling) pump block-up protection is activated. This function regularly acti- vates pumps which are controlled by the main unit to prevent pump blockage during extensive shutdown periods.

  • Page 89: Fault Finding And Troubleshooting

    Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series 12 Fault Finding and Troubleshooting ATTENTION Damage to the unit! If alarms occur, inform FläktGroup Service immediately! Reset an alarm only after detecting and eliminating the cause of failure. If alarms are reset without eliminating the fault, serious unit damage and expiration of the guarantee can be the consequence.
  • Page 90 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Phase sequence/ Phase sequence relay tripped and prevents unit start. voltage outside the allowable Possible reasons to be investigated: range Electrical system: – Incorrectly connected rotating field (clockwise rotating field is mandatory) –...
  • Page 91 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Evaporator frost protection Water outlet temperature of evaporator equals or lower than set frost protection val- Standard frost protection value ranges between 3 °C and 4 °C, i.e. if water outlet temperature from evaporator is lower or equals above values - frost protection alarm is activated.
  • Page 92 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Maintenance pump 1 Sum of operating hours exceeds maintenance interval stored in controller. With units fitted with a single pump - pump 1 is evaporator pump. General alarm contact is closed, but the unit continues to operate.
  • Page 93 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Overload protection, pump 1 Overload relay of pump 1 tripped and prevents pump start. With units fitted with a single pump - pump 1 is evaporator pump. Possible reasons to be investigated: General: –...
  • Page 94 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Isolation expansion See alarm message 091 "Isolation expansion with address 1" only for extension 4 Slave with address 4 of Slave Isolation expansion See alarm message 091 "Isolation expansion with address 1" only for extension 5 Slave with address 5 of Slave Oil compressor 1...
  • Page 95 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Fault, compressor 1 Motor protection relay and/or automatic circuit breaker tripped for compressor 1. Possible reasons to be investigated: Refrigeration circuit – Insufficient refrigerant – Faulty expansion valve –...
  • Page 96 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action High pressure, circuit 1 High pressure switch of refrigeration circuit 1 tripped because of too high pressure. Possible reasons to be investigated: General/Water circuit: – Operation outside operating limits –...
  • Page 97 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Overload protection, fan cir- See message 221 „Overload protection fans circuit 1“, only for fans in circuit 4 cuit 4 Low pressure, circuit 1 Low pressure sensor or low pressure switch of refrigeration circuit 1 is deactivated because of too low pressure.
  • Page 98 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action High pressure through High pressure sensor of refrigeration circuit 1 tripped because of too high pressure. Possible reasons to be investigated: Converter 1 General/Water circuit: –...
  • Page 99 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Missing freon in circuit 1 If alarm 251 has been active for more than 8 hours, alarm message 261 is displayed Missing freon in circuit 2 If alarm 252 has been active for more than 8 hours, alarm message 262 is displayed Missing freon in circuit 3 If alarm 253 has been active for more than 8 hours, alarm message 263 is displayed...
  • Page 100 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Fault, sensor 10 Received readings for sensor 10 on the main PCB (Master) are outside limiting val- ues. Use the wiring diagram to establish if a temperature or pressure sensor is connect- ed to terminal B10 on the main PCB (Master).
  • Page 101 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Slave faulty sensor 10 See message 400, but for sensor B10 of main PCB (Slave) Slave faulty sensor 1 See message 400, but for sensor B1 of main PCB (Slave) Slave faulty sensor 2 See message 400, but for sensor B2 of main PCB (Slave) Slave faulty sensor 3...
  • Page 102 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Pre-alarm high pressure Pre-alarm is a signal message transmitted to building management system Unit continues to operate and informs beforehand about expected fault message. Gen- Circuit 1 eral alarm contact is not closed.
  • Page 103 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Checking operating range: Alarm indicates that discharge temperature exceeded maximum allowed discharge discharge temperature too temperature while in operation. high for circuit 1 Setpoint for the minimum discharge temperature is determined at the compressor depending on the pressure condition.
  • Page 104 Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series ALARM DESCRIPTION Details RESET Action Checking operating range: Refer to alarm message 671 „Checking operating range: discharge temperature too high pressure too low for cir- low in circuit 1“, only for refrigeration circuit 2 cuit 2 Checking operating range: Refer to alarm message 671 „Checking operating range: discharge temperature too...

