Energy-efficient, Low-noise And Compact Variations For Indoor And

Transcript

OPERATION MANUAL Chillers and Heat Pumps GL-Series Energy-efficient, low-noise and compact variations for indoor and outdoor installation Chillers & Heat Pumps GL Series Table of Contents 1 Unit Identification Plate .............................................................. 4 2 Unit Type Code ............................................................................ 5 3 Overview of Units and Packaged Content ................................ 6 3.1 3.2 3.3 3.4 4 Availability of the operation manual ........................................................... 7 Scope of the operation manual .................................................................. 7 Symbols used ............................................................................................ 7 Identification of safety information ............................................................. 8 Used safety symbols .................................................................................. 9 Safety-conscious work procedures .......................................................... 10 Modifications and changes ...................................................................... 13 Spare parts .............................................................................................. 13 Disposal ................................................................................................... 13 Selection and qualification of personnel .................................................. 13 Technical Description ............................................................... 14 5.1 5.2 5.3 5.4 6 6 6 6 6 Safety and User Instructions ..................................................... 7 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5 Series ......................................................................................................... Unit overview ............................................................................................. Packaged content ...................................................................................... Accessories and special equipment ........................................................... Description of the unit .............................................................................. Functional description .............................................................................. Technical Specifications .......................................................................... Operating limits ........................................................................................ 14 15 19 20 Shipping and Storage ............................................................... 21 6.1 Delivery .................................................................................................... 21 6.2 Transport .................................................................................................. 21 6.3 Storage .................................................................................................... 23 7 Assembly ................................................................................... 24 7.1 7.2 7.3 7.4 8 Positioning the unit ................................................................................... Assembling the unit .................................................................................. Installing accessories ............................................................................... Installation of unit accessories ................................................................. Medium Connections ................................................................ 40 8.1 Requirements ........................................................................................... 8.2 Connecting water circuit (chilled and warm water) .................................. 8.3 Check and adjust inlet pressure in expansion tank (for units with installed hydraulic or pump module with expansion tank) 8.4 Charging water circuit .............................................................................. 8.5 Connecting cooling water circuit (only GLWC and GLWH units) ............. 8.6 Connecting refrigeration circuit to an external condenser (by others, only GLRC) 8.7 Connect Desuperheater/Heat Recovery Circuit ....................................... 2 24 28 30 34 40 43 44 46 50 54 62 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series 9 Electrical Connection ............................................................... 63 9.1 Requirements ........................................................................................... 63 9.2 Connect mains electrical supply ............................................................... 64 9.3 Connecting control contacts and controller ............................................... 65 10 Commissioning ......................................................................... 69 10.1 Requirements ........................................................................................... 69 10.2 Commissioning procedure ........................................................................ 69 10.3 Warm-up phase before operation ............................................................. 72 11 Operating Unit ........................................................................... 76 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 Overview of operator elements ................................................................. 76 POWER OFF and ON ............................................................................... 76 Operating controller .................................................................................. 78 Overview of operator elements ................................................................. 80 POWER OFF and ON ............................................................................... 80 Operating controller .................................................................................. 81 Disconnecting from power supply ............................................................. 86 Draining water circuit ................................................................................ 87 What to do in case of alarm and error messages ..................................... 88 12 Fault Finding and Troubleshooting ......................................... 89 12.1 Alarms ....................................................................................................... 89 12.2 Overview of alarm messages ................................................................... 89 12.3 Resistance temperature sensor for DencoHappel HVAC systems controller 105 13 Servicing and Maintenance .................................................... 106 13.1 13.2 13.3 13.4 Statutory limit values of leakage checks on refrigeration systems ......... 106 Overview of maintenance intervals ......................................................... 107 Maintenance of air-cooled heat exchangers ........................................... 108 Recommendation: Two services per year .............................................. 110 14 Dismantling and Disposal ...................................................... 111 14.1 Dismantling ............................................................................................. 111 14.2 Disposal .................................................................................................. 112 15 Appendix .................................................................................. 113 15.1 Technical Requirements for Function Testing or Maintenance of Chiller/Heat Pump 114 15.2 Commissioning Report ........................................................................... 115 15.3 Measuring Report GLAC Chiller ............................................................. 117 15.4 Generally accepted translation of diagrams, plans and drawings in order-related documentation 149 15 Log Book for Chiller, Heat Pumps and Compressor/Condenser Units 156 – Original operation manual – Copyright note Disclosing, copying, distributing or taking any action in reliance on the contents of this document is strictly prohibited without express prior consent. Violations entail liability for any damages or other liability arising. All rights in relation to patents, utility patents or design patents are reserved. PR-2013-0112-GB • Subject to modifications • R1-01/2016 3 Chillers & Heat Pumps GL Series Unit Identification Plate 1 Unit Identification Plate The unit identification plate is secured on the unit and is explained as follows. Enter the data from the unit identification plate in the operation manual. This record establishes the relationship between the unit and the operation manual. If this condition is met, the operation manual can then be used to enter test and inspection data for your unit. Company logo Company name Unit type Item number Serial Number Year of manufacture Operating weight Refrigerant Refrigerant charge volume Oil type Power supply Max. operating pressure high and low pressure side Max. power consumption Max. operating pressure on water side Max. current consumption Max. storage and shipping temperature CE symbol with certification number Drawing number of wiring diagram Fig. 1-1 4 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series or DencoHappel heat pumps GL Global Large A Air cooled (outdoor installation) D Air cooled (indoor installation) F Air cooled with free-cooling function (outdoor installation) R without condenser (indoor installation) W Water cooled (indoor installation) C Chillers H Heat Pump 2 2 compressors 3 3 compressors 4 4 compressors 5 5 compressors 6 6 compressors 8 8 compressors 015 - 960 Unit capacity stage # Unit series, continued A R-134a and Bitzer screw compressor D R-410A and scroll compressor 1 400 Volt/3 Ph~/ 50 Hz/+N/+PE 2 400 Volt/3 Ph~/ 50 Hz/+PE - Standard .SL SL unit - especially quiet model .HE HE unit - high efficiency model .LT LT-Version: heating at low ambient temperatures, only for heat pumps .D D unit - with desuperheater .SD SD unit - especially quiet model with desuperheater .HD HD unit - high efficiency model with desuperheater 4 0 C A 2 .HE Design version No. of compressors DencoHappel chiller 8 Supply voltage 4 Refrigerant C Series A Capacity stage G L Operating mode DencoHappel GL Series Condensation Unit Type Code DencoHappel GL Series 2 Unit Type Code Notice! For detailed planning please only use the order-related documentation. Detailed dimensional drawings can be obtained on request from your responsible DencoHappel sales office. Specifications and technical data are subject to regular updates. The manufacturer reserves the right to make necessary changes to information without prior written notice PR-2013-0112-GB • Subject to modifications • R1-01/2016 5 Chillers & Heat Pumps GL Series Overview of Units and Packaged Content 3 Overview of Units and Packaged Content 3.1 Series For detailed technical specifications on individual unit series refer to the Data&Facts catalog or your quotation for the unit. 3.2 Unit overview For detailed technical description and unit configuration refer to Data&Facts and orderrelated documentation supplied with the unit. 3.3 Packaged content The following components are included in the delivery package: – Unit according to designation on the unit identification plate – Operation manual including all data on the supplied unit – Operation manual including all data on the supplied controller – Order-specific wiring diagram – Order-related dimensional drawings with specification of weight and shipping data – Order-related refrigeration circuit diagrams – Order-related hydraulic circuit diagram, if necessary – Possible accessories and special equipment (only if ordered). Consider supplied operation and installation manuals for enclosed accessory items. Notice! Use only provided order-related documentation for commissioning, maintenance and service of the unit. It is not allowed to use general data which may not include specifications of actually installed individual components and special accessories. 3.4 Accessories and special equipment For specific data on accessories refer to Data&Facts catalogue of the relevant unit series, quotations for the unit or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for chillers and heat pumps. 6 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series 4 Safety and User Instructions Safety and User Instructions DencoHappel GL units are constructed using state-of-the-art technology and according to recognized safety regulations. Use the DencoHappel units in a technically sound condition for the intended purpose observing the operation manual, taking safety aspects and potential hazards into account. Failure to follow the instructions in this manual may result in danger to health and safety, damage to materials and incorrect unit operation. Have all faults repaired by an authorized specialist without delay! ATTENTION Damage to the unit! In case of alarms and faults, always make sure that the cause of the fault is identified. In particular, a manual reset of an alarm without first rectifying the cause can damage the unit and invalidate the warranty. 4.1 Availability of the operation manual This operation manual contains important instructions regarding safe and correct operation of the DencoHappel unit. This operation manual must be available at the location of the unit at all times. Anyone who works with or at the unit must read and observe this operation manual. The operation manual is intended for use by fitting and installation companies, building services engineers, technical personnel or trained persons as well as electrical and airconditioning engineering specialists. 4.2 Scope of the operation manual This operation manual provides information about the following: – Assembly/disassembly – Installation – Commissioning – Use and operation – Maintenance and Troubleshooting 4.3 Symbols used The following symbols are used to highlight particular text sections in this operation manual: – This symbol is used to indicate normal lists. • This symbol indicates handling instructions.  This symbol indicates the result of an action. Notice! Additional details on using the unit are specified here. Recycling! This symbol is used to highlight instructions for the recycling of packaging material and disused unit components, which must be separated depending on the material type. PR-2013-0112-GB • Subject to modifications • R1-01/2016 7 Chillers & Heat Pumps GL Series Safety and User Instructions 4.4 Identification of safety information To designate the safety instructions the following symbols and notices are provided in appropriate places throughout this document: 4.4.1 DANGER - Death/serious irreversible injury Indicates an extremely hazardous situation which will result in death or serious irreversible injury, if the safety instruction is not followed. Example: Electrocution through hazardous voltage will lead to death or serious injury! • Disconnect the unit from the power supply and ensure the power cannot be switched back on. • Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. 4.4.2 WARNING - Death/serious injury Indicates a hazardous situation which can result in death or serious irreversible injury, if the safety instruction is not followed. Example: Warning of high pressure! When working on hydraulic or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. • Wear protective clothing and safety glasses • Exercise due caution and attention when carrying out this work. 4.4.3 CAUTION - Minor or moderate injury Indicates a hazardous situation which can result in minor or moderate injury, if the safety instruction is not followed. Example: Sharp edges can cause injuries! Observe precaution when cleaning due to risk of cuts on thin and sharp edges. • Wear chemical resistant gloves. 4.4.4 ATTENTION – Environmental or material damage ATTENTION Indicates actions that can result in equipment or property-damage only accidents. 8 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Safety and User Instructions Examples: ATTENTION Risk of environmental damage! Heavily contaminated filters can have a negative impact on production processes. Depending on the filtered-out materials, contaminated filters are therefore classified as hazardous waste and must be properly disposed of according to the prevailing guidelines and laws. ATTENTION Damage through static discharge! While carrying out adjustment work on the Controller System, make sure that you discharge yourself statically before touching the circuit board and electrical components. 4.5 Used safety symbols Electrical hazard PERSONAL injury Overhead loads Risk of tipping Rotating components! Crushing of limbs Sharp cutting edges Hot surfaces Static discharge Environmental damage Damage to the unit PR-2013-0112-GB • Subject to modifications • R1-01/2016 9 Chillers & Heat Pumps GL Series Safety and User Instructions 4.6 Safety-conscious work procedures Observe the following instructions when carrying out installation, adjustment or repair jobs: • Wear suitable protective clothing during work, such as protective footwear, gloves, safety goggles, etc. • Avoid flame sources, especially burning cigarettes. Open flame sources and smoking in the proximity to the unit are prohibited. Filters and especially used filters can easily catch fire. Leaking refrigerant can catch fire and emit noxious substances. General Notes: – As long as the unit operates and rotating parts still move, do not remove any unit covers and protective covers. – Before switching on the unit again, make sure that the unit covers and protective covers are properly attached. When working within range of mains voltage: Electrocution through hazardous voltage will lead to death or serious injury! • Disconnect the unit from the power supply and ensure the power cannot be switched back on. • Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. – For units with integrated compensation of reactive current wait at least 5 minutes after opening the main switch before starting any work. – Check the ground connection of the unit before re-energizing it. – External voltage can exist in the switch cabinet despite open main switch. When working with refrigerants: Please consider section „4.6.1 Handling refrigerants“ Danger due to toxic substances! High concentrations of refrigerants in the air may have an anaesthetic effect and cause unconsciousness. Prolonged 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 • Exercise due caution and attention when carrying out this work. Contact with refrigerant can lead to injuries! Contact with a liquid refrigerant can result in skin burns or injury to other organs. • Wear protective clothing and protective gloves. • Exercise due caution and attention when carrying out this work. For all kinds of work: 10 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Safety and User Instructions Warning of high pressure! When working on hydraulic or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. • Before opening pipe connections, check if they are pressure-free. • Wear protective clothing and safety glasses • Exercise due caution and attention when carrying out this work. Contact with unit surfaces can lead to injuries! The surfaces of the unit and the pipework can be both very cold and hot. This can cause burns. • Wear protective clothing • Exercise due caution and attention when carrying out this work. Danger due to toxic substances!! Glycols and other antifreeze agents are harmful for humans and animals, if swallowed. • Consult a doctor immediately if swallowed by mistake. • Exercise due caution and attention when carrying out this work. After skin contact with glycol: • Rinse the affected body parts using lukewarm water for at least 5 min. After eye contact with glycol: • Do not rub your eyes. • Remove contact lenses if you have any. • Rinse your eyes with much water. • Please comply with the installation and shipping instructions for DencoHappel units. • Observe the pre-commissioning check points. • Always make sure that the DencoHappel unit is accessible only to authorized and • • • trained technical personnel. If necessary, use appropriate equipment to keep unauthorized persons away from the unit. Have all leaks eliminated by the DencoHappel Service or a specialist refrigeration company immediately (refer to section 4.10). The safety sheet stating the type of refrigerant charged on the given unit shall be firmly secured in the machine room of the unit in a well