Chiller GLWC-0152-1204BD2 - BA - 2008-01

Operation Manual
db^=`
Indoor installation - water-cooled - 43 to 370 kW GLWC 0152-0612 BD2 - GLWC 0604-1204 BD2
GLWC 0152-0612 BD2
Table of Contents
GLWC 0604-1204 BD2
Table of Contents 1 2 Product Type Code ..................................................................... 4 Overview of Units and Scope of Delivery ................................. 5
2.1 Unit overview ............................................................................................. 5 2.2 Scope of delivery ....................................................................................... 6 2.3 Accessories and special equipment ........................................................... 6
Safety and User Information ...................................................... 9

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 Availability of the operation manual ........................................................... 9 Scope of the operation manual .................................................................. 9 Used symbols ............................................................................................ 9 Labelling of safety information ................................................................. 10 Safety-conscious working ........................................................................ 11 Proper use ............................................................................................... 12 Modifications and changes ...................................................................... 12 Spare parts .............................................................................................. 12 Disposal ................................................................................................... 12 Personnel selection and qualifications ..................................................... 12
Technical Description ............................................................... 13

4.1 4.2 4.3 4.4 4.5 Unit description ........................................................................................ Functional description .............................................................................. Temperature control ................................................................................. Technical data .......................................................................................... Operating limits ........................................................................................ 13 17 17 20 24
Transport and Storage .............................................................. 25

5.1 Delivery .................................................................................................... 25 5.2 Transportation .......................................................................................... 25 5.3 Storage .................................................................................................... 26
Installation ................................................................................. 27
6.1 Installing the unit ...................................................................................... 27 6.2 Assembling the unit .................................................................................. 28
Medium Connections ................................................................ 29

7.1 7.2 7.3 7.4 7.5 Requirements ........................................................................................... Schematic representation of various hydraulic chilled water circuits ....... Schematic representation of various hydraulic heat rejection circuits ..... Function of a 3-way valve ........................................................................ Connecting chilled and cool water circuit ................................................. 29 31 32 34 35
Electrical Connection ............................................................... 36

8.1 8.2 8.3 8.4 Requirements ........................................................................................... Connecting supply voltage ....................................................................... Electrical integration ................................................................................. Connecting control contacts and controller .............................................. 36 37 38 40
Commissioning ......................................................................... 42
9.1 9.2 9.3 9.4 Requirements ........................................................................................... Checking and testing ............................................................................... Switching on the main isolator ................................................................. Calibration ................................................................................................ 42 42 43 44
PR-2008-0006-GB Subject to modifications Status 01/2008
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Table of Contents
10 Operation ................................................................................... 45
10.1 10.2 10.3 10.4 Overview of the controls ........................................................................... 45 Switching on and off ................................................................................. 45 Disconnecting the unit from the power supply .......................................... 49 What to do in case of alarm and error messages ..................................... 49
11 Care and Maintenance .............................................................. 50

11.1 Care and cleaning ..................................................................................... 50 11.2 Maintenance ............................................................................................. 50
12 Troubleshooting ........................................................................ 51
12.1 Alarms ....................................................................................................... 51 12.2 Alarm messages in overview .................................................................... 52
13 Dismantling and Disposal ........................................................ 54

13.1 Dismantling ............................................................................................... 54 13.2 Disposal .................................................................................................... 54
14 Appendix .................................................................................... 55
14.1 Technical Requirements for Function Testing or Chiller Maintenance ..... 56 14.2 GL Chiller Commissioning Form ............................................................... 57 14.3 GL Chiller Measuring Report .................................................................... 58
Copyright note Disclosing, copying, distributing or taking any action in reliance on the contents of this document is strictly prohibited without express prior consent. Violations entail liability for any damages or other liability arising. All rights in relation to patents, utility patents or design patents are reserved.
PR-2008-0006-GB Subject to modifications Status 01/2008 3
Product Type Code
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Product Type Code

G L W C 0 5 1 2 B D 2
Chiller
Operation mode
Capacity stage
GL W C 015, 018, 020, 025, 026, 030, 035, 041 045, 051, 055, 061, 060, 070, 080, 090, 100, 110, 120 2 4 B D 2
GEA Large Water cooled (indoor installation) Chiller 2 compressors 2 compressors 2 compressors 2 compressors 2 compressors 2 compressors 4 compressors 4 compressors 4 compressors 4 compressors Number of compressors: 2 Number of compressors: 4 Unit series B R 410A 400 V/3~/50 Hz (+PE)
Supply voltage
Condensing
GEA Chiller
Refrigerant
(example) GEA Chiller (water cooled) for indoor installation GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Number of compressors
Series
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Overview of Units and Scope of Delivery
2
2.1

Unit overview
Cooling capacity from 43 to 186 kW Cooling capacity from 174 to 370 kW
GLWC 0152-0612 BD2
GLWC 0604-1204 BD2
The units of this series have have a basically similar design, with however different dimesions. As an example a unit for each series is presented here. Dimensions and actual appearance of your unit can be found in the project-related documentation.
Fig. 2-1:
Overview of units with cooling capacity between 43 and 186 kW

3) Water inlet evaporator 4) Water outlet evaporator 5) Supply voltage 6) Main isolator
1) Water inlet condenser 2) Water outlet condenser
Fig. 2-2:
Overview of units with cooling capacity between 174 and 370 kW

3) Water inlet evaporator 4) Water outlet evaporator 5) Supply voltage 6) Main isolator
1) Water inlet condenser 2) Water outlet condenser
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
2.2
Scope of delivery
The following components are included in the scope of delivery: Units of series GLWC 0152-0612 BD2 or GLWC 0604-1204 BD2 (compare Product Type Code on page 4) further on refered to as GEA Chiller or shortly unit with an integrated microprocessor Operation manual including all information on the supplied unit. Wiring diagrams and dimensional drawings Possible accessories and special equipment (only if ordered)
2.3
Accessories and special equipment

Accessories for controls Operation status message from compressor (.E03) Connection to the building management system with the following protocols using the serial card: RS 485 (Modbus Siemens, Johnson Controls, Honeywell) (.E14) LONWORKS (.E15) BacNet (.E17) Trend (Serial card by others)
Fig. 3:
Serial card for connection to building management system or for master/slave control
Fig. 4:
Remote control
Second control connection for remote monitoring. Up to 10 units of the W 3000 controller family can be connected to only one additional remote control. Remote control for up to 200 meters distance (.E19) Remote control for between 200 and 500 meters distance (.E20) 2nd setpoint via normally open contact by others (.E22 only for 0604-1204) Load shedding contact (.E29 for 0152-0612 or E23 for 0604-1204) Setpoint adjustment via 4-20 mA (.E29 for 0152-0612; with 0604-1204 standard) Upsteam master/slave control. Up to a maximum 5 units of the W3000 controller family can be used in a hydraulic circuit and connected to a sequencer. The sequencer is supplied in a separate switch cabinet with two temperature sensors, that must be installed in a commonn water inlet and outlet. Depending on the water inlet temperature individual capacity stages or units are switched on or off. Each chiller requires a serial card of type RS485 (.E14) for the communication with the sequencer as well as separate chilled water pump, that is also controlled by the chiller. Sequencer (.E18) Sequencer with integration to a BMS via RS485 protocol (.E24) Sequencer with integration to a BMS via LONWORKS protocol (.E25) Sequencer with integration to a BMS via BACnet protocol (.E27) Unit information can be called up via the Internet and LAN
Fig. 5:
Sequencer
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Electrical accessories
Soft start for compressor drive motors* (.E06)

*Each compressor motor is operated via a soft start. Soft start reduces the starting current of each compressor to 60%. Example of maximum starting current for unit size 0412: 1. Maximum current consumption of a compressor that is already in operation (36.1 A) 2. starting current of compressor, that is additionally switched (225 A * 0,6 = 135 A - factor 0,6 because of soft start) 3. Sum of results from step 1 and 2 (36,1 A + 135 A = 171,1 A)
Refrigeration circuit accessories Accessories installation
Solenoid valve on liquid line (.R01 only series 0604-1204) Shut-off valve on common compressor discharge side (.R02) Shut-off valve on common compressor suction side (.R10) Rubber anti-vibration mounts for unit installation (.I02) Flow switch with paddle for installation in hydraulic circuit at unit outlet (supplied loose) (.I10) Water filter for installation in hydraulic circuit at unit outlet of evaporator (.I12) and the unit inlet of condenser (.I30) (supplied loose). Before the direct inlet into the heat exchanger (evaporator and condenser) a water filter must be installed, that protects the heat exchanger from dirt and sediments. The water filter of Y-type has a mesh width of 0,9 mm. The filter body can be trouble-free removed and cleaned for maintenance purposes without dismantling the valve body.
Fig. 6:
Water filter
Compressor sound insulation (-4 dB(A) sound power level) (.I17) (only 0152-0612) Additional sound insulating casing compressor room (.I44) (only 0604-1204) Reduction of sound power level for series 0604-1204 with option .I44:
GLWC
without option .I44 with option .I44
0604
86 dB(A) 76 dB(A)
0704
87 dB(A) 77 dB(A)
0804
88 dB(A) 78 dB(A)
0904
89 dB(A) 79 dB(A)
1004
90 dB(A) 80 dB(A)
1104
91 dB(A) 81 dB(A)
1204
91 dB(A) 81 dB(A)
Fig. -3: Reduction of sound power level
3-way valve for cool water temperature control (supplied loose) (.I31) Water connections from above (.I32) (only 0152-0612 with GLPE and/or GLPC)
Fig. 7:
Groove lock coupling
Groove lock coupling with counter piece with thread with and without GLPE/GLPC (.I33) (only 0152-0612) Groove lock coupling with counter piece with thread without GLPE/GLPC and water collector (.I34) (only 0604-1204) Groove lock coupling with counter piece with thread with GLPE and without water collector (.I35) (only 0604-1204) Groove lock coupling with counter piece with thread with GLPC and without water collector (.I36) (only 0604-1204) Groove lock coupling with counter piece with thread each with a pump for GLPE and GLPC and without water collector (.I37) (only 0604-1204) Groove lock coupling with counter piece with thread with a total 3 or 4 pumps for GLPE and GLPC and without water collector (.I38) (only 0604-1204)
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Fig. 8:
Water collector for connection
Unit accessories
Packaging accessories
Water collector for evaporator and condenser side without GLPE and GLPC (.I39) (only 0604-1204) Water collector for evaporator and condenser side with GLPE (.I40) (only 0604-1204) Water collector for evaporator and condenser side with GLPC (.I41) (only 0604-1204) Water collector for evaporator and condenser side each with pump for GLPE and GLPC (.I42) (only 0604-1204) Water collector for evaporator and condenser side each with a total 3 or 4 pumps for GLPE and GLPC (.I43) (only 0604-1204) Pump group for evaporator (GLPE) and/or condenser (GLPC) with a pump, safety valve, expansion tank, pressure gauge, filling, drain and air vent valve. Following versions are available: 1 pump with standard head 2 pumps with standard head and non-return valve 1 pump with high head 2 pumps with high head and non-return valve Nylon film for unit weather-proof protection. The unit is additionally supplied in an open wooden crate (.O01).
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Safety and User Information

GEA Chiller of series GLWC 0152-0612 BD2 or GLWC 0604-1204 BD2 are manufactured in accordance with the state-of-the-art technological standards and established technical safety codes and regulations. Only use the GEA Chiller when it is in a technically sound condition for the intended purpose observing current operation manual, taking safety aspects and potential hazards into account. Otherwise there may be risk to life and limb of users or third parties or impaired performance of the chiller itself, connected units or other equipment. Have all malfunctions rectified by an expert without delay. DAMAGE TO THE UNIT. The manual error and fault messages may not be reset without GEAs permission or that of an authorized customer service office. Non-compliance with the above-mentioned condition invalidates the warranty.
3.1
Availability of the operation manual

This operation manual contains important information regarding safe and correct operation of the GEA unit. This manual must always be available at the location where unit is installed. Every person working with or around the unit must read and use this manual. The operation manual is intended for operators, in-house technicians, technical personnel or instructed persons as well as electricians and refrigeration engineers.
3.2
Scope of the operation manual

This operation manual provides you with information about the following: Assembly/disassembly Installation Commissioning Operation Maintenance and troubleshooting
3.3
Used symbols
The following symbols are used to highlight particular text sections in this operation manual: This symbol indicates a normal list. This symbol indicates instructions to follow. This symbol denotes the result of an action. NOTE! Here you will find additional details on using the GEA unit.
RECYCLING! This symbol is used to highlight information on proper reuse of packaging material and disused components (separated according to recyclable materials).
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
WEAR PROTECTIVE SHOES. This symbol points out that protective shoes must be worn. WEAR GLOVES. This symbol points out that gloves must be worn.
3.4
Labelling of safety information

