chiller GLWC-0152-1204BD2_BA_2008-01

Operation Manual

db^=`ÜáääÉêIndoor installation - water-cooled - 43 to 370 kWGLWC 0152-0612 BD2 - GLWC 0604-1204 BD2

GLWC 0152-0612 BD2Table of Contents GLWC 0604-1204 BD2

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

Table of Contents

1 Product Type Code ..................................................................... 4

2 Overview of Units and Scope of Delivery ................................. 52.1 Unit overview ............................................................................................. 52.2 Scope of delivery ....................................................................................... 62.3 Accessories and special equipment ........................................................... 6

3 Safety and User Information ...................................................... 93.1 Availability of the operation manual ........................................................... 93.2 Scope of the operation manual .................................................................. 93.3 Used symbols ............................................................................................ 93.4 Labelling of safety information ................................................................. 103.5 Safety-conscious working ........................................................................ 113.6 Proper use ............................................................................................... 123.7 Modifications and changes ...................................................................... 123.8 Spare parts .............................................................................................. 123.9 Disposal ................................................................................................... 123.10 Personnel selection and qualifications ..................................................... 12

4 Technical Description ............................................................... 134.1 Unit description ........................................................................................ 134.2 Functional description .............................................................................. 174.3 Temperature control ................................................................................. 174.4 Technical data .......................................................................................... 204.5 Operating limits ........................................................................................ 24

5 Transport and Storage .............................................................. 255.1 Delivery .................................................................................................... 255.2 Transportation .......................................................................................... 255.3 Storage .................................................................................................... 26

6 Installation ................................................................................. 276.1 Installing the unit ...................................................................................... 276.2 Assembling the unit .................................................................................. 28

7 Medium Connections ................................................................ 297.1 Requirements ........................................................................................... 297.2 Schematic representation of various hydraulic chilled water circuits ....... 317.3 Schematic representation of various hydraulic heat rejection circuits ..... 327.4 Function of a 3-way valve ........................................................................ 347.5 Connecting chilled and cool water circuit ................................................. 35

8 Electrical Connection ............................................................... 368.1 Requirements ........................................................................................... 368.2 Connecting supply voltage ....................................................................... 378.3 Electrical integration ................................................................................. 388.4 Connecting control contacts and controller .............................................. 40

9 Commissioning ......................................................................... 429.1 Requirements ........................................................................................... 429.2 Checking and testing ............................................................................... 429.3 Switching on the main isolator ................................................................. 439.4 Calibration ................................................................................................ 44

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Table of Contents

PR-2008-0006-GB • Subject to modifications • Status 01/2008 3

10 Operation ................................................................................... 4510.1 Overview of the controls ........................................................................... 4510.2 Switching on and off ................................................................................. 4510.3 Disconnecting the unit from the power supply .......................................... 4910.4 What to do in case of alarm and error messages ..................................... 49

11 Care and Maintenance .............................................................. 5011.1 Care and cleaning ..................................................................................... 5011.2 Maintenance ............................................................................................. 50

12 Troubleshooting ........................................................................ 5112.1 Alarms ....................................................................................................... 5112.2 Alarm messages in overview .................................................................... 52

13 Dismantling and Disposal ........................................................ 5413.1 Dismantling ............................................................................................... 5413.2 Disposal .................................................................................................... 54

14 Appendix .................................................................................... 5514.1 Technical Requirements for Function Testing or Chiller Maintenance ..... 5614.2 GL Chiller Commissioning Form ............................................................... 5714.3 GL Chiller Measuring Report .................................................................... 58

Copyright noteDisclosing, copying, distributing or taking any action in reliance on the contents of this document is strictlyprohibited 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.

GLWC 0152-0612 BD2Product Type Code GLWC 0604-1204 BD2


1 Product Type Code

Chiller G L W C 0 5 1 2 B D 2

(example)GEA Chiller (water cooled)for indoor installationGLWC 0152-0612 BD2GLWC 0604-1204 BD2

GE

A C

hille

r

Con

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ratio

n m

ode

Cap

acity

sta

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Num

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Ser

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GL GEA Large

W Water cooled (indoor installation)

C Chiller

015, 018, 2 compressors



035, 041 2 compressors






120 4 compressors

2 Number of compressors: 2

4 Number of compressors: 4

B Unit series B

D R 410A

2 400 V/3~/50 Hz (+PE)

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Overview of Units and Scope of Delivery


2 Overview of Units and Scope of Delivery2.1 Unit overview

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.

Cooling capacity from 43 to 186 kW Cooling capacity from 174 to 370 kW

GLWC 0152-0612 BD2 GLWC 0604-1204 BD2

Fig. 2-1: Overview of units with cooling capacity between 43 and 186 kW

1) Water inlet condenser 2) Water outlet condenser

3) Water inlet evaporator4) Water outlet evaporator

5) Supply voltage6) Main isolator

Fig. 2-2: Overview of units with cooling capacity between 174 and 370 kW

1) Water inlet condenser 2) Water outlet condenser

3) Water inlet evaporator4) Water outlet evaporator

5) Supply voltage6) Main isolator

GLWC 0152-0612 BD2Overview of Units and Scope of Delivery GLWC 0604-1204 BD2


2.2 Scope of deliveryThe 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)

– Second control connection for remote monitoring. Up to 10 units of the W 3000 con-troller 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. 3: Serial card for connec-tion to building man-agement system or for master/slave control

Fig. 4: Remote control

Fig. 5: Sequencer

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Overview of Units and Scope of Delivery


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 circuitaccessories

– 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)

Accessories installation – 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 trou-ble-free removed and cleaned for maintenance purposes without dismantling the valve body.

– 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:

– 3-way valve for cool water temperature control (supplied loose) (.I31)– Water connections from above (.I32) (only 0152-0612 with GLPE and/or GLPC)

– 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)

Fig. 6: Water filter

GLWC 0604 0704 0804 0904 1004 1104 1204without option .I44 86 dB(A) 87 dB(A) 88 dB(A) 89 dB(A) 90 dB(A) 91 dB(A) 91 dB(A)with option .I44 76 dB(A) 77 dB(A) 78 dB(A) 79 dB(A) 80 dB(A) 81 dB(A) 81 dB(A)

Fig. -3: Reduction of sound power level

Fig. 7: Groove lock coupling

GLWC 0152-0612 BD2Overview of Units and Scope of Delivery GLWC 0604-1204 BD2


– Water collector for evaporator and condenser side withoutGLPE and GLPC (.I39) (only 0604-1204)

– Water collector for evaporator and condenser side withGLPE (.I40) (only 0604-1204)

– Water collector for evaporator and condenser side withGLPC (.I41) (only 0604-1204)

– Water collector for evaporator and condenser side each withpump for GLPE and GLPC (.I42) (only 0604-1204)

– Water collector for evaporator and condenser side each witha total 3 or 4 pumps for GLPE and GLPC (.I43) (only 0604-1204)

Unit accessories – 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

Packaging accessories – Nylon film for unit weather-proof protection. The unit is additionally supplied in an open wooden crate (.O01).

Fig. 8: Water collector for connection

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Safety and User Information


3 Safety and User InformationGEA Chiller of series GLWC 0152-0612 BD2 or GLWC 0604-1204 BD2 are manufac-tured 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 haz-ards 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.

3.1 Availability of the operation manualThis operation manual contains important information regarding safe and correct oper-ation of the GEA unit.

This manual must always be available at the location where unit is installed. Every per-son working with or around the unit must read and use this manual.

The operation manual is intended for operators, in-house technicians, technical per-sonnel or instructed persons as well as electricians and refrigeration engineers.

3.2 Scope of the operation manualThis operation manual provides you with information about the following:– Assembly/disassembly– Installation– Commissioning– Operation– Maintenance and troubleshooting

3.3 Used symbolsThe 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.

DAMAGE TO THE UNIT.The manual error and fault messages may not be reset without GEA’s permission or that of an authorized customer service office. Non-compliance with the above-men-tioned condition invalidates the warranty.