visible manner (refer to unit identification plate or operation manual for the unit). Ensure that proper trays or similar vessels are mounted below the unit in order to reliably capture oil and glycol liquids and prevent contact with the environment. PR-2013-0112-GB • Subject to modifications • R1-01/2016 11 Chillers & Heat Pumps GL Series Safety and User Instructions 4.6.1 Handling refrigerants According to DIN EN 378 Part 1, the refrigerant R-134a, R-407C and R-410A belong to the A1 group. Refer to the unit identification plate for data and charge volume of a particular refrigerant. Observe the usage details in accordance with EC regulation 517/2014. The used refrigerants contain fluorinated gases which are regulated by the Kyoto Protocol and contribute to the greenhouse effect. Therefore, refrigerants must not be released to the atmosphere. Features of applicable refrigerant types: – Non-combustible – No direct toxic effect – Colorless and odorless – Heavier than air – Contains fluorinated greenhouse gases as defined by the Kyoto protocol – Ozone-depleting potential OPD: 0 – RefrigerantR134aR410AR407C GWP143020881774 Safety groupA1A1A1 – Water hazard class WGK: 1, with a slight risk to water • Wear appropriate clothes when performing jobs with refrigerants and in the proximity to a refrigeration circuit, e.g. – Sealing protective goggles – PVA or leather gloves – Protective clothes for entire body – If necessary, an autonomous breathing apparatus First aid Inhalation First aid measures directly after or during contact with refrigerants: – Ensure your own protection against leaking refrigerant. – Under all circumstances - call a doctor or and/an ambulance. – Remove clothes contaminated by the refrigerant. Additional measures after inhalation of refrigerants: – Take the injured person to a well-ventilated location. – Ensure that the injured person is in a stable lateral position. – Consumption of food and beverages must be avoided. – If the injured person collapses or loses consciousness – perform mouth-to-mouth respiration. Skin contact Additional measures after skin contact with refrigerants: – Rinse the affected body parts using lukewarm water for at least 15 min. Eye contact Additional measures after eye contact with refrigerants: – Do not rub your eyes. – Remove contact lenses if you have any. – Rinse your eyes with much water. Refrigerant or leaking refrigerant can cause oxygen deficiency, especially in closed rooms. Therefore, plant rooms must be adequately ventilated according to EN 378-9 and the nationally applicable regulations. If necessary, refrigerant detectors must be used. 12 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Safety and User Instructions 4.6.2 Proper use Units are only used to produce chilled water for air treatment units in comfort air conditioning or to provide chilled water for process cooling in enclosed circuits of manufacturing facilities. Unit are partially equipped with a heat-pump cycle. Proper use also requires adherence to the operation manual for the controller and suitable and regular inspection and maintenance, following guidelines specified by DencoHappel. Improper use Any use other than that described above is considered improper. The manufacturer/ supplier is not liable for damage arising from improper use. The user alone bears the risk. Personal injury and equipment damage! It is not allowed to operate DencoHappel units: – In areas subject to explosion risk – in environment with strong electromagnetic fields, – in environment with high levels of air contamination, – in environment with corrosive and/or aggressive air, 4.7 Modifications and changes You are not allowed to change, add to or modify the DencoHappel units in any way. Any changes or modifications to the DencoHappel units will invalidate the CE conformity certificate and render and all warranty claims null and void. 4.8 Spare parts Only original DencoHappel spare parts are allowed, since DencoHappel is not liable if third-party spare parts are used. 4.9 Disposal Main and operating supply materials must be disposed of according to material type in a safe and environmentally friendly manner - please refer to section 14.2 "Disposal". 4.10 Selection and qualification of personnel Ensure that every person working on the unit has read and understood entire operation manual. Please read this document fully before commencing any work, and not while performing a task. Electrical and water connections must be established by qualified licensed staff or other individuals with proper professional training and experience in the following areas: – Occupational health and safety regulations – Accident prevention regulations – Directives and recognized codes of practice All jobs with the refrigeration circuit shall be performed only by certified and licensed staff in accordance with the valid EG Regulation 517/2014, EG Regulation 303/2008 Article 4 and 5 as well as "Ordinance on climate protection against changes caused by release of certain fluorinated greenhouse gases" §5. All skilled staff must be able to assess the entrusted work and be able to recognize and avoid all associated dangers. PR-2013-0112-GB • Subject to modifications • R1-01/2016 13 Chillers & Heat Pumps GL Series Technical Description 5 Technical Description 5.1 Description of the unit These DencoHappel units are performed as chillers or heat pumps. In the factory units are filled with refrigerator oil and refrigerant and a test run is performed, so that when the units are installed on site only chilled water and electrical connections have to be completed. Carry out a functional test as well. The DencoHappel units are only designed to be operated with the refrigerant specified on the unit identification plate. Directives and regulations Units meet the following directives and standards: – Directive on Machinery 2006/42/EC – Low Voltage Directive 89/336/EEC & 2006/95/EC – Electromagnetic Compatibility 2004/108/EC – Pressure Equipment Directive 97/23/EC according to module H1 – Certified Corporate Quality Management System ISO 9001 5.1.1 Components For installed components on the individual unit series, refer to the Data&Facts catalog or your quotation for the unit. 5.1.2 Switch cabinet For data on the switch cabinet refer to the Data&Facts catalogue or your quotation text for the unit. 5.1.3 Electronic controls For the data on electronic controls, refer to supplied functional description for the controller (also refer to chapter "11.1"). Fig. 5-1: Display Alternative display for air cooled units with screw compressor and GLFC unit series (also refer to chapter "11.4" and attached operation manual of the controller). Fig. 5-2: Alternative display Alternative display for water cooled units with screw compressor and GLFC unit series (also refer to chapter "11.4" and attached operation manual of the controller). Fig. 5-3: 14 Alternative display PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series 5.2 Technical Description Functional description 5.2.1 GLAC – air cooled chillers designed for outside installation and GLDC – air cooled chillers for inside installation Refrigeration circuit The refrigeration system generates a refrigeration output in a thermodynamic cycle by means of heat removal, this is used to cool a water circuit (indirect cooling). 2 3 4 5 1 Fig. 5-4 The compressor (1), condenser (2), expansion device (3) and evaporator (4) are linked together in a closed thermodynamic system. A refrigerant circulates within this circuit. 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 air-cooled 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 (4) the expansion valve (3) sprays liquid refrigerant into the evaporator (4). The liquid refrigerant vaporises completely in the evaporator (4) and absorbs the heat. The necessary thermal energy needed for this is taken from the chilled water system (5) which in turn is cooled. 5.2.2 GLAH – air cooled heat pumps In cooling mode the unit operates as specified in chapter 5.2.1 GLAC – air cooled chillers designed for outside installation and GLDC – air cooled chillers for inside installation. Heating circuit - GLAH units are additionally equipped with a 4-way valve. In such way it is possible not only to dissipate heat just like in chiller mode but to supply heat as well. The air-cooled condenser (2) becomes an evaporator and absorbs heat from outside air. The evaporator (4) becomes a condenser and transfers heat to the connected water or water/glycol circuit. Thus a chiller turns into a heat pump. PR-2013-0112-GB • Subject to modifications • R1-01/2016 15 Chillers & Heat Pumps GL Series Technical Description 5.2.3 GLFC - air cooled chillers with a free-cooling function for outside installation Summer operation: During summer operation a 3-way valve directs water for cooling not through an additional air cooled heat exchanger but directly into the evaporator. This reduces the water-side pressure drop to a minimum. Evaporating refrigerant cools water in the heat exchanger, cooled water is supplied then to different consumers. Free cooling function is deactivated and the unit operates as a chiller - refer to chapter GLAC - air cooled chillers for outside installation and GLDC - air cooled chillers for inside installation. Fig. 5-5 Transition time: Fig. 5-6 During transition seasons in spring and autumn the unit operates with an additional air-cooled freecooling heat exchanger as well as using usual evaporative cooling. As soon as outdoor air temperature falls 1 °C below the set return temperature of the chilled water system, the 3-way valve is activated and a connection with a free-cooling heat exchanger is enabled. The fans increase their speed in order to cool water as much as possible and thus reduce compressor run time and associated electric power consumption. Now water passes through both heat exchangers. Missing cooling energy, which is not recovered by free cooling, is provided by the one or multiple compressors. Already during transition seasons significant energy savings can be achieved. Winter operation: Only the free-cooling heat exchanger is activated during winter season. The temperature difference between outdoor air and water setpoint is large enough to operate completely without compressor activation. The only energy consumers of the unit are fan motors that considerably reduce their speed with falling outdoor temperatures and thus contribute to further energy conservation. Fig. 5-7 16 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Technical Description 5.2.4 GLRC - chiller without condenser for inside installation In cooling mode the unit operates as specified in chapter 5.2.1 GLAC – air cooled chillers designed for outside installation and GLDC – air cooled chillers for inside installation. With this configuration the condenser is not located in the unit itself and must be provided by others on site, the corresponding pipework has to be established by others as well. 5.2.5 GLWC - water cooled chiller for inside installation Refrigeration circuit The refrigeration system generates a refrigeration output in a thermodynamic cycle by means of heat removal, this is used to cool a water circuit (indirect cooling). 2 3 4 5 1 6 Fig. 5-8: Refrigeration circuit The compressor (1), condenser (2), expansion valve (3) and evaporator (5) are linked together in a closed thermodynamic system. A refrigerant circulates within this circuit. The electrically driven compressor (1) draws in overheated gaseous refrigerant and compresses it to a high pressure/temperature level. The gaseous overheated refrigerant is cooled and liquefied by releasing its thermal energy in the water-cooled (4) condenser (2). Liquid refrigerant under high pressure is now in front of the expansion valve (3). Taking into account the pressure and the temperature at the evaporator outlet (5) the expansion valve (3) sprays liquid refrigerant into the evaporator (5). The liquid refrigerant vaporises completely in the evaporator (5) and absorbs the heat. The necessary thermal energy, which this process requires, is removed from the chilled water circuit (6) resulting in its cooling. PR-2013-0112-GB • Subject to modifications • R1-01/2016 17 Chillers & Heat Pumps GL Series Technical Description 5.2.6 GLWH-#D2 - water cooled heat pumps for inside installation with integrated 4-way valve Refrigeration circuit The refrigeration system generates a refrigeration output in a thermodynamic cycle by means of heat removal, this is used to cool a water circuit (indirect cooling). 2 3 4 5 1 6 Fig. 5-9: Refrigeration circuit The compressor (1), condenser (2), expansion valve (3) and evaporator (5) are linked together in a closed thermodynamic system. A refrigerant circulates within this circuit. The electrically driven compressor (1) draws in overheated gaseous refrigerant and compresses it to a high pressure/temperature level. The gaseous overheated refrigerant is cooled and liquefied by releasing its thermal energy in the water-cooled (4) condenser (2). Liquid refrigerant under high pressure is now in front of the expansion valve (3). Taking into account the pressure and the temperature at the evaporator outlet (5) the expansion valve (3) sprays liquid refrigerant into the evaporator (5). The liquid refrigerant vaporises completely in the evaporator (5) and absorbs the heat. The necessary thermal energy, which this process requires, is removed from the chilled water circuit (6) resulting in its cooling. Heating circuit The GLWH unit series are additionally equipped with a 4-way valve. In such way it is possible to supply heat additionally to dissipating heat in a chiller mode. The water-cooled condenser (2) becomes an evaporator and absorbs heat from medium flow. The evaporator (4) becomes a condenser and transfers heat to the connected water or water/glycol circuit. Thus a chiller turns into a heat pump. 18 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Technical Description 5.2.7 GLWH-#A2 - water cooled heat pumps for inside installation Refrigeration circuit The refrigeration system generates a refrigeration output in a thermodynamic cycle by means of heat removal, this is used to cool a water circuit (indirect cooling). 2 3 5 4 1 6 Fig. 5-10: Refrigeration circuit The compressor (1), condenser (2), expansion valve (3) and evaporator (4) are linked together in a closed thermodynamic system. A refrigerant circulates within this circuit. 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 condensing water (5) of the water-cooled 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 (4) the expansion valve (3) sprays liquid refrigerant into the evaporator (4). The liquid refrigerant vaporises completely in the evaporator (4) and absorbs the heat. The necessary thermal energy, which this process requires, is removed from the chilled water circuit (6) resulting in its cooling. Heating circuit The unit series GLWH are supplied with additional two temperature sensors for the common condenser inlet and outlet. The temperature sensors must be mounted by others on site and connected according to the wiring diagram. As soon as the unit changes its operating mode from cooling into heating (or the other way round) - the setpoints that control and adjust the unit's capacity are changed automatically. In cooling mode it is either a sensor at the inlet or outlet of the evaporator (depending on controller's configuration) that requires individual capacity stages of the unit using the microprocessor. In heating mode it is either a temperature sensor at common condenser inlet or outlet (depending on controller's configuration) that activates or deactivates individual capacity stages of the unit. 5.3 Technical Specifications For general and electric data refer to Data&Facts catalogue of the relevant unit series, quotation text for the unit or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for chillers and heat pumps. PR-2013-0112-GB • Subject to modifications • R1-01/2016 19 Technical Description 5.4 Chillers & Heat Pumps GL Series Operating limits For unit operating limits refer to Data&Facts catalogue of the relevant unit series or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for chillers and heat pumps. Notice! – Protect all water-conducting components from freezing at ambient temperatures below 5°C. DencoHappel recommends to use at least 30 % ethylene glycol. – Protect all water-conducting components from freezing at water temperatures below 5°C. For operational reasons water must be protected from freezing by adding glycol. – Maintain the maximum chilled water outlet temperature for safe operation of the unit immediately after the compressor is started. For maximum chilled water outlet temperature refer to the Data&Facts catalogue of the relevant unit series or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for chillers and heat pumps. – Maintain the minimum warm water outlet temperature for safe operation of the unit immediately after the compressor is started. For minimum warm water outlet temperature refer to the Data&Facts catalogue of the relevant unit series or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) (for heat pump units only). – At low outside-air temperatures, install the unit in a wind-protected area with wind velocity below 0.5 m/s. For exact outside-air temperature refer to the Data&Facts catalogue of the relevant unit series or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for chillers and heat pumps. – The relative humidity during operation must not exceed 90 %. 20 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Shipping and Storage 6 Shipping and Storage 6.1 Delivery Upon receipt of the units, inspect the units for damage and verify that the shipment is complete (refer to section 3.2 "Packaged content") according to the freight bill. It is necessary to take photographs of all visible transit damage. Notice! Missing parts or claims of shipping damage shall only be reported to the transport insurance if the damage has been confirmed by the delivering carrier. Notice! We recommend to keep the equipment in the original packaging for protection, ease of handling, shipping and storage. Only remove the original packaging just before installation. If the unit is stored for a period of time before installation or commissioning, protect it from damage through elements, build-up of dust and dirt! 6.2 Transport Danger due to high loads! Inappropriate handling with high loads can lead to death or serious injuries. For unit weight, refer to the order-related documentation and the unit identification plate. • Use proper lifting gear (crane equipment) for lifting and handling. • Never use a fork lift truck or pallet truck, as there is a risk of the unit toppling over. • Only transport the units using the transport lugs or lifting points provided by the manufacturer. For locating lifting points; refer to the order-related dimensional drawing or adhesive label on the unit. In addition, the lifting points are marked in colour on the casing structure. Fig. 6-1 Fig. 6-2 • Depending on the unit model, the units can be lifted with pipe rods on-site (Fig. 6-1) • • • or with eyebolts (Fig. 6-2). Never attach lifting hooks or similar gear directly to the unit construction - only proper lifting gear must be used (refer to Fig. 6-3). When handling and shipping, do not tilt the unit by more than 6 degrees! For your own safety wear gloves and safety footwear when lifting or shipping the unit. PR-2013-0112-GB • Subject to modifications • R1-01/2016 21 Chillers & Heat Pumps GL Series Shipping and Storage Danger due to overhead loads! Never stand beneath suspended loads, since there is always a risk that the lifting gear, tackle, ropes or slings are faulty or damaged. Failure to follow safety precautions could result in death or serious injury. • Wear safety clothing and protective helmet. • Never stand under suspended loads! • Before lifting or shipping the unit, make sure that all mountings are fixed and • • • • • • secured. Only use lifting gear with sufficient load-bearing capacity. Never use damaged lifting equipment. Ropes/chains must not be knotted and/or be exposed to sharp edges. Only use ropes/chains of the same length. Only use the designated lifting gear (refer to Fig. 6-2) (provided by on site). A girder with suitable load-bearing capacity must be used to ensure the stability of the lifted load and to avoid that the lifting gear comes in contact with the unit. • • • • Move the unit carefully without fast irregular movements. Do not move the unit in case of strong wind conditions. Always set the unit down gently, without bumping it. If necessary, use a specialist company to transport the unit. Fig. 6-3 LIFTING USE N°4 LIFTING ROPES WITH EQUAL LENGHT ONLY (min.3000) c1 C2 Fig. 6-4: Example of unit shipment procedure - air cooled chiller for outdoor installation For exact positioning refer to the orderrelated dimensional drawing Notice! Use only supplied documentation and enclosed detailed dimensional drawings when transporting the unit. 22 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series 6.3 Shipping and Storage Storage Permitted storage conditions / permitted air condition for uninstalled units The storage conditions depend on the type of refrigerant. The used refrigerant can be taken from the unit identification plate: Air temperature: Refrigerant R410A: -15 °C bis +46 °C Refrigerant R134a: -15 °C to +55 °C Refrigerant R407C: -15 °C to +46 °C Air humidity: PR-2013-0112-GB • Subject to modifications • R1-01/2016 up to 85 % (relative humidity with no condensation) 23 Chillers & Heat Pumps GL Series Assembly 7 Assembly Note on assembling and installing the unit! Here you will find information on how to mount and install the unit. Placement, installation and assembly must only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes. Notice on moving the unit! If the DencoHappel units have been moved from one plant/location to another, repeated commissioning is required. Refer to the description in the chapter "Commissioning". 