  • Page 105: Resistance Temperature Sensor For Fläktgroup Hvac Systems Controller

    Fault Finding and Troubleshooting Chillers & Heat Pumps FG/GL Series 12.3 Resistance temperature sensor for FläktGroup HVAC systems controller Temperature Resistance Temperature Resistance Temperature Resistance [°C] [kOhm] [°C] [kOhm] [°C] [kOhm] 32.92 53.39 5.83 27.70 42.25 4.91 24.75 33.89 4.16 20.98 27.28 3.54...

  • Page 106: Servicing And Maintenance

    Servicing and Maintenance Chillers & Heat Pumps FG/GL Series 13 Servicing and Maintenance For a safe and energy efficient operation, a maintenance of the unit is necessary at reg- ular intervals. In the Appendix of this operation manual you can find a logbook for chillers, heat pumps and compressor/condenser units.

  • Page 107: Overview Of Maintenance Intervals

    Servicing and Maintenance Chillers & Heat Pumps FG/GL Series 13.2 Overview of maintenance intervals In the following list you can find the general maintenance intervals for all units. For doc- umenting the maintenance, use the relevant measuring report in Appendix III. Action Interval in months Note...

  • Page 108: Maintenance Of Air-Cooled Heat Exchangers

    Servicing and Maintenance Chillers & Heat Pumps FG/GL Series Action Interval in months Note Hydraulics Check functional principle of the flow switch Check functional principle of the water differential pressure switch Check rotation direction of the water pump Air vent hydraulic circuit Fill hydraulic circuit, if necessary Clean water filter Check water-side pressure drop of the heat exchangers...
  • Page 109 Servicing and Maintenance Chillers & Heat Pumps FG/GL Series Regular Cleaning: ATTENTION Damage to the unit! Cleaning of the heat exchanger with a high pressure cleaner is not allowed. The high pressure cleaner can cause permanent damage on the fins and the pipes. •...

  • Page 110: Recommendation: Two Services Per Year

    Servicing and Maintenance Chillers & Heat Pumps FG/GL Series Regular Cleaning: • When installing near coastal and industrial areas, it is compulsory to clean the heat monthly: exchangers of salt, dirt and other residues once a month. • Rinse the heat exchanger only with water. Chemical cleaning agents are not allowed as they can cause corrosion.

  • Page 111: Dismantling And Disposal

    Dismantling and Disposal Chillers & Heat Pumps FG/GL Series 14 Dismantling and Disposal ATTENTION Risk of environmental damage! Have qualified licensed staff dismantle and dispose of the unit! 14.1 Dismantling To dismantle the units proceed as follows: Electrocution through hazardous voltage will lead to death or serious injury! When carrying out decommissioning and dismantling work on the unit you must: •...

  • Page 112: Disposal

    Dismantling and Disposal Chillers & Heat Pumps FG/GL Series 14.2 Disposal Notice! The operator of the refrigeration unit is responsible for taking all necessary precau- tionary measures and ensures that only certified and licensed staff properly recov- ers, recycles, processes and disposes of fluorinated refrigerants containing greenhouse gases (F-Gases).

  • Page 113: Appendix

    Appendix Chillers & Heat Pumps FG/GL Series 15 Appendix The following pages contain check lists and reports: On 15.1 Appendix I 15.1 Technical Requirements for Function Testing or Mainte- nance of Chiller/Heat Pump See Appendix I For commissioning: We recommend to use the checklist “Technical requirements for commissioning report/ client witness test of chiller/heat pump”...
  • Page 114 Appendix Chillers & Heat Pumps Appendix I FG/GL Series 15.1 Technical Requirements for Function Testing or Maintenance of Chiller/Heat Pump V1.2 07/2018 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 115 Appendix Chillers & Heat Pumps Appendix II FG/GL Series 15.2 Commissioning Report Warranty: Please send a copy to: V1.2 07/2018 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 116 Appendix Chillers & Heat Pumps FG/GL Series Installation Buffer tank Water filter position of 3-way- Flow switch Pump (vertical) valve Shut-off valve Safety valve Temperature sensor Buffer tank (horizontal) Flow regulating Unit valve Pressure gauge No return valve Hydraulic switch 2-way-valve Expansion vessel Consumer...

  • Page 117: Measuring Report Chiller

    15.3 Measuring Report GLAC Chiller Appendix III FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 118 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 119 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 120 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 121 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 122 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 123 Appendix III FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 124 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 125 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 126 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 127 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 128 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 129 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 130 Appendix III FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 131 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 132 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 133 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 134 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 135 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 136 Appendix III FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 137 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 138 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 139 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 140 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 141 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 142 Appendix III FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 143 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 144 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 145 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 146 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 147 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 148 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...