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 BD2Safety and User Information GLWC 0604-1204 BD2


3.4 Labelling of safety information

WEAR PROTECTIVE SHOES.This symbol points out that protective shoes must be worn.

WEAR GLOVES.This symbol points out that gloves must be worn.

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 preven-tion 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 preven-tion 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 pre-vention 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.

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Safety and User Information


3.5 Safety-conscious workingWhen working on 400 V/50 Hz power supplies:

When carrying out any kind of work in general:

• 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.

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 compo-nents. Failure to do so may lead to serious injuries or death.

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 com-ponents or piping, there is a risk of injury from fluids or gases escaping at high pres-sure. 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 environ-ment. 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.

GLWC 0152-0612 BD2Safety and User Information GLWC 0604-1204 BD2


3.6 Proper useUnits 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 treat-ment 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.

3.7 Modifications and changesYou 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 war-ranty claims as null and void.

3.8 Spare partsYou 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 DisposalMake 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 qualificationsEvery 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.

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,

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Technical Description


4 Technical Description

4.1 Unit descriptionThese 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 refrig-erant 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 compres-sors.The newly designed condensers have larger exchange surface areas, as do the new evaporators, which enable even better and more efficient distribution of the refrig-erant 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 imple-mented in these units produces considerable energy savings and vastly reduces oper-ating 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 sys-tem content. The main difference when compared to conventional units is the intelli-gent controller system. All units can be optionally equipped with integrated hydraulic components.

GLWC 0152-0612 BD2Technical Description GLWC 0604-1204 BD2


Basic construction

UnitsGLWC 0152-0612 BD2GLWC 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 compres-sor complete with oil heating for safe compressor start-up, electronic overheating pro-tection 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 com-pressors in each refrigeration circuit. The sizes 0604-1204 consist of 4 compressors, with two copmressors integrated in each of two refrigeration circuits.

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 refriger-ant 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 -8°C.

Fig. 4-1: Scroll compressor

Fig. 4-2: Plate heatexchanger



Refrigeration circuit size 0152-0612

Refrigeration circuit size 0604-1204

Note: Chillers of series GLWC 0604-1204 BD2 consist of two identical refrigeration circuits.

Acronym Description Acronym DescriptionC Scroll compressor RA Shut-off valve suction side (optional)CD Condenser RL Shut-off valve on liquid line (only 0452-0612)EV Evaporator RM Shut-off on discharge side (optional)FE Filter drier T Pressure sensor (only with 3-way valve)MA High-pressure gauge (optional) VA High-pressure safety valveMB Low-pressure gauge (optional) VB Low-pressure safety valvePmin Low-pressure pressostat VEH Thermostatic expansion valvePmax High-pressure pressostat VS Sight glass with humidity indicatorPP Service Schrader valve

Fig. 4-3: Refrigeration circuit scheme size 0152-0612

Acronym Description Acronym DescriptionC Scroll compressor RL Shut-off valve on liquid line (only 0804-1204)CD Condenser RM Shut-off on discharge side (optional)ES Solenoid valve (optional) S1 Temperature sensor water inletEV Evaporator S2 Temperature sensor water outletFE Filter drier VA High-pressure safety valvePmin Low-pressure pressostat VB Low-pressure safety valvePmax High-pressure pressostat VEH Thermostatic expansion valvePP Service Schrader valve VS Sight glass with humidity indicatorRA Shut-off valve suction side (optional) T Pressure sensor (only with 3-way valve)

Fig. 4-4: Refrigeration circuit scheme size 0604-1204



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, mini-

mum 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



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).

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 expan-sion 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

1

2

3

4

5

6



4.3.1 Proportional control via the evaporator water inlet temperature (2 speeds (size 0152-0612))

In the following example it is assumed that the tem-perature 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:

2,5 K / 2 capacity stages = 1,25 K / capacity stage

If the water inlet temperature amounts to 12,0 °C or more, all compressors will be run-ning (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 10,75°C 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 temper-ature 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)

In the following example it is assumed that the tem-perature 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 pro-portional band is distributed among these four ca-pacity stages in appropriately equal ranges. This results in the following:

5,0 K / 4 capacity stages = 1,25 K / capacity stage

If the water inlet temperature amounts to 12,0 °C or more, all compressors will be run-ning (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

100

50

[%]

9,5 1210,75[°C]

Capacity

Setpoint Proportional band 2.5 K

Fig. 4-7:

Water inlet

Setpoint

Fig. 4-8:

Water inlet

Proportional band 5 KSetpoint

Capacity



100 % = 7,0 °C). At 10,75°C 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 temper-ature 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 tem-perature 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)

With this type of control system the chilled water in-let or outlet temperature is used as the control var-iable. In this case only the setpoint is specified, and the controller automatically determines all other switching thresholds in dynamic mode during oper-ation. With this self-adjusting algorithm for temperature control of the chiller the setpoint stays within a neu-tral range. If the evaporator water temperature is within the neutral range, the number of active com-pressors and/or capacity stages is not changed. If load fluctuations in the system lead to tempera-ture values outside the neutral range, compressors and capacity stages are activated or deactivated to return the temperature to the neutral range.

If this is not possible due to the output, another capacity stage is activated or deacti-vated. 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 var-iances, but also in relation to the temperature change-over time, which allows conclu-sions to be drawn about the output.

↑↓Capacity Neutral zone

Capacity increased

Setpoint cooling

Fig. 4-9:

Capacity reduced

Capacity

Variable zone

Temperature



4.4 Technical data

4.4.1 Unit types 0152-0612

Tab. 4-1

Unit type 0152 0182 0202 0252 0262 0302 0352 0412 0452 0512 0552 0612Refrigeration capacity 1) Qe [kW] 43.4 50.1 58.9 66.4 72.6 86.7 101.2 114.7 128.6 143.5 164.9 186.3

Total unit power consumption P [kW] 10.0 11.3 13.0 15.2 16.6 19.5 22.7 25.9 28.9 32.2 36.9 41.6

Condenser capacity Qc [kW] 52.8 60.7 71.2 80.7 88.2 105.0 122.5 139.0 155.8 173.8 199.6 225.4

Chilled water volume flow Ve [m³/h] 7.46 8.62 10.15 11.43 12.49 14.92 17.43 19.74 22.14 24.71 28.39 32.07

Pressure drop (chilled water) Δpe [kPa] 57.78 49.39 49.53 47.04 56.20 34.28 32.80 42.10 39.72 38.46 34.65 44.22

Cool water volume flow Vc [m³/h] 9.14 10.52 12.33 13.97 15.28 18.19 21.22 24.08 26.99 30.10 34.57 39.04

Pressure drop (cool water side) Δpc [kPa] 35.90 37.52 41.97 44.13 52.76 36.71 36.04 35.96 36.43 33.52 35.85 38.10

IPLV 5.93 6.10 6.13 5.80 5.70 5.78 5.91 5.83 5.91 5.90 6.05 5.92

ESEER 5.81 5.98 6.01 5.69 5.59 5.66 5.80 5.71 5.79 5.78 5.93 5.80

Controls W3000 compact

Compressor Fully hermetic Copeland scroll compressor

Number of compressors n 2 2 2 2 2 2 2 2 2 2 2 2

Number of refrigeration circuits n 1 1 1 1 1 1 1 1 1 1 1 1

Capacity stages per unit n 2 2 2 2 2 2 2 2 2 2 2 2

Compressor type 1 ZP 90 ZP 103 ZP 120 ZP 137 ZP154 ZP 180 ZP 180 ZP 235 ZP 235 ZP 295 ZP 295 ZP 385

Compressor type 2 ZP 90 ZP 103 ZP 120 ZP 137 ZP154 ZP 180 ZP 235 ZP 235 ZP 295 ZP 295 ZP 385 ZP 385

Oil type Arctic EAL 22 CC

Oil heating [W] 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

Coil resistance per coil/ compressor [Ω] 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 Soldered stainless steel plate heat exchanger