7.1 Positioning the unit Notice! Use only the supplied order-related documentation and enclosed detailed dimensional drawings when transporting the unit. ATTENTION Damage to the unit! Units for outdoor installation must not be installed in buildings (GLAC, GLAH, GLFC series) Units for indoor installation must not be installed outdoors (GLWC, GLWH, GLRC, GLDC series) • For air-cooled units for outdoor installation, check if the coating of the air-cooled heat exchanger is suitable for this installation site. The unit must be installed at a location that fulfils the following requirements: – Ensure that the foundation or the bottom base are level and that it can support the weight of the equipment, so that no vibrations or operating noise occurs when the unit is operating. – The foundation or frame construction must be able to carry the unit weight, the weight of the medium charge and possible snow load. Pay attention to appropriate safety measures. – The foundation or the frame construction must be installed horizontally. – The unit must be installed in such a way that it is only accessible to trained and authorized technical personnel. If necessary, use appropriate equipment to keep unauthorized persons away from the unit. – Ensure sufficient clearance around the unit to carry out maintenance or repair work. For required clearances, refer to the Data&Facts catalog for your unit or the orderrelated dimensional drawing. – The area where the unit is installed must have sufficient ventilation. – Make sure that possibly leaking media do not damage the installation site or the environment. Observe the nationally valid regulations. – Choose the installation location so that operating noise does not cause a disturbance. 24 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Assembly R2 R3 R4 R1 Fig. 7-1: – Check if requirements for the installation site defined by EN 378-3 are fulfilled (refrigerating systems and heat pumps - safety and environmental requirements Part 3: installation site and personal protection). These requirements especially apply to units for indoor installation. – There must be sufficient clearance around the unit to carry out maintenance or repair work. – The necessary clearances near and over the unit may exceed the depicted maintenance clearance by many times. Clearances Further notices on air cooled units GLAC, GLAH and GLFC series: Wind protection Wind protection R2 Clearances for air supply! – Unit must freely discharge air upwards. Air short-circuiting must be impossible! – If two or more units are installed next to each other, the relevant clearances must be kept for each unit (see fig. 71) Overlapping of clearances is not allowed! R1 Clearances Clearances Fig. 7-2 A R2 Clearances B R1 R2 Clearances R1 – At low outside-air temperatures, install the unit in a windprotected area with wind velocity below 0.5 m/s. For exact temperature refer to the Data&Facts catalog of the unit. Take appropriate measures for this purpose. Make sure that the air flow is not obstructed and consider the clearances of the unit. – Choose the installation location of the unit so that the heat exchanger is protected against dirt, like dust, leaves, pollen and similar. Fig. 7-3 Notices on ambient conditions such as ice and snow. ATTENTION Damage to the unit! Buildup of snow and ice around the unit can lead to unit damage. Irrepairable damage to unit and refrigerant leak can be the consequence. • Free the unit from heavy snow masses. • Keep the unit free of ice. – Due to static and operational reasons the unit must be protected from snow. This problem can occur if an air-cooled heat exchanger is surrounded by snow. If required, provide a base to ensure free air suction for a heat exchanger during all seasons. In regions with much snow the specified clearances can increase in order to avoid excessive buildup of snow around the unit. PR-2013-0112-GB • Subject to modifications • R1-01/2016 25 Chillers & Heat Pumps GL Series Assembly 7.1.1 Overview of application areas and types of heat exchanger coatings Comfort Climate Control The following tables specifiy the most frequent application areas of units for comfort climate control. Essentially these are urban and suburban areas as well as coastal regions. Typical application fields are listed here: – Living units – Hotels and holiday villages – Offices and business buildings – Shops and malls – Movie houses and theaters – Schools and universities – Clinics and hospitals Installation site Aggressive substances Special characteristics Coating of heat exchanger Micro-Channel Micro-Channel with powder coating Copper-Aluminum Std.* .I55/.I56/.I57 Std.* + + + + + + Chloride Low chloride concentration, foam - + o 1.2 Sea environment for coastal regions in the Chloride immediate vicinity of the coast High chloride concentration - + - Accessory code Urban environments COx Suburban environments Sea environments for coastal regions, up to many kilometers away from the coast Tab. 7-1 Installation site Aggressive substances Special characteristics Coating of heat exchanger Copper-aluminum with painted fins Copper-aluminum with polyurethane varnish paint Copper - Copper .I03/.I23/.I52 .I18/.I22/.I51 On request + + + + + + Chloride Low chloride concentration, foam + + + Sea environment for coastal regions in the Chloride immediate vicinity of the coast High chloride concentration - + - Accessory code Urban environments COx Suburban environments Sea environments for coastal regions, up to many kilometers away from the coast Tab. 7-2 Std.* Find the specification of the heat exchanger unit type used (micro-channel or copper-aluminum). + Use at the respective installation site is possible. o The use of the accessory could be connected with functional restrictions according to the remarks provided. - The use of the heat exchanger at this installation site is not possible. The heat exchanger and the fin packet can be affected, which can lead to the refrigerant escaping into the atmosphere. 1 Depending on the distance to the coast and the concentration of the aggressive substance. 2 Over time, the fins can be damaged and the properties of the unit can be affected. The consequence can be irreparable damage to the heat exchanger and refrigerant escaping into the atmosphere. 26 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Assembly Special applications The following table provides and overview about typical installations in industrial environments or rural environments. This applies both for units for comfort air conditioning as well as for process cooling. Even though these applications represent a minority of uses, these operational areas are of enormous importance due to existing air pollution, and should therefore be given special attention. These include industrial processes for handling raw materials and processing food as well as facilities for ageing and maturing food products and and processing wine. Additional attention must be paid to the selection of a suitable heat exchanger coating for installations located in the indirect or immediate environments of airports or military bases. Installation site Aggressive substances Special characteristics Accessory code Coating of heat exchanger Micro-Channel Micro-Channel with powder coating Copper-Aluminum Std.* .I55/.I56/.I57 Std.* Rural environments SOx, NOx Fertilizer, organic compounds - + o 1.2 Rough sea conditions, such as on ships, in harbors and on offshore oil platforms Chloride High chloride concentration, foam - - - Rough industrial environment, Steel industry Sulfur, SOx, NOx Soot - - - Grease, air humidity - + o 1.2 Food & beverage industry Waste disposal industry Ammonia Particles, organic suspended particles - + o 1.2 Environment in the vicinity of wastewater and sewage treatment plants sulfur, ammonia Organic suspended particles - - - Copper-alumi- Copper-aluminum with num with painted polyurethane varnish fins paint Accessory code Copper - Copper .I03/.I23/.I52 .I18/.I22/.I51 On request Rural environments SOx, NOx Fertilizer, organic compounds + + + Rough sea conditions, such as on ships, in harbors and on offshore oil platforms Chloride High chloride concentration, foam - o 1,2,3,4 - Rough industrial environment, steel industry Sulfur, SOx, NOx Soot - o 1,2,3,4 - Grease, air humidity + + + Ammonia Particles, organic suspended particles + + + sulfur, ammonia Organic suspended particles - o 1,2,3,4 - Food & beverage industry Waste disposal industry Environment in the vicinity of wastewater and sewage treatment plants Tab. 7-3 Std.* Find the specification of the heat exchanger unit type used (micro-channel or copper-aluminum). + Use at the respective installation site is possible. o The use of the accessory could be connected with functional restrictions according to the remarks provided. - The use of the heat exchanger at this installation site is not possible. The heat exchanger and the fin packet can be affected, which can lead to the refrigerant escaping into the atmosphere. 1 Depending on the concentration of the aggressive substance. 2 Over time, the fins can be damaged and the properties of the unit can be affected. The consequence can be irreparable damage to the heat exchanger and refrigerant escaping into the atmosphere. 3 In the long term, the pipes can corrode and refrigerant escaping into the atmosphere can be the consequence. 4 Regular maintenance jobs must be carried out to preserve the protective coating. PR-2013-0112-GB • Subject to modifications • R1-01/2016 27 Chillers & Heat Pumps GL Series Assembly Additional notice for GLAH units: PERSONAL injury! Frozen surfaces around the unit as a result of random or irregular condensate drainage during defrosting can lead to personal injuries. • Keep the area around the unit free of ice during cold weather conditions. – Ensure orderly and free water drainage for air-cooled heat pumps in heating mode to divert collected water during defrosting. At low outside temperatures, provide a heated tray and condensate drainage. 7.2 Assembling the unit In order to reduce the transmission of vibrations and avoid unit damage, anti-vibration isolators must be installed: – Under all circumstances, anti-vibration isolators must be used to separate the unit from the foundation when installing the unit in locations where no special requirements for neutralizing structure-borne noise apply. – For very special acoustic requirements please consult an acoustic engineer to select the most suitable method for neutralizing structure-borne noise. To install the unit, proceed as follows: ATTENTION Damage to the unit! Please consider that suitable anti-vibration isolators must be installed below the unit as well as pipework compensators on water inlet and outlet of the unit. The antivibration isolators ensure that the vibration is reduced and compensated making it possible to avoid mechanical defects on the unit. The latter is a requirement for safe and trouble-free operation of the unit and thus constitutes an integral part for the validity of the guarantee. • The unit must be fixed in position and secured according to the order-related • dimensional drawing using anti-vibration isolators (also see fig. 7-4 and following pages) or other suitable gear at each of the fixing points W1 to Wn. Connect and secure the anti-vibration isolators with the foundation/frame construction. R2 W1 W3 N° 4 HOLES M12 R3 R4 W4 W2 R1 Fig. 7-4: 28 Example for mounting position For exact positioning refer to the order-related dimensional drawing PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Assembly • Do not install the unit on the supplied rubber pads. These are meant for easy loading and unloading only and are not suitable for the operation of the unit. • The unit must be installed horizontally. • Do not attach on-site loads on the unit, such as pipes. Vibrations and the additional weight can cause damage. Fig. 7-5: Rubber pad 7.2.1 Safety valves • The unit is equipped with safety valves (cf. refrigeration circuit diagrams). The valves • • blow off the refrigerant at high pressure and high temperature when the high pressure is exceeded. Keep persons and objects away when refrigerants are discharged, as this can result is injuries and/or damage. The discharged medium types must be released appropriately according to EN 3783 and the locally valid regulations. Inform the DencoHappel Service immediately as soon as the safety valve opens. 7.2.2 Assembly of the common water outlet sensor For units of the GLWC(H) series with more than one evaporator (regarding the cooling operation), the temperature sensor for the common water outlet must be installed by others on-site. • Install the separately supplied temperature sensor on the chilled water side in the • • • • • • • • joint water outlet pipe to measure the common water outlet temperature. Install the temperature sensor in a suitable immersion sleeve. An installation on the pipe is not allowed due to inaccurate temperature measurement. Do not mount the immersion sleeve directly in or after fittings. Due to the occuring turbulences, a correct water temperature is not measured there. In any case, use thermally conductive paste to ensure a good heat transfer. Secure the temperature sensor to prevent it from falling out of the immersion sleeve. Check the temperature sensor for tightness and a good thermal transfer. Connect the temperature sensor for the common chilled water outlet in the switch cabinet of the unit according to the supplied wiring diagram. Check if electrical connection is tight. Check the temperature values displayed in controller with an own control measurement. If required, the sensor value is to be calibrated (see operation manual of the unit). . 1 Legend: 1) Temperature sensor 2) Thermally conductive paste 2 3) Seal with silicone 4) Immersion sleeve 3 5) Temperature sensor 6) Immersion sleeve (on-site) 4 7) common evaporator outlet 5 6 Evaporator water outlet sensor must be installed in the common water outlet pipe on-site. 7 PR-2013-0112-GB • Subject to modifications • R1-01/2016 29 Chillers & Heat Pumps GL Series Assembly To find out if the unit is equipped with one or more evaporators, refer to the unit description in the Data&Facts catalog, unit quotation text or order-related dimensional drawing. 7.3 Installing accessories 7.3.1 Rubber anti-vibration isolators For exact type of rubber anti-vibration isolators necessary for each unit refer to the unitrelated Data&Facts catalog. BOLT BASEMENT LITTLE PLANE WASHER BASEMENT ANTIVIBRATING MOUNTING FIXING BRACKET 45 66 LITTLE PLANE WASHER GROVER ELASTIC WASHER NUT BASEMENT OF E OH NUT A GROVER ELASTIC WASHER C D BIG PLANE WASHER RUBBER TYPE ANTIVIBRATING MOUNTING D D BIG PLANE WASHER OG D B C NUT B Fig. 7-6: Mounting rubber anti-vibration isolators Type A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) G (mm) H FZ 100-57 FZ 200-51 56 80 67 6.5 60 25 6.5 M12 72 108 90 9 60 40 8.5 M12 FZ 200-57 72 108 90 9 60 60 8.5 M12 FZ 400-51 95 155 125 15 60 65 12.5 M14 Tab. 7-4 30 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Assembly FZ 400-57 95 155 125 15 60 70 12.5 M16 FZ 600-51 95 175 140 17.5 FZ 600-57 95 175 140 17.5 60 75 14 M18 60 100 14 M20 FZ 1000-57 95 205 162 21.5 60 80 16 M20 Tab. 7-4 Fig. 7-7: Installation of anti-vibration isolators PR-2013-0112-GB • Subject to modifications • R1-01/2016 31 Chillers & Heat Pumps GL Series Assembly Type A B C D E ØF ØG ØH AA100N 60 80 67 6.5 60 25 6.5 M12 AA200N 75 108 90 9.0 60 40 8.5 M12 AA300N 81 135 110 12.5 60 60 10.5 M14 AA400N 95 155 125 15.0 60 65 12.5 M14 AA1000N 145 200 162 19 60 100 16 M20 AA1500N 155 220 182 19 100 80 17 M20 Tab. 7-5: Size in [mm] Fig. 7-8: Installation of anti-vibration isolators 32 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Assembly Type A B C D E F G H I AA600N 175 100 77 70 14 140 15 M16 30 AA800N 180 120 92 75 15 150 16 M18 35 Tab. 7-6: Size in [mm] Anti-vibration spring isolator Refer to the order-related unit documentation to select the correct type of spring antivibration isolators to be installed below the relevant points W1 to Wn. 45 66 ØA f Ø C 50 DH L F A Li Fz 75 100 12 F [kg]: refer to weight k [kg]: see below 50 f [mm] = F/k 50 140 12 116 12 Fig. 7-9 PR-2013-0112-GB • Subject to modifications • R1-01/2016 33 Chillers & Heat Pumps GL Series Assembly A [mm] ?C L [mm] Li [mm] Fz [N] ΔH [mm] Frequency (Hz) SR21-550H-AM/L 185 M12 100 80 180-650 from 25 to 58* 5 - 2.65 SR21-800-AM/L 185 M12 100 80 270-800 from 25 to 58* 5 - 2.95 SR21-1000-AM/L 185 M12 100 80 350-1000 from 25 to 58* 5-3 SR21-1200-AM/L 185 M12 100 80 480-1200 from 25 to 58* 5 - 3.2 Type Tab. 7-7: Size of anti-vibration isolators * applies to unit feet with 10 mm thick carrying frame 7.4 Installation of unit accessories The following chapters contain instructions for the installation of unit accessories which are supplied separately. In addition to the notices provided here, observe the operation and installation manuals of the supplied accessory items. 7.4.1 Accessories GLZ########.I10/.I46 - flow switch Notice! Under all circumstances remember to install an additional flow switch at chilled water outlet of the unit and connect it to terminals A-B in the switch box of the unit. The additional flow switch can be optionally ordered and is a requirement for safe and trouble-free operation of the unit and thus constitutes an integral requirement to uphold the validity of the warranty. Notice! Only for water-cooled, reversible heat pumps (GLWH-#D unit series): Install a flow switch in each water outlet of the unit and connect to terminals A-B (for chilled-water circuit in cooling mode) and terminals A1-B1 (for warm-water circuit in cooling mode). Hydraulic integration • Make sure that the maximum allowable operating pressure of the flow switch is not exceeded. 