  • Page 149: Generally Accepted Translation Of Diagrams, Plans And Drawings In Order-Related Documentation

    Appendix Chillers & Heat Pumps FG/GL Series 15.4 Generally accepted translation of diagrams, plans and drawings in order-related documentation 15.4.1 Terminology used in dimensional drawings English German Air inlet Luft Eintritt Air outlet Luft Austritt Anti vibration mounts Gummischwingungsdämpfer ATTN: Use N° X Lifting ropes with equal length only Achtung: Verwenden Sie X Trageseile mit gleicher Länge Centre of Gravity Gewichtsschwerpunkt...
  • Page 150 Appendix Chillers & Heat Pumps FG/GL Series English German Total gesamt Type User water inlet Wasser für Verbraucher-/Gebäudeseite Eintritt User water outlet Wasser für Verbraucher-/Gebäudeseite Austritt Version Ausführung View table beachte Tabelle Weight distribution Gewichtsverteilung Weight for unit with Copper/Copper coils Gewichte für Geräte mit Cu/Cu Verflüssiger Well/Tower water inlet Brunnenwasser/Rückkühlerwasser Eintritt...
  • Page 151 Appendix Chillers & Heat Pumps FG/GL Series Acronym English German Evaporator anti freeze heater Frostschutzheizung Verdampfer Evaporator inlet temperature probe Temperaturfühler Verdampfer Eintritt Evaporator outlet temperature probe Temperaturfühler Verdampfer Austritt Exp. module Erweiterungskarte Expansion module Erweiterungskarte External Air probe Temperaturfühler Außenluft Fan (speed) contactors Lastschütze für Ventilatormotoren Fan speed regulation (automatic) circuit breakers...
  • Page 152 Appendix Chillers & Heat Pumps FG/GL Series Acronym English German Thermostatic controller Treiber für elektronisches Expansionsventil Thermostatic equalisation valves Magnetventile für äußeren Druckausgleich am Expansionsventil Three phase capacitors Kondensatoren zur Blindstromkompensation Three phase capacitors automatic circuit breakers Sicherungsautomaten Kondensatoren Three phase capacitors contactors Lastschütz zur Blindstromkompensation Time delay relay Zeitrelais...
  • Page 153 Appendix Chillers & Heat Pumps FG/GL Series English German Summer/Winter (remote) Umschaltung Heizen/Kühlen Thermal Compr. Motorvollschutz Verdichter Two pumps Zwei Pumpen Unit Gerät Ventilation circuit Lüfter Kreislauf White Weiß Yellow Gelb 15.4.4 Terminology in legends and refrigeration circuit diagrams Acronym English German Suction line connection Anschluss Sauggasleitung...
  • Page 154 Appendix Chillers & Heat Pumps FG/GL Series Acronym English German Pilot valve Pilotventil Check valve/no return valve Rückschlagventil Sight glass Schauglas 15.4.5 Terminology in refrigeration circuit diagrams English German Chiller Betrieb Kaltwassererzeuger Discharge to refrigerant system Austritt Gerät zum externen Kältekreislauf Wasser Heat pump Betrieb Wärmepumpe...
  • Page 155 Appendix Chillers & Heat Pumps FG/GL Series Acronym English German 3-way valve 3-Wege-Ventil VA(H) Safety valve Sicherheitsventil Expansion tank Ausdehnungsgefäß VR(H) Check valve/No return valve Rückschlagventil 15.4.7 Terminology in hydraulic circuit diagrams English German Discharge to hydraulic system Wasseraustritt Gerät Legend Legende Only with 2 pumps...

  • Page 156: Log Book For Chiller, Heat Pumps And Compressor/Condenser Units

    Log Book for Chiller, Heat Pumps and Compressor/Condenser Units FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 157 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 158 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 159 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 160 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 161 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 162 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 163 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications...
  • Page 164 WWW.FLAKTGROUP.COM FG/GL-SERIES FläktGroup is the European market leader for smart and energy efficient Indoor Air and Critical Air solutions to support every application area. We offer our customers innovative technologies, high quality and outstanding performance supported by more than a century of accumulated industry experience. The widest product range in the market, and strong market presence in 65 countries worldwide, guarantee that we are always by your side, ready to deliver Excellence in Solutions.

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