PERSONAL INJURY! Here you will find special information as well as rules and restrictions for preventing personal injury. ELECTRICAL HAZARD! This symbol indicates that there is a risk of electric shock.
HOT SURFACE DANGER! Here you can find special information as well as rules and restrictions for the prevention of personal injuries due to hot surfaces. DANGER SHARP CUTTING EDGES! Here you will find special information as well as rules and restrictions for the prevention of personal injuries due to cutting on thin metal fins. HIGH PRESSURE HAZARD! Here you can find special information as well as rules and restrictions for the prevention of personal injuries due to high pressure. DANGER DUE TO LOW TEMPERATURES! Here you can find special information, rules and restrictions regarding the prevention of personal injuries due to escaping liquid refrigerants. DANGER DUE TO OVERHEAD LOADS. This symbol warns you about personal injury and damage caused by overhead loads. ENVIRONMENTAL DAMAGE. This symbol warns you about damage to the environment and turns your attention you to all existing national environmental protection regulations. DANGER DUE TO TOXIC SUBSTANCES. This symbol warns you about dangers due to toxic substances.
DAMAGE TO THE UNIT! Here you will find special information, rules and restrictions regarding the prevention of damage to the GEA unit.
10
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
3.5
Safety-conscious working
When working on 400 V/50 Hz power supplies: ELECTRICAL HAZARD! Power down the unit, secure it against being powered up and make sure it is isolated, earth and short circuit the GEA Chiller, cover or shield off neighbouring live components. Failure to do so may lead to serious injuries or death. When carrying out any kind of work in general: PERSONAL INJURY! Ethylene glycols are harmful for humans and animals if swallowed. Consult a doctor immediately if swallowed by mistake. DANGER OF HIGH PRESSURE AND LOW TEMPERATURES. When working on hydraulic or refrigeration circuits or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. Exercise due caution and attention when carrying out this work.
DANGER DUE TO TOXIC SUBSTANCES. High concentrations of refrigerants in the air may have an anaesthetic effect and cause unconsciousness. Extended exposure may cause irregular heartbeat and sudden death. Very high concentrations of refrigerant may cause suffocation by reducing the oxygen content in the surrounding air. You should therefore only work in an adequately ventilated environment, and exercise due care and attention when carrying out the work. ENVIRONMENTAL DAMAGE. Do not pollute the environment with liquid products, refrigerants or oils. Dispose of them in accordance with local laws and regulations by avoiding harm to the environment. Ethylene glycol and propylene glycol are in Water Hazard Class 1 (slightly water endangering) of the catalogue of water-endangering substances. This also applies to mixtures with water.
Please comply with the installation and transport instructions for the GEA Chiller. Observe the commissioning requirements. Always make sure that the GEA Chiller is accessible only to authorized, trained,
technical personnel. If necessary, use appropriate equipment to keep unauthorized persons away from the unit. Do not keep any inflammable liquids in close proximity to the GEA Chiller.
11
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
3.6
Proper use
Units of series GLWC 0152-0612 BD2 or GLWC 0604-1204 BD2 are water cooled GEA Chillers for indoor installation and are used only to produce chilled water for air treatment units in comfort air conditioning or to provide chilled water for process cooling in enclosed circuits. Proper use also includes observance of the operation manual and compliance with the inspection and maintenance conditions stipulated by GEA. Improper use Any use other than that described above is considered improper. The manufacturer/ supplier is not liable for any damage arising from improper use. The user alone bears the risk. PERSONAL INJURY AND DAMAGE TO THE UNIT. The GEA Chiller may not be operated: in areas where there is a risk of explosion, in environments where there are strong electromagnetic fields, in environments with high levels of air contamination, in environments where there is corrosive and/or aggressive air,
3.7
Modifications and changes

You may not change, add to or modify the GEA Chiller in any way. Any changes or modifications of GEA Chiller will invalidate the CE conformity and render and all warranty claims as null and void.
3.8
Spare parts
You may use only original GEA Air Treatment spare parts, since GEA Air Treatment is not liable if third-party spare parts are used.
3.9
Disposal
Make sure that operating and auxiliary materials and components are disposed of properly and in an environmentally friendly manner See Disposal on page 54.
3.10 Personnel selection and qualifications

Every person working on the GEA Chiller must read and understand this operation manual fully. It is too late to do this during work on the unit. The electrical and chilled water connections may only be established by qualified staff who, based on their technical training and experience, have sufficient knowledge in the following subjects: Safety and occupational health regulations Accident prevention regulations Guidelines and recognized codes and rules of engineering. Work on refrigeration systems must only be carried out by specialist personnel with appropriate training in refrigeration equipment and possibly also proof of competence according to relevant legislation in the handling of operating materials/refrigerants. All skilled persons must be able to assess the work entrusted to them and be able to recognize and avoid possible risks.
12
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Technical Description
4
4.1
Unit description
These GEA Chillers are water-cooled units, designed for indoor installation and equipped with plate heat exchangers. In the factory they are filled with refrigerator oil and refrigerant and a test run is performed, so that when they are installed on site only water and electrical connections have to be established. A functional test must also be carried out. The chillers of series GLWC 0152-0612 BD2 and GLWC 0604-1204 BD2 can also be optionally supplied with pump module GLPE for chilled water side as well as with a pump module GLPC for the cool water side. This GEA Chiller series is designed only to be used with the environmentally friendly refrigerant R410A.
4.1.1 Components Chiller with high EER This new unit generation has a high energy efficiency ratio (EER) and uses the refrigerant R410A. An optimum result was achieved by carefully designing all internal com-nents so as to fully exploit the performance characteristics of the specific refrigerant. Particular attention was paid to the surfaces of the heat exchangers and the compressors.The newly designed condensers have larger exchange surface areas, as do the new evaporators, which enable even better and more efficient distribution of the refrigerant in a liquid and gaseous state. The intelligent control of the evaporator water outlet temperature reduces fluctuations in relation to the specified setpoint and vastly reduces the time the system needs until it is ready for operation. The precision and rapid reaction of the intelligent control system facilitate optimum control in the event of load fluctuations which means that stable operating conditions can be achieved very quickly, even during partial load operation. A carefully dimensioned system implemented in these units produces considerable energy savings and vastly reduces operating costs. State-of-the-art system The GLWC unit series are water cooling systems that are particularly suitable for small and medium-sized air conditioning systems, or for systems designed for low water system content. The main difference when compared to conventional units is the intelligent controller system. All units can be optionally equipped with integrated hydraulic components.
13
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Basic construction Units GLWC 0152-0612 BD2 GLWC 0604-1204 BD2 The frames and panels are made of galvanized, plastic-coated sheet steel (RAL 9002). The self-supporting construction offers excellent access to the individual components during maintenance and repair work.
Compressor Fully hermetic, low-vibration and suction-refrigerant cooled Copeland scroll compressor complete with oil heating for safe compressor start-up, electronic overheating protection with manual reset and a two-pole electric motor. These Copeland scroll compressors are also highly economical to run and have a sound power level that is some 6 dB(A) lower than piston compressors. The sizes 0152-0612 have two compressors in each refrigeration circuit. The sizes 0604-1204 consist of 4 compressors, with two copmressors integrated in each of two refrigeration circuits.
Fig. 4-1: Scroll compressor
Evaporator The evaporators and condensers used in this unit series are plate heat exchangers made of AISI 316. The advantages of plate heat exchangers are their very compact construction combined with high performance. The channel plates consist of stamped stainless steel plates that are closely connected using a special soldering technique. This means that a high-turbulence flow occurs on both the primary and secondary sides, and therefore also an extremely efficient exchange of heat between the refrigerant and the heat transfer medium. This construction also means that the required amount of refrigerant can be reduced to a minimum. The evaporator is non-permeable and is provided with comprehensive abrasion-resistant insulation. During operation the evaporator is protected by a differential pressure switch installed between the chilled water inlet and outlet. The unit can also be operated with glycol as standard with outlet temperatures of up to -8C.
Fig. 4-2:
Plate heat exchanger
14
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Refrigeration circuit size 0152-0612
Acronym
C CD EV FE MA MB Pmin Pmax PP
Description
Scroll compressor Condenser Evaporator Filter drier High-pressure gauge (optional) Low-pressure gauge (optional) Low-pressure pressostat High-pressure pressostat Service Schrader valve
Acronym
RA RL RM T VA VB VEH VS
Description
Shut-off valve suction side (optional) Shut-off valve on liquid line (only 0452-0612) Shut-off on discharge side (optional) Pressure sensor (only with 3-way valve) High-pressure safety valve Low-pressure safety valve Thermostatic expansion valve Sight glass with humidity indicator
Fig. 4-3:
Refrigeration circuit scheme size 0152-0612
Refrigeration circuit size 0604-1204
Acronym
C CD ES EV FE Pmin Pmax PP RA
Description
Scroll compressor Condenser Solenoid valve (optional) Evaporator Filter drier Low-pressure pressostat High-pressure pressostat Service Schrader valve Shut-off valve suction side (optional)
Acronym
RL RM S1 S2 VA VB VEH VS T
Description
Shut-off valve on liquid line (only 0804-1204) Shut-off on discharge side (optional) Temperature sensor water inlet Temperature sensor water outlet High-pressure safety valve Low-pressure safety valve Thermostatic expansion valve Sight glass with humidity indicator Pressure sensor (only with 3-way valve)
Fig. 4-4:
Refrigeration circuit scheme size 0604-1204
Note: Chillers of series GLWC 0604-1204 BD2 consist of two identical refrigeration circuits.
15
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Switch cabinet Switch cabinet is divided into power and control module and manufactured according to EN 60204-1/IEC204-1 regulations, complete with: Transformer for generating the control voltage Door locking main isolator Motor protection switch and contactors for compressor and fans Terminal strip control voltage Switch cabinet in a separate casing within the unit sealed and designed for outdoor installation. Phase sequence protection for the compressor Remote On/Off contact Pump relay Numbered cable (only GLWC 0152-0612 BD2) Contact for general error message. Electronic control system The electronic control system which uses a compact W3000 microprocessor has the following characteristics: Plain text alphanumerical LCD display Remote ON/OFF via potential-free NO contact by others Collective error message as a potential-free contact Automatic self-diagnostics of electronics Display of all analogue recorded temperature and pressure values Display of faults in compressors and refrigeration circuits Display of general unit faults Optional control of chilled water inlet or outlet temperature Safety times for compressor, like for example: Compressor cycle protection, minimum run time of compressors or maximum start-ups per hour (depending on type of the control system) Operating hours counter for compressor and chilled water pump Automatic operating hours compensation for compressor Notification about maintenance intervals of compressors and pumps (can be adjusted) Potential-free contact for chilled water pump by others Pump lead and overrun times for switching unit on and off safely Setpoint shift via 4-20 mA signal (only GLWC 0604-1204 BD2) Service possible via PC and system software
Fig. 4-5:
Control display
16
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
4.2
Functional description
Refrigeration circuit The refrigeration system generates a refrigeration output in a thermodynamic cycle by means of heat removal, this is used to cool a water circuit (indirect cooling).
2 3
5 1 6
Fig. 4-6:
Refrigeration circuit
The compressor (1), condenser (2), expansion valve (3) and evaporator (5) are linked together in a closed thermodynamic system. A refrigerant circulates in this system. The electrically driven compressor (1) draws in overheated gaseous refrigerant and compresses it to a high pressure-temperature level. The gaseous overheated refrigerant is cooled and liquefied by releasing its thermal energy in the water-cooled (4) condenser (2). Liquid refrigerant under high pressure is now in front of the expansion valve (3).Taking into account the pressure and the temperature at the evaporator outlet (5) the expansion valve sprays (3) liquid refrigerant into the evaporator (5). The liquid refrigerant vaporises completely in the evaporator (5) and absorbs the heat. The necessary thermal energy needed for this is taken from the chilled water circuit (6) which in turn is cooled.
4.3
Temperature control
The W3000 microprocessor controller is able to control temperature in two ways: Temperature control via chilled water inlet temperature Temperature control via the chilled water outlet temperature P-I control with neutral zone via water outlet or water inlet
17
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
4.3.1 Proportional control via the evaporator water inlet temperature (2 speeds (size 0152-0612)) Capacity
[%]
100
In the following example it is assumed that the temperature difference across the evaporator amounts to 5 K at 100 % cooling capacity of the unit and that the water content of the unit is sufficient. The setpoint is adjusted to 9,5 C (standard value with inlet temperature control) and proportional range of 2,5 K (also standard value). Thanks to its two compressors the unit has two capacity stages. The proportional band is distributed among these two capacity stages in appropriately equal ranges. This results in the following:
[C]
50
Water inlet
9,5 10,75 12
Setpoint
Proportional band 2.5 K
2,5 K / 2 capacity stages = 1,25 K / capacity stage
Fig. 4-7:
If the water inlet temperature amounts to 12,0 C or more, all compressors will be running (setpoint 9,5 C + proportional band 2,5 K = 12,0 C). If the water temperature entering the evaporator makes up 12,0 C, the outlet temperature will amount to 7 C (12,0 C water inlet temperature - 5 K temperature difference across the evaporator at 100 % = 7,0 C). At 10,75C the water outlet temperature will only reach 5,75 C. At 10,75 C one of the compressors switches off, and the cooling capacity is 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. With water inlet temperature of 9,5 C and water outlet temperature of 7 C at water outlet the last compressor switches off. At 10,75 C (setpoint 9,5 C + proportional band /2 1,25 K = 10,75 C) one compressor is activated again. With this kind of temperature control and assuming continuous operation, the water outlet temperature will fluctuate between 5,75 C and 8,25 C.
4.3.2 Proportional control via chilled water inlet temperature (4 speeds - sizes 0604-1204)
Capacity
In the following example it is assumed that the temperature difference across the evaporator amounts to 5 K at 100 % cooling capacity of the unit and that the water content of the unit is sufficient. The setpoint is adjusted to 7,0 C (standard value with inlet temperature control) and proportional range of 5,0 K (also standard value). Thanks to its four compressors in two independent refrigeration circuits the unit has two capacity stages. The proportional band is distributed among these four capacity stages in appropriately equal ranges. This results in the following: 5,0 K / 4 capacity stages = 1,25 K / capacity stage
Water inlet
Setpoint Setpoint
Proportional band 5 K
Fig. 4-8:
If the water inlet temperature amounts to 12,0 C or more, all compressors will be running (setpoint 7,0 C + proportional band 5,0 K = 12,0 C). If the water temperature entering the evaporator makes up 12,0 C, the outlet temperature will amount to 7 C (12,0 C water inlet temperature - 5 K temperature difference across the evaporator at
18 PR-2008-0006-GB Subject to modifications Status 01/2008
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
100 % = 7,0 C). At 10,75C the water outlet temperature will only reach 5,75 C. At 10,75 C one of the compressors switches off, and the cooling capacity is reduced to 75 %. Therefore the temperature difference across the evaporator goes down as well by 25 % to 3,75 K. As a result, the water outlet temperature rises at water inlet temperature of 10,75 C from 5,75 C with four active compressors to 7,0 C with only three active compressors. With water inlet temperature of 7,0 C the evaporators water outlet temperature amounts to 5,75 C with one active compressor corresponding to 25% total capacity. At 7,0 C the last compressor switches off. At 8,25 C (setpoint 7,0 C + proportional band /4 1,25 K = 8,25 C) one compressor is activated again. With this kind of temperature control and assuming continuous operation, the water outlet temperature will fluctuate between 5,75 C and 7,0 C.
4.3.3 Graduated control with neutral range via evaporator water inlet or outlet (all sizes) Capacity reduced
Setpoint cooling
Capacity increased
Capacity
Neutral zone
Capacity Temperature
With this type of control system the chilled water inlet or outlet temperature is used as the control variable. In this case only the setpoint is specified, and the controller automatically determines all other switching thresholds in dynamic mode during operation. With this self-adjusting algorithm for temperature control of the chiller the setpoint stays within a neutral range. If the evaporator water temperature is within the neutral range, the number of active compressors and/or capacity stages is not changed. If load fluctuations in the system lead to temperature values outside the neutral range, compressors and capacity stages are activated or deactivated to return the temperature to the neutral range.
Variable zone
Fig. 4-9:
If this is not possible due to the output, another capacity stage is activated or deactivated. The width of the neutral range depends on the dynamic properties of the system, especially the system content and the decreased load. The self-adjusting algorithm is able to determine the dynamics of the system. The neutral range is calculated so that the compressor switching times and the max. permissible start-up frequency (e.g. 8 times per hour) only cause very small temperature deviations from the setpoint. Other implemented functions reduce the compressors start-up frequency at low loads. Capacity stages are activated and deactivated not only as a result of wide setpoint variances, but also in relation to the temperature change-over time, which allows conclusions to be drawn about the output.
19
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
4.4
Technical data
4.4.1 Unit types 0152-0612