1¼"x1" 1¼" • Install the flow switch in a horizontal pipe on the water-side outlet of the unit. • Consider a sufficient distance of 5 x diameter before and after the flow switch to pipe bends and cross-section constrictions to avoid a turbulent flow. • Make sure that the flow switch is freely accessible for maintenance and service • Fig. 7-10: Flow Switch • 34 work. Consider the right length of the paddle. The paddles must not touch or tilt the tube bottom. The paddles must be freely movable in the pipe. Shorthen the paddles, if required. For reasons of stability, keep the shorter paddle screwed. It is useful to install the smaller paddles behind the largest paddle to ensure more stability. PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Number of paddles used: Assembly Pipe diameter Paddle 1" 1 1¼" 1 1½" 1 2" 1, 2 2½" 1, 2 3" 1, 2, 3 4" 1, 2, 3 4"Z 1, 2, 3, 4 5" 1, 2, 3 5"Z 1, 2, 3, 4 6" 1, 2, 3 6"Z 1, 2, 3, 4 8" 1, 2, 3 8"Z 1, 2, 3, 4 Tab. 7-8: Number of paddles used • Screw the flow switch into the T-fitting (DIN 2950) using sealing tape. • Observe the flow direction of the flow switch. The paddle must move with the water • flow. The flow direction is additionally marked with an arrow on the screw connection. Check the connections for tightness/leakage. Electric connection: • Connect the contacts of the flow switch in the switch cabinet of the unit (see also the • • • • • order related wiring diagram supplied with the unit). Place a 3-wire cable with a minimum cable cross section of 1.5 mm² from the switch cabinet of the unit to the flow switch. For the terminal designation on which you install the flow switch, refer to the order related wiring diagram which is supplied with the unit. It is not permitted to use other contacts than the ones specified in the wiring diagram. Apply the protective conductor. Measure the contacts of the flow switch. The contacts must be used in such a way that they are closed when the water flow is sufficient: – Red-White: Closed when water flow is sufficient – Red-Blue: Closed when water flow is insufficient Make sure that the casing of the flow switch is protected against water and humidity. Fig. 7-11 Adjustment: • The sensitivity or the trigger characteristic of the flow switch can be adjusted via an • • adjusting screw. The flow switch is delivered with a minimum output switch off value by the manufacturer. The sensivity is reduced by a clockwise movement of the adjusting screw. The cut-out point must be higher than the minimum switch-off point to ensure a safe function of the flow switch. PR-2013-0112-GB • Subject to modifications • R1-01/2016 35 Chillers & Heat Pumps GL Series Assembly 7.4.2 Accessories GLZ########.E19/.E20 - external control panel Unit: • Install a T connector in the switch cabinet of the unit. External switch cabinet • Install a T-Connector directly where the additional external control panel is meant to • • be installed. The T-Connector must be installed dry and protected against humidity. Consider the maximum cable length between T-Connector and control panel of 0.8 m. Unit: • Connect the 6-core telephone cable of the controller circuit board with the connection position B on the T-Connector. • Connect the control panel of the unit with the connection A of the T-Connector via the separately supplied telephone cable. Fig. 7-12: T-Connector • Use a shielded, twisted triple cable (AWG20-22) for the connection of both T• • Connectors. Depending on the option, consider the maximum cable length between both T-Connectors: – Option GLZ########.E19 for maximum distances of 200 m – Option GLZ########.E20 for maximum distances of 500 m with additional mains transformer for the power supply of the T-Connector in the external switch cabinet. An external power supply of 230 V/50 Hz is required for the mains transformer Connect both T-Connectors via the screwed joints SC 0-6 according to the supplied and order-related wiring diagram. Screwed joint SC Description 0 Protective conductor/shield 1 +VRL, 30V 2 GND 3 Rx-/Tx- 4 Rx+/Tx+ 5 GND 6 +VRL, 30 V Tab. 7-9 • When connecting, pay attention to the difference of the models with and without mains transformer. • Set the jumpers J14 and J15 to position 1-2. • Install the external control panel according to the supplied operation manual. • Set the address of the external control panel to 32. 36 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Assembly Setting the address of the external control panel: • Press the keys [ ], [ ] and [ ] simultaneously for several seconds. Enter the desired address with the key [ [ ] and [ ]. If an empty display appears, press the key [ Confirm with [ • • • • ] and confirm with ]. ] Adjust settings as displayed in the figure. Place the Cursor with the key [ ] on "No“. Change the value with the key [ ] or [ ] to "Yes“. Confirm with the key [ ]. You will find additional notices for setting the addresses in the supplied operation manual of the unit. PR-2013-0112-GB • Subject to modifications • R1-01/2016 37 Chillers & Heat Pumps GL Series Assembly 7.4.3 Accessories GLZ########.I31 – 3-way valve for cooling water regulation. 3-way valve Servo motor • Remove the plastic caps before installing the 3-way valve. • Install the 3-way valve as described in the following examples: Unit GLWC #### #D2 – unit without GLPC pump module Unit: GLWC #### #D2 – unit with GLPC pump module Unit GLWH #### #D2 – unit without GLPC pump module 38 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Assembly Unit: GLWH #### #D2 – unit with GLPC pump module Legend: CD CD/EV 3WV Condensers Condenser/evaporator (depending on operating mode) 3-way valve 1 Unit water outlet (to hydraulic network) 2 Unit water inlet (from hydraulic network) 3 Unit water inlet (from hydraulic network) 4 Unit water outlet (to hydraulic network) Tab. 7-10 • • • • • Connect the servo motor with the 3-way valve. Wire the servo motor with the switch cabinet of the unit. Use a minimum cable cross section of 1 mm². For the connections of how the 3-way valve is regulated, refer to the supplied and order-related wiring diagram of the unit. Check hydraulic connections for tightness/leakage. PR-2013-0112-GB • Subject to modifications • R1-01/2016 39 Chillers & Heat Pumps GL Series Medium Connections 8 Medium Connections Medium connections must only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes (also refer to section 4.10 „Personnel selection and qualification“). 8.1 Requirements Components Keep in mind: • The entire chilled water system must be designed and implemented in accordance with the current standards and guidelines. • Hydraulic circuit components supplied as standard with the unit, e.g. expansion tanks, are dimensioned primarily for the unit and not for on-site hydraulic circuits with arbitrary ratings. That is why - check which parts are still necessary for proper and regulation conform arrangement of the entire hydraulic system. 8.1.1 Glycols Danger due to toxic substances! Glycols and other antifreeze agents are harmful for humans and animals, if swallowed. • Consult a doctor immediately if swallowed by mistake. • Exercise due caution and attention when carrying out this work. After skin contact with glycol: • Rinse the affected body parts using lukewarm water for at least 5 min. After eye contact with glycol: • Do not rub your eyes. • Remove contact lenses if you have any. • Rinse your eyes with much water. ATTENTION Environmental damage! Ethylene glycol and propylene glycol are covered by Water Hazard Class 1 (slightly water-endangering) of the catalogue of water-endangering substances. This also applies to mixtures with water. 40 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections • 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 unit 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 – an increased power and current consumption of the pump – a lower cooling/heating 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 of the pump is not unnecessarily increased by excessively high concentrations of glycol, the latter should be added to match the ambient temperatures. A water-glycol mixture does not have a burst effect starting from frost resistance of -20°C, as slush ice forms when the mixture is cooled below the freezing point. Do not use Teflon seals if using water-glycol mixtures. Charge the system with a prepared water-glycol mixture. After having filled the system, check the glycol concentration with a suitable and approved measuring instrument. When designing the system, remember that thermal expansion of a water/glycol mixture is far more larger than water. Use only one sort of glycol, do not mix different types. Maximum glycol concentration must not exceed 50 %. PR-2013-0112-GB • Subject to modifications • R1-01/2016 41 Chillers & Heat Pumps GL Series Medium Connections 8.1.2 Water quality recommendations A good water quality – e.g. salt and lime free drinking water – considerably increases the service life and efficiency of the unit and the connected secondary system. Check the limit values in the table once a year to avoid damage to the hydraulic system components. If necessary, inhibitors must be added. Description Symbol Values Effects in case of difference 1 Hydrogen ion concentration pH 7.5 - 9 < 7.5 >9 Corrosion Incrustation 2 Calcium and magnesium content Hardness (Ca/ Mg) 4 - 8.5 °D > 8.5 Incrustation 3 Chlorine ions Cl– < 150 ppm Corrosion 4 Iron ions Fe³+ < 0.5 ppm Corrosion 5 Manganese ions Mn²+ < 0.05 ppm Corrosion 6 Carbon dioxide CO2 < 10 ppm Corrosion 7 Hydrogen sulphide H2S < 50 ppb Corrosion 8 Oxygen O2 < 0.1 ppm Corrosion 9 Chlorine Cl2 < 0.5 ppm Corrosion 10 Ammonia NH3 < 0.5 ppm Corrosion Bicarbonate/sulphate ratio HCO3-/SO4²- >1 Point 11 Tab. 8-1: <1 Corrosion 1/1.78 °D = 1 °Fr with 1 °Fr = 10 g CaCO3/m³ ppm = parts per million (mg/l) ppb = parts per billion (μg/l) Explanations: To point 1: A concentration of hydrogen ions (pH) over 9 poses a high risk of deposition, while a pH-value under 7 means a high risk of corrosion. To point 2: Hardness is measured by the proportion of the calcium carbonate and magnesium carbonate dissolved in water, in water temperatures below 100 °C (momentary hardness). A high degree of hardness poses a high risk of deposition. To point 3: A concentration of Chlorine ions of higher values than specified leads to corrosion symptoms. To point 4, 5 and 8: Present iron, manganese and oxygen ions lead to corrosion symptoms. To point 6 and 7: Carbonic acid and hydrogen sulphide are pollution which promote corrosion. To point 9: The typical value in mains water is between 0.2 and 0.3 ppm. High values will cause corrosion To point 10: Ammonia increases the oxidizing effects of oxygen. To point 11: If the values are lower than indicated in the table, there is a risk of corrosion by triggering galvanic currents between copper and the other less noble metals. When other fluids are used (e.g. mixtures that contain ethylene or propylene glycol) it is recommended to always use fluids with specific inhibitors which provide thermal stability and corrosion protection in the operating temperature interval. For dirty or aggressive water it is absolutely necessary to install an intermediate heat exchanger before the main heat exchanger. 42 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series 8.2 Medium Connections Connecting water circuit (chilled and warm water) Check the following before commencing medium connections of the unit: • The entire chilled water system must be designed and implemented in accordance with the current standards and guidelines. • Avoid rigid connections between unit and connected hydraulic circuit. Therefore, use vibration compensators. • Drainage valves must be installed at all low points of the water system in order to ensure that the water circuit can be fully drained for maintenance or repair purposes. • Air vents must be installed at all high points in the chilled water system at easily accessible locations. • Insulate the entire water circuit to prevent condensation and capacity losses. The exterior surface of steel piping must be protected against corrosion using protective paint. • Run the hydraulic circuit in such a way that it prevents water from flowing through the heat exchangers against the flow direction. For this purpose, use non-return valves ATTENTION Damage to the unit! The DencoHappel units may only be used in a closed-loop water system. Use in an open water system can lead to excessive corrosion. • Flush the piping system by others and draw up a cleaning report. Enclose the cleaning report to Appendix I „Technical Requirements for Function Testing or Chiller/Heat Pump Maintenance". ATTENTION Damage to the unit! When connecting the chilled water system, counter hold the connecting spigots with a pipe wrench to prevent damage. ATTENTION Damage to the unit! Under all circumstances please remember to install a water filter before the direct inlet into the water side heat exchanger. The water filter prevents formation of dirt and scale of all kinds on the heat exchangers. Water filters are optional and can be ordered separately but are needed for safe and trouble-free operation of the unit and thus constitute a requirement for upholding the validity of the warranty. ATTENTION Damage to the unit! The heat exchangers in the unit must be protected against ice formation during system shutdown or if the ambient temperatures fall below freezing. Use an antifreeze agent in the water system, if the chilled water pipes are not frost-safe or if the unit is not installed in a frost-safe location (refer to section 5.4 „Operating limits“). ATTENTION Damage to the unit! Mixing up of water inlet and outlet results in significant capacity losses of the unit and in the worst case - destruction of the heat exchanger. PR-2013-0112-GB • Subject to modifications • R1-01/2016 43 Chillers & Heat Pumps GL Series Medium Connections • Connect the piping system by others to the chilled water inlet and outlet. • For exact positions of the water inlet and outlet refer to the order-related • • documentation and compare these positions with data on the unit stickers. For terminological overview and better understanding refer to Kapitel 15.4 „Generally accepted translation of diagrams, plans and drawings in order-related documentation“ on page 149. Contact your DencoHappel sales office in case of queries or unclear points. 8.2.1 Description of pipe connections Description of pipe connections Threaded connections (defined as of UNI ISO 7/1) Rp XX ["] Parallel internal thread with seal through thread Rc XX ["] Conical internal thread with seal through thread R XX ["] Conical external thread with seal through thread Threaded connections (defined as of UNI ISO 228/1) XX ["] ISO G: parallel external thread with no seal through thread Flange connections DN XX / PN XX - Nominal diameter with pressure class (e. g.DN 80 PN16: nominal diameter 80 mm, nominal pressure 16 bar) Groove-lock connections G / Victaulic groove lock coupling ["] flexible joint: rated diameter (also known as "Victaulic®" trade mark) Tab. 8-2 Notice! For detailed planning please only use the order-related documentation. Detailed dimensional drawings can be obtained on request from your responsible DencoHappel sales office. Specifications and technical data are subject to regular updates. The manufacturer reserves the right to make necessary changes to information without prior written notice • Check the water circuit for tightness. • Flush the piping system by others and draw up a cleaning report. Enclose the cleaning report to Appendix I „Technical Requirements for Function Testing or Chiller/Heat Pump Maintenance". 8.3 Check and adjust inlet pressure in expansion tank (for units with installed hydraulic or pump module with expansion tank) To find out if an expansion tank is included in the packaged content, refer to the hydraulic circuit diagram in the supplied order-related documentation, Data&Facts catalogue or unit quotation text. The adjusted inlet pressure and the volume of the expansion tank is specified in the Data & Facts, the quotation text of the unit or on the unit identification plate of the expansion tank. The pressure of the safety valve can be taken from the Data & Facts catalog, the unit quotation text or from the safety valve. When charging the unit with water or a water-glycol mixture, the initial pressure in expansion tank of hydraulic or pump module must be checked and if necessary adjusted. Only correctly adjusted expansion tank can can perform the following tasks: – Provision of water receiver – Intake of temperature conditioned volume increase of unit water Besides, the system pressure has to be measured at the unit and adjusted in order to ensure correct operation of the expansion tank. 44 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections H [ m ] + 0, 3 Pv = ------------10, 2 Inlet pressure (estimated): Plant filling pressure min. (estimated): PA min = Pv + 0, 3 PA max = Psv – 0, 3 Plant filling pressure max.: Pv : Initial pressure [bar], measured at pressure connection of expansion tank Minimum setting 0.5 bar H : Height of water column over expansion tank PAmin : Minimum plant filling pressure [bar], measured at unit PAmax: Maximum plant filling pressure, measured at unit Psv : Safety valve pressure at opening If the vertical difference over the expansion tank is less than 10 m, the inlet pressure may remain unchanged. If the expansion tank is installed at the highest point of the hydraulic system, the inlet pressure may remain unchanged. Notice! – For adjusting the inlet pressure the hydraulic circuit must be completely drained. – Only dry nitrogen is allowed to adjust the calculated inlet pressure. – The minimum inlet pressure of the expansion tank may not exceed 0.5 bar. – The maximum inlet pressure of the expansion tank must amount to a minimum of 0.3 bar below the opening pressure of the safety valve. – Refer to the unit identification plate of the expansion tank for the approved setpoint range of the inlet pressure. – Do not exceed the maximum water column above the unit, depending on the maximum operating pressure of the expansion tank and the pressure of the safety valve. ATTENTION Damage to the unit! Incorrect inlet pressure can lead to a pump damage and impair the entire unit. • Check if the volume of the expansion tank is sufficient and suitable for the entire system content of the connected hydraulic circuit. The volume of the expansion tank is specified on the unit identification plate and unit documentation. Should the volume of the expansion tank be insufficient, an additional expansion tank must be installed by others on site. PR-2013-0112-GB • Subject to modifications • R1-01/2016 45 Chillers & Heat Pumps GL Series Medium Connections D. 1 Minimum initial pressure of expansion tank Pv [bar] 3 2,5 2 1,5 1 0,5 0 0 5 10 15 20 25 Height of water column over expansion tank H [m] 8.4 Charging water circuit • Connect the water supply or the pre-mixed water-glycol to the filling valve. • Open shut off valves. • Use air vents to let all air escape when charging the water circuit. ATTENTION Damage to the unit! The unit may only be operated with excessive pressure. The suction side pump pressure must always be higher than the ambient pressure. During pump operation all shut off valves must be open, besides it is not allowed to keep valves closed when pump is running. Notice! Ensure constant water flow rate in the evaporator during unit operation when the remote ON/OFF is closed. The volume flow rate must correspond to the unit layout parameters. If 3-way valves are fitted in the (primary) chilled water circuit, ensure that volume flow is provided in the water cooled heat exchanger regardless of valve position. Notice! Glycol may be used; however the concentration must not exceed 50% of the content of the entire system. A higher quantity can cause operating faults. 