Min. chilled water volume flow Ve,min [m³/h] 4.6 5.3 6.2 7.0 7.7 9.2 10.8 12.2 13.7 15.3 17.7 20.0

Maximum chilled water flow rate Ve,max [m³/h] 12.6 14.4 16.9 19.1 20.9 24.9 29.1 32.9 36.9 41.3 47.4 53.6

Maximum chilled water relatedoperating pressure* [bar] 10 10 10 10 10 10 10 10 10 10 10 10

Evaporator inlet connection G** [''] 1"½ 1"½ 1"½ 1"½ 1"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½

Evaporator outlet connection G** [''] 1"½ 1"½ 1"½ 1"½ 1"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½

Condenser Soldered stainless steel plate heat exchanger

Min. cool water volume flow Vc,min [m³/h] 2.7 3.2 3.7 4.3 4.7 5.6 6.5 7.4 8.3 9.3 10.7 12.1

Max. cool water volume flow Vc,max [m³/h] 11.5 13.2 15.5 17.6 19.2 22.9 26.6 30.2 33.9 37.7 43.4 48.9

Maximum chilled water relatedoperating pressure* [bar] 10 10 10 10 10 10 10 10 10 10 10 10

Evaporator inlet connection G** [''] 1"½ 1"½ 1"½ 1"½ 1"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½

Evaporator outlet connection G** [''] 1"½ 1"½ 1"½ 1"½ 1"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½

Filling quantitiesRefrigerant R410A [kg] 4 5 6 6 6 9 10 10 12 13 15 16

Oil [kg] 5 7 7 7 7 8 9 9 12 14 13 13

Chilled water minimum system content [l] 200 250 300 350 400 450 500 600 650 700 800 950

WeightTransport weight [kg] 280 295 300 310 315 565 605 635 675 715 765 795

Sound valuesSound power level 2) [dB(A)] 73 74 74 74 75 76 77 77 78 78 79 79

Sound pressure level3 [dB(A)] 44 45 45 45 46 47 48 48 49 49 50 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 off2 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“)

•

•

•

•

•

•

•

•



Unit type 0152 0182 0202 0252 0262 0302 0352 0412 0452 0512 0552 0612

Compressor

Max. power consumption [kW] 2x9 2x10.1 2x11.8 2x13.2 2x14.4 2x16.9 1x16,9+1x22,3 2x22.3 1x22,3+

1x27,4 2x27.4 1x27,4+1x35,8 2x35.8

Max. current consumption [A] 2x15.3 2x16.4 2x20.4 2x22.6 2x25.5 2x27.9 1x27,9+1x36,1 2x36.1 1x36,1+

1x45,8 2x45.8 1x45,8+1x58,9 2x58.9

Starting current of eachcompressor [A] 2x95 2x111 2x118 2x118 2x140 2x198 1x198+

1x225 2x225 1x225+1x272 2x272 1x272+

1x310 2x310

Insgesamt 1,2)

Max. power consumption [kW] 18.0 20.2 23.6 26.4 28.8 33.8 39.2 44.6 49.7 54.8 63.2 71.6

Max. current consumption [A] 30.6 32.8 40.8 45.2 51.0 55.8 64.0 72.2 81.9 91.6 104.7 117.8

Starting current of entire unit [A] 110 127 138 141 166 226 253 261 308 318 356 369

Maximum connectable cable cross-sections 1,2)

Round [mm] 50 50 50 50 50 50 50 50 50 50 120 120

Rectangular [mm²] - - - - - 16x3 16x3 16x3 16x3 16x3 20x5 20x5

Maximum permissible backup fuse ratings (fuse type gLgG) 2)

Back up fuse [A] 63 63 80 80 80 100 100 100 125 125 160 160

DimensionsA 3) (length) [mm] 1055 1055 1055 1055 1055 1222 1222 1222 1222 1222 1222 1222

A 4) (length) [mm] 1706 1706 1706 1706 1706 2000 2000 2000 2000 2000 2000 2000

B (width) [mm] 649 649 649 649 649 873 873 873 873 873 873 873

H (height) [mm] 1255 1255 1255 1255 1255 1496 1496 1496 1496 1496 1496 1496

ClearancesR1 [mm] 600 600 600 600 600 600 600 600 600 600 600 600

R2 [mm] 600 600 600 600 600 600 600 600 600 600 600 600

R3 [mm] 800 800 800 800 800 800 800 800 800 800 800 800

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 GLPC4 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.



4.4.2 Unit types 0604-1204

Tab. 4-3

Unit type 0604 0704 0804 0904 1004 1104 1204Refrigeration capacity 1) Qe [kW] 173.9 202.7 228.0 257.9 288.1 328.5 371.1

Total unit power consumption P [kW] 38.9 45.2 51.6 58.0 64.0 74.0 83.5

Condenser capacity Qc [kW] 210.5 245.2 276.4 312.4 348.3 398.0 449.7

Chilled water volume flow Ve [m³/h] 29.9 34.9 39.2 44.4 49.6 56.6 63.9

Pressure drop (chilled water) Δpe [kPa] 35.0 32.9 41.6 39.4 39.4 35.2 44.9

Cool water volume flow Vc [m³/h] 36.5 42.5 47.9 54.1 60.3 68.9 77.9

Pressure drop (cool water side) Δpc [kPa] 37.0 36.1 35.5 36.6 33.7 35.6 37.9

IPLV 5.90 6.04 5.94 6.04 6.05 6.11 6.00

ESEER 5.79 5.92 5.82 5.93 5.93 5.99 5.89

Controls W3000 compact

Compressor Fully hermetic Copeland scroll compressor

Number of compressors n 4 4 4 4 4 4 4

Number of refrigeration circuits n 2 2 2 2 2 2 2

Capacity stages per unit n 4 4 4 4 4 4 4

Compressor type 1 ZP 180 KCE ZP 180 KCE ZP 235 KCE ZP 235 KCE ZP 295 KCE ZP 295 KCE ZP 385 KCE




Oil type Arctic EAL 22 CC

Oil heating [W] 4 x 70 2 x 70/2x120 4 x 120 2x120/2x150 4 x 150 4 x 150 4 x 150

Coil resistance per coil/ compressor [Ω] 4 x 0,70 2x0.7/2x0.63 4 x 0.63 2x0.63/2x0.51 4 x 0,51 2x0.51/

2x0.35 4 x 0.35

Evaporator Soldered stainless steel plate heat exchanger

Min. chilled water volume flow Ve,min [m³/h] 18.6 21.7 24.4 27.7 30.9 35.3 39.8

Maximum chilled water flow rate Ve,max [m³/h] 49.9 58.3 65.4 74.1 82.8 94.4 106.6

Maximum chilled water related operat-ing pressure* [bar] 10 10 10 10 10 10 10

Evaporator inlet connection G** [''] 2"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½

Evaporator outlet connection G** [''] 2"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½

Condenser Soldered stainless steel plate heat exchanger

Min. cool water volume flow Vc,min [m³/h] 11.3 13.2 14.9 16.8 18.7 21.4 24.2

Max. cool water volume flow Vc,max [m³/h] 45.7 53.2 60.0 67.7 75.5 86.2 97.5

Maximum chilled water related operat-ing pressure* [bar] 10 10 10 10 10 10 10

Evaporator inlet connection G** [''] 2"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½

Evaporator outlet connection G** [''] 2"½ 2"½ 2"½ 2"½ 2"½ 2"½ 2"½

Filling quantitiesRefrigerant R410A [kg] 17 19 20 24 26 30 32

Oil [kg] 17 18 19 23 27 26 25

Chilled water minimum system content [l] 850 1000 1150 1250 1450 1650 1860

WeightTransport weight kg 1055 1130 1190 1270 1355 1450 1510

Sound valuesSound power level 2) [dB(A)] 86 87 88 89 90 91 91

Sound pressure level3 [dB(A)] 57 58 59 60 61 62 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 off2 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“)