Unit type
Refrigeration capacity
1)
0152
Qe P Qc Ve pe Vc pc

0182
50.1 11.3 60.7 8.62 49.39 10.52 37.52 6.10 5.98
0202
58.9 13.0 71.2 10.15 49.53 12.33 41.97 6.13 6.01
0252
66.4 15.2 80.7 11.43 47.04 13.97 44.13 5.80 5.69
0262
72.6 16.6 88.2 12.49 56.20 15.28 52.76 5.70 5.59
0302
86.7 19.5 105.0 14.92 34.28 18.19 36.71 5.78 5.66
0352
101.2 22.7 122.5 17.43 32.80 21.22 36.04 5.91 5.80
0412
114.7 25.9 139.0 19.74 42.10 24.08 35.96 5.83 5.71
0452
128.6 28.9 155.8 22.14 39.72 26.99 36.43 5.91 5.79
0512
143.5 32.2 173.8 24.71 38.46 30.10 33.52 5.90 5.78
0552
164.9 36.9 199.6 28.39 34.65 34.57 35.85 6.05 5.93
0612
186.3 41.6 225.4 32.07 44.22 39.04 38.10 5.92 5.80
[kW]
43.4 10.0 52.8 7.46 57.78 9.14 35.90 5.93 5.81
Total unit power consumption Condenser capacity Chilled water volume flow Pressure drop (chilled water) Cool water volume flow Pressure drop (cool water side) IPLV ESEER Controls
[kW]
[kW] [m/h] [kPa] [m/h] [kPa]
W3000 compact
Compressor
Number of compressors Number of refrigeration circuits Capacity stages per unit Compressor type 1 Compressor type 2 Oil type Oil heating Coil resistance per coil/ compressor
[W] [] n n n
Fully hermetic Copeland scroll compressor

2 1 2 2 1 2 2 1 2 2 1 2 2 1 2 2 1 2 2 1 2 2 1 2 2 1 2 2 1 2 2 1 2 2 1 2
ZP 90 ZP 103 ZP 120 ZP 137 ZP154 ZP 180 ZP 180 ZP 235 ZP 235 ZP 295 ZP 295 ZP 385 ZP 90 ZP 103 ZP 120 ZP 137 ZP154 ZP 180 ZP 235 ZP 235 ZP 295 ZP 295 ZP 385 ZP 385 Arctic EAL 22 CC 2 x 90 2 x 90 2 x 90 2 x 90 2 x 90 2 x 70 70/120 2 x 120 120/150 2 x 150 2 x 150 2 x 150 1.61 1.37 1.24 1.24 0.70 0.70 0.70/ 0.63 0.63 0.63/ 0.51 0.51 0.51/ 0.35 0.35
Evaporator
Min. chilled water volume flow
Ve,min

Soldered stainless steel plate heat exchanger

[m/h]
4.6 12.6 10 1" 1"
5.3 14.4 10 1" 1"
6.2 16.9 10 1" 1"
7.0 19.1 10 1" 1"
7.7 20.9 10 1" 1"
9.2 24.9 10 2" 2"
10.8 29.1 10 2" 2"
12.2 32.9 10 2" 2"
13.7 36.9 10 2" 2"
15.3 41.3 10 2" 2"
17.7 47.4 10 2" 2"
20.0 53.6 10 2" 2"
Maximum chilled water flow rate Ve,max [m/h] Maximum chilled water related operating pressure* Evaporator inlet connection Evaporator outlet connection
G** G** [bar] [''] ['']
Condenser
Min. cool water volume flow Max. cool water volume flow Maximum chilled water related operating pressure* Evaporator inlet connection Evaporator outlet connection
G** G** Vc,min


[m/h]
2.7 11.5 10 1" 1"
3.2 13.2 10 1" 1"
3.7 15.5 10 1" 1"
4.3 17.6 10 1" 1"
4.7 19.2 10 1" 1"
5.6 22.9 10 2" 2"
6.5 26.6 10 2" 2"
7.4 30.2 10 2" 2"
8.3 33.9 10 2" 2"
9.3 37.7 10 2" 2"
10.7 43.4 10 2" 2"
12.1 48.9 10 2" 2"
Vc,max [m/h] [bar] [''] ['']
Filling quantities
Refrigerant R410A Oil Chilled water minimum system content
[kg] [kg] [l]
4 5 200
5 7 250
6 7 300
6 7 350
6 7 400
9 8 450
10 9 500
10 9 600
12 12 650
13 14 700
15 13 800
16 13 950
Weight
Transport weight
[kg]
280
295
300
310
315
565
605
635
675
715
765
795
Sound values
Sound power level 2) Sound pressure level3
[dB(A)] [dB(A)]
73 44
74 45
74 45
74 45
75 46
76 47
77 48
77 48
78 49
78 49
79 50
79 50
* only if no pump module GLPE/GLPC was supplied, with pump module GLPE/GLPC: 3 bar ** G: Gloove lock (Victaulic) coupling connection: The Victaulic coupling can be optionally ordered with a counter piece. 1 Performance data for input parameters: chilled water temperatures (inlet/outlet) 12/7 C; cool water temperatures (inlet/outlet) 30/35 C; values partially rounded off 2 Sound power level in accordance with Eurovent ISO 3744 (Also see Sound data at full load) 3 In 10 meters (Also see "Sound data at full load)
Tab. 4-1
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Unit type Compressor

Max. power consumption Max. current consumption Starting current of each compressor
[kW] [A] [A]
0152
0182
0202
0252
0262
0302
0352
0412
0452
0512
0552
0612
2x9 2x15.3 2x95
2x10.1 2x16.4 2x111
2x11.8 2x20.4 2x118
2x13.2 2x22.6 2x118
2x14.4 2x25.5 2x140
2x16.9 2x27.9 2x198
1x27,4+ 1x22,3+ 1x16,9+ 2x35.8 2x27.4 2x22.3 1x35,8 1x27,4 1x22,3 1x27,9+ 1x36,1+ 1x45,8+ 1x36,1 2x36.1 1x45,8 2x45.8 1x58,9 2x58.9 1x198+ 1x225 2x225 1x225+ 1x272 2x272 1x272+ 1x310 2x310
Insgesamt 1,2)
Max. power consumption Max. current consumption Starting current of entire unit
[kW] [A] [A]
18.0 30.6 110
20.2 32.8 127
23.6 40.8 138
26.4 45.2 141
28.8 51.0 166
33.8 55.8 226
39.2 64.0 253
44.6 72.2 261
49.7 81.9 308
54.8 91.6 318
63.2 104.7 356
71.6 117.8 369
Maximum connectable cable cross-sections 1,2)

Round Rectangular
[mm] [mm]
50 -
50 -
50 -
50 -
50 2)
50 16x3
50 16x3
50 16x3
50 16x3
50 16x3
120 20x5
120 20x5
Maximum permissible backup fuse ratings (fuse type gLgG)

Back up fuse
[A]
63
63
80
80
80
100
100
100
125
125
160
160
Dimensions
A 3) (length) A 4) (length) B (width) H (height)
[mm] [mm] [mm] [mm]
1055 1706 649 1255
1055 1706 649 1255
1055 1706 649 1255
1055 1706 649 1255
1055 1706 649 1255
1222 2000 873 1496
1222 2000 873 1496
1222 2000 873 1496
1222 2000 873 1496
1222 2000 873 1496
1222 2000 873 1496
1222 2000 873 1496
Clearances
R1 R2 R3
[mm] [mm] [mm]
600 600 800
600 600 800
600 600 800
600 600 800
600 600 800
600 600 800
600 600 800
600 600 800
600 600 800
600 600 800
600 600 800
600 600 800
Tab. 4-2
Fig. 4-10: Clearances

1 Please observe the applicable regional safety regulations and constructional conditions relevant to the dimensioning of the supply line. 2 Please observe the applicable regional standards for cable cross sections and backup fuses.Voltage tolerance: max. 10%, voltage deviation between phases: max. 3%. 3 Unit without pump module GLPE and/or GLPC 4 Unit with pump module GLPE and/or GLPC
NOTE!
For detailed planning please only use the documentation enclosed with the unit. Detailed dimensional drawings can be obtained on request from your relevant GEA sales office. Specifications and technical data are subject to regular updates. The manufacturer reserves the right to make any changes to infor-mation without prior written notice.
21
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
4.4.2 Unit types 0604-1204

Unit type
Refrigeration capacity 1) Total unit power consumption Condenser capacity Chilled water volume flow Pressure drop (chilled water) Cool water volume flow Pressure drop (cool water side) IPLV ESEER Controls
Qe P Qc Ve pe Vc pc

0604
[kW]
0704
202.7 45.2 245.2 34.9 32.9 42.5 36.1 6.04 5.92
0804
228.0 51.6 276.4 39.2 41.6 47.9 35.5 5.94 5.82
0904
257.9 58.0 312.4 44.4 39.4 54.1 36.6 6.04 5.93 W3000 compact
1004
288.1 64.0 348.3 49.6 39.4 60.3 33.7 6.05 5.93
1104
328.5 74.0 398.0 56.6 35.2 68.9 35.6 6.11 5.99
1204
371.1 83.5 449.7 63.9 44.9 77.9 37.9 6.00 5.89
173.9 38.9 210.5 29.9 35.0 36.5 37.0 5.90 5.79
[kW]
[kW] [m/h] [kPa] [m/h] [kPa]
Compressor
Number of compressors Number of refrigeration circuits Capacity stages per unit Compressor type 1 Compressor type 2 Compressor type 3 Compressor type 4 Oil type Oil heating Coil resistance per coil/ compressor
[W] [] n n n
Fully hermetic Copeland scroll compressor

4 2 4 4 2 4 4 2 4 4 2 4 4 2 4 4 2 4 4 2 4
ZP 180 KCE ZP 180 KCE ZP 235 KCE ZP 235 KCE ZP 295 KCE ZP 295 KCE ZP 385 KCE ZP 180 KCE ZP 235 KCE ZP 235 KCE ZP 295 KCE ZP 295 KCE ZP 385 KCE ZP 385 KCE ZP 180 KCE ZP 180 KCE ZP 235 KCE ZP 235 KCE ZP 295 KCE ZP 295 KCE ZP 385 KCE ZP 180 KCE ZP 235 KCE ZP 235 KCE ZP 295 KCE ZP 295 KCE ZP 385 KCE ZP 385 KCE Arctic EAL 22 CC 4 x 70 4 x 0,70 2 x 70/2x120 2x0.7/2x0.63 4 x 120 4 x 0.63 2x120/2x150 2x0.63/ 2x0.51 4 x 150 4 x 0,51 4 x 150 2x0.51/ 2x0.35 4 x 150 4 x 0.35
Evaporator
Min. chilled water volume flow
Ve,min


[m/h]
18.6 49.9 10 2" 2"
21.7 58.3 10 2" 2"
24.4 65.4 10 2" 2"
27.7 74.1 10 2" 2"
30.9 82.8 10 2" 2"
35.3 94.4 10 2" 2"
39.8 106.6 10 2" 2"
Maximum chilled water flow rate Ve,max [m/h] Maximum chilled water related operating pressure* Evaporator inlet connection Evaporator outlet connection
G** G** [bar] [''] ['']
Condenser
Min. cool water volume flow Max. cool water volume flow
Vc,min