46 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections 8.4.1 Schematic representation of various hydraulic circuits (examples) The following components must be installed in every cold or warm water circuit in compliance with the correct order. – Pressure gauge on the water inlet and outlet of the unit – Stop cocks for pressure gauges – Air vents at the highest locations of the hydraulic circuit. – Vibration compensators on the water inlet and outlet of the unit. – Flow switches adapted for air flow of the unit – Double regulating valve on unit outlet – Shut-off valves on the water inlet and outlet of the unit – Water filter with a maximum of 1 mm mesh width before the immediate water inlet (maximum distance 2 m) of the unit. – Drain valves at the lowest locations of the hydraulic circuit – Water pump on unit inlet The following two hydraulic circuits are presented as examples for conceptual knowledge and do not substitute proper planning and layout of the entire system. DH Unit 8.4.2 Single circuit buffer tank with one pump for the entire system Fig. 8-1: Hydraulic circuit of single-circuit buffer tank 1 Pressure gauge 10 Expansion tank 2 Stop cock 11 Filling valve 3 Automatic venting 12 Flow switch 4 Vibration damping connection 13 Balancing valve/Double regulating valve 5 Unit-independent pipeline fixing point 14 3-way valve 6 Water filter (maximum mesh size 1 mm2) 15 DencoHappel Unit 7 Drain valve 16 Single circuit buffer tank 8 Pump – primary circuit 17 Consumer 9 Safety valve Items 4, 5, 6 and 12 are also specified by DencoHappel in addition to the internal parts required by legal regulations. The hydraulic integration of the single circuit buffer tank as illustrated above can be used for both a chilled and a warm water circuit. PR-2013-0112-GB • Subject to modifications • R1-01/2016 47 Chillers & Heat Pumps GL Series Medium Connections 48 Purpose: With a single circuit buffer tank, the buffer tank serves primarily to increase the volume in the hydraulic system in order to guarantee the compressor's minimum runtime and to prevent the unit from being repeatedly switched on and off unnecessarily. Application: With small to medium-sized air-conditioning systems, a single circuit buffer tank system is used, wherever possible, with identical consumers requiring the same volume flow and identical water temperatures. Hydraulics: The water flows at the required capacity reduction from the buffer tank via the water pump into the unit. The water is cooled/heated. The chilled/warm water now flows via the consumer(s) and is heated/cooled again. The 3-way valve is fully open in position A - AB. The bypass line B is closed. If the load reduction of the consumers drops, the bypass line B is opened. This ensures a constant water/volume flow across the unit, regardless of the load reduction. The unit requires a constant water/volume flow for trouble-free operation. Therefore, pumps that are speed-regulated during operation must not be used. If the bypass line B is fully open due to a missing load reduction, water in consumers stops circulating. The water temperature approaches the setpoint of the unit and the compressor switches off gradually. The water pump continuously remains in operation in order to record the current water temperatures in the system. If the load reduction increases again, the unit switches on the individual compressors again depending on how far the temperature deviates from the setpoint. Control: The external enabling of the unit should, for example, be switched by a timer and/or the outside air temperature. Switching the external enabling via the water temperature or the position of the 3-way valve is not permitted, as this would prevent the unit from automatically regulating the capacity to optimise energy consumption. This would cause an undesirable cycle operation. The compressor's capacity is controlled depending on the temperature difference (setpoint and actual value) from the unit. Depending on the unit configuration, the water pump control function can be withdrawn from the unit. The consumers and the 3-way valve are controlled by others. Hydraulic or pump modules: Depending on unit configuration and the selected accessories, the unit can also be supplied with one or two water pumps, a buffer tank and other hydraulic components (see the available accessories). PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections DencoHappel Unit 8.4.3 Dual circuit buffer tank with multiple pumps for the entire system Fig. 8-2: Hydraulic circuit of twin-circuit buffer tank 1 Pressure gauge 10 Expansion tank 2 Stop cock 11 Filling valve 3 Automatic venting 12 Flow switch 4 Vibration damping connection 13 Balancing valve/Double regulating valve 5 Unit-independent pipeline fixing point 14 Pump – secondary circuit 15 DencoHappel Unit 16 Hydraulic switch/buffer tank suitable for chilled and warm water systems 17 Consumer 6 Water filter (maximum mesh size 1 7 Drain valve 8 Pump – primary circuit 9 Safety valve mm2) Items 4, 5, 6 and 12 are also specified by DencoHappel in addition to the internal parts required by legal regulations. The hydraulic integration of the dual circuit buffer tank as illustrated above can be used for both chilled and warm water circuits. With the warm water circuit, however, it must be noted that the pump for the primary circuit takes the supply from the buffer tank from below, where the chilled water collects. The water is conveyed to the unit by the primary pump. The supply to the pump for the secondary circuit must be taken from the buffer tank from above, as the warmest water can be taken from here. The secondary pump conveys the water to the consumers. Purpose: In the case of a dual circuit buffer tank, the buffer tank fulfils two main tasks. First, the buffer tank increases the volume. A generously dimensioned buffer tank not only guarantees the compressor's minimum running time, it also achieves proper thermal layering within the buffer tank. The second task is to separate the water volume flows on the primary and secondary sides. This enables the most diverse of consumers to be individually supplied and regulated in the secondary side. Application: A dual circuit buffer tank is used mainly in medium to large air-conditioning systems containing a number of different consumers. The required water volume flow of the individual consumers can vary. The consumer can be supplied by various, speed-regulated secondary pumps. Chilled water operation: The water flows at the required capacity reduction out of the buffer tank from below and into the unit via the water pump in the primary circuit. The water is cooled and returned to the buffer tank from below. The chilled water in the secondary circuit is taken from the buffer tank from below and fed to the consumers via additional secondary pumps. The heated water flows back to the buffer tank from above. Warm water operation: The water flows at the required capacity reduction out of the buffer tank from below and into the unit via the water pump in the primary circuit. The water is heated and returned to the buffer tank from above. The warm water in the secondary circuit is taken from the buffer tank from above and fed to the consumers via additional secondary pumps. The cooled water flows back to the buffer tank from below. PR-2013-0112-GB • Subject to modifications • R1-01/2016 49 Chillers & Heat Pumps GL Series Medium Connections A constant water volume flow across the unit must be ensured in the primary circuit. The water volume flow on the secondary side, i.e. at the consumers, can vary due to hydraulic separation, thus enabling the use of speed-regulated pumps. With a dual-circuit buffer tank, individual consumer circuits can also be switched off and on depending on demand. The transported volume of the primary pumps must be greater than the total transported volume on the secondary side. This ensures that the return flow temperatures of the secondary circuit do not influence the inlet temperatures of the secondary circuit. If the water temperature in the buffer tank approaches the setpoint, the compressors are switched off gradually via the unit control system. The water pump on the primary side continuously remains in operation in order to record the current water temperatures in the system. If the load reduction increases again, the unit switches on the individual compressors again depending on how far the temperature deviates from the setpoint. Control: Hydraulic or pump modules: The external enabling of the unit should, for example, be switched by a timer and/or the outside air temperature. Switching the external enabling via the water temperature in the buffer tank is not permitted, as this would prevent the unit from automatically regulating the capacity to optimise energy consumption. This would cause an undesirable cycle operation. The compressor's capacity is controlled depending on the temperature difference (setpoint and actual value) from the unit. Depending on the unit configuration, the water pump control function can be withdrawn from the unit. The consumers and the secondary pumps are controlled by others. Depending on unit configuration and the selected accessories, the unit can also be supplied with one or two water pumps, a buffer tank and other hydraulic components (see the available accessories). ATTENTION Damage to the unit! Under all circumstances please remember to install a water filter before the direct inlet into the water side heat exchanger. The water filter prevents formation of dirt and scale of all kinds on the heat exchangers. Water filters are optional and can be ordered separately but are needed for safe and trouble-free operation of the unit and thus constitute a requirement for upholding the validity of the warranty. ATTENTION Damage to the unit! Consider that a constant water volume flow must be secured in the evaporator/condenser during unit operation. Refer to the "Planning Manual on Chillers" for further instructions on hydraulic integration of chillers and heat pumps. Notice! For additional information regarding installation of different cold, hot and cooling water circuits refer to our manual on hydraulic systems for chillers and heat pumps. Please contact your DencoHappel sales office. 8.5 Connecting cooling water circuit (only GLWC and GLWH units) For connecting cooling water circuit the points specified in Kapitel 8.2 also apply: – Connecting water circuit (chilled and warm water) – Description of pipe connections – Check and adjust nominal inlet pressure in expansion tank – Charging water circuit The following two hydraulic circuits are presented as examples for conceptual knowledge and do not substitute proper planning and layout of the entire system: 50 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections Fig. 8-3: Heat rejection circuit with cooling water pump with speed control and/or speed control of the heat rejection unit Fig. 8-4: Heat rejection circuit with a 3-way valve and/or fan speed control of the heat rejection unit 1 Pressure gauge 9 Safety valve 2 Stop cock 10 Expansion tank 3 Automatic venting 11 Filling valve 4 Vibration damping connection 18 DencoHappel Unit 5 Unit-independent pipeline fixing point 19 Drycoolers 2 6 Water filter (maximum mesh size 1 mm ) 20 Temperature sensor fan heat-rejection unit 7 Drain valve 21 3-port valve 8 Pump – primary circuit 22 Temperature sensor 3-way valve PR-2013-0112-GB • Subject to modifications • R1-01/2016 51 Chillers & Heat Pumps GL Series Medium Connections ATTENTION Damage to the unit! Consider to install a water filter directly before the water inlet of the evaporator and condenser. The water filter (mesh width from 0.5 to 1 mm) prevents formation of dirt and scale on the coils.The water filter is a requirement for safe and trouble-free operation of the unit and in therefore is covered by the warranty. Frost protection The DencoHappel chiller and heat pumps of the GLWC and GLWH series are designed for indoor installation. Therefore protection of the chilled water circuit from frost at chilled water temperatures above 5 °C is usually not required. 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 effects. As antifreeze agent DencoHappel recommends to use ethylene glycol. Sizing Dimension the DencoHappel heat rejection unit in such a way that the cooling water temperature within the operating limits remains as low as possible. The lower the cooling water temperature, the higher the achieved refrigeration capacity and the lower the energy consumption of the unit. Design the cooling water circuit between inlet and outlet lines of the condenser and the heat rejection unit for a temperature difference of 5 K. Minimum cooling water outlet temperature Possibility 1: Possibility 2: Possibility 3: To ensure safe operation of the unit, operator must maintain minimum cooling water outlet temperature. For minimum cooling water outlet temperature refer to Data&Facts catalogue of the relevant unit series, quotations for the unit or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for chillers and heat pumps. This situation is not always the case because of cold weather. Therefore there are several technical possibilities to ensure the minimum cooling water outlet temperature. – Option 1 enables control of the fan speed depending on the cooling water outlet temperature. For all circumstances GEA recommends to control the fan speed in order to ensure continuous operation of the unit under constant conditions. – Option 2 should be implemented if, despite the speed control of fan motors resulting from e.g. a year-round unit operation, the minimum cooling water temperature can not be ensured. In this case the operator can use the cooling water pump if the limits for minimum and maximum water volume in heat exchanger are adhered to (refer to Fig. 8-3 on page 51). The cooling water pump is regulated by the cooling water outlet temperature. – Option 3 can alternatively be used in order to provide for the minimum cool water outlet temperature of the unit. In this case a 3-way valve is installed in cooling water inlet additionally to the fan speed control to provide valve regulation depending on the cooling water inlet temperature of the unit (refer to Fig. 8-4 on page 51). Notice! To guarantee a constant condensing pressure in chilled water operation, a minimum cooling water outlet temperature must be ensured. For minimum cooling water outlet temperature refer to Data&Facts catalogue of the relevant unit series, quotations for the unit or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for chillers and heat pumps. A direct control of the chilled water outlet temperature is not possible for most units because units can have several condensers arranged in parallel. In part-load operating mode only a common mixed temperature is recorded, but not the temperature of every condenser outlet which needs to be regulated. Therefore, unit faults can occur. Observe the unit operating limits when switching between heating and cooling mode of a heat pump. 52 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections Notice! For additional information regarding installation of different cold, hot and cooling water circuits refer to our manual on hydraulic systems for chillers and heat pumps. Please contact your DencoHappel sales office. 8.5.1 Operation of a 3-way valve (by others) Ensure a minimum cooling water outlet temperature after compressor start. For minimum cooling water outlet temperature refer to Data&Facts catalogue of the relevant unit series, quotations for the unit or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for chillers and heat pumps. The cooling water temperature determines the condensing pressure with an effect on the evaporation pressure in the refrigeration circuit. In order to avoid low pressure disturbances at insufficiently high cooling water temperature, GEA recommends to use a 3-way valve for units operated in transition periods and in winter. The function of a 3-way valve is to bring the cooling water temperature to the required level during the unit start up even if the cooling water in the heat rejection system is too cold as a result of low ambient temperature. Please note the operating limits of the unit. A 3-way valve is suitable for use in heat rejection units, cooling towers, evaporative condensers and earth loops. – Constant water flow in the water-side heat exchanger Fig. 8-5: Scheme of a 3-way valve 8.5.2 Functional description of a 3-way valve Depending on the condensing pressure, the following positions of a 3-way valve can be set: position A - AB, B - AB or mixed position A - B - AB. Install the 3-way valve on the cooling water side. The above-mentioned configurations are only relevant for the cooling operation, however they can accordingly be applied for the heating operation. Using a 3-way valve in heating mode is reasonable as integrated microprocessor control of a 3-way valve enables to regulate unit operation at constant water temperature and ensure safe and trouble-free unit performance. PR-2013-0112-GB • Subject to modifications • R1-01/2016 53 Medium Connections 8.6 Chillers & Heat Pumps GL Series Connecting refrigeration circuit to an external condenser (by others, only GLRC) Warning of high pressure! When working on hydraulic or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. • Before opening pipe connections, check if they are pressure-free. • Wear protective clothing and safety glasses. • Exercise due caution and attention when carrying out this work. Contact with refrigerant can lead to injuries! Contact with a liquid refrigerant can result in skin burns or injury to other organs. • Wear protective clothing and protective gloves. • Exercise due caution and attention when carrying out this work. 8.6.1 Basic requirements Condensers Set the condensing temperature for the chiller. Consider the operating limits of the unit. Refer to section 5.4. for the corresponding operating limits. Large temperaturedifference... The larger difference between condensing temperature and ambient temperature in the layout stage, the smaller condenser can be selected. Disadvantages of a smallerdimensioned condenser are increased noise levels as a result of high air velocity and/ or increased energy consumption because of higher condensing temperature together with reduced cooling capacity. Small temperature difference... The smaller difference between condensing temperature and ambient temperature in the layout stage, the larger condenser should be dimensioned. Through a large-dimensioned condenser the condensing temperature can be maintained low, which enhances capacity and energy efficiency. The disadvantage is about larger refrigerant charge volume for the designed condenser and increased installation space requirements. Depending on the region, practical values for temperature difference between condensing temperature and ambient temperature in the layout stage amount to 10 to 15 K, i.e. condensing temperature exceeds the layout parameters of ambient temperature by 10 to 15 Kelvin. Fan regulation and control Under all circumstances the condenser must be selected at least with the corresponding fan regulation or optimally with a fan speed control in order to ensure constant condensing pressure throughout the year. Significant fluctuations in condensing pressure should be avoided. In any case, the minimum condensing pressure after compressor start must be ensured. Maximum allowed condensing temperature must not be exceeded. Single circuit or dual circuit To find out if the unit is equipped with one or two refrigeration circuits, refer to the unit description in the Data&Facts catalog, unit quotation text or order-related dimensional drawing. – For units with one refrigeration circuit select a single-circuit condenser. – For units with two refrigeration circuits select a double-circuit condenser. Using a single-circuit condenser for units with two refrigeration circuits is not allowed because of different oil and refrigerant flow. Subcooler circuit 54 Select a condenser with an integrated subcooler circuit. Minimum subcooling must amount to at least 3 K, because only under these conditions the expansion valve receives a bubble-free liquid in case of 10 m rising liquid line. If the subcooling is smaller or the height difference is greater, the expansion valve can be damaged and the unit must operate with a reduced output anyway. PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections Refer to the relevant documentation provided by the manufacturer for further details on layout and installation of air cooled condensers. Refrigerant lines Only copper refrigerant lines meeting DIN EN12735-1 standards may be used. The relevant requirements especially apply to: – Quality of internal surfaces – Sealed pipe ends – Pipe labelling – Testing – Pressure resistance Line lengths and dimensions Short line lengths Keep the pipe length as short as possible. The greater the distance between chiller and field-provided condenser, the greater are the pressure drops in connected pipes, resulting in worse energy efficiency of the unit. Refer to the following "Placement and installation examples" in Kapitel 8.6.2 for the maximum distance and height difference between chiller and field-provided condenser. Oil transportation must be ensured When dimensioning the pipes, make sure that oil transportation is ensured under all operating conditions. Oil transportation must be ensured using the corresponding pipe dimensioning and pipe routing. Keep pressure drop as low as possible It is also important that the pressure drop in the pipework is minimized to avoid unnecessary decreases in capacity. The greater the selected pipe diameter, the lower is the speed in the pipe, and the more difficult is the oil return. The smaller the selected pipe diameter, the higher the speed and the greater the pressure drop in the pipe. The units loses capacity and energy efficiency. 