•

•

•

•

•

•

•

•



Unit type 0604 0704 0804 0904 1004 1104 1204

Compressor

Max. power consumption [kW] 4x16.9 2x16,9+2x22,3 4x22.3 2x22,3+

2x27,4 4x27.4 2x27,4+2x35,8 4x35.8

Max. current consumption [A] 4x27.9 2x27,9+2x36,1 4x36.1 2x36,1+

2x45,8 4x45.8 2x45,8+2x58,9 4x58.9

Starting current of eachcompressor [A] 4x198 2x198+2x225 4x225 2x225+2x272 4x272 2x272+2x310 4x310

Insgesamt 1,2)

Max. power consumption [kW] 68 78 89 99 110 126 143

Max. current consumption [A] 111.6 128.0 144.4 163.8 183.2 209.4 235.6

Starting current of entire unit [A] 282 317 333 390 409 461 487

Maximum connectable cable cross-sections 1,2)

Round [mm] 120 120 120 120 120 240 240

Rectangular [mm²] 20x5 20x5 20x5 20x5 20x5 2x25x5 2x25x5

Maximum permissible backup fuse ratings (fuse type gLgG) 2)

Back up fuse [A] 160 200 200 250 250 315 315

DimensionsA 3) (length) [mm] 2227 2227 2227 2227 2227 2227 2227

A 4) (length) [mm] 2962 2962 2962 2962 2962 2962 2962

B (width) [mm] 877 877 877 877 877 877 877

H (height) [mm] 1780 1780 1780 1780 1780 1780 1780

ClearancesR1 [mm] 1000 1000 1000 1000 1000 1000 1000

R2 [mm] 1000 1000 1000 1000 1000 1000 1000

R3 [mm] 1000 1000 1000 1000 1000 1000 1000

R4 [mm] 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 pumps4 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.



1: with cool water (In/out): 30/35 °C2: with chilled water (In/out): 12/7 °C

For detailed design please contact your GEA sales office

4.5 Operating limits D. 1

Coo

l wat

er o

utle

t tem

pera

ture

at c

onde

nser

(Tco

) [°

C]

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 ΔT 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 ... BDEvaporator Condenser

Min. Max. Min. Max.Water inlet [°C] -41 231 102 512

Water outlet [°C] -81 151 262 552

Δ T [K] 3 8 4 16

Tab. 4-5

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 temperatureat 26 °C for safe operation of the chiller.

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Transport and Storage


5 Transport and Storage

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.

5.2 Transportation

• 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.

• 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.

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 stor-age until the unit is ready for commissioning.

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.

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.

GLWC 0152-0612 BD2Transport and Storage GLWC 0604-1204 BD2


Fig. 5-1: Transport unit (example GLWC 0152-0252 BD2)

Weight sizes 0152-0612

Weight sizes 0604-1204

5.3 StoragePermitted storage conditions / permitted air condition for units which have not yet been installed

Air temperature: -20 °C up to +50 °C

Air humidity: up to 85 % (relative humidity, non condensing)

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

Units with pump moduleTransport weight 435 450 460 470 475 840 880 915 955 1005 1045 1085Operating weight 455 470 480 490 495 860 900 935 975 1025 1065 1105

Tab. 5-1: All weight in kg

Unit type 0604 0704 0804 0904 1004 1104 1204Transport weight 1055 1130 1190 1270 1355 1450 1510Operating weight 1065 1140 1200 1280 1365 1460 1520

Units with 1 or 2 pumpsTransport weight 1350 1430 1495 1605 1695 1785 1820Operating weight 1370 1450 1515 1625 1715 1805 1840

Units with 3 or 4 pumpsTransport weight 1590 1680 1745 1880 1975 2065 2135Operating weight 1620 1710 1775 1910 2005 2095 2165

Tab. 5-2: All weight in kg

NOTE!Use only supplied documentation and enclosed detailed dimesional drawings when transporting the unit.

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Installation


6 Installation

6.1 Installing the unit

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 envi-

ronment.– Choose the installation location so that operating noise does not cause a distur-

bance.– Requirements for the installation location must be verified and adhered to in accord-

ance with EN 378.

INFORMATION ON ASSEMBLY AND INSTALLATION OF THE UNITHere 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 UNITIf 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.

NOTE!For detailed planning use only the order-related documentation which is supplied with the unit and observe all dimensional drawings.

GLWC 0152-0612 BD2Installation GLWC 0604-1204 BD2


6.2 Assembling the unitIn 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 founda-

tion when installing it in a location where no special requirements for the neutralisa-tion of structure-borne noise apply.

– For sound-related technical requirements please select the additional sound insu-lating accessories for compressor in accessories and special equipment.

– For very special acoustic requirements please consult an acoustic engineer to se-lect 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:

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Medium Connections


7 Medium Connections

7.1 RequirementsKeep in mind:

• The complete chilled water circuit must be designed and implemented in accordance with the current standards and guidelines.

Glycols

• 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 -20°C 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.

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.

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.

GLWC 0152-0612 BD2Medium Connections 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 unit’s water system.

• Air vents must be installed at all high points in the chilled water system at easily accessible locations.

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 providebasic informationon water quality

and do not form anybasis for a guarantee.

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.

Description Symbol Values Effects if values are not adhered to

Hydrogen ion concentration pH 7.5 – 9 < 7.5> 9

CorrosionIncrustation

Calcium and magnesium content Hardness (Ca/Mg) 4 – 8,5 °D > 8.5 Incrustation

Chlorine ions Cl– < 50 ppm Corrosion

Iron ions Fe³+ < 0,5 ppm Corrosion

Magnesium ions Mg²+ < 0,05 ppm Corrosion

Carbon dioxide CO2 < 10 ppm Corrosion

Hydrogen sulphide H2S < 50 ppb Corrosion

Oxygen O2 < 0,1 ppm Corrosion

Chlorine Cl2 < 0,5 ppm Corrosion

Ammonia NH3 < 0,5 ppm Corrosion

Bicarbonate/sulphate ratio HCO3-/SO4²- > 1 < 1 Corrosion

Tab. 7-1: 1/1.78 °D = 1 °Fr mit 1 °Fr = 10 g CaCO3/m³ ppm = parts per million (mg/l)ppb = parts per billion (μg/l)



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

1: Pressure gauge2: Shut off cock3: Automatic venting4: Vibration damping connection5: Unit-independent pipeline fixing point6: GEA water filter (maximum mesh size 1 mm2)7: Drain valve8: Pump – primary circuit9: Safety valve10: Expansion tank11: Filling valve12: GEA flow switch

13: Balancing valve14: Pump – secondary circuit15: GEA Chiller16: Buffer tank/hydraulic switch suitable for chilled water systems17: Consumer18: GEA Condenser19: GEA Heat rejection unit20: 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 trouble-free operation of the unit and in such a way this requirement constitutes an integral part for the validity of the guarantee.



7.3 Schematic representation of various hydraulic heat rejection circuits

Installing water filter Under all circumstances please remember to install a water filter of mesh size 0,5-1 mm before direct inlet into the evaporator and condenser in order to avoid dirt forma-tion and damage in the heat exchanger. This requirement constitutes an integral part for the validity of the guarantee.

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.



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 tem-perature, the higher the achieved refrigeration capacity and the lower the energy con-sumption 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 outlettemperature

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 situ-ation is not always the case because of cold weather. Therefore there are several tech-nical possibilities to ensure the minimum cool water outlet temperature.

Possibility 1: – 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.

Possibility 2: – 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).

Possibility 3: – Option 3 can also be used in order to provide for the minimum cool water outlet tem-perature of the unit. In this case a 3-way valve is installed in cool water inlet addi-tionally 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).



7.4 Function of a 3-way valveWithin 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 rec-ommended 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 3-way 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

• Flush the piping system by others and compile a cleaning report.

Unit type 0152 0182 0202 0252 0302 0352 0412 0452 0512 0552 0612kvs-value 19 19 19 31 31 31 49 49 49 49 49

Abb. 8: 7

Unit type 0604 0704 0804 0904 1004 1104 1204kvs-value 78 78 78 78 124 124 124

Tab. 7-1



7.5 Connecting chilled and cool water circuit

• 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.When connecting the primary chilled and cool water system, counterhold the con-necting spigots with a pipe wrench to prevent damage.