[m/h]
11.3 45.7 10 2" 2"
13.2 53.2 10 2" 2"
14.9 60.0 10 2" 2"
16.8 67.7 10 2" 2"
18.7 75.5 10 2" 2"
21.4 86.2 10 2" 2"
24.2 97.5 10 2" 2"
Vc,max [m/h] [bar] [''] ['']
Maximum chilled water related operating pressure* Evaporator inlet connection Evaporator outlet connection
G** G**
Filling quantities
Refrigerant R410A Oil Chilled water minimum system content
[kg] [kg] [l]
17 17 850
19 18 1000
20 19 1150
24 23 1250
26 27 1450
30 26 1650
32 25 1860
Weight
Transport weight
kg
1055
1130
1190
1270
1355
1450
1510
Sound values
Sound power level 2) Sound pressure level
3
[dB(A)] [dB(A)]
86 57
87 58
88 59
89 60
90 61
91 62
91 62
* only if no pump module GLPE/GLPC was supplied, with pump module GLPE/GLPC: 3 bar ** G: Gloove lock (Victaulic) coupling connection: The Victaulic coupling can be optionally ordered with a counter piece. 1 Performance data for input parameters: chilled water temperatures (inlet/outlet) 12/7 C; cool water temperatures (inlet/outlet) 30/35 C; values partially rounded off 2 Sound power level in accordance with Eurovent ISO 3744 (Also see Sound data at full load) 3 In 10 meters (Also see "Sound data at full load)
Tab. 4-3
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Unit type Compressor

Max. power consumption Max. current consumption Starting current of each compressor
[kW] [A] [A]
0604
0704
0804
0904
1004
1104
1204
4x16.9 4x27.9 4x198
2x16,9+ 2x22,3 2x27,9+ 2x36,1 2x198+2x225
4x22.3 4x36.1 4x225
2x22,3+ 2x27,4 2x36,1+ 2x45,8 2x225+2x272
4x27.4 4x45.8 4x272
2x27,4+ 2x35,8 2x45,8+ 2x58,9 2x272+2x310
4x35.8 4x58.9 4x310
Insgesamt 1,2)
Max. power consumption Max. current consumption Starting current of entire unit
[kW] [A] [A]
68 111.6 282
78 128.0 317
89 144.4 333
99 163.8 390
110 183.2 409
126 209.4 461
143 235.6 487
Maximum connectable cable cross-sections 1,2)

Round Rectangular
[mm] [mm]
120 20x5
120 20x5
120 20x5
2)
120 20x5
120 20x5
240 2x25x5
240 2x25x5
Maximum permissible backup fuse ratings (fuse type gLgG)

Back up fuse
[A]
160
200
200
250
250
315
315
Dimensions
A 3) (length) A 4) (length) B (width) H (height)
[mm] [mm] [mm] [mm]
2227 2962 877 1780
2227 2962 877 1780
2227 2962 877 1780
2227 2962 877 1780
2227 2962 877 1780
2227 2962 877 1780
2227 2962 877 1780
Clearances
R1 R2 R3 R4
[mm] [mm] [mm] [mm]
1000 1000 1000 1000
1000 1000 1000 1000
1000 1000 1000 1000
1000 1000 1000 1000
1000 1000 1000 1000
1000 1000 1000 1000
1000 1000 1000 1000
Tab. 4-4
Fig. 4-11: Clearances

1 Please observe the applicable regional safety regulations and constructional conditions relevant to the dimensioning of the supply line. 2 Please observe the applicable regional standards for cable cross sections and backup fuses.Voltage tolerance: max. 10%, voltage deviation between phases: max. 3%. 3 Unit with a maximum 2 pumps 4 Unit with 3-4 pumps
NOTE!
For detailed planning please only use the documentation enclosed with the unit. Detailed dimensional drawings can be obtained on request from your relevant GEA sales office. Specifications and technical data are subject to regular updates. The manufacturer reserves the right to make any changes to infor-mation without prior written notice.
23
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
4.5
Cool water outlet temperature at condenser (Tco) [C]
Operating limits
D. 1
Chilled water outlet temperature at evaporator (Teo) [C]

The operating limits apply for continuous operation of the unit and the chilled water pump, and the proper commissioning, cleaning, maintenance and setup/installation of the chiller and the system. For operational reasons the chilled water must be protected from freezing by adding glycol. GEA recommends the use of at least 30% ethylene glycol. This diagram presents relative minimum and maximum water outlet heat exchanger temperatures. Please note that depending on the design point, the T across heat exchanger can be smaller or larger than 5 K. The following results in the fact, that under circumstances the pressure drop across heat exchangers turns out to be too high or the minimum or maximum volume flows in heat exchangers cannot be reached or can be exceeded.
GLWC ... BD Evaporator Min.

Water inlet Water outlet [C] [C] [K] -41 -81 3
Condenser Max.
231 151 8
Min.
102 262 4
Max.
512 552 16
T Tab. 4-5
1: with cool water (In/out): 30/35 C 2: with chilled water (In/out): 12/7 C
For detailed design please contact your GEA sales office
NOTE! Protect the cool water side and heat rejection unit from frost. GEA recommends the use of at least 30% ethylene glycol. Under circumstances it can be necessary that the chilled water side has to be frost protected, if the chiller or components of the hydraulic network have not been installed and run in a frost-proof manner. After the compressor start keep the minimum cool water outlet temperature at 26 C for safe operation of the chiller.
24
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Transport and Storage
5
5.1

Delivery When the GEA Chiller is delivered, check that the delivery is correct and complete
according to the delivery note, (See Scope of delivery on page 6) and inspect for any shipping damage. If possible, take photographs of all visible shipping damage. NOTE! Missing parts or damage in transit can only be claimed with the transport insurance if the damage has been confirmed by the delivering carrier.
NOTE! We recommend that you transport or store the GEA Chiller in its original packaging. Remove the original packaging only before installation. Protect the unit from the build-up of dust and dirt. Be aware of damage during storage until the unit is ready for commissioning.
5.2
Transportation
PERSONAL INJURY! The weight of the GEA Chiller is indicated on the following pages or on the unit type plate. In order to avoid any injuries or damage, use only appropriate lifting devices (crane equipment) for transportation. Never use a fork lift truck or pallet truck, as there is a risk of the unit toppling over.
Only transport the GEA Chiller using the transport lugs or lifting points provided by
the manufacturer!
During transportation do not tilt the unit more than 15. For your own safety wear gloves and safety footwear when transporting the unit.
DANGER DUE TO OVERHEAD LOADS. Never stand beneath suspended loads, there is always a risk that the lifting gear, tackle, ropes or chains could be damaged. This could lead to serious injuries or death.
Before transporting the unit, make sure that all mountings are fixed and secured. Only use lifting gear with sufficient load carrying capacity. Never use damaged lifting equipment. Ropes/chains should not be knotted and/or be exposed to sharp edges. Only use ropes/chains of the same length. Only use the indicated lifting gear (provided by others). Move the unit carefully without jerky movements. Always set the unit down gently, without bumping it. If necessary, use a specialist company to transport the unit.
25
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Fig. 5-1:
Transport unit (example GLWC 0152-0252 BD2)
Weight sizes 0152-0612

Unit type
Transport weight Operating weight
0152
280 290
0182
295 305
0202
300 310
0252
310 320
0262
315 325
0302
565 575
0352
605 615
0412
635 645
0452
675 685
0512
715 725
0552
765 775
0612
795 805
Units with pump module

435 455 450 470 460 480 470 490 475 495 840 860 880 900 915 935 955 975 1005 1025 1045 1065 1085 1105
Tab. 5-1:
All weight in kg
Weight sizes 0604-1204

Unit type
0604
1055 1065
0704
1130 1140
0804
1190 1200
0904
1270 1280
1004
1355 1365
1104
1450 1460
1204
1510 1520
Units with 1 or 2 pumps

1350 1370 1430 1450 1495 1515 1605 1625 1695 1715 1785 1805 1820 1840
Units with 3 or 4 pumps

1590 1620 1680 1710 1745 1775 1880 1910 1975 2005 2065 2095 2135 2165
Tab. 5-2:
All weight in kg
NOTE! Use only supplied documentation and enclosed detailed dimesional drawings when transporting the unit.
5.3
Storage
Permitted storage conditions / permitted air condition for units which have not yet been installed Air temperature: Air humidity: -20 C up to +50 C up to 85 % (relative humidity, non condensing)
26
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Installation
Installation
INFORMATION ON ASSEMBLY AND INSTALLATION OF THE UNIT Here you will find information about assembling and installing the unit. Installation and assembly must only be carried out by qualified staff who, based on their training and experience, have sufficient knowledge of the relevant accident pre-vention regulations, as well as other generally recognized safety and occupational health regulations. INFORMATION ON MOVING THE UNIT If the GEA Chiller has been moved from one plant/location to another, it must also be commissioned again as described in chapter Commissioning on page 42.
6.1
Installing the unit

NOTE! For detailed planning use only the order-related documentation which is supplied with the unit and observe all dimensional drawings.
The unit must be installed at a location that fulfils the following requirements: The foundations must be level and stable enough to ensure that no vibrations or operating noises occur when the unit is in operation. The unit should be installed in such a way that it is only accessible to authorized, trained, technical personnel. If necessary, use appropriate equipment to keep unauthorized persons away from the unit. There must be sufficient clearance around the unit to carry out maintenance or repair work. The sizes for service and maintenance clearances can be found in Tab. 4-2 on page 21 and Tab. 4-4 on page 23. The area where the unit is installed should have sufficient ventilation. Make sure that leaking media do not damage the installation location or the environment. Choose the installation location so that operating noise does not cause a disturbance. Requirements for the installation location must be verified and adhered to in accordance with EN 378.
27
Installation
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
6.2
Assembling the unit

In order to reduce the transmission of vibration from the unit to the supporting structure, you must install anti-vibration mounts: We recommend the use of e.g. rubber plates to separate the unit from the foundation when installing it in a location where no special requirements for the neutralisation of structure-borne noise apply. For sound-related technical requirements please select the additional sound insulating accessories for compressor in accessories and special equipment. For very special acoustic requirements please consult an acoustic engineer to select the most suitable method for neutralising structure-borne noise.
6.2.1 Installing chiller To install the unit, proceed as follows:
The unit must be fixed in position and secured according to the supplied drawing
using anti-vibration mounts (also see Fig. 6-1) or other suitable devices at each of the fixing points W1 to Wn.
Fig. 6-1:
28
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Medium Connections
Medium Connections
The chilled and cool water connection must only be carried out by qualified staff who based on their training and experience have sufficient knowledge of the relevant accident prevention regulations, as well as the other generally established technical safety and occupational health regulations and codes.
7.1
Requirements
Keep in mind:
The complete chilled water circuit must be designed and implemented in

accordance with the current standards and guidelines. Glycols PERSONAL INJURY! Ethylene glycols are harmful for humans and animals if swallowed. Contact a doctor immediately if ingested by mistake. ENVIRONMENTAL DAMAGE. Ethylene glycol and propylene glycol are classified in Water Hazard Class 1 (slightly water-endangering substances). This also applies to mixtures with water.
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. There are considerable differences between water and water-glycol mixtures in terms of their thermodynamic and physical properties. This affects the performance values of the GEA Chiller and all components and, consequently, the design of the entire hydraulic system. If glycol is mixed with the medium, the result is a lower specific heat capacity, higher viscosity and heat transfer and, consequently, an increased flow rate, increased pressure drops, increased pumping capacity, and lower cooling capacity. When choosing ethylene glycol (e.g. Antifrogen N) or propylene glycol (e.g. Antifrogen L), it should be considered that the physical properties of ethylene glycol offer more benefits for the design and energy consumption of the system. Propylene glycol, which is food safe, must be used where the heat transfer medium could come into contact with drinking water and/or food. The minimum proportion of ethylene glycol is 20% by volume and of propylene glycol, 25% by volume, because lower concentration leads to poorer corrosion protection and even contributes to corrosion. To ensure that energy consumption is not unnecessarily increased by excessively high concentrations of glycol, the latter should be added to match the ambient temperatures. The water-glycol mixture no longer has a burst effect from frost resistance of -20C with Central European weather conditions, as slush ice forms when the mixture is cooled below the freezing point. Do not use Teflon seals if using water-glycol mixtures. Fill the system with a prepared water-glycol mixture. After you have filled the system, check the glycol concentration with a suitable and approved measuring instrument. When designing the system, remember that a water/glycol mixture expands to a bigger extent than just water. Use only one sort of glycol, do not mix different types.
29
Medium Connections
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Check the following points before you start the medium connections of the unit: Drainage valves must be installed at all low points of the chilled water system in order to ensure that the chilled water circuit can be fully drained for maintenance or repair purposes. A drain with shut-off valve must be provided for emptying the units water system. Air vents must be installed at all high points in the chilled water system at easily accessible locations. DAMAGE TO THE UNIT. The GEA Chiller may only be used in a closed chilled water system. Use in an open chilled water system can lead to excessive corrosion.
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. If necessary, inhibitors must be added. Note! These limit values are only intended to provide basic information on water quality and do not form any basis for a guarantee.
Description
Hydrogen ion concentration Calcium and magnesium content Chlorine ions Iron ions Magnesium ions Carbon dioxide Hydrogen sulphide Oxygen Chlorine Ammonia Bicarbonate/sulphate ratio
Symbol
pH Hardness (Ca/ Mg) Cl Fe+ Mg
+
Values
7.5 9 4 8,5 D < 50 ppm < 0,5 ppm < 0,05 ppm < 10 ppm < 50 ppb < 0,1 ppm < 0,5 ppm < 0,5 ppm
Effects if values are not adhered to

< 7.5 >9 > 8.5 Corrosion Incrustation Incrustation Corrosion Corrosion Corrosion Corrosion Corrosion Corrosion Corrosion Corrosion <1 Corrosion
CO2 H2 S O2 Cl2 NH3 HCO3 /SO4