1 % slope • Always provide a 1 % slope (1° cm/m) for the discharge line in the direction of flow. • Install oil top and bottom trap, as described in Kapitel 8.6.2 and following pages. Dimensioning of refrigerant lines for water inlet and outlet temperature of 12/7 °C and condensing temperature of 47 °C is presented in the Data&Facts catalogue of the unit. For other temperatures individual pipework calculation must be performed. Oil traps With long and winding pipe runs and often low load reduction combined with short compressor running times it is reasonable to install an oil separator in the field-provided discharge line. Consider the manufacturer's instructions regarding the layout of an oil separator and the relevant manual for the installation. Refrigerant receiver Installing a refrigerant receiver is not mandatory. With long pipe runs and year-round operation of the unit it is, however, recommended to install a refrigerant receiver. In case of a year-round operation, ensure that a minimum condensing temperature is maintained. If necessary, winter start regulation must be installed to maintain a minimum condensing temperature. If a receiver is not installed, the refrigerant must be selected and charged with due care. When charging the unit with refrigerant at low ambient temperature, ensure that the system is not overfilled and the unit can be trouble-free operated at high ambient temperature as well. Consider the manufacturer's instructions on layout of a refrigerant receiver and installation manual for mounting a receiver. PR-2013-0112-GB • Subject to modifications • R1-01/2016 55 Chillers & Heat Pumps GL Series Medium Connections 8.6.2 Placement and installation examples Example 1 GLRC chiller and condenser at the same vertical level with horizontal pipe routing GLRC chiller Discharge line  1 % slope (1 cm/m) Circuit 2 Fig. 8-6: Condensers Liquid Line GLRC chiller and condenser at the same vertical level Shut off valve is included in the unit packaged content  If necessary, a liquid-line solenoid valve can be optionally ordered. (.R01) The solenoid valve can be regulated by a dry contact using a GLRC switch box. Example 2 GLRC chiller above the condenser at different vertical levels GLRC chiller Discharge line 1 % slope (1 cm/m)  max. 10 vertical meters Circuit 2 Condensers Hot Gas Line 1 % slope (1 cm/m) Liquid Line Fig. 8-7: GLRC chiller above the condenser Shut off valve is included in the unit packaged content  56 If necessary, a liquid-line solenoid valve can be optionally ordered. (.R01) The solenoid valve can be regulated by a dry contact using a GLRC switch box. PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections Example 3 GLRC chiller below the condenser at different vertical levels. Condensers Discharge line  1 % slope (1 cm/m)  GLRC chiller Hot Gas Line max. 10 vertical meters per 5 vertical meters  1 % slope (1 cm/m)  Circuit 2 Fig. 8-8: Liquid Line GLRC chiller below the condenser Shut off valve is included in the unit packaged content     If necessary, a liquid-line solenoid valve can be optionally ordered. (.R01) The solenoid valve can be regulated by a dry contact using a GLRC switch box. Top oil trap is mandatory! 1 x 90° bend, 2 x 45° bend Bottom oil trap is mandatory! 2 x 90° bend, 2 x 45° bend Top oil trap is mandatory! 1 x 90° bend, 2 x 45° bend Notes! – The maximum equivalent pipe length must not exceed 50 m. – The maximum vertical difference between the GLRC chiller and condenser must not exceed 10 m. 8.6.3 Connecting refrigerating circuit • Connect the field-provided piping system to the liquid and discharge line. The precise positions of the connections can be determined from the order-specific dimensional drawing of the unit. Notice! To find out if the unit is equipped with one or two refrigeration circuits, refer to the unit description in the Data&Facts catalog, unit quotation text or order-related dimensional drawing. Two refrigeration circuits must be executed separately. Uniting these refrigeration circuits is not allowed. Dimensions of pipe connections on the unit are not decisive for the refrigerant lines to be routed. The dimensioning of the piping can be determined from the Data & Facts of the unit. PR-2013-0112-GB • Subject to modifications • R1-01/2016 57 Chillers & Heat Pumps GL Series Medium Connections Routing refrigerant lines Notice! When routing the pipes, always make sure that the pipe ends are sealed. Even if the unit setup is incomplete, seal all pipe ends after the job is finished. Only this way can penetration of dirt and humidity be prevented. • Pipes should always be routed with a slight slope to the flow direction.  Thus, the refrigerant oil return to the compressor is facilitated. The refrigerant flows Cutting Deburring in gaseous state under high pressure and temperature to the condenser. From the condenser liquid refrigerant flow under high pressure back to the liquid line connection of the unit. • Observe temperature-related changes in the length of pipe! Use a pipe cutter to cut pipes, and cut slowly to avoid copper pipe deformation. Cut surfaces must be deburred. Ensure that copper chips do not penetrate into the pipe. Soldering and brazing Brazing is the prescribed connection technique and is performed as hard-soldering method defined according to DIN EN 1044. Possibly apply a flux material according to DIN EN 1045. Soldering and brazing requires extensive experience and must be performed by a qualified and licensed refrigeration technician. To avoid the formation of an oxide film on the pipe internal surfaces during brazing, this job must be exclusively performed using nitrogen (N2). Precaution measure for brazing Avoid oxidation during brazing 58 – Brazing heat must be as high as necessary. – During brazing it is not allowed to overheat material. Surfaces of brazed material can oxidize due to heat exposure. If internal surfaces of pipes oxidize as a result of heat effects, scale can build up and penetrate into the refrigeration circuit as dust, which can lead to system faults. Brazing must therefore be performed at appropriately low brazing temperature and the smallest possible surface should be heated. To avoid thermal damage or interference with components near the brazing point, take precautionary measures, e.g. shielding using a metal panel or applying a moist cloth or other heat-absorbing material. – Brazing points must be absolutely tight. – Avoid shocks and vibrations during brazing to prevent build-up of cracks in the brazing joints. – Refrigerant lines must not be clogged through scale or flux. – A brazed joint may not obstruct refrigerant flow. – Corrosion may not occur on brazed joints. – Avoid oxidation. To improve the efficiency of brazing, different commercially available antioxidants can be purchased. These antioxydants can contain different aggressive components that attack pipe material and can adversely affect refrigerants or refrigerator oil, and should be used with extreme care. DencoHappel recommendation: use nitrogen! • • • • Connect a pressure-reducing valve at the nitrogen bottle. Mount a flow meter on the nitrogen bottle. Nitrogen should be directed in the refrigerant pipe to be brazed using a copper pipe. Seal the intermediate space between the nitrogen and refrigerant pipe to prevent nitrogen leakage.  While nitrogen is flowing through refrigerant lines, the opposite pipe end must remain open. • Use the pressure-reducing valve to set the value below 0.05 m³/h or 0.2 bar for the nitrogen flow. • After brazing/soldering, maintain the nitrogen supply until the refrigerant pipe has cooled down sufficiently to be manually handled. • After brazing/soldering, completely remove the remaining flux. PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections Drying systems Notice! When replacing components within the refrigeration circuit, the drier must always be replaced too! The drier must always be replaced last. The new drier is vacuum-packed. After opening the vacuum packing, commence with brazing as soon as possible. Evacuation must be performed within 2 hours. The drier must also be replaced if the entire refrigerant has escaped because of a leak. Insulation Insulation for the liquid line is not mandatory. Proper thermal insulation for the discharge line must be provided, in order to prevent scalding risk posed by hot refrigeration pipework. Moreover, fire protection regulations must be observed. If the thermal insulation is subjected to direct sunlight, proper materials must be used in this case. Notice! Refer to DIN EN 378-2 for further instructions on proper running of refrigerant lines. 8.6.4 Leak testing • Connect the manometer to the service connections of the respective refrigeration circuit on the suction and pressure side. • Before leak testing, examine the pressure values on the high and low-pressure manometer  Indicated pressure must be within the overpressure range. • In this case, open the liquid shut off valve and discharge line shut off valve for leak testing.  If no overpressure is measured in the refrigeration circuit of the device, it should be assumed that the refrigeration circuit in the unit possibly has a leak. • If this is the case, close the liquid shut-off valve and the hot-gas shut-off valve to test for leakage. • At first, test the refrigeration circuit in the unit on seal effectiveness and possibly remedy leaks • Thereafter, open the shut-off valves in the liquid and discharge line and examine the remaining refrigeration circuit on seal effectiveness. The system must be depressurized with dry nitrogen to test for leakage as long as the pipework is accessible and not yet insulated. For successful testing, test pressure must be as high as possible, but not exceeding the maximum allowed operating pressure. Introduce nitrogen for depressurizing using a pressure-reducing valve on the cylinder valve of the unit. The control gauge on the pressure-reducing valve must be set to the maximum test pressure of the system. • Increase pressure in the system in steps, first to 0.1 MPa (1 bar) overpressure and • • • • then to around 0.5 MPa (5 bar) overpressure. All pipe connections must be leak tested using foaming Leak Detection Spray. If no leaks are detected at 0.5 MPa (5 bar) overpressure, pressure is increased to the maximum allowed test pressure. Perform the pressure test using the maximum allowed test pressure for at least two hours. Subsequently, overpressure in the system can be reduced. PR-2013-0112-GB • Subject to modifications • R1-01/2016 59 Chillers & Heat Pumps GL Series Medium Connections 8.6.5 Evacuation Reasons for evacuation Before charging the system with a refrigerant, the refrigeration circuit must be evacuated using a vacuum pump in order to remove air and humidity. Air in the refrigeration circuit has the following effects: – Increase in energy consumption of compressors – Reduction in cooling capacity – Increase of discharge temperature – Poor heat transfer in the condenser. High-pressure failures can be the consequence already at relatively low ambient temperatures. Humidity in the refrigeration circuit has the following effects: – Internal ice formation in the expansion valve and capillary ducts. – Origination of acid in connection with refrigeration oil – Copper cladding – Chemical disintegration of refrigerant. Procedure for evacuation Reducing pressure in the unit components to values below the water vapour pressure leads to evaporation of water. The higher the ambient temperature, the faster and more efficiently humidity can be removed thanks to a higher vapor pressure. Because of this reason, it is not always possible to sufficiently dry the refrigeration circuit at low ambient temperature. • Connect the service manometer assembly to the service ports. Compare the orderrelated refrigeration circuit diagrams. For evacuation, use the vacuum pump (0.0003 bar) fitted with a high-grade pressure gauge a with 0 to 150 mbar abs scale range, to reach a pressure below water vapor pressure at the current ambient temperature. Vapour pressure for water (Ps) T [°C] Ps [MPa] abs. Ps [bar] abs. +5 0.0009 0.009 +10 0.0012 0.012 +15 0.0017 0.017 +20 0.0023 0.023 +25 0.0032 0.032 Tab. 8-3 At ambient temperature of 15 °C water begins to evaporate at a pressure of 0.0017 MPa (0.017 bar). The required dryness of the system is ensured if an absolute vacuum of around 0.00003 MPa or 0.0003 bar is reached and this condition can be maintained for more than 6 hours with a deactivated vacuum pump. If this value can not be reached, break the vacuum by introducing dry nitrogen and repeat the evacuation procedure. 60 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Medium Connections Pressure rise after evacuation 0,018 1 Absolute pressure [bar] 0,016 Humid and leaking 0,014 0,012 Humid and leak-free at Ta = +10 °C 0,01 2 0,008 0,006 0,004 3 0,002 Dry and leak-free 0 0 5 10 15 20 25 30 Time [h] Fig. 8-9: Pressure rise after evacuation 8.6.6 Charging Warning of high pressure! When working on hydraulic or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. • Before opening pipe connections, check if they are pressure-free. • Wear protective clothing and safety glasses • Exercise due caution and attention when carrying out this work. Contact with refrigerant can lead to injuries! Contact with a liquid refrigerant can result in skin burns or injury to other organs. • Wear protective clothing and protective gloves. • Exercise due caution and attention when carrying out this work. R-410A The plant is only approved for operation with the refrigerant R-410A. R-410A is almost an azeotropic mixture, consisting two individual refrigerants. As this mixture reaches its defined composition only in the liquid state, it is only allowed to charge a liquid R-410A refrigerant. • Use the service port of the liquid line to charge liquid refrigerant in each refrigeration • circuit of the unit. The refrigerant volume for charging or its approximate calculation is provided in the Data&Facts catalog of the relevant unit series. To avoid overcharging, first charge around 80% of the calculated volume. Use the liquid refrigerant to fill each liquid line of the unit refrigeration circuit. After breaking the vacuum with a liquid refrigerant, all shut-off valves of the unit must be opened. During the function test and for topping up the refrigerant, observe the liquid flow through the liquid line sight glass to receive an overall picture. • Check for bubble-free flow in the sight glass! PR-2013-0112-GB • Subject to modifications • R1-01/2016 61 Chillers & Heat Pumps GL Series Medium Connections 8.7 Connect Desuperheater/Heat Recovery Circuit Refer to the unit identification plate to see if the unit is equipped with a desuperheater/ heat recovery circuit. Compare unit identification plate with chapter 2 unit type code. For connecting desuperheater/heat recovery circuit the points specified in chapter 8.2 also apply: – Connecting water circuit (chilled and warm water) – Description of pipe connections – Check and adjust nominal inlet pressure in expansion tank – Charging water circuit Notice! For additional information regarding installation of different cold, hot and cooling water circuits refer to our manual on hydraulic systems for chillers and heat pumps. Please contact your DencoHappel sales office. 62 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series 9 Electrical Connection Electrical Connection Electrical connections may only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes. Ensure and observe protective measures! When installing and connecting the unit, protective measures for low-voltage systems according to the EU Directive as well as regulations and codes of the local utility provider shall be observed. Potential equalization must be provided and equipment with all connected components must be earthed. Electrocution through hazardous voltage will lead to death or serious injury! • Disconnect the unit from the power supply and ensure the power cannot be switched back on. • Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. Notice! The cabling must be carried out according to the enclosed unit-specific wiring diagrams. Only separate mains power cable may be used. Never connect other units to this mains power cable. 9.1 Requirements Before you start setting up the unit's electrical connections, check the following points without fail: – The properties of the mains power supply must comply with EN 60204-1 regulations and the power requirements of the unit. – Power supply must correspond to the type TN(S). – Earth leakage circuit breaker must correspond to type A or type B. – Voltage tolerance of mains power supply must not exceed tolerances ± 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 the warranty. To check, use the following formula (see example). – If phase asymmetry displays a value higher than 3 %, contact the power provider. – Before commissioning, check if electrical equipment is supplied in such a way that the conformity according to the directive 2004/108/EG (electromagnetic compatibility) is ensured. voltage imbalance from average value ------------------------------------------------------------------------------------------------------ x 100 Voltage imbalance [%] Δ U max = max. average voltage U m Notice! When connecting the supply voltage, make sure you observe the clockwise rotation direction! If the rotation direction is wrong, change the phases at the main power supply of the unit. Change the phase sequence of the power supply line at the on-site source, never change the wiring in the unit switch box. PR-2013-0112-GB • Subject to modifications • R1-01/2016 63 Chillers & Heat Pumps GL Series Electrical Connection EXAMPLE  Result Input data Requirements Rated voltage Calculate and determine specific input data and measurements beforehand. Voltage between phases 1nd Step Average Hum.  400 V/50 Hz/3 phases  L1/L2 = 409 V; L2/L3 = 398 V; L1/L3 = 396 V  Determine averagevoltage Um ΣU U m = ------3 ( 409 + 398 + 396 ) = 401 V ----------------------------------------------3 Determine the maximum voltage imbalance ΔUmax 2nd Step Voltage imbalance ΔUmax in %? Umax = 409 V Um = 401 V 9.2   Um = 401 V voltage imbalance Δ U max = max. ------------------------------------------------------- x 100 Um ( 409 – 401 )V ----------------------------------- ? 100 = 2 % 401 V  ΔUmax = 2 % ✓ Connect mains electrical supply To connect the unit, provide mains supply of 400 V /50 Hz /3 phases ~ /+N for units with supply voltage code 1 and 400 V /50 Hz /3 phases for units with supply voltage code 2 (compare chapter 2 unit type code). The power line must have the necessary protective devices – every phase must be equipped with a slow-blow circuit breaker. The size of the pre-fuse must be determined on the basis of the maximum operating current of the unit by a qualified licensed electrician – for maximum cable cross-sections and fuses refer to Data&Facts catalog. For the supply cable grommets refer to the enclosed order-related documentation and electrical wiring diagram. The cable grommet in the switch cabinet must be sealed with a cable grommet fastener (cable gland), in order to maintain the IP protection of the unit. • Run the power-supply cables through specially designated openings. It is not • allowed to use other openings, because they provide ventilation for the switch cabinet! Connect the power supply to the main isolator (observe clockwise rotating direction). Refer to electric wiring diagram supplied with the unit. Cable strain relief must be performed by others on site. Direct contact with hot or sharp surfaces must be avoided. L1 L2 L3 N PE Fig. 9-1: Connection of mains isolator for unit with supply-voltage code 1 1 Q S1 L1 L2 L3 N PE 400V / 3 / 50Hz 64 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Electrical Connection Fig. 9-2: Connection of mains isolator for unit with supply-voltage code 2 L1 L2 L3 PE 1 Q S1 L1 L2 L3 PE 400 V / 3 / 50 Hz 9.3 Connecting control contacts and controller NOTICE! Run the power supply cable of unit separately from the internal unit cabling and onsite provided supply lines of the unit. 9.3.1 Connecting control system • Connect control contacts according to instructions in section 9.3. Keep in mind: – Maximum cable length: 100 m – Minimum cable cross-section: 1.5 mm² • Secure the on-site single-ended cables (digital outputs) according to national • • • • regulations and codes. For details on cable grommets for control voltage/supply line refer to the enclosed order-related documentation and electrical wiring diagram. Run the control cables through specially designated openings. It is not allowed to use other openings, because they provide ventilation for the switch cabinet! 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. Cable strain relief must be performed by others on site. PR-2013-0112-GB • Subject to modifications • R1-01/2016 65 Chillers & Heat Pumps GL Series Electrical Connection 9.3.2 Integrating common fault signal ATTENTION Damage to the unit! Do not open the remote on/off contact, e.g. via the changeover contact of the on-site relay, if the system is faulty. – As a result, the fault can be reset, – and the cause of the malfunction cannot be determined. The entire unit stops operating although only one refrigeration circuit is possibly affected. • Connect the cable for common fault signal DencoHappel Unit E F A X B Y 230 V / 50 Hz / 2 A Contact Us Remote On/Off* Flow switch On-site relay On-site Relay Fig. 9-3: (volt free dry contact, suitable for 230 V AC / 50 Hz / 2 A). See the electrical wiring diagram supplied with unit, terminals X-Y. Common Fault signal Electric integration of error message Terminals: A - B: E - F: X - Y: Connecting flow switch by others Remote contact for switching the unit on and off using the NOC by others Common fault signal (voltage by others max. 230 V/50 Hz / 2 A) For the exact terminal designation refer to the order-related wiring diagram. 