DAMAGE TO THE UNIT.The heat exchangers in the unit must be protected against ice formation during sys-tem 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.

GLWC 0152-0612 BD2Electrical Connection GLWC 0604-1204 BD2


8 Electrical Connection

8.1 RequirementsBefore you start setting up the unit’s 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:

Electrical connections may only be carried out by qualified staff who, based on their training and experience, have sufficient knowledge of the relevant accident preven-tion 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 sys-tems 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 dia-grams.Only separate mains power cable may be used. Never connect other units to this mains power cable.

voltage deviation ΔUmaxMax. voltage deviation from average value

Average voltage Um---------------------------------------------------------------------------------------------------- 100×=

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Electrical Connection


8.2 Connecting supply voltageA 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 wir-ing 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

NOTE!When connecting the supply voltage, make sure you observe theclockwise rotating direction!

Input data ➯ Result

Requirements

You must first determine certain in-put data/measured values.

Nominal voltage

Voltage between phases

➔ 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

Average voltage ➔

➔ Um = 401 V

2. Step

Determine the maximum voltagedeviation ΔUmax

Voltage deviation ΔUmax in %?

➔

Umax = 409 V

Um = 401 V ➔ ΔUmax = 1,99 % ✓

EXAMPLE

UmΣU3

-------=

409 398 396+ +( )3

----------------------------------------------- 401 V=

ΔUmaxmax. voltage deviation

Um----------------------------------------------------- 100×=

409 401–( )V401 V

----------------------------------- 100 × 1,99 %=



8.3 Electrical integration

Fig. 8-2: Electrical integration GLWC 0152-0612 BD2Terminals: A - B: Connecting the flow switch by others

E - F: Remote contact for switching the machine off and on via the NO contact by othersP1 - 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 pres-sure 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 con-stitutes an integral part for the validity of the guarantee.

Setpoint shift 4-20 mA signal By others

Error message* Load shedding*

GEA Chiller GLWC 0152 - 0612 BD2Serial card RS485/Modbus (option)

Remote contact on/off*

Flow switch* General error message

#230 V/50 Hz/2 A

Operation mes-sage compres-sor 1 #(option)


Option extension card (.E29)

Relay for chilled water pump by others #230 V/

50 Hz/2 A

1Y13-way-valve*(option)



Fig. 8-3: Electrical integration GLWC 0604-1204 BD2Terminals: A - B: Connecting the flow switch by others

E - F: Remote contact for switching the machine off and on via the NO contact by othersP1 - 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 signal039-040: 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)

cc1)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 waterpressure 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 con-stitutes an integral part for the validity of the guarantee.

Setpoint shift4-20 mA signal

GEA Chiller GLWC 0604 - 1204 BD2Serial card RS485/Modbus (option)

Remote contact on/off*

Flow switch* General error message

#230 V/50 Hz/2 A



Relay for chilled water pump by

others #230 V/50 Hz/2 A

Error message by others*

Loadshedding*

(Option)

2. Setpoint*

(Option)



4Y13-way-valve*(option)



8.4 Connecting control contacts and controllerWe 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

• Connect the external flow switch. See the elec-trical wiring diagram enclosed with the unit, ter-minals 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 mm².

Fig. 8-4: Electrical integration of flow switchTerminals: A - B: Connecting the flow switch by othersTerminals: E - F: Remote contact for switching the unit off and on via NO contact by othersTerminals: 15 - 16: General error message (voltage by others max. 230 V AC/50 Hz/2 A)

8.4.2 Integration of collective error message

• Connect the line for the collective error mes-sage (potential free contact, suitable for230 V AC / 50 Hz / 2 A).

Fig. 8-5: Electrical integration of collective error messageTerminals: A - B: Connecting the flow switch by others

E - F: Remote contact for switching the unit off and on via NO contact by others15 - 16: General error message (voltage by others max. 230 V AC/50 Hz/2 A)

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 chiller’s switch cabinet. The flow switch acts as a safety device and not as a regular switching device for the chiller.

GEA Chiller

ContactRemote On/Off*

Flowswitch

Flowswitch Relay by others

230V/50Hz/2A

Generalerror 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

ContactRemote On/Off*

By othersRelay

Flowswitch Relay by others

230V/50Hz/2A

Generalerror message



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:

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 mm².

Pump control

Operation on/offChilled waterChiller

GLWC 0152-0612 BD2Commissioning GLWC 0604-1204 BD2


9 Commissioning

9.1 RequirementsSpecific 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 com-missioning 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.

Obligatory!A commissining report must

be sent to GEA

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.

9.2 Checking and testing

Check the following before switching on the main isolator and after installation of the unit:

Visual inspection ofmechanical components

• 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.

Check electricalconnection

• 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.

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 tech-nical knowledge in the relevant areas.

ELECTRICAL HAZARD!There is a danger of electric shock when checking and testing the unit if it is con-nected to the power supply.

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Commissioning


Checking refrigerationcircuit

• 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.

• Check all screw connections and tighten where necessary.

Check chilled and cool waterpiping 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.

9.3 Switching on the main isolator• Switch on the unit’s 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.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.

ENVIRONMENTAL DAMAGEDispose of any escaping media or oil immediately in an environmen-tally-friendly manner and in compliance with local laws and regula-tions.

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.

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.

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 com-pressors can be damaged if this warm-up phase is not carried out.

GLWC 0152-0612 BD2Commissioning GLWC 0604-1204 BD2


9.4 Calibration8 hours of uninterrupted oil preheating operation will ensure that there is no more refrig-erant in the oil. The unit can now be put into operation and calibrated.

Reliable recording of correctly measured values is only possible during stable opera-tion 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.

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.

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Operation


10 Operation

For controller operation also refer to Unknown source of cross-reference and the fol-lowing pages.

10.1 Overview of the controlsW3000 compact control and display elements:

10.2 Switching on and offAs soon as all necessary requirements for the commissioning have been met, there are several ways to switch the unit on and off.

Priorities of various options:Highest priority: – on/off by entering parameters (Com.: on/ Com.: off)

– on/off via digital input on/off (see page 46)

Lowest priority: – 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.

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.

Fig. 10-1: Control display W3000 compact

Controlelement Description

Serves to display and reset alarms.

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 pa-rameters that need to be changed.

Is used to navigate the screens and to enter/change parameter values down-wards.

GLWC 0152-0612 BD2Operation GLWC 0604-1204 BD2


10.2.1 Switching on

10.2.2 Switching off

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 chiller’s 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.

• 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.

• 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!



10.2.4 Adjust the water inlet and outlet temperature controls

To adjust the control system type, proceed as follows:

10.2.5 Adjusting the chilled water setpoint

To modify the chilled water setpoint, proceed as follows:

NOTE!For controller operation also see „Temperature control“ on page 17.

• 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.


• Use the arrow keys to set the parameter “Type of control system”.


• Two parameters can be adjusted here:– “by steps” as control system type with corresponding parameters:

“INPUT” “OUTPUT”

Speed stage control using chilled water inlet temperature is not adjustable.

– “Quick Mind” as control system type with corresponding parameters:“INPUT” “OUTPUT”

Graduated control with neutral zone via the chilled water inlet temperature.

• Toggle between “Quick Mind” and “by steps” using the arrow keys.


• Toggle between “INPUT” and “OUTPUT” using the arrow keys.


• Press the "Esc" key to return to the start screen.

• Press “Prg” key.

• Select the “Setpoint” menu with the arrow keys.

GLWC 0152-0612 BD2Operation GLWC 0604-1204 BD2



Use the arrow keys to adjust the parameter “Chiller setpoint”.


• Change the parameter using the arrow keys.