-
>1
Tab. 7-1:
1/1.78 D = 1 Fr mit 1 Fr = 10 g CaCO3/m ppm = parts per million (mg/l) ppb = parts per billion (g/l)
30
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Medium Connections
7.2
Schematic representation of various hydraulic chilled water circuits
Fig. 7-1:
Hydraulic circuit of twin-circuit buffer tank
Fig. 7-2:
Hydraulic circuit of single-circuit buffer tank

13: Balancing valve 14: Pump secondary circuit 15: GEA Chiller 16: Buffer tank/hydraulic switch suitable for chilled water systems 17: Consumer
1: Pressure gauge 2: Shut off cock 3: Automatic venting 4: Vibration damping connection 5: Unit-independent pipeline fixing point 6: GEA water filter (maximum mesh size 1 mm2) 7: Drain valve 8: Pump primary circuit 9: Safety valve 10: Expansion tank 11: Filling valve 12: GEA flow switch
18: GEA Condenser 19: GEA Heat rejection unit 20: Temperature sensor (by others) 21: 3-way valve
Items 4, 5, 6 and 12 are also specified by GEA in addition to the internal parts required by legal regulations.
NOTE! Under all circumastances please remember to install a water filter before direct inlet into the heat exchanger (evaporator and condenser). The water filter protects the evaporator from sediments and dirt. The water filter can be optionally ordered and is a requirement for safe and troublefree operation of the unit and in such a way this requirement constitutes an integral part for the validity of the guarantee.
PR-2008-0006-GB Subject to modifications Status 01/2008 31
Medium Connections
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
7.3
Schematic representation of various hydraulic heat rejection circuits
Fig. 7-3:
Heat rejection circuit with cool water pump with speed control and/or speed control of the heat rejection unit.
Fig. 7-4:
Heat rejection circuit with a 3-way valve and/or fan speed control of the heat rejection unit.
Installing water filter
Under all circumstances please remember to install a water filter of mesh size 0,51 mm before direct inlet into the evaporator and condenser in order to avoid dirt formation and damage in the heat exchanger. This requirement constitutes an integral part for the validity of the guarantee.
32
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Medium Connections
Frost protection
The GEA Chiller of the GLWC series are designed for indoor installation. Because of this reason it is normally not necessary to protect the chilled water side from frost at chilled water temperatures above 6 C, as it is assumed that chilled water lines are run frost-safe inside a building. If this is not the case use the antifreeze agent. In most common cases the cool water circuit of the heat rejection unit has to be frost protected, because the latter is usually installed outdoor and is exposed to weather influence. GEA recommends to use ethylene glycol (also see Water-glycol mixes on page 37 in the relevant Data & Facts).
Dimensioning
Dimension the GEA heat rejection unit in such a way that the cool water temperature within the operating limits remains as low as possible. The lower the cool water temperature, the higher the achieved refrigeration capacity and the lower the energy consumption of the chiller. Carry out the design of the cool water circuit between inlet and return at the condenser as well as inlet and return at the heat rejection unit with a temperature difference of 5 K (also see Capacity data from page 20 and following page).
Minimum cool water outlet temperature
Possibility 1:
Possibility 2:
Possibility 3:
In order to ensure safe operation of the chiller it is necessary to provide minimum cool water outlet temperature (comp. Tabelle 4-5 on page 24). This temperature amounts to 26 C and should be reached 90 seconds after the unit was switched on. This situation is not always the case because of cold weather. Therefore there are several technical possibilities to ensure the minimum cool water outlet temperature. It is possible in option 1 to control the fan RPM speed in relation to the cool water outlet temperature. Under all circumstances it is recommended to control the fan RPM speed in order to ensure continuous operation of the chiller under constant conditions. Option 2 should be implemented if the minimum cool water temperature cannot be ensured, despite the speed control of fan motors due to e.g. year round operation of the unit. In this case it is possible to use a cool water pump that is controlled in relation to cool water outlet temperature given that the minimum and maximum water volume through the condenser is provided (compare Fig. 7-3: on page 32). Option 3 can also be used in order to provide for the minimum cool water outlet temperature of the unit. In this case a 3-way valve is installed in cool water inlet additionally to the fan speed control in order to regulate this valve depending on thr cool water outlet temperature (compare Fig. 7-4: on page 32).
33
Medium Connections
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
7.4
Function of a 3-way valve

Within 120 seconds after the compressor start a minimum cool water temperature of 26 C has to be reached. The cool water temperature defines the condensing pressure which has an effect on the evaporation pressure of the refrigeration circuit. In order to avoid low pressure disturbances at insufficiently high cool water temperatures it is recommended to use a 3-way valve for units that are operated during the transition period as well as in winter. As an option a 3-way valve can be supplied for cool water side with chillers of series GLWC 0152-0612 BD2 and GLWC 0604-1204. The function of a 3way valve is to bring the cool water temperature to the required level during the unit start up - even if due to low ambient temperature the cool water of the heat rejection system is too cold. Consider the operating limits of the unit on page 24. The optionally supplied 3-way valve is suitable for use in heat rejection units, cooling towers, evaporative condensers and earth loops. Constant water volume flow across condenser Can be used for applications with and without GLPC pump module
Fig. 7-5:
Scheme of a 3-way valve
7.4.1 Functional description of a 3-way valve Depending on the condensing pressure which is measured by the already installed pressure sensor, the following positions of a 3-way valve can be set: position A - AB, B - AB or mixed position A - B - AB The 3-way valve is supplied loose and must be installed in a common cool water side. The electrical connection of a 3-way valve shall be carried out in accordance with the supplied wiring diagram or shall be wired in compliance with the electrical integration on page 38 for the unit series 0152-0612 or on page 39 for the unit series 0604-1204.
7.4.2 Kvs-values of 3-way valve

Unit type
kvs-value
0152
19
0182
19
0202
19
0252
31
0302
31
0352
31
0412
49
0452
49
0512
49
0552
49
0612
49
Abb. 8: 7 Unit type

kvs-value
0604
78
0704
78
0804
78
0904
78
1004
124
1104
124
1204
124
Tab. 7-1
Flush the piping system by others and compile a cleaning report.
34
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Medium Connections
7.5
Connecting chilled and cool water circuit

DAMAGE TO THE UNIT. When connecting the primary chilled and cool water system, counterhold the connecting spigots with a pipe wrench to prevent damage.
Connect the piping system by others to the chilled and cool water inlet and outlet. The exact positions of the connections can be taken from the documentation
supplied with the unit, the dimensional drawings and diagrams.
Connect the water supply to the filling valve. Open the shut off valves. Use the air vent valves to let all air escape when filling the chilled and cool water
system. Insulate the entire chilled and cool water system to reduce condensation and capacity losses. The exterior surface of steel piping should also be protected against corrosion using protective paint. DAMAGE TO THE UNIT. The heat exchangers in the unit must be protected against ice formation during system shutdown or if the ambient temperatures fall below freezing. Use an anti-freeze agent in the cool water circuit and if necessary on chilled water side if the chilled water pipes are not frost-proof or if the unit is not installed in a frost-free location. NOTE! Glycol may be used; however the concentration must not exceed 50% of the content of the entire system. A higher quantity can cause malfunctions.
35
Electrical Connection
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Electrical connections may only be carried out by qualified staff who, based on their training and experience, have sufficient knowledge of the relevant accident prevention regulations as well as other generally recognized safety and occupational health regulations. Take protective measures. When installing and connecting the unit, protective measures for low-voltage systems according to the EU Directive as well as regulations and codes of the local utility provider shall be observed. Ensure earthing and potential equalization of the unit and all connected components. ELECTRICAL HAZARD! All power supply connections must be switched off and be voltage-free and secured against unintentional switching on. Failure to do so may lead to serious injuries or death. NOTE: The cabling must be carried out according to the enclosed unit-specific wiring diagrams. Only separate mains power cable may be used. Never connect other units to this mains power cable.
8.1
Requirements
Before you start setting up the units electrical connections, check the following: The properties of the mains power supply must comply with EN 60204-1 regulations and the power requirements of the unit. The mains power supply voltage must have a rating of 10% with a maximum phase difference of 3%. Do not operate the motors if the voltage difference between the phases exceeds 3% as this will invalidate all warranty claims. Use the following formula for checking:
voltage deviation -------------------------------------------------------------------------------------------------- U max = Max. voltage deviation from average value 100
Average voltage U m
36
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
NOTE! When connecting the supply voltage, make sure you observe the clockwise rotating direction!
EXAMPLE Input data Requirements

You must first determine certain input data/measured values. Nominal voltage Voltage between phases Average voltage
Result
400 V / 50 Hz / 3 phases L1/L2 = 409 V; L2/L3 = 398 V; L1/L3 = 396 V
1. Step
Determine the average voltage Um
U U m = -----3
( 409 + 398 + 396 ) = 401 V ----------------------------------------------3
Um = 401 V
2. Step
Determine the maximum voltage deviation Umax
Voltage deviation Umax in %? Umax = 409 V Um = 401 V
--------------------------------------------------- U max = max. voltage deviation 100 U

m
( 409 401 )V ---------------------------------- 100 = 1,99 % 401 V
Umax = 1,99 %
8.2
Connecting supply voltage

A 3-phase 400 V/50 Hz mains supply must be available to connect the unit. The power line must have the necessary protective devices every phase must have a time-lag fuse. The size of the backup fuse must be determined on the basis of the unit rated current by a qualified electrician for maximum cable cross-sections and fuses see "Technical data" on page 20 and following pages. For the supply cable grommets refer to the enclosed documentation and electrical wiring diagram. The cable grommet in the switch cabinet must be sealed with a cable grommet fastener (cable gland), in order to maintain the IP protection of the unit. Connect the power supply to the main isolator (observe clockwise rotating direction). See electrical wiring diagram enclosed with the unit.
Fig. 8-1:
GLWC main isolator
37
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
8.3
Electrical integration
Option extension card (.E29)
1Y1 3-way-valve*(option) Setpoint shift 4-20 mA signal
By others Error message*
Load shedding*
Serial card RS485/Modbus (option)
GEA Chiller GLWC 0152 - 0612 BD2
Remote contact Flow switch* on/off*
Relay for chilled water pump by others #230 V/ 50 Hz/2 A
General error message #230 V/50 Hz/ 2A
Operation message compressor 1 #(option)
Operation message compressor 2 #(option)
Fig. 8-2: Terminals:
Electrical integration GLWC 0152-0612 BD2 A - B: Connecting the flow switch by others E - F: Remote contact for switching the machine off and on via the NO contact by others P1 - P2: Relay for activating the chilled water pump by others(pre-wired on units with GLPE hydraulic module and/or GLPC) 15 - 16: General error message (voltage by others max. 230 V/2 A/AC/50 Hz) 67 - 68: Operation status message compressor 1 (optional) 69 - 70: Operation status message compressor 2 (optional) 037-038: Setpoint shift via 4-20 mA signal (optional extension card) 039-040: Error message contact by others (optional extension card)1) R - S: Load shedding by unit, power limiting via NC contact by others (optional extension card)2) 1-2-3: Connection to serial card (optional)3) 9 - 10 - 11 : 3-way valve for heat rejection circuit for cold weather start regulation (option) # * Cabling by others potential to be supplied by others (max. 230 V / 50 Hz / 2 A) potential may not be supplied by others (supplied by controller)
1)The
unit is stopped by opening a contact by others and an error message appears. The contact can also be used to stop the unit if the water pressure in the connected water network drops (pressure switch by others). 2)Reduction of refrigeration capacity (load shedding switch) and of electrical power consumption by opening a potential-free contact by others. 3) The serial card is required to link the chiller to a building management system or for communication with a master/slave control sequencer.
NOTE! Under all circumstances please remember to install an additional flow switch at chilled water outlet of the unit and connect it to terminals A-B in the switch cabinet of the chiller. The additional flow switch can be optionally ordered and is a requirement for safe and trouble-free operation of the unit and in such a way this requirement constitutes an integral part for the validity of the guarantee.
38
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Setpoint shift Error message by others* 4-20 mA signal
4Y1 3-way-valve*(option)
Load shedding* (Option)
2. Setpoint* (Option)
Serial card RS485/Modbus (option)
GEA Chiller GLWC 0604 - 1204 BD2
Remote contact on/off*
Flow switch*
General error message #230 V/50 Hz/ 2A
Operation mes- Operation mes- Operation mes- Operation mes- Relay for chilled sage compres- sage compres- sage compres- sage compres- water pump by sor 1 #(option) sor 2 #(option) sor 3 #(option) sor 4 #(option) others #230 V/50 Hz/2 A
Electrical integration GLWC 0604-1204 BD2 A - B: Connecting the flow switch by others E - F: Remote contact for switching the machine off and on via the NO contact by others P1 - P2: Relay for activating the chilled water pump by others (pre-wired on units with GLPE hydraulic module and/or GLPC) 15 - 16: General error message (voltage by others max. 230 V/2 A/AC/50 Hz) 67 - 68: Operation status message compressor 1 (optional) 69 - 70: Operation status message compressor 2 (option) 71 -72: Operation status message compressor 3 (Option) 73 -74: Operation status message compressor 4 (Option) 037-038: Setpoint shift via 4-20 mA signal 039-040: Error contact by others 1) L - M: Activation of 2nd setpoint via NO contact by others (Option) R - S: Load shedding by unit, capacity limitation via NC contact by others (Option)2) 1-2-3: Connection to serial card (option)3) 19 - 20 - 21 : 3-way valve for heat rejection circuit for cold weather start regulation (option) Cabling by others # potential to be supplied by others (max. 230 V / 50 Hz / 2 A) * potential may not be supplied by others (supplied by controller)
1)
cc
The unit is stopped by opening a contact by others and an error message appears. The contact can also be used to stop the unit if the water pressure in the connected water network drops (pressure switch by others). 2) Reduction of refrigeration capacity (load shedding switch) and of electrical power consumption by opening a potential-free contact by others. 3) The serial card is required to link the chiller to a building management system or for communication with a master/slave control sequencer.
NOTE! Under all circumstances please remember to install an additional flow switch at chilled water outlet of the unit and connect it to terminals A-B in the switch cabinet of the chiller. The additional flow switch can be optionally ordered and is a requirement for safe and trouble-free operation of the unit and in such a way this requirement constitutes an integral part for the validity of the guarantee.
39
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
8.4
Connecting control contacts and controller