9.3.3 Integrating flow switch ATTENTION 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 box. The flow switch acts as a safety device and not as a regular switching device for the unit. • Connect the external flow switch. See the DencoHappel Unit E F A Contact Us Remote On/Off* Flow switch Fig. 9-4: Terminals: X B Y 230 V / 50 HZ / 2 A Flow switch electrical wiring diagram enclosed with the unit, terminals A/B. Cable specification: terminals under voltage for wiring a volt-free contact by others. Maximum cable length 100 m, minimum cable cross-section 1.5 mm². On-site relay Common fault signal Electrical integration of flow switch A - B: Connection of flow switch by others E - F: Remote contact for switching the unit on and off using the Normally Open Contact (NOC) by others X - Y: Common fault signal (voltage by others max. 230 V AC/50 Hz / 2 A). For the exact terminal designation refer to the order-related wiring diagram. Notice! Under all circumstances remember to install an additional flow switch at chilled water outlet of the unit and connect it to terminals A-B in the switch box of the unit. The additional flow switch can be optionally ordered and is a requirement for safe and trouble-free operation of the unit and thus constitutes an integral requirement to uphold the validity of the warranty. 66 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Electrical Connection Notice! Only for water-cooled, reversible heat pumps (GLWH-BD unit series): Install a flow switch in each water outlet of unit and connect to terminals A-B (for chilled-water circuit in cooling mode) and terminals A1-B1 (for warm-water circuit in cooling mode). 9.3.4 Pump enabling The pump enabling contact activates chilled water pump by others, in heat pump units - the warm water pump and in water cooled units - the cool water pump. It is always recommended to use the pump enabling contact of the unit to ensure its trouble-free operation. The unit controller provides for the necessary pump lead and run-on time. with integrated hydraulic or pump module In units with an integrated hydraulic or pump module the cabling for pump controls is already done as standard and therefore no additional work is required on site. The contacts P1 and P2 for pump control are already wired. with scroll compressors Units with scroll compressors and R410A refrigerant the pump enabling is included as standard. with screw compressors In units with screw compressors and R134a refrigerant the pump enabling can be ordered optionally. • Connect the pump enabling (suitable volt free contact; for 230 V/50 Hz/2 A). See electric 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 activated minimum 60 seconds before closing the external enabling contact. – The water pump can be deactivated only after expiration of 60 seconds following opening of the external enabling contact of the unit. An external control must observe the following times: Pump control Operation on/off Unit 9.3.5 Remote ON/OFF (if necessary) • Connect the external ON/OFF to terminals E/F. Refer to electric wiring diagram • supplied with the unit. To use the contacts, the functionality of the jumper between terminals E-F must be replaced by an external volt-free switch contact. Cable specification: single ended terminals for connection of on-site dry contact. Maximum cable length 100 m, minimum cable cross-section 1.5 mm². Switch the remote ON/OFF using ambient temperature and/or external clock timer. Notice! Switching the remote ON/OFF using water temperature of a buffer tank is not allowed. This type of control does not make it possible for the unit to reduce own capacity independently and thus operate in a energy-optimized way. As soon as the external control (contact E-F) of the unit closes, the contacts P1-P2 close (pump control contact) and the pump (by others) is activated. The heat exchanger(s) is(are) circulated with water and the compressor(s) is(are) activated depending on the temperature difference to the setpoint after expiration of 60 PR-2013-0112-GB • Subject to modifications • R1-01/2016 67 Chillers & Heat Pumps GL Series Electrical Connection seconds of the pump lead time. Upon opening the external enabling contact (contact E-F) the compressors are consecutively switched off and the contact P1-P2 (pump enabling contact) opens 60 seconds later. The request of the pump (by others) is removed. As long as the external enabling contact is closed and the unit is activated using the display - the pump is operated in order to measure water temperatures in the hydraulic system. To reduce power consumption of pumps and depending of the controller settings, the pump can be deactivated in intervals via contacts P1-P2 during closed terminals for external enabling and deactivated compressors. ATTENTION Damage to the unit! Before the contact of the external enabling is closed, make sure that the hydraulic circuit is completely air vented and the minimum water pressure of 1 bar on the intake side of the pump is ensured during operation. Notice! Even if the remote ON/OFF contact is open, failures in the frost protection function can occur, if the temperature for frost protection sensor falls below the set limit for frost protection as a result of very low ambient temperature. 68 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Commissioning 10 Commissioning This information applies to initial commissioning of the DencoHappel units as well as re-commissioning after an extended shut-down period. All commissioning work must be entrusted only to qualified licensed staff or other individuals with proper professional training and experience in the relevant regulations and codes of practice! 10.1 Requirements Specific requirements for unit commissioning must be met. The function test must be carried out by DencoHappel Service or specialist refrigeration company (see section 4.10) and the commissioning report must be drawn up and sent to DencoHappel. Recommendation! Pre-Commissioning Checklist We recommend that the checklist “Technical requirements for commissioning report/ client witness test or maintenance of chillers/heat pumps” is used to ensure that the onsite requirements for drawing up the commissioning report are met. This can also save additional work and costs because DencoHappel Service or a specialist refrigeration company (see section 4.10) will possibly have to visit your unit again, if the on-site requirements are not met by others beforehand. This check list can be found in Appendix I. Obligatory! Send Commissioning report to DencoHappel! The commissioning report must be drawn up by DencoHappel Service or a specialist refrigeration company (see section 4.10). You must send the commissioning report to DencoHappel - for exact form see Appendix II. If you do not send the commissioning report to DencoHappel, the warranty for your DencoHappel unit will be rendered null and void! Obligatory! Compile logbook With refrigeration units / chillers / heat pumps with a refrigerant charge exceeding 3 kg, the owner or operator must draw up and continuously update the logbook after the system is commissioned. Check by third parties Check in advance together with the authorized inspection agencies whether a separate acceptance of the unit before commissioning is obligatory and by whom it can be carried out. To find out to which validation group the individual components of the unit belong, refer to the supplied Declaration of Conformity. 10.2 Commissioning procedure Electrocution through hazardous voltage will lead to death or serious injury! • Once the electric supply is provided to the unit, beware of electric shock during checking and commissioning the unit. • For this job - due caution and attention are required! • For all checks and tests the following protective clothes are mandatory, in particular: – – – – – Sealing protective goggles PVA or leather gloves Protective clothes for entire body Safety boots If necessary, an autonomous breathing apparatus Notice! Follow the commissioning procedure as described below. Ensure to carefully check each specified work step. PR-2013-0112-GB • Subject to modifications • R1-01/2016 69 Chillers & Heat Pumps GL Series Commissioning • Contact your system manufacturer to request the filled-in report „Technical • requirements for client witness test or maintenance of chillers/heat pumps” (refer to Appendix I). Keep the operation manual as well as order-related documentation for the unit at hand. The order-related documentation comprises: – Operation manual for unit – Operation manual for controller – Declaration of Conformity – Dimensional drawing of the unit – Wiring diagram – Refrigerant circuit diagram – Hydraulic circuit diagram (if available) – Installation manual for accessories (once ordered and enclosed) Check the following before the mains isolator is applied to the unit and after all necessary installation work has been completed: Checking mechanical condition and installation • Carefully check the unit internally and externally for damage, e.g. damaged components or buckled pipes. It is necessary to take photographs of damaged components, including shipping damage. • Is the right installation site selected? Units for outdoor installation are: GLAC, GLAH and GLFC Units for indoor installation are: GLWC, GLWH, GLDC and GLRC • Are the clearances, specified in the dimensional drawing, adhered to? Consider that for installation of two units the clearance must be added together, i.e. are doubled (refer to section 7.1 "Unit placement"). • With air cooled units (GLAC, GLAH and GLFC) ensure that fans can freely discharge air upwards. • Check if anti-vibration isolators are installed beneath points W1 to Wn (compare the order-related dimensional drawing of unit and section 7.2 "Unit installation"). • Check if the unit is properly set up and anchored down to avoid unusual operating noise and vibrations. Checking hydraulic components • Check if the hydraulic connection is performed properly. Compare the on-site connection with the description in the order-related dimensional drawing of the unit (refer to section 8.2). • Check if the piping system by others is flushed before connecting the latter to the unit. An appropriate cleaning report must be available. • Check if a water filter is fitted before each water cooled heat exchanger. • Ensure that the pipework by others and all equipment (e.g. DencoHappel strainer, DencoHappel flow switch) is properly installed in accordance with the specifications and conditions specified in chapter 8 "Medium Connections". • Check if the connected chilled water circuit is properly charged and vented correctly and that entire pipework and all pipe connections are leak-free and insulated. • Air vent the hydraulic circuit several times. Under certain circumstances, the hydraulic circuit needs to be filled once again. • Check that all filling valves and vent cocks are closed. • Check if the water side safety devices are installed. Check these devices for proper function. • Ensure that water flow through the unit is not obstructed, open all corresponding shut off valves! • Check if a flow switch is installed and wired according to the wiring diagram in the switch box of the unit (terminals A-B). With reversible water cooled heat pumps two flow switches must be installed and wired (refer to section 9.2.2 „Integration of flow switch“). 70 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Commissioning • Check if a pump contact (terminals C-D) in units with screw compressors without an integrated hydraulic module is wired according to the wiring diagram (refer to section 9.2.4 „Pump enabling“). ATTENTION Damage to the unit! The pump can be damaged, if the unit is operated without water flowing through a water cooled heat exchanger, e.g. if the shut off valves are closed. Besides, the heat exchanger and the unit itself can be destroyed by freezing water. • Check if constant water flow rate is provided in the evaporator. • Check if • – all shut off valves in the water circuit are open – the 3-way valve is correctly mounted (position AB of 3-way valve must face the unit in most cases) – the buffer tank is installed before the unit inlet – the pump is installed before the unit inlet. Check if glycol is charged for the water circuit (refer to section 8.1.1). Unit GLAC/H GLWC/H GLRC GLDC GLFC Installation Outdoor Inside Inside Inside Outdoor ✓1) ✗3) ✗3) ✗3) ✓2) ✗ ✓1) ✗ ✗ ✗ Evaporator/ Cooling coil(s) Condensers 1) Alternatively, charging glycol is not necessary, if e.g. a pipework trace heating is provided or the pipework is run in a frost-safe way. Consider that the hydraulic circuit in the unit must also be protected. In this case the minimum water outlet temperature must not fall below 5 °C. 2) Free cooling unit must always be operated with glycol. 3) It is assumed that charging with pure water always means frost-safe condition of the unit and relevant pipework. In this case the minimum water outlet temperature must not fall below 5 °C. • Check for glycol concentration in the water circuit several times. • Check the water pressure in the system. Water pressure at the unit should amount • to at least 1 bar with an operating pump. After extended time of pump operation check the water strainer(s) for contamination. Checking electrical connection Electrocution through hazardous voltage will lead to death or serious injury! • Disconnect the unit from the power supply and ensure the power cannot be switched back on. • Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. PR-2013-0112-GB • Subject to modifications • R1-01/2016 71 Chillers & Heat Pumps GL Series Commissioning • Disconnect the unit from the power supply. Re-tighten all electrical connections in • • • • • the switch cabinet and in the terminal boards of the consumers. Check that all connections are tight. Check that the earth conductors are connected correctly and that the earth terminals are securely tightened. Check the inside of the switch cabinet for damaged components. Ensure that the on-site wiring is carried out in accordance with the instructions and requirements specified in chapter "Electrical Connection". This chapter stipulates the observance of instructions in the electrical wiring diagrams and setting up the electrical connection in accordance with European, national and local regulations of utility providers. Check electrical connection of the mains isolator. Check the on-site wiring in the unit control cabinet. – Digital inputs are single ended! It is not allowed to connect a potential provided on-site. – Digital outputs are volt free contacts. The maximum voltage and electrical load must not be exceeded (230 V/50 Hz/~/2 A). Switching on mains isolator Electrocution through hazardous voltage will lead to death or serious injury! Once the electric supply is provided to the unit, beware of electric shock during checking and commissioning the unit. • This job requires due caution and attention. For the following steps refer to chapter 9 „Electrical Connection“. ATTENTION Damage to the unit! If the unit is equipped with a pump enabling function (see chapter 9.3.6 pump enabling) pump block-up protection is activated. This function regularly activates pumps which are controlled by the main unit to prevent pump blockage during extensive shutdown periods. The pump block-up protection is also active even the unit is deactivated via display or digital contact of an external remote ON/OFF. Evaporator trace heating and where available frost protection heating in the buffer tank can result in serious unit damage. • Therefore, before activating the main isolator check that the hydraulic network, evaporator and, where available, buffer tank are filled and air vented. • Before the hydraulic network is drained, ensure that the main isolator of the unit is deactivated, the unit is de-energised to prevent inadvertent activation. • Switch on the unit’s mains isolator.  The background lighting of the display and keyboard of the control panel is activated.  The oil heating is in operation. • Operating the control panel is not necessary at this point! 10.3 Warm-up phase before operation ATTENTION Damage to the unit! Before commissioning, the unit must be supplied with electricity for at least 8 hours with main isolator switched on. This preheats the oil in the compressors. The compressors can be damaged if this warm-up phase is not carried out. Use a measuring device to check the operation of oil heating. 72 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Commissioning • Check supply voltage. The voltage must match the details on the plate/identification or the unit-specific documentation. • Check the phase tolerance. • Check if the clockwise rotating field is applied. It is important that the rotating direction is correct for proper unit operation: clockwise rotating field! • If necessary, check the rotating direction using a rotating field measuring equipment. 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. ATTENTION Damage to the unit! If the rotation direction is incorrect, an adjustment must be performed by changing the phases using the main connection of the unit. Change the phase sequence of the power supply line through others – never change the wiring in the unit control cabinet. Checks during and following the warm-up phase • 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 DencoHappel Service. . ATTENTION Environmental damage! Dispose of any escaping media or oil immediately in an environmentally-friendly manner and in compliance with local laws and regulations. NOTE for specialist refrigeration company! • Make sure that all manually operated shut-off valves in the refrigeration circuit are open. These checks may only be carried out by licensed and qualified staff! • Check the oil level of compressors. • Connect your refrigerant manometer assembly and open all shut off valves in the refrigeration circuit. • Perform a leak test of the entire refrigeration circuit. • Compare temperature and pressure readings of manometers/sensors with indicated • • • pressure and temperature readings of the controller. If necessary, these values need to be calibrated (also refer to the operation manual of the controller) Check the pump current consumption If the current consumption of the pump exceeds the maximum operating current, regulate the water-volume flow via the double regulating valve. Check the flow switch(es) for satisfactory operation. Procedure: • Deactivate all compressors and refrigeration circuits (unit menu) and switch on the pump. • Stop the water flow. • The unit controller must deactivate the system. An alarm message is displayed on the controller (AL 003, AL 045, AL 046). • Restore unobstructed water flow again. • Reset this alarm (refer to chapter 12) Check if oil heater of compressors has been activate for at least 8 hours, before the unit is switched on for the first time. PR-2013-0112-GB • Subject to modifications • R1-01/2016 73 Chillers & Heat Pumps GL Series Commissioning Calibration 8 hours of uninterrupted oil heater operation will ensure that there is no more refrigerant in the oil. The unit can now be put into operation and calibrated. Contact with unit surfaces can lead to injuries! The surfaces of the unit and the pipework can be both very cold and hot. This can cause burns. • Wear protective clothing • Exercise due caution and attention when carrying out this work. • Activate the 1st compressor (unit menu) and measure the current consumption and refrigerant pressure. Reliable recording of correctly measured values is only possible during stable operation of the unit. A stable operating state is reached approximately 0.5 h following the unit activation. Only then can calibration begin. • Record measured values and enter them in the commissioning report (Appendix II). • After 30 minutes have elapsed, measure the following parameters of compressors: – – – – – – High and low pressure Suction gas temperature, superheat temperature Discharge temperature Fluid temperature Current consumption of activated consumers Inlet and outlet temperature of heat exchangers • If the unit is operating under design and layout conditions, check the sight glass for bubbles in the refrigeration circuit. • Check if safety devices are installed in the refrigeration circuit. • Repeat the above-mentioned steps regarding 1st compressor for the remaining compressors. • Check various controller settings, e.g.: – Type of temperature regulation – Set-points – External enabling (ON/OFF) – Notification of maintenance intervals – Alarm readings including frost protection – etc. and if necessary, make the corresponding adjustments (refer to chapter 11). • Activate all compressors and fill in the commissioning report in Appendix II. • For complete and full documenting of commissioning, it is recommended to fill in the Measuring Report in Appendix III. 74 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Commissioning In the table below you will find typical temperature and pressure values of the unit. Compare the values below with your measured readings. Operating limits may vary depending on the unit series. Refer to Data&Facts catalogue of the relevant unit series, quotations for the unit or web-based unit selection and layout software Aid@ (www.aida.dencohappel.com) for specific unit data. Water circuit: Evaporator: Condenser (GLWC/GLWH) Outside air/ condensation temperature Refrigeration circuit: Inlet: min. -5 °C – max. 23 °C Outlet: min. -8 °C – max. 15 °C ΔT: min. 3 K – max. 8 K Inlet: min. 10 °C – max. 47-51 °C Outlet: min. 26 °C – max. 51-55 °C ΔT: min. 4 K – max. 16 K See unit operating range (compare chapter 5.4) Superheating: 5 - 10 K Subcooling: 3-5K Discharge temperature: Max. 120°C Suction pressure Economiser: 1.5 - 2 bar > suction pressure Notice! You must send the commissioning report to DencoHappel! If you do not send the commissioning report to DencoHappel, the warranty for your DencoHappel unit will be rendered null and void! PR-2013-0112-GB • Subject to modifications • R1-01/2016 75 Chillers & Heat Pumps GL Series Operating Unit 11 Operating Unit ATTENTION Damage to the unit! The unit must not be operated unless proper function test has been carried out. Ensure that all steps specified in chapter 10 "Commissioning" have been carried out. ATTENTION Damage to the unit! If the main isolator has been off for more than 3 hours, the oil preheating must be activated for 8 hours before the compressor can be switched on. Failure to comply with this instruction will invalidate the warranty. For controller operation refer to section 11.3.2. 