– „by steps“„INPUT“:

As control mode for unit sizes 0604-1204 the standard set-point of 7,0°C is displayed here; with the preset proportional band this corresponds to an actual setpoint of 12°C (7,0°C + 5,0°C P-band = 12°C).For unit sizes 0152-0612 the standard setpoint of 9,5°C is displayed here; with the preset proportional band this corre-sponds to an actual setpoint of 12°C (9,5°C + 2,5°C P-band = 12°C).

– „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 "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 +4°C at chilled water outlet).



10.3 Disconnecting the unit from the power supply• Switch the main isolator off.

The unit is now disconnected from the power supply.

10.4 What to do in case of alarm and error messages

See „Troubleshooting“ on page 51 for instructions in the event of alarm messages.

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.

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.

GLWC 0152-0612 BD2GLWC 0604-1204 BD2


11 Care and Maintenance

11.1 Care and cleaning

11.2 MaintenanceThe maintenance of the unit may only be carried out by GEA Service or a special-ist 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 • The glycol concentration in the system must be checked annually and always when the liquid level is topped up.

At least every 2 years • 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).

Obligatory!1 annual maintenance

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 mainte-nance of refrigeration systems/chillers and connected systems.

Recommendation!2 services per year

We recommend that you have your unit serviced twice a year.

DANGER – SHARP CUTTING EDGES!Exercise caution when cleaning the unit as the thin fins may inflict cuts.

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.

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Troubleshooting


12 Troubleshooting

12.1 AlarmsWhat to do in case of alarms:

1. Inform GEA Service.

2. Have GEA Service eliminate the fault’s cause.

3. Only GEA Service may reset the fault.

In case of an alarm the “ALARM” key lights up red.

To read out the alarm messages, proceed as follows:

12.1.1 Only for service team

To reset the alarm:

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.

DAMAGE TO THE UNIT.If alarms are reset several times without eliminating the fault, this may seriously dam-age the unit. Faults must not be reset manually without the agreement of the refrig-eration engineering company or GEA service.

• 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.

• Eliminate malfunction.

• Hold the “ALARM” key pressed down until “No Alarm detected” appears.

If this is not displayed, the alarm is still active.

GLWC 0152-0612 BD2Troubleshooting GLWC 0604-1204 BD2


12.2 Alarm messages in overview

Alarm Description Details Reset

002 Phase sequence not correctShows a false phase connection and switches off the en-tire unit. (Optional, only visible when the input is connect-ed.)

A

003 Flow switch, evaporator

– 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.

A, M A

005 Water temperature at evaporator inlet too low Active only in “heat pump” mode. Shows that the water temperature at the evaporator inlet is too low. S-A

006 Water temperature at evaporator inlet is too high Active only in "chiller/cooling" mode. Shows that the water temperature at the evaporator inlet is high. S-A

010 Frost protection, evaporatorLow water temperature at evaporator outlet. Besides, the evaporator (with more than one evaporator) where the alarm was triggered is displayed.

M

014 Missing of remote ON/OFF control contactOnly 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.

M

017 Low outside air temperature Displays that outdoor air temperature fell below set value. S

021 Too little water in the system The water outlet temperature at the evaporator changes too quickly, caused by too little water in the system. S

022 Low water flow rate in the systemThe temperature difference between inlet and outlet at evaporator is too high resulting from too low pump water volume flow.

M

051 Maintenance pump 1The specified maintenance interval in operating hours has been exceeded (in units with one pump, pump 1 is the chilled water pump)

S

052 Maintenance pump 2(Units with more than one pump). The specified mainte-nance interval in operating hours for pump 2 has been ex-ceeded.

S

081 Overload protection, pump 1 Shows that pump 1 is overheating (in units with one pump, pump 1 is the chilled water pump) M

082 Overload protection, pump 2 (units with more than one pump). This alarm shows that pump 2 has overheated. M

131 Fault, compressor 1 Indicates that the electric motor of compressor no. 1 is overheated or has another malfunction. M - A/M

132 Fault, compressor 2 “As above for compressor no.°2” M - A/M133 Fault, compressor 3 “As above for compressor no.°3” M - A/M134 Fault, compressor 4 “As above for compressor no.°4” M - A/M

151 Maintenance, compressor 1 The specified maintenance interval in operating hours for compressor no. 1 has been exceeded. S

152 Maintenance, compressor 2 “As above for compressor no.°2” S153 Maintenance, compressor 3 “As above for compressor no.°3” S154 Maintenance, compressor 4 “As above for compressor no.°4” S

181 Compressor 1 increased start ups The maximum number of compressor start ups per hour was exceeded S

182 Compressor 2 increased start ups “As above for compressor no.°2” S183 Compressor 3 increased start ups “As above for compressor no.°3” S184 Compressor 4 increased start ups “As above for compressor no.°4” S211 High pressure, circuit 1 Signals too high pressure in circuit Nr. 1 M212 High pressure, circuit 2 “As above for circuit no.°2” M

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Troubleshooting


221 Overload protection, fan circuit 1 Displays overheating of condenser fans electric motor in circuit 1, with following stop of the latter. M

222 Overload protection, fan circuit 2 “As above for circuit no.2” M

231 Low pressure, circuit 1 Displays too low pressure, measured by converter/pres-sure switch, in circuit no. 1 A/M

232 Low pressure, circuit 2 “As above for circuit no.°2” A/M

241 High pressure via converter 1 Displays too high pressure, measured by converter, in cir-cuit no. 1 M

242 High pressure via converter 2 “As above for circuit no.°2” M251 Timeout, start-up circuit 1 Possible start-up attempt with no refrigerant in circuit no. 1. A252 Timeout, start-up circuit 2 “As above for circuit no.2” A

261 No refrigerant in circuit 1Refrigeration circuit no. 1 is possibly without refrigerant, because alarm "Time out of start-up" has run for at least 8 hours.

S

262 No refrigerant in circuit 2 “As above for circuit no.2” S271 Condenser heat exchanger, circuit 1 Displays that air-cooled condenser of circuit no. 1 is added A/M272 Condenser heat exchanger, circuit 2 “As above for circuit no.2” A/M400 Fault, sensor 10 Sensor no. 10 defect or outside operating range A401 Fault, sensor 1 „as above“ A402 Fault, sensor 2 „as above“ A403 Fault, sensor 3 „as above“ A404 Fault, sensor 4 „as above“ A405 Fault, sensor 5 „as above“ A406 Fault, sensor 6 „as above“ A407 Fault, sensor 7 „as above“ A408 Fault, sensor 8 „as above“ A409 Fault, sensor 9 „as above“ A611 Frost protection warning for evaporator 1 Warning on too low outlet temperatures at evaporator 1 S612 Frost protection warning for evaporator 2 Warning on too low outlet temperatures at evaporator 2 S641 High pressure warning for circuit 1 High pressure warning by high pressure sensor for circuit 1 S642 High pressure warning for circuit 2 High pressure warning by high pressure sensor for circuit 2 S

Alarm Description Details Reset

M = Alarm with manual reset (when the cause of the alarm has been rectified, the alarm must be reset by the Service team)

A = Alarm with automatic reset (when the cause of the alarm has been rectified, the alarm is reset automatically)

A/M = 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 rec-tified.

S = Message on the display (without switching off and without activation of “collective fault”)

S - A = Display (unit is not switched off) or alarm with automatic reset. The various operating modes can be selected via parameters.

M - A/M = Alarm with manual reset (with screw compressors). With first three contacts automatic, after that manual (with scroll compressors)

GLWC 0152-0612 BD2Dismantling and Disposal GLWC 0604-1204 BD2


13 Dismantling and Disposal

13.1 DismantlingTo dismantle the GEA Chiller proceed as follows:

• 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.

The unit is ready for transporting.• It is important that all information on shipping is taken into account - see page 25.

13.2 DisposalA 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 proper-

ties.

ENVIRONMENTAL DAMAGE.Only appropriately trained personnel may dismantle and dispose of the unit.

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 unintention-ally 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.

PERSONAL INJURYSecure the unit against slipping.

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.