We recommend that the connecting cable for the safety devices is installed separately for the power cables. If this is not possible, use shielded cables.
8.4.1 Integrating flow switch DAMAGE TO THE UNIT. Do not use the flow switch to switch the remote On/Off contact. Connect the flow switch to terminals A-B in the chillers switch cabinet. The flow switch acts as a safety device and not as a regular switching device for the chiller.
GEA Chiller
Connect the external flow switch. See the electrical wiring diagram enclosed with the unit, terminals A/B. Cable specification: terminals under voltage for connecting a potential-free contact by others. Maximum cable length 100 m, minimum cable cross-section 1.5 mm.
Contact Remote On/Off*
230V/50Hz/2A Flow switch Relay by others General error message
Flow switch
Fig. 8-4: Terminals: Terminals: Terminals:
Electrical integration of flow switch A - B: E - F: 15 - 16: Connecting the flow switch by others Remote contact for switching the unit off and on via NO contact by others General error message (voltage by others max. 230 V AC/50 Hz/2 A)
8.4.2 Integration of collective error message DAMAGE TO THE UNIT. Do not open the remote on/off contact, e.g. via the changeover contact of the relay by others, if there is a fault in the system. The error can in such a way be reset. The cause of the malfunction cannot be determined. The entire unit stops operating although it is possible that only one refrigeration circuit is affected.
GEA Chiller
Connect the line for the collective error message (potential free contact, suitable for 230 V AC / 50 Hz / 2 A).
Contact Remote On/Off* By others Relay
230V/50Hz/2A Flow switch Relay by others General error message
Electrical integration of collective error message A - B: E - F: 15 - 16: Connecting the flow switch by others Remote contact for switching the unit off and on via NO contact by others General error message (voltage by others max. 230 V AC/50 Hz/2 A)
40
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
8.4.3 Pump control contact (option) Connect the pump control contact (option) floating (potential-free) contact; suitable for 230 V/50 Hz/1 A). See wiring diagram supplied with the unit, terminals P1/P2. If you do not use the pump control contact via contact terminals P1/P2, please observe the following points: The water pump must be switched on for at least 60 seconds before the GEA Chiller is started.The water pump may only be switched off 120 seconds after the GEA Chiller is switched off/to standby. An external control must observe the following times:
Pump control Operation on/off Chilled water Chiller
8.4.4 External ON/OFF control contact (if necessary) Connect the external ON/OFF contact to terminals E/F. See the electrical wiring diagram enclosed with the unit. To use the bridge function between terminals E/F must be replaced by an external floating (potential-free) switch contact. Cable specification: single ended terminals for connection of floating contact by others. Maximum cable length 100 m, minimum cable cross-section 1.5 mm.
41
Commissioning
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Commissioning
NOTE: This information applies to initial commissioning of the GEA Chiller and also for repeated commissioning after an extended standstill period. Commissioning must only be carried out by qualified technicians with sufficient technical knowledge in the relevant areas.
9.1
Requirements
Specific prerequisites must be satisfied regarding the commissioning of the unit. The function test must be carried out by a specialist company/GEA Service and the commissioning protocol must be drawn up and sent to GEA. Recommendation! Requirements check list We recommend that the checklist Technical Requirements for Function Testing or Chiller Maintenance is used to ensure that the on-site prerequisites for drawing up the commissioning report are met. This can also save work and costs because the service team may have to visit your unit again if the on-site requirements are not met by others beforehand. This checklist is printed on page 56. The commissioning protocol must be compiled by a specialist company/GEA Service. You must send to GEA the commissioning report in the following form: see GL Chiller Commissioning Form on page 57. If you do not send the commissioning report to GEA, the warranty for your GEA Chiller will be rendered null and void.
Obligatory! A commissining report must be sent to GEA
9.2
Checking and testing

ELECTRICAL HAZARD! There is a danger of electric shock when checking and testing the unit if it is connected to the power supply. Check the following before switching on the main isolator and after installation of the unit: Check that the unit has been correctly set up and anchored down to avoid unusual operating noise and vibrations. Check the unit inside and outside for damage; damaged components or buckled pipes, for example. First make sure that wiring by others has been carried out in accordance with the specifications and the requirements of Electrical Connection on page 36 of this section. This stipulates observing of the information in the electrical wiring diagrams and setting up electrical connection in accordance with European, national and local energy provider regulations. Check that the earth leads are connected correctly and that the earthing terminals are securely tightened. Check the inside of the switch cabinet for loose connections or damaged components. Tighten all connecting terminals in the motor terminal clamps. Check the mains supply. The voltage must match the details on the plate/ identification or the unit-specific documentation Immediately check the rotating direction It is important that the rotating direction is correct for proper unit operation: clockwise rotating direction! If necessary, check the rotating direction using an instrument especially designed for this purpose. Depending on the unit model, the correct direction of the rotating field is indicated by an LED on the phase-sequence safety relay in the switch cabinet.
Visual inspection of mechanical components
Check electrical connection
42
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Commissioning
DAMAGE TO THE UNIT. If the direction of the rotating field direction is incorrect an adjustment must be made at the main connection by changing the phases. Change the phase sequence of the power supply line by others never change the wiring in the unit switch cabinet. Checking refrigeration circuit
Check the refrigerant circuit for damage and leaks. Check the compressor and piping for damage and escaping medium or oil. If you
find a refrigerant or oil leak please consult GEA Service. ENVIRONMENTAL DAMAGE Dispose of any escaping media or oil immediately in an environmentally-friendly manner and in compliance with local laws and regulations.
Check all screw connections and tighten where necessary.

NOTE FOR REFRIGERATION COMPANY. Make sure that all manually operated shut-off valves in the refrigeration circuit are open. These checks must only be carried out by a specialist refrigeration company. Check chilled and cool water piping and connections
First make sure that the piping sets by others and all equipment (including GEA
strainer, GEA flow switch) has been fully installed in accordance with the specifications and conditions contained in chapter Medium Connections on page 29. Check that the connected chilled and cool water system has been filled and vented correctly and that all pipes and pipe connections are sealed and insulated. Check whether the water safety devices are installed. Make sure that these devices function correctly. Check whether the piping system by others has been flushed before connecting it to the unit. An appropriate cleaning report must be available. Check that all filling valves and air vents are closed. Make sure that the water flow through the unit is not restricted in any way, open all corresponding shut-off valves. DAMAGE TO THE UNIT. The pump will be damaged if the chiller is operated without water flowing through the evaporator, e.g. when the shut-off valves are closed.
9.3
Switching on the main isolator Switch on the units main isolator.

The background lighting of the display and keyboard of the control panel are activated. The oil preheating is in operation. Operation via the control panel is not necessary at this point.
Warm-up phase before operation DAMAGE TO THE UNIT. Before commissioning, the unit must be supplied with electricity for at least 8 hours with main isolator switched on. This preheats the oil in the compressors. The compressors can be damaged if this warm-up phase is not carried out.
43
Commissioning
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
9.4
Calibration
8 hours of uninterrupted oil preheating operation will ensure that there is no more refrigerant in the oil. The unit can now be put into operation and calibrated. HOT SURFACE DANGER! Certain components and surfaces of the unit and media can get hot during operation. There is a risk that burns may be inflicted when taking measurements. Reliable recording of correctly measured values is only possible during stable operation of the unit. A stable operating state is reached approximately 0.5 h after the unit has been switched on. After that calibration can be started.
Record measured values, enter them in the report and send it to GEA.
44
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Operation
10 Operation
DAMAGE TO THE UNIT. The unit must not be operated unless proper function testing has been carried out. Make sure that all conditions specified in chapter Commissioning from page 42 and following pages are met. DAMAGE TO THE UNIT. If the main switch has been off for more than 3 hours, the oil preheating must be operated for 8 hours again before the compressor can be switched on. Failure to comply with this instruction will invalidate all warranty claims. For controller operation also refer to Unknown source of cross-reference and the following pages.
10.1 Overview of the controls

W3000 compact control and display elements:
Control element Description
Serves to display and reset alarms.
Fig. 10-1:
Control display W3000 compact
Provides access to the main menu.
Allows the user to go back to the next higher level in the screen tree from the title screen; also allows the user to return to the start page.
Used to navigate the screens and to enter/change parameter values upwards.
Use the Enter key to confirm the selection and to place the cursor below parameters that need to be changed. Is used to navigate the screens and to enter/change parameter values downwards.
10.2 Switching on and off

As soon as all necessary requirements for the commissioning have been met, there are several ways to switch the unit on and off. Highest priority: Lowest priority: Priorities of various options: on/off by entering parameters (Com.: on/ Com.: off) on/off via digital input on/off (see page 46) on/off by means of monitoring protocol The following is displayed in the first line at the W3000 compact operator control unit: "Com.: on or Com.: off parameters. off shows that the unit is switched off,on shows that it is switched on.
45
Operation
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
10.2.1 Switching on
If Com.: off is not displayed, press the Esc key until Com.: off appears
in the display.
Select the off parameter using the Enter key.

The first character of the off parameter flashes.
Select on using the Up or Down key. Confirm the setting with the Enter key.
If On remains on the display, the unit is switched on.
10.2.2 Switching off
If Com.: on is not displayed, press the Esc key until Com.: on appears in
the display.
Select the on parameter using the Enter key.

The first character of the on parameter flashes
Select off using the Up or Down key. Confirm the setting with the Enter key.
If off remains displayed the unit is switched on. NOTE! The oil preheating remains active!
10.2.3 External remote ON/OFF contact via digital input [ON/OFF] It is possible to switch the unit on and off using the digital contact (terminals E/F). This contact is already enabled in the controller configuration so that the terminals E/F have to be connected in the chillers switch cabinet in accordance with the wiring diagram. When the digital contact is open the unit is off and OFF dig. in. is displayed on the start screen. If the digital contact is closed the unit is on and ON dig. in. appears on the start screen.
46
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Operation
10.2.4 Adjust the water inlet and outlet temperature controls NOTE! For controller operation also see Temperature control on page 17.
To adjust the control system type, proceed as follows:
Press Prg key. Select the User menu with the arrow keys. Press the Enter key to confirm. Enter the password "1234" using the arrow keys. Press the Enter key to confirm. Use the arrow keys to set the parameter Type of control system. Press the Enter key to confirm. Two parameters can be adjusted here: by steps as control system type with corresponding parameters:
INPUT Speed stage control using chilled water inlet temperature is not OUTPUT adjustable. Quick Mind as control system type with corresponding parameters: INPUT Graduated control with neutral zone via the chilled water inlet OUTPUT temperature.
Toggle between Quick Mind and by steps using the arrow keys. Press the Enter key to confirm. Toggle between INPUT and OUTPUT using the arrow keys. Press the Enter key to confirm. Press the "Esc" key to return to the start screen.
10.2.5 Adjusting the chilled water setpoint To modify the chilled water setpoint, proceed as follows:
Press Prg key. Select the Setpoint menu with the arrow keys.
47
Operation
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Press the Enter key to confirm.

Use the arrow keys to adjust the parameter Chiller setpoint.
Press the Enter key to confirm. Change the parameter using the arrow keys.
by As control mode for unit sizes 0604-1204 the standard setstepsIN point of 7,0C is displayed here; with the preset proportional PUT: band this corresponds to an actual setpoint of 12C (7,0C + 5,0C P-band = 12C). For unit sizes 0152-0612 the standard setpoint of 9,5C is displayed here; with the preset proportional band this corresponds to an actual setpoint of 12C (9,5C + 2,5C P-band = 12C). Quick Mind as control mode INPUT: the standard setpoint 7,0 C is displayed here.OUTPUT: in this case the standard setpoint 11,0 C is displayed.
Press the Enter key to confirm. Press the "Esc" key to return to the start screen.
NOTE! Changing the setpoint downwards may trigger a frost protection malfunction warning (AL 010: frost protection for evaporator; standard switching value of +4C at chilled water outlet).
48
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Operation
10.3 Disconnecting the unit from the power supply Switch the main isolator off.
The unit is now disconnected from the power supply. DAMAGE TO THE UNIT. Frost protection using internal frost protection heating can no longer be ensured. The oil preheating is no longer active. DAMAGE TO THE UNIT. If the unit has been switched off for more than 3 hours, it must be supplied with electricity with the main isolator switched on for at least 8 hours before putting it back into operation. This preheats the oil in the compressors. The compressors can be damaged if this warm-up phase is not carried out See Warm-up phase prior to operation on page 42.
10.4 What to do in case of alarm and error messages

DAMAGE TO THE UNIT. In the case of alarms and faults always make sure that the cause of the fault is identified. In particular, repeated manual resetting of an alarm message may damage the unit and invariably leads to invalidation of the warranty. See Troubleshooting on page 51 for instructions in the event of alarm messages.
49
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
11 Care and Maintenance

11.1 Care and cleaning
DANGER SHARP CUTTING EDGES! Exercise caution when cleaning the unit as the thin fins may inflict cuts.
11.2 Maintenance
The maintenance of the unit may only be carried out by GEA Service or a specialist refrigeration company. All work occupational safety codes must be complied with during maintenance. Before maintenance can be carried out, the "Technical Requirements for Function Testing or Chiller Maintenance" have to be complied with - this checklist is printed in the appendix, refer to page 56. Annualy At least every 2 years
The glycol concentration in the system must be checked annually and always when
the liquid level is topped up.
A sample of the water-glycol mixture must be taken from the system at least every
2 years and its corrosion protection performance checked (e.g. by a specialist outlet). You must have the system serviced at least once a year. This is a prerequisite for the recognition of your rights under the warranty. The personnel of the technical services department, carrying out the maintenance, draw up a maintenance report. They should provide you with a copy of this report (or the original) listing all maintenance work carried out and obtained measured values. The appendix contains a sample report that specifies the maintenance work that must be carried out according to GEA conditions (See GL Chiller Measuring Report on page 58). You can use this report to check whether your technical services department has carried out all the specified maintenance work and measurements. Please note that in addition the legal requirements apply regarding the maintenance of refrigeration systems/chillers and connected systems.
Obligatory! 1 annual maintenance
Recommendation! 2 services per year
We recommend that you have your unit serviced twice a year.
NOTE: If leaks or liquid or oil losses occur, switch off the unit immediately and inform GEA Service.
ENVIRONMENTAL DAMAGE. Dispose of any escaping liquids in an environmentally friendly manner according to local laws and regulations.
50
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Troubleshooting
12 Troubleshooting
DAMAGE TO THE UNIT. In the event of malfunctions always identify and eliminate the cause of the fault. In particular, repeated manual resetting of an error message may damage the unit and invariably leads to the invalidation of the warranty.
12.1 Alarms
What to do in case of alarms: 1. Inform GEA Service. 2. Have GEA Service eliminate the faults cause. 3. Only GEA Service may reset the fault. DAMAGE TO THE UNIT. If alarms are reset several times without eliminating the fault, this may seriously damage the unit. Faults must not be reset manually without the agreement of the refrigeration engineering company or GEA service. In case of an alarm the ALARM key lights up red. To read out the alarm messages, proceed as follows:
Press ALARM key.