11.1 Overview of operator elements Operator and display elements DencoHappel HVAC systems - Step I and DencoHappel HVAC systems - Step II, excluding units of the GLFC series: Operator element Description Serves to display and reset alarms. Fig. 11-1: Unit display Provides access to the main menu. Allows the user to go back to the next higher level in the screen tree from the title screen; also allows the user to return to the start page. Used to navigate the screens and to enter/change parameter values upwards. Use the Enter key to confirm the selection and to place the cursor below parameters that need to be changed. Is used to navigate the screens and to enter/change parameter values downwards. 11.2 POWER OFF and ON As soon as all necessary requirements for the commissioning have been met, there are several ways to switch the unit on and off. Highest priority: Lowest priority: Priorities of various options: – Activation/deactivation by entering parameters (Com.: ON/ Com.: OFF) – Activation/deactivation via digital input (refer to "External enabling through digital input", Chapter 11.3.1) – Activation/deactivation using integrated timer programme (only DencoHappel HVAC systems Step II and Step III) – Activation/deactivation using Building Management System  The first line of DencoHappel HVAC systems compact operator control panel displays "Com.: ON" or “Com.: OFF”. “OFF” means that the unit is switched off, “ON” indicates that the unit is switched on. 76 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Operating Unit 11.2.1 Switching on Notice! Before switching the unit on, make sure you are aware of the operating mode HEATING or COOLING (only for GLAH and GLWH) Contacts G-H open = HEATING Contacts G-H open = COOLING • 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. 11.2.2 Switching off • If "Com.: on" is not displayed, press the "Esc" key until "Com.: on" appears in the display. • Select the “ON” parameter using the “Enter” key.  The first character of the “ON” parameter flashes • Select “OFF” using the “Up” or “Down” key. • Confirm the setting with the “Enter” key.  If “OFF” remains displayed - the unit is switched off. Notice! The oil preheating remains active! PR-2013-0112-GB • Subject to modifications • R1-01/2016 77 Chillers & Heat Pumps GL Series Operating Unit 11.3 Operating controller 11.3.1 External remote ON/OFF via digital input [ON/OFF] The unit can only be switched on and off via the digital contact (terminals E/F), if the contact is enabled in the user menu (USER) and connected in the unit’s switch cabinet in accordance with the wiring diagram. To enable the digital contact for remote on/off, proceed as follows: • Press “Prg” key. • Select the “USER” menu with the arrow keys. • Press the “Enter” key to confirm. • Enter the password "1234" using the arrow keys. • Press the “Enter” key to confirm. • In the “User” menu use the arrow keys to set “Ing. dig. enabled: on/off ” Set enable via Dig.Input: on/off“). • Press the “Enter” key to confirm. • With the arrow key change “N” to “Y”. • Press the “Enter” key to confirm. • Press the "Esc" key to return to the start screen.  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 activated and “ON dig. in.” appears on the start screen. 11.3.2 Adjust water inlet and outlet temperature regulation If you change the control mode, refer to chapter 11.6.3 Temperature regulation , consult the operation manual for the controller. 11.3.3 Adjusting the chilled water setpoint Notice! Refer to the supplied manual on controller to change warm water temperature in heat pump operation. The factory default setting is 42.5 °C. To modify the chilled water setpoint, proceed as follows: • Press “Prg” key. 78 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Operating Unit • Select the “Setpoint” menu with the arrow keys. • Press the “Enter” key to confirm.  Use the arrow keys to adjust the parameter “Chiller setpoint”. • Press the “Enter” key to confirm. • Change the parameter using the arrow keys. – "by steps" With DencoHappel HVAC systems Step II controller, the standard set"INPUT": point of 7°C is displayed here, which in the preset proportional band corresponds to the actual setpoint of 12°C (7.0°C + 5.0°C P-band = 12.0°C). With DencoHappel HVAC systems Step II controller, the standard setpoint of 9.5°C is displayed here, which in the preset proportional band corresponds to the actual setpoint of 12°C (9.5°C + 2.5°C P-band = 12.0°C) – "Quick Mind" as control mode, "INPUT": standard setpoint 11.0 °C is displayed here. „OUTPUT“: standard setpoint 7.0 °C is displayed here • Press the “Enter” key to confirm. • Press the "Esc" key to return to the start screen. Notice! Changing the setpoint downwards may trigger a frost protection malfunction warning. (AL 010: evaporator frost protection; standard switch value +4 °C chilled water outlet) PR-2013-0112-GB • Subject to modifications • R1-01/2016 79 Chillers & Heat Pumps GL Series Operating Unit 11.4 Overview of operator elements Operator and display elements DencoHappel HVAC systems Step III and units of the GLFC series: Operator element Description Enables unit switching on and off. ! Serves to display and reset alarms. Provides access to the main menu. + Provides direct access to the main menu "Setpoint". 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. Is used to navigate the screens and to enter/change parameter values downwards. Fig. 11-2: Used to navigate the screens and to enter/change parameter values upwards. Alternative displays of the unit Use the Enter key to confirm the selection and to place the cursor below parameters that need to be changed. Display element LED colour green Red Description LED ON: compressor is activated. LED is flashing: compressor is requested to switch, however, it is blocked due to the internal saftey time. The compressor is blocked by a compressor or circuit alarm. Green The circuit is in chilled water mode Green The circuit is in heat pump mode Green The circuit is in free-cooling mode Green LED on: The circuit is in heat recovery mode LED flashes: The circuit has an alarm in heat recovery mode Green LED on: The circuit is in defrost mode LED flashes: The circuit is in drip mode after defrosting 11.5 POWER OFF and ON As soon as all necessary requirements for the commissioning have been met, there are several ways to switch the unit on and off. Highest priority: Lowest priority: Priorities of various options: – on/off by entering parameters (Com.: on/ Com.: off) – on/off via digital input (refer to „external enabling through digital input“) – on/off using a timer programme (see operation manual for "DencoHappel HVAC systems controller") – on/off using monitoring protocol (see operation manual "DencoHappel HVAC systems controller")  The first line of DencoHappel HVAC systems control panel displays the parameter "Com.: on" or "Com.: off". "off" shows that the unit is switched off, "on" shows that the unit is switched on. 80 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Operating Unit 11.5.1 Switching on • If "Com.: off" is not displayed, press the "Esc" key until "Com.: off" appears in the display. • Use „On/Off“ to switch the unit.  If “On” remains on the display, the unit is switched on. 11.5.2 Switching off • If "Com.: on" is not displayed, press the "Esc" key until "Com.: on" appears in the display. • Use „On/Off“ to switch the unit off.  If “off” remains displayed - the unit is switched off. NOTICE! The oil preheating remains active! 11.6 Operating controller 11.6.1 External remote ON/OFF via digital input [ON/OFF] As standard the contact for external enabling is already activated in the controller menu. By opening contacts E-F the unit is deactivated. By closing contacts E-F the unit is activated. 11.6.2 Adjusting the chilled water setpoint To modify the chilled water setpoint, proceed as follows: • Use the display to switch the unit off (refer to "Switching off" in the current chapter). • Press „Setpoint“ button. • Use the arrow keys to adjust the parameter “Chiller setpoint”. • Press the “Enter” key to confirm. • Change the parameter using the arrow keys. – "by steps" "INPUT": As a control system type The standard setpoint of 7°C is displayed here; with the preset proportional band this corresponds to an actual setpoint of 12°C (7°C + 5°C P-band = 12°C). – „Quick Mind“ „OUTPUT“: as control mode standard setpoint 7.0 °C is displayed here • Press the “Enter” key to confirm. PR-2013-0112-GB • Subject to modifications • R1-01/2016 81 Chillers & Heat Pumps GL Series Operating Unit • Press the "Esc" key to return to the start screen. • Activate unit (refer to „Switching on“). Notice! Changing the setpoint downwards may trigger a frost protection malfunction warning (AL 010: frost protection for evaporator; standard switching value of +4°C at evaporator water outlet). For further controller settings refer to controller operation manual. 11.6.3 Temperature regulation The DencoHappel HVAC systems controller can regulate temperature as follows: – Proportional control via water inlet temperature – Auto-adaptive temperature control with neutral range via water inlet temperature – Auto-adaptive temperature control with neutral range via water outlet temperature Proportional control via chilled water inlet temperature - unit with 2 capacity stages Example cooling: Power Water inlet Setpoint Proportional band 2.5 K Fig. 11-3: Proportional control 2 speeds In the following example it is assumed that the temperature difference in the evaporator amounts to 5 K at 100 % cooling capacity of the unit and that the water content in the unit is sufficient. The setpoint is adjusted to 9.5 °C (standard value with inlet temperature control) and proportional band 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, both compressors are running (setpoint 9.5 °C + proportional band 2.5 K = 12.0 °C). If the water temperature entering the evaporator makes up 12.0 °C, the water outlet temperature amounts to 7 °C (12.0 °C water inlet temperature - 5 K temperature difference in the evaporator at 100 % unit duty = 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 82 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Operating Unit reduced to 50 %. Therefore the temperature difference across the evaporator goes down as well by 50 % to 2.5 K. As a result, the water outlet temperature rises at water inlet temperature of 10.75 °C from 5.75 °C with two active compressors to 8.25 °C with only one active compressor. With water inlet temperature of 9.5 °C and water outlet temperature of 7 °C 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. Proportional control via chilled water inlet temperature - unit with 4 capacity stages Example cooling: Capacity Setpoint Water inlet Setpoint Proportional band 5 K Fig. 11-4: Proportional control 4 speeds In the following example it is assumed that the temperature difference in the evaporator amounts to 5 K at 100 % cooling capacity of the unit and that the water content in the unit is sufficient. The setpoint is adjusted to 7.0 °C (standard value with inlet temperature control) and proportional band of 5.0 K (also standard value). Thanks to its four compressors in two independent refrigeration circuits the unit has four capacity stages. The proportional band is distributed among these four capacity stages in appropriately equal ranges. This results in the following: 5.0 K / 4 capacity stages = 1.25 K / capacity stage If the water inlet temperature amounts to 12.0 °C or more, all compressors are running (setpoint 7.0 °C + proportional band 5.0 K = 12.0 °C). If the water temperature entering the evaporator makes up 12.0 °C, the water outlet temperature amounts to 7.0 °C (12.0 °C water inlet temperature - 5 K temperature difference in the evaporator at 100 % unit duty = 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 in the evaporator goes down as well by 25 % to 3.75 K. As a result, at water inlet temperature of 10.75 °C the water outlet temperature rises from 5.75 °C with four active compressors to 7.0 °C with three active compressors. The described sequence is thus continued. 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 = 8.28 °C) one compressor is activated again. With this kind of temperPR-2013-0112-GB • Subject to modifications • R1-01/2016 83 Chillers & Heat Pumps GL Series Operating Unit ature control and assuming continuous operation, the water outlet temperature will fluctuate between 5.75 °C and 8.25 °C. Proportional control via chilled water inlet temperature - unit with 2 capacity stages Example heating: Power Water inlet Setpoint Proportional band 2.5 K Fig. 11-5: Proportional control 2 speeds In the following example it is assumed that the temperature difference across the plate heat exchanger amounts to 5 K at 100 % heating capacity of the unit and that the water content of the unit is sufficient. The setpoint is adjusted to 42.5 °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 range 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 40.0 °C or less, both compressors will be running (setpoint 42.5 °C - proportional band 2.5 K = 40.0 °C). If the water temperature entering the evaporator makes up 40.0 °C, the outlet temperature will amount to 45.0 °C (40.0 °C water inlet temperature + 5 K temperature difference across the evaporator at 100 % = 45.0 °C). At 41.25°C the water outlet temperature will only reach 46.25 °C. At 41.25 °C one of the compressors switches off, and the heating capacity is reduced to 50 %. Therefore the temperature difference in the evaporator goes down as well by 50 % to 2.5 K. As a result the water outlet temperature goes down to 43.75 °C, because only 1 compressor is in operation. With water inlet temperature of 42.5 °C and water outlet temperature of 45.0 °C the last compressor switches off. At 41.25 °C (setpoint 42.5 °C + proportional band /2 1.25 K = 41.25 °C) one compressor is activated again. With this kind of temperature control and assuming continuous operation, the water outlet temperature will fluctuate between 43.75 °C and 46.25 °C. 84 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Operating Unit Proportional control via chilled water inlet temperature - unit with 4 capacity stages Example heating: Capacity Water inlet Setpoint Setpoint Proportional band 5 K Fig. 11-6: Proportional control 4 speeds In the following example it is assumed that the temperature difference across the heat exchanger amounts to 5 K at 100 % heating capacity of the unit and that the water content of the unit is sufficient. The setpoint is adjusted to 42.5 °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 four capacity stages. The proportional range is distributed among these four capacity stages in appropriately equal ranges. This results in the following: 5.0 K / 4 capacity stages = 1.25 K / capacity stage If the water inlet temperature amounts to 37.5 °C or less, all compressors will be running (setpoint 42.5 °C - proportional band 5.0 K = 37.5 °C). If the water temperature entering the evaporator makes up 37.5 °C, the outlet temperature will amount to 42.5 °C (37.5 °C water inlet temperature + 5 K temperature difference across the evaporator at 100 % = 42.5 °C). At 38.75°C the water outlet temperature will reach 43.75 °C. At 38.75 °C one of the compressors switches off, and the heating capacity is reduced to 75 %. Therefore the temperature difference in the heat exchanger goes down as well by 25 % to 3.75 K.As a result the water outlet temperature goes down to 42.5 °C, because only 3 compressors are in operation. The described sequence is thus continued. With water inlet temperature of 42.5 °C the evaporator water outlet temperature amounts to 43.75 °C with one active compressor corresponding to 25% total capacity. At 42.5 °C the last compressor switches off. At 41.25 °C (setpoint 42.5 °C + proportional band /4 1.25 K = 41.25 °C) one compressor is activated again. With this kind of temperature control and assuming continuous operation, the water outlet temperature will fluctuate between 42.5 °C and 43.75 °C. PR-2013-0112-GB • Subject to modifications • R1-01/2016 85 Chillers & Heat Pumps GL Series Operating Unit Auto-adaptive control with neutral range via water outlet or inlet temperature Capacity reduced Capacity increased Setpoint cooling/heating Power ↓ Neutral zone Power ↑ Temperature Variable zone Fig. 11-7: Auto-adaptive control With this type of control system the chilled water inlet or outlet temperature is used as the control variable. In this case only the setpoint is specified, and the controller automatically determines all other switching thresholds in dynamic mode during operation. With this self-adjusting algorithm for temperature control of the unit the setpoint stays within a neutral range. If the evaporator water temperature is within the neutral range, the number of active compressors and/or capacity stages is not changed. If load fluctuations in the system result in temperature 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 decreased load, another capacity stage is activated or deactivated. The width of the neutral range depends on the dynamic properties of the system, especially the system content and the decreased load. The self-adjusting algorithm is able to determine the dynamics of the system. The neutral range is calculated so that the compressor switching times and the max. permissible start-up frequency (e.g. 8 times per hour) only cause very small temperature deviations from the setpoint. Other implemented functions reduce the compressors’ start-up frequency at low loads. Capacity stages are activated and deactivated not only as a result of wide setpoint variances, but also in relation to the temperature change-over time, which allows to make conclusions about the output. You will find additional notices and setting possibilities for the controller in the supplied Controller Operating Manual. 11.7 Disconnecting from power supply ATTENTION Damage to the unit! After these measures, observe the following: – Frost protection using internal frost