GLWC 0152-0612 BD2GLWC 0604-1204 BD2 Appendix


14 AppendixThe following pages contain check lists and reports:

On 14.1 - Technical Requirements for Function Testing or Chiller MaintenanceSee 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 com-missioning 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 oth-ers 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 circuitSee 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 pro-tocol must be compiled by a specialist company/GEA Service.

For this purpose see schematic representation of a hydraulic chilled water circuit.

On 14.3 GL KWE Maintenance reportSee 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 main-tenance of refrigeration systems/chillers and connected systems.

NOTE!You must send the commissioning report to GEA. If you do not send the commission-ing report to GEA, the warranty for your GEA Chiller will be rendered null and void.

56

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 °C

Chilled water temperature at outlet °C

Cool water temperature at inlet °C

Cool water temperature at outlet °C

Glycol ratio in chilled water %

Freezing point °C

Type of glycol used (chilled water):

Chilled water volume flow [m³/h]

Glycol ratio in cool water %

Freezing point cool water °C

Type of glycol used (cool water):

Chilled water volume flow [m³/h]

Prerequisites to be met by others prior to function test Checked& OK

1. Electrical connections as per local utility guidelines incl. necessary fusing

2. Electrical cabling between the components (pump, pump tank station, flow monitoring device, external air-cooled condenser/ heat rejection unit etc.) including data cable performed

3. Water connection and pipe network filled and bled as per locally and officially defined guidelines.

4. Strainer and flow switch fitted directly before the water-side inlet to the plate heat exchanger or the hydraulic module.

5. Water-side safety device installed and tested for correct function, fixtures such as thermometer, differential pressure gauge fitted above the heat exchanger.

6. Pipe system by others rinsed clean before connection to the unit. Cleaning protocol present.

7. Output discharge (at least 50%) continually guaranteed

8. 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)

To be instructed Name: Company:

Date: Place: Signature of contractor/ operator

57

14.2 GL Chiller Commissioning Form

Commissioning requested from:

compr. n° 1 compr. n° 2 compr. n° 3 compr. n° 4

EVAPORATING PRESSURE bar

CONDENSING PRESSURE bar

DISCHARGE TEMP. C°

SUPERHEATING TEMP. C°

SUBCOOLING TEMP. C°

COMPRESSOR CURRENT INPUT A

circuit n° 1 circuit n° 2 circuit n° 3 circuit n° 4

FANS CURRENT INPUT A

1. MANOMETER YES NO

2. SHUT OFF VALVE (MANOMETER) YES NO

3. AUOTM. DEARIATION VALVE YES NO

4/5. ANTIVIBRATION JOINT (EVAPORATOR) YES NO

6. WATER FILTER YES NO

7. DRAIN VALVE YES NO

8. CIRCULATING PUMP (PRIMARY CIRCUIT) YES NO

9. RELIEF VAVLE YES NO

10. EXPANSION VESSEL YES NO

11. FILLING VALVE YES NO

12. FLOW SWITCH (Paddle type) YES NO

13. WATER FLOW CONTROL VALVE (EVAP.) YES NO

14. CIRCULATING PUMP (SECONDARY CIRCUIT) YES NO

16. BUFFER TANK Volume:___________ YES NO

PUMP OPERATION CONTACTS YES NO

SHUT OFF VALVE (EVAPORATOR) YES NO

HYDRAULIC CIRCUIT (finished?) YES NO

UNIT’S DISTANCE FROM WALLS (CM)

a: _____ c: _____

b: d:

Technician’s name Date

User / Customer’s name and signature (for acceptance)

HYDRAULIC PLANT CHECK (Ref. Point 4.4 Hydraulic Circuit Diagram, General Manual for Installation) UNIT CHECK

ELECTRIC CONNECTIONS (checked?) YES NO

Values / Function check when possible. RATING CHECK

LOW PRESSURE SWITCH bar YES NO

HIGH PRESSURE SWITCH bar YES NO

ANTIFREEZE THERMOSTAT °C YES X NO

COLD WATER TEMP.CONTROL °C YES NO

HYDR. PRESSURE SWITCH bar YES NO

NOTES

GL KWE COMMISSIONING FORM

UNIT’S WORKING DATA

H2O/AIR EVAPORATOR CONDENSER WATER PUMP T IN [°C] TYPE

T OUT [°C] CURRENT / / Delta P [kPa]

EXT AIR. AUX. VOLTS POW. SUPPLY GLYCOL [°C] [V] [V] [%]

COMPANY

ADDRESS

CITY

WITNESSED BY PHONE

UNIT TYPE Ord. #

SERIAL NUMBER

STORAGE TANK S.N.

REMOTE CONDENSER S.N.

USER / CUSTOMER’S DATA UNIT’S DATA

INSTALLER’S NAMEUSER / CUSTOMER’S NAME

GEA Air Treatment

YOUR COMPANY’S NAME

ONE COPY to be send to: GEA Airmas FAX: +49 2325 468 412 or to your local GEA sales office

GEA GL Chiller 11/03 ENG

ab

c

d

58

14.3 GL Chiller Measuring Report

GLWC Chiller Measuring ReportService technician Cost unit: Date:

GEA Order No. Service-Nr.: GEA ORDER NO. (at bottom on identification plate) Plant operator Contact Tel. Street Fax.: Town / postcode E-Mail: Plant constructed by Contact Tel. Street Fax.: Town / postcode E-Mail:

Function test Maintenance Repair

Chiller Model Produc. year Hydraulic module: yes no Serial Nr.: Refrigerant: R 407C R 134a R 410A R

1. Electrical measurement of unit Values

L1 - L2 L2 - L3 L1 - L3 Unit

1.1 Power supply: V

L1 - N L2 - N L3 - N V

1.2 Power supply: V

1.3 Control voltage: V

Tested by:

1.4 Phase sequence relay: O. K. not O. K.

1.5 Contactors: O. K. not O. K.

1.6 Control relays: O. K. not O. K.

1.7 Relays: O. K. not O. K.

1.8 Thermostats: O. K. not O. K.

1.9 Sensors: O. K. not O. K.

1.10 Pressure sensor: O. K. not O. K.

1.11 Solenoid valves: O. K. not O. K.

1.12 Output adjustment: O. K. not O. K.

1.13 Flow switches: O. K. not O. K.

1.14 Frost protect. switch: O. K. not O. K. Value: °C

1.15 Evaporator heating 1: O. K. not O. K. Current: [A]

1.16 Evaporator heating 2: O. K. not O. K. Current: [A]

59

Ver.08/2007

2. Refrigeration circuit Serial Nr.: Date:

Measurement Measured values Compressor 1: Compressor

2:Compressor

3:Compressor

4: Unit

Values under load: 100 100 100 100 %

2.1 Condensation pressure: bar

2.2 Condensation temperature: °C

2.3 Fluid temperature: °C

2.4 Subcooling (Bubble Point): K

2.5 Hot gas temperature °C

2.6 Suction pressure: bar

2.7 Evaporation temperature: °C

2.8 Suction gas temperature: °C

2.9 Overheating (dew point): K

2.10 Blow off pressure as per valve display:

bar

2.11 Tested HP switch point: bar

2.12 Tested LP switch point: bar

2.13 Oil level: O.K / not O.K

2.14 Crank case heating: A

Compressor at 100 % Current consumption

2.15 L1 A

2.16 L2 A

2.17 L3 A

2.18 Oleic acid test OK / not OK

2.19 Sight window: OK / not OK

2.20 Indicator: OK / not OK

2.21 Filter drier: OK / not OK

2.22 Leak test: OK / not OK

2.23 MV – Compressor cooling: OK / not OK

2.24 Compressor type 1 Serial–Nr.




Notes:

60

3. Evaporator Serial Nr.: Date:

Type: Evaporator serial number:

Medium: Glycol % / °C Glycol type: Water

Measurement Values

Values at full load (100%) Circuit 1: Circuit 2: Circuit 3: Circuit 4: Unit

3.1 Temperature at medium inlet °C

3.2 Temperature at medium outlet °C

3.3 T: K

3.4 Water pressure at inlet bar

3.5 Water pressure at outlet bar

3.6 p bar

3.7 GEA Hydraulic module yes no by others

3.8 Hydraulic module type: Serial Nr.:

3.9 Buffer tank present / size Liter Single circuit tank Dual circuit tank

3.10 Strainer present yes no Cleaned: yes no

3.11 Flow switch present yes no Function: ok not ok

3.12 Pressure gauge present yes no

3.13 Shut off valves present yes no

3.14 Expansion tank present yes no

3.15 Safety valve present yes no Pressure bar

3.16 Current consumption of pumps L 1 L 2 L 3

3.17 Water pump 1 A

3.18 Water pump 2 A

3.19 Water pump type 1 Serial Nr.

3.20 Water pump type 2 Serial Nr.

Note:

R1 mm

R2 mm

R3 mm

R4 mm

61

4. Condenser Serial Nr.: Date:

Type Serial number:

Medium Glycol %/ °C Glycol type: Water

Parameter Measured values

Values at full load (100%) Circuit 1: Circuit 2: Circuit 3: Circuit 4: Unit

4.1 Temperature medium inlet °C

4.2 Temperature medium outlet °C

4.3 T: K

4.4 Water pressure inlet bar

4.5 Water pressure outlet bar

4.6 p: bar

4.7 Difference 2.3 and 4.2 K

4.8 GEA hydraulic module available yes no by others

4.9 Type of hydraulic module Serial No.

4.10 Strainer yes no Cleaned: yes no 4.11 Flow switch yes no Function: ok not ok 4.12 Pressure gauge yes no 4.13 Shut-off valves yes no 4.14 Expansion tank yes no 4.15 Safety valve yes no Pressure Bar 4.16 Pump current consumption L1 L2 L3 4.17 Chilled water pump 1 A 4.18 Chilled water pump 2 A 4.29 Chilled water pump type Serial No. 4.20 Chilled water pump type Serial No. 4.21 3-way valve yes no GEA By others 4.22 Control for 3-way valve yes no GEA By others 4.23 Fan control heat rejection unit yes no 4.24 Inverter controlled pump yes no

Note:

62

5. Controller and setting Serial Nr.: Date:

Used controller: Software Version:

Setting values Comment:

5.1 Remote ON/OFF used: yes no

5.2 General error message yes no

5.3 Does error message lock remote ON/OFF

yes no

5.4 Pump lead time: sec. by controller: by others:

5.5 Pump overrun time: sec by controller: by others:

5.6 Type of temperature control Proportional control Quick Mind

5.7 Temperature control according to Inlet Outlet

5.8 Setpoint cooling °C Proportional band °C

5.9 2nd setpoint cooling yes no °C

5.10 Setpoint shift 4-20 mA yes no Min. / Max. / °C

5.11 Load shedding switch yes no %

5.12 Connection to BMS yes no Report

5.13 Set frost protection value: °C Dif. °C

5.14 Starting value for evaporator heating:

°C Dif. °C

5.15 Operating hours compressor 1: h Maintenance interval x h 5.16 Operating hours compressor 2: h Maintenance interval x h 5.17 Operating hours compressor 3: h Maintenance interval x h

5.18 Operating hours compressor 4: h Maintenance interval x h

5.19 Operating hours CW pump 1: h Maintenance interval x h

5.20 Operating hours CW pump 2: h Maintenance interval x h

5.21 Min. idle time of compressor sec.

5.22 Mini. idle between 2 compressor starts

sec.

5.23 Min. running time of compressor sec.

5.24 Max compressor start ups per hour / h

Note:

63

6 Check / visual inspection Serial Nr.: Date:

O. k. not O. K. 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



6.3 Evaporator



6.4 System parts

6.4.1 Check externally isolation for damage

6.4.2 Check fixing

6.4.3 Check refrigerant conducting unit parts for leaks (visual check)

6.4.4 Check externally compensators for damage

6.5 Electrical devices

6.5.1 Check optical and acoustical control devices

6.5.2 Check if connecting terminals are tight, tighten, if necessary

Notes:

Date: Name: Signature:

GB Denco Ltd.UK-HR4 8DS HerefordTel. +44 / 1432 / 277 277

N GEA Klimaprodukter ASN-0484 OsloTel. +47 / 220 / 27990

UA GEA Ukraina t.o.v.UA-01135 KyivTel. +38 / 044 / 4619356

TR ISISANTR-80700 BalmumcuIstanbulTel. +90 / 212 / 2757171

SLO GEA KlimatizacijskaTehnika d.o.o.SI-1000 LjubljanaTel. +386 / 1 / 2573850

SK GEA Klimatizácia s.r.o.SK-83104 BratislavaTel. +421 / 7 / 44457917

GEA KlimatehnikaRS-11070 Novi BeogradTel. +381 / 11 / 3193955

SRB

S GEA EXOSVentilation ABS-74528 EnköpingTel. +46 / 171 / 85530

RUS GEA KondicionerMoskvaRU-105094 MoskvaTel. +7 / 495 / 9566674

P Nónio, Lda.P-1269-090 LisboaTel. +351 / 21 / 3826160

LV GEA Klimatechnik UABLT-01141 VilniusTel. +370 / 5 / 2106060

LT GEA Klimatechnik UABLT-01141 VilniusTel. +370 / 5 / 2106060

L GEA Happel LuxembourgL-4940 BascharageTel. +352 / 26 / 502970

IS Rafn JenssonIS-110 ReykjavikTel. +354 / 56 / 780-30

PL GEAKlimatyzacja Sp. z o.o.PL-54610 WroclawTel. +48 / 71 / 3737952

IE Aspect Environmental Ltd.Ardee, Co. LouthIrelandTel. +353 / 41 / 6858983

HR GEA Klima-rashladnatehnika d.o.o.HR-10000 ZagrebTel. +385 / 1 / 6064900

FIN OY TEKNOCALOR ABFIN-01300 VantaaTel. + 358 / 9 / 82546020

F GEA Happel France sarlF-59436 Roncq CedexTel. +33 / 3 / 20689020

EST GEA Klimatechnik UABLT-01141 VilniusTel. +370 / 5 / 2106060

E GEA Air TreatmentMarketing ServicesInt. GmbH - oficina EspañaE-28036 MadridTel. +34 / 91 / 3837701

DK GEA Klimateknik ApSDK-2610 RødovreTel. +45 / 38 / 887070

H GEA Klimatechnika KftH-1037 BudapestTel. +36 / 1 / 4393200

D GEA HappelKlimatechnik GmbHD-44625 HerneTel. +49 / 2325 / 468-00

CZCZ-46312 LiberecTel. +420 / 48 / 5225-111GEA Klimatizace spol. s r.o.CZ-46312 LiberecTel. +420 / 48 / 5225-303

GEA LVZ, a.s.

CH GEA KlimatecSchweiz AGCH-3065 Bolligen-StationTel. +41 / 31 / 9171919

BY GEA Klimatechnik UABLT-01141 VilniusTel. +370 / 5 / 2106060

BIH GEA KlimatehnikaRS-11070 Novi BeogradTel. +381 / 11 / 3193955

BG EVISS Ltd.BG-7000 RousseTel. +359 / 82 / 81000

B GEA Happel Belgium N.V.B-1130 BrusselsTel. +32 / 2 / 2406161

A GEAKlimatechnik GmbHA-4673 GaspoltshofenTel. +43 / 7735 / 8000-0

NL GEA HappelNederland B.V.NL-2909 LLCapelle a/d IjsselTel. +31 / 10 / 2350606

RO GEA Klimatechnik s.r.l.RO-300222 TimisoaraTel. +40 / 356 / 423703

GEA KlimatehnikaRS-11070 Novi BeogradTel. +381 / 11 / 3193955

MWE

Our Market in Europe

Air Treatment Division For detailed information on all corporate areas,go to www.gea-airtreatment.com or contactus by email [email protected] company of GEA Group

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Documents

chiller GLWC-0152-1204BD2_BA_2008-01