If no alarms are pending, No Alarm detected is displayed; otherwise AL... is displayed together with the alarm code and a short description.
If several alarms are pending, you can scroll through the current alarm list with the
arrow keys.
Press any key to exit the menu. Inform GEA Service.

12.1.1 Only for service team To reset the alarm:
Eliminate malfunction. Hold the ALARM key pressed down until No Alarm detected appears.
If this is not displayed, the alarm is still active.
51
Troubleshooting
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
12.2 Alarm messages in overview

Alarm 002 Description Phase sequence not correct Details Shows a false phase connection and switches off the entire unit. (Optional, only visible when the input is connected.) In units where there is no distinction between the flow switch and the overload protection, this alarm shows that the electric pump motor is overheated or that there is no flow in the evaporator. In case of no flow, the alarm is automatically reset when the fault is rectified; if, however, the pump is overheated, the alarm must be reset manually (on the pump). Only visible if the digital input and the chilled water pump thermoswitch are separate. Indicates that there is no flow in the evaporator. Reset A
003
Flow switch, evaporator
A, M A
005 006 010
Water temperature at evaporator inlet too low Water temperature at evaporator inlet is too high Frost protection, evaporator
Active only in heat pump mode. Shows that the water temperature at the evaporator inlet is too low. Active only in "chiller/cooling" mode. Shows that the water temperature at the evaporator inlet is high. Low water temperature at evaporator outlet. Besides, the evaporator (with more than one evaporator) where the alarm was triggered is displayed. Only visible when the function is activated in the software (see I/O menu). Shows when the unit is stopped due to a missing remote ON/OFF. Displays that outdoor air temperature fell below set value. The water outlet temperature at the evaporator changes too quickly, caused by too little water in the system. The temperature difference between inlet and outlet at evaporator is too high resulting from too low pump water volume flow. The specified maintenance interval in operating hours has been exceeded (in units with one pump, pump 1 is the chilled water pump) (Units with more than one pump). The specified maintenance interval in operating hours for pump 2 has been exceeded. Shows that pump 1 is overheating (in units with one pump, pump 1 is the chilled water pump) (units with more than one pump). This alarm shows that pump 2 has overheated. Indicates that the electric motor of compressor no. 1 is overheated or has another malfunction. As above for compressor no.2 As above for compressor no.3 As above for compressor no.4 The specified maintenance interval in operating hours for compressor no. 1 has been exceeded. As above for compressor no.2 As above for compressor no.3 As above for compressor no.4 The maximum number of compressor start ups per hour was exceeded As above for compressor no.2 As above for compressor no.3 As above for compressor no.4 Signals too high pressure in circuit Nr. 1 As above for circuit no.2
S-A S-A M
014 017 021 022
Missing of remote ON/OFF control contact Low outside air temperature Too little water in the system Low water flow rate in the system
M S S M
051
Maintenance pump 1
052 081 082 131 132 133 134 151 152 153 154 181 182 183 184 211 212
Maintenance pump 2 Overload protection, pump 1 Overload protection, pump 2 Fault, compressor 1 Fault, compressor 2 Fault, compressor 3 Fault, compressor 4 Maintenance, compressor 1 Maintenance, compressor 2 Maintenance, compressor 3 Maintenance, compressor 4 Compressor 1 increased start ups Compressor 2 increased start ups Compressor 3 increased start ups Compressor 4 increased start ups High pressure, circuit 1 High pressure, circuit 2
S M M M - A/M M - A/M M - A/M M - A/M S S S S S S S S M M
52
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Troubleshooting
Alarm 221 222 231 232 241 242 251 252 261 262 271 272 400 401 402 403 404 405 406 407 408 409 611 612 641 642
M= A= A/M = S= S-A= M - A/M =
Description Overload protection, fan circuit 1 Overload protection, fan circuit 2 Low pressure, circuit 1 Low pressure, circuit 2 High pressure via converter 1 High pressure via converter 2 Timeout, start-up circuit 1 Timeout, start-up circuit 2 No refrigerant in circuit 1 No refrigerant in circuit 2 Condenser heat exchanger, circuit 1 Condenser heat exchanger, circuit 2 Fault, sensor 10 Fault, sensor 1 Fault, sensor 2 Fault, sensor 3 Fault, sensor 4 Fault, sensor 5 Fault, sensor 6 Fault, sensor 7 Fault, sensor 8 Fault, sensor 9 Frost protection warning for evaporator 1 Frost protection warning for evaporator 2 High pressure warning for circuit 1 High pressure warning for circuit 2
Details Displays overheating of condenser fans electric motor in circuit 1, with following stop of the latter. As above for circuit no.2 Displays too low pressure, measured by converter/pressure switch, in circuit no. 1 As above for circuit no.2 Displays too high pressure, measured by converter, in circuit no. 1 As above for circuit no.2 Possible start-up attempt with no refrigerant in circuit no. 1. As above for circuit no.2 Refrigeration circuit no. 1 is possibly without refrigerant, because alarm "Time out of start-up" has run for at least 8 hours. As above for circuit no.2 Displays that air-cooled condenser of circuit no. 1 is added As above for circuit no.2 Sensor no. 10 defect or outside operating range as above as above as above as above as above as above as above as above as above Warning on too low outlet temperatures at evaporator 1 Warning on too low outlet temperatures at evaporator 2 High pressure warning by high pressure sensor for circuit 1 High pressure warning by high pressure sensor for circuit 2
Reset M M A/M A/M M M A A S S A/M A/M A A A A A A A A A A S S S S
Alarm with manual reset (when the cause of the alarm has been rectified, the alarm must be reset by the Service team) Alarm with automatic reset (when the cause of the alarm has been rectified, the alarm is reset automatically) Automatic reset for the first three alarms of this type, then manual reset by the Service team once the cause of the alarm has been rectified. Message on the display (without switching off and without activation of collective fault) Display (unit is not switched off) or alarm with automatic reset. The various operating modes can be selected via parameters. Alarm with manual reset (with screw compressors). With first three contacts automatic, after that manual (with scroll compressors)
53
Dismantling and Disposal
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
13 Dismantling and Disposal

ENVIRONMENTAL DAMAGE. Only appropriately trained personnel may dismantle and dispose of the unit.
13.1 Dismantling
To dismantle the GEA Chiller proceed as follows: ELECTRICAL HAZARD! When carrying out any decommissioning and dismantling work on the unit, switch off all power supply connections, ensure they cannot be switched back on unintentionally and verify that they have been disconnected. Earth and short-circuit them, and cover or otherwise isolate any neighbouring live parts. Failure to do so may lead to serious injuries or death. HIGH PRESSURE HAZARD! When carrying out decommissioning and dismantling work on or around the unit, close off and empty all connected pipes until the pressure has equalized with the ambient air pressure. Failure to comply may lead to injury.
Make sure that the water circuits have been switched off. Close all hydraulic shut-off valves. Disconnect all connections, at the same time making sure that no operating
materials such as oil, refrigerant and water-glycol mixture escape.
Release the fixing to the base.

PERSONAL INJURY Secure the unit against slipping.
The unit is ready for transporting.
It is important that all information on shipping is taken into account - see page 25. 13.2 Disposal
A technical services department with the appropriate competence must dispose of the unit or individual components. This technical services department must ensure that: the components are separated according to material types the operating materials are sorted and separated in accordance with their properties. ENVIRONMENTAL DAMAGE. Dispose of all components and operating materials (such as oil, refrigerant and water-glycol mixture) separately and in an environmentally-friendly manner according to material type and in conformity with local laws and regulations.
54
GLWC 0152-0612 BD2 GLWC 0604-1204 BD2
Appendix
14 Appendix
The following pages contain check lists and reports: On 14.1 - Technical Requirements for Function Testing or Chiller Maintenance See page 56 For commissioning: We recommend that the checklist Technical requirements for function testing or chiller maintenance is used to ensure that the on-site prerequisites for drawing up the commissioning report (see below) are met. This can also save work and costs because the service team may have to visit you again if the on-site requirements are not met by others beforehand. Pre-maintenance work: The Technical Requirements for Chiller Maintenance must also be satisfied before any maintenance work can be carried out and a Maintenance and Measuring Report can be compiled (see below).
On 14.2 GL KWE Chiller commissioning form and scheme of a hydraulic circuit See page 57 The function test must be carried out by a specialist company/GEA Service and the commissioning protocol must be drawn up and sent to GEA. The commissioning protocol must be compiled by a specialist company/GEA Service. NOTE! You must send the commissioning report to GEA. If you do not send the commissioning report to GEA, the warranty for your GEA Chiller will be rendered null and void.
For this purpose see schematic representation of a hydraulic chilled water circuit.
On 14.3 GL KWE Maintenance report See page 58 You must have the system serviced at least once a year. This is a prerequisite for the recognition of your rights under the warranty. The personnel of the technical services department, carrying out the maintenance, shall draw up a maintenance report. They should provide you with a copy of this report (or the original) listing all maintenance work carried out and obtained measured values. This report contains the maintenance procedures that must be carried out according to GEA. You can use this report to check whether your technical services department has carried out all the specified maintenance work and measurements. Please note that in addition there the legal requirements apply regarding the maintenance of refrigeration systems/chillers and connected systems.
55
14.1
Technical Requirements for Function Testing or Chiller Maintenance
Technical Requirements for Function Testing or Chiller Maintenance.
Information on dimensioning data Chilled water temperature at inlet Chilled water temperature at outlet Cool water temperature at inlet Cool water temperature at outlet Glycol ratio in chilled water Freezing point Type of glycol used (chilled water): Chilled water volume flow Glycol ratio in cool water Freezing point cool water Type of glycol used (cool water): Chilled water volume flow Prerequisites to be met by others prior to function test 1. 2. Electrical connections as per local utility guidelines incl. necessary fusing Electrical cabling between the components (pump, pump tank station, flow monitoring device, external air-cooled condenser/ heat rejection unit etc.) including data cable performed Water connection and pipe network filled and bled as per locally and officially defined guidelines. Strainer and flow switch fitted directly before the water-side inlet to the plate heat exchanger or the hydraulic module. Water-side safety device installed and tested for correct function, fixtures such as thermometer, differential pressure gauge fitted above the heat exchanger. Pipe system by others rinsed clean before connection to the unit. Cleaning protocol present. Output discharge (at least 50%) continually guaranteed The system must be powered with electricity for at least 8 hours before the function test and the main switch must be switched on (preheating of oil in compressor) Name: Place: Company: Signature of contractor/ operator [m/h] Checked & OK [m/h] % C C C C C % C
3. 4. 5. 6. 7. 8.
To be instructed Date:
56
14.2
GL Chiller Commissioning Form
GEA Air Treatment YOUR COMPANYS NAME
GL KWE COMMISSIONING FORM

USER / CUSTOMERS NAME INSTALLERS NAME
GEA GL Chiller 11/03 ENG
USER / CUSTOMERS DATA
UNITS DATA
COMPANY ADDRESS CITY WITNESSED BY Commissioning requested from:

UNITS WORKING DATA
UNIT TYPE SERIAL NUMBER STORAGE TANK S.N. PHONE REMOTE CONDENSER S.N.
Ord. #
H2O/AIR
T IN [C] T OUT [C] Delta P [kPa]
EVAPORATOR
CONDENSER TYPE CURRENT /
WATER PUMP /
EXT AIR.
[C]
AUX. VOLTS
[V]
POW. SUPPLY
[V]
GLYCOL [%]
compr. n 3 compr. n 4
compr. n 1
compr. n 2
EVAPORATING PRESSURE CONDENSING PRESSURE DISCHARGE TEMP. SUPERHEATING TEMP. SUBCOOLING TEMP.
COMPRESSOR CURRENT INPUT
bar bar C C C A
circuit n 1
circuit n 2
circuit n 3
circuit n 4
FANS CURRENT INPUT
HYDRAULIC PLANT CHECK (Ref. Point 4.4 Hydraulic Circuit Diagram, General Manual for Installation)
UNIT CHECK
1. MANOMETER 2. SHUT OFF VALVE (MANOMETER) 3. AUOTM. DEARIATION VALVE 4/5. ANTIVIBRATION JOINT (EVAPORATOR) 6. WATER FILTER 7. DRAIN VALVE 8. CIRCULATING PUMP (PRIMARY CIRCUIT) 9. RELIEF VAVLE 10. EXPANSION VESSEL 11. FILLING VALVE 12. FLOW SWITCH (Paddle type) 13. WATER FLOW CONTROL VALVE (EVAP.) 14. CIRCULATING PUMP (SECONDARY CIRCUIT) 16. BUFFER TANK Volume:___________
YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES
NO NO NO NO NO NO NO
ELECTRIC CONNECTIONS (checked?) Values / Function check when RATING possible. LOW PRESSURE SWITCH HIGH PRESSURE SWITCH ANTIFREEZE THERMOSTAT COLD WATER TEMP.CONTROL
bar bar C C bar
YES
CHECK
NO
YES YES YES YES YES
NO NO
NO NO NO
NO NO NO NO NO NO NO NO
HYDR. PRESSURE SWITCH NOTES
PUMP OPERATION CONTACTS SHUT OFF VALVE (EVAPORATOR) HYDRAULIC CIRCUIT (finished?)
NO
NO
UNITS DISTANCE FROM WALLS (CM)

b
Technicians name
a c
Date
a: _____ c: _____ b: d:
User / Customers name and signature (for acceptance)

d
ONE COPY to be send to: GEA Airmas FAX: +49 2325 468 412 or to your local GEA sales office
57
14.3
GL Chiller Measuring Report
GLWC Chiller Measuring Report

Service technician GEA Order No. GEA ORDER NO. Plant operator Contact Street Town / postcode Plant constructed by Contact Street Town / postcode Function test Chiller Hydraulic module: Refrigerant: 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Electrical measurement of unit L1 - L2 Power supply: L1 - N Power supply: Control voltage: Tested by: Phase sequence relay: Contactors: Control relays: Relays: Thermostats: Sensors: O. K. O. K. O. K. O. K. O. K. O. K. O. K. O. K. O. K. O. K. O. K. O. K. O. K. not O. K. not O. K. not O. K. not O. K. not O. K. not O. K. not O. K. not O. K. not O. K. not O. K. not O. K. not O. K. not O. K. Value: Current: Current: C [A] [A] L2 - N L3 - N yes Maintenance Model no Serial Nr.: R 407C R 134a R 410A Values L2 - L3 L1 - L3 Unit V V V V R Repair Produc. year Tel. Fax.: E-Mail: Tel. Fax.: E-Mail: Cost unit: Service-Nr.: (at bottom on identification plate) Date:
1.10 Pressure sensor: 1.11 Solenoid valves: 1.12 Output adjustment: 1.13 Flow switches: 1.14 Frost protect. switch: 1.15 Evaporator heating 1: 1.16 Evaporator heating 2:
58
Ver.08/2007
2.
Refrigeration circuit Measurement
Serial Nr.:
Compressor 1: Compressor 2: Compressor 3:
Date: Measured values

Compressor 4:
Unit % bar C C K C bar C C K bar bar bar O.K / not O.K A
Values under load: 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 Condensation pressure: Condensation temperature: Fluid temperature: Subcooling (Bubble Point): Hot gas temperature Suction pressure: Evaporation temperature: Suction gas temperature: Overheating (dew point): Blow off pressure as per valve display: Tested HP switch point: Tested LP switch point: Oil level: Crank case heating: Compressor at 100 % L1 L2 L3 Oleic acid test Sight window: Indicator: Filter drier: Leak test: MV Compressor cooling: Compressor type 1 Compressor type 2 Compressor type 3 Compressor type 4
100
100
100
100
Current consumption A A A OK / not OK OK / not OK OK / not OK OK / not OK OK / not OK OK / not OK SerialNr. SerialNr. SerialNr. SerialNr. Notes:
59
3. Type:
Evaporator Glycol Measurement Values at full load (100%) %/
Serial Nr.: Evaporator serial number: C Circuit 1: Glycol type: Values Circuit 2: Circuit 3:
Date:
Medium:
Water Circuit 4: Unit C C K bar bar bar
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20
Temperature at medium inlet Temperature at medium outlet T: Water pressure at inlet Water pressure at outlet p GEA Hydraulic module Hydraulic module type: Buffer tank present / size Strainer present Flow switch present Pressure gauge present Shut off valves present Expansion tank present Safety valve present Current consumption of pumps Water pump 1 Water pump 2 Water pump type 1 Water pump type 2 Note: Serial Nr. Serial Nr. Liter yes yes yes yes yes yes L1 no no no no no no L2 Pressure L3 bar yes no by others Serial Nr.: Single circuit tank Cleaned: Function:
Dual circuit tank yes ok no not ok
A A
R1 R2 R3 R4
mm mm mm mm
60
4. Type
Condenser Glycol %/
Serial Nr.: Serial number: C Circuit 1: Glycol type:
Date:
Medium Parameter
Water Circuit 3: Circuit 4: Unit C C K bar bar bar K
Measured values Circuit 2:
Values at full load (100%) 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.29 4.20 4.21 4.22 4.23 4.24 Temperature medium inlet Temperature medium outlet T: Water pressure inlet Water pressure outlet p: Difference 2.3 and 4.2 GEA hydraulic module available Type of hydraulic module Strainer Flow switch Pressure gauge Shut-off valves Expansion tank Safety valve Pump current consumption Chilled water pump 1 Chilled water pump 2 Chilled water pump type Chilled water pump type 3-way valve Control for 3-way valve Fan control heat rejection unit Inverter controlled pump
yes yes yes yes yes yes yes L1 L2 no no no no no no
no
by others Serial No. Cleaned: Function: yes ok no not ok
Pressure L3
Bar A A
Serial No. Serial No. yes yes yes yes Note: no no no no GEA GEA By others By others
61
5.
Controller and setting
Serial Nr.: Software Version:
Date:
Used controller: Setting values 5.1 Remote ON/OFF used: 5.2 General error message 5.3 Does error message lock remote ON/OFF 5.4 Pump lead time: 5.5 Pump overrun time: 5.6 Type of temperature control 5.7 Temperature control according to 5.8 Setpoint cooling 5.9 2nd setpoint cooling 5.10 Setpoint shift 4-20 mA 5.11 Load shedding switch 5.12 Connection to BMS 5.13 Set frost protection value: 5.14 Starting value for evaporator heating: 5.15 Operating hours compressor 1: 5.16 Operating hours compressor 2: 5.17 Operating hours compressor 3: 5.18 Operating hours compressor 4: 5.19 Operating hours CW pump 1: 5.20 Operating hours CW pump 2: 5.21 Min. idle time of compressor 5.22 Mini. idle between 2 compressor starts 5.23 Min. running time of compressor 5.24 Max compressor start ups per hour yes yes yes yes C C yes yes yes
Comment: no no no sec. by controller: sec Inlet C Proportional band no no no no Dif. Dif. Report C C x x x x x x h h h h h h C Min. / Max. % / C by controller: Outlet C Proportional control by others: by others: Quick Mind
h h h h h h sec. sec. sec. /h Note:
Maintenance interval Maintenance interval Maintenance interval Maintenance interval Maintenance interval Maintenance interval
62
Check / visual inspection
Serial Nr.: O. k. not O. K.
Date: Comment / action required
6.1 Compressor 6.1.1 Check externally for soiling, damage and corrosion
6.1.2 Check fixing and operating noises 6.1.3 Check for leaks (visual inspection) 6.2 Condenser Check externally for soiling, damage and 6.2.1 corrosion 6.2.2 Check for leaks (visual inspection) 6.3 Evaporator Check externally for soiling, damage and 6.3.1 corrosion 6.3.2 Check for leaks (visual inspection) 6.4 System parts Check externally isolation for damage 6.4.1 6.4.2 Check fixing Check refrigerant conducting unit parts for 6.4.3 leaks (visual check) Check externally compensators for damage 6.4.4 6.5 Electrical devices Check optical and acoustical control 6.5.1 devices Check if connecting terminals are tight, 6.5.2 tighten, if necessary
Notes:
Date:
Name:
Signature:
63
Our Market in Europe
E B
GEA Happel Belgium N.V. B-1130 Brussels Tel. +32 / 2 / 2406161 EVISS Ltd. BG-7000 Rousse Tel. +359 / 82 / 81000 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatec Schweiz AG CH-3065 Bolligen-Station Tel. +41 / 31 / 9171919 GEA LVZ, a.s. CZ-46312 Liberec Tel. +420 / 48 / 5225-111 GEA Klimatizace spol. s r.o. CZ-46312 Liberec Tel. +420 / 48 / 5225-303 GEA Happel Klimatechnik GmbH D-44625 Herne Tel. +49 / 2325 / 468-00
EST
GEA Air Treatment Marketing Services Int. GmbH - oficina Espaa E-28036 Madrid Tel. +34 / 91 / 3837701 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Happel France sarl F-59436 Roncq Cedex Tel. +33 / 3 / 20689020 OY TEKNOCALOR AB FIN-01300 Vantaa Tel. + 358 / 9 / 82546020 Denco Ltd. UK-HR4 8DS Hereford Tel. +44 / 1432 / 277 277 GEA Klimatechnika Kft H-1037 Budapest Tel. +36 / 1 / 4393200 GEA Klima-rashladna tehnika d.o.o. HR-10000 Zagreb Tel. +385 / 1 / 6064900 Aspect Environmental Ltd. Ardee, Co. Louth Ireland Tel. +353 / 41 / 6858983
GEA Happel Luxembourg L-4940 Bascharage Tel. +352 / 26 / 502970 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 GEA Klimaprodukter AS N-0484 Oslo Tel. +47 / 220 / 27990 GEA Happel Nederland B.V. NL-2909 LL Capelle a/d Ijssel Tel. +31 / 10 / 2350606 Nnio, Lda. P-1269-090 Lisboa Tel. +351 / 21 / 3826160 GEA Klimatyzacja Sp. z o.o. PL-54610 Wroclaw Tel. +48 / 71 / 3737952
RUS
GEA Kondicioner Moskva RU-105094 Moskva Tel. +7 / 495 / 9566674 GEA EXOS Ventilation AB S -74528 Enkping Tel. +46 / 171 / 85530 GEA Klimatizcia s.r.o. SK-83104 Bratislava Tel. +421 / 7 / 44457917 GEA Klimatizacijska Tehnika d.o.o. SI-1000 Ljubljana Tel. +386 / 1 / 2573850 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 ISISAN TR-80700 Balmumcu Istanbul Tel. +90 / 212 / 2757171 GEA Ukraina t.o.v. UA-01135 Kyiv Tel. +38 / 044 / 4619356
LT
BG
LV
BIH
SK
MWE
BY
FIN
SLO
CH
GB
SRB
NL
CZ
TR
HR
UA
PL IE
Air Treatment Division
For detailed information on all corporate areas, go to www.gea-airtreatment.com or contact
A company of GEA Group
us by email info@gea-airtreatment.com
Copyright GEA Air Treatment
GEA Klimatechnik GmbH A-4673 Gaspoltshofen Tel. +43 / 7735 / 8000-0
DK
GEA Klimateknik ApS DK-2610 Rdovre Tel. +45 / 38 / 887070
IS
Rafn Jensson IS-110 Reykjavik Tel. +354 / 56 / 780-30
RO
GEA Klimatechnik s.r.l. RO-300222 Timisoara Tel. +40 / 356 / 423703

Chiller GLWC-0152-1204BD2 - BA - 2008-01

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Chiller GLWC-0152-1204BD2 - BA - 2008-01

Transféré par

Droits d'auteur :

Formats disponibles

Operation Manual

GLWC 0152-0612 BD2

GLWC 0604-1204 BD2

Safety and User Information ...................................................... 9

Technical Description ............................................................... 13

Transport and Storage .............................................................. 25

Medium Connections ................................................................ 29

Electrical Connection ............................................................... 36

PR-2008-0006-GB Subject to modifications Status 01/2008

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

11 Care and Maintenance .............................................................. 50

13 Dismantling and Disposal ........................................................ 54

Product Type Code

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Product Type Code

PR-2008-0006-GB Subject to modifications Status 01/2008

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Overview of Units and Scope of Delivery

Overview of Units and Scope of Delivery

GLWC 0152-0612 BD2

GLWC 0604-1204 BD2

Overview of units with cooling capacity between 43 and 186 kW

1) Water inlet condenser 2) Water outlet condenser

Overview of units with cooling capacity between 174 and 370 kW

1) Water inlet condenser 2) Water outlet condenser

PR-2008-0006-GB Subject to modifications Status 01/2008

Overview of Units and Scope of Delivery

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Accessories and special equipment

PR-2008-0006-GB Subject to modifications Status 01/2008

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Overview of Units and Scope of Delivery

Soft start for compressor drive motors* (.E06)

Refrigeration circuit accessories Accessories installation

Fig. -3: Reduction of sound power level

Groove lock coupling

PR-2008-0006-GB Subject to modifications Status 01/2008

Overview of Units and Scope of Delivery

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Water collector for connection

PR-2008-0006-GB Subject to modifications Status 01/2008

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Safety and User Information

Safety and User Information

Availability of the operation manual

Scope of the operation manual

PR-2008-0006-GB Subject to modifications Status 01/2008

Safety and User Information

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Labelling of safety information

PR-2008-0006-GB Subject to modifications Status 01/2008

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Safety and User Information

PR-2008-0006-GB Subject to modifications Status 01/2008

Safety and User Information

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Modifications and changes

3.10 Personnel selection and qualifications

PR-2008-0006-GB Subject to modifications Status 01/2008

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

PR-2008-0006-GB Subject to modifications Status 01/2008

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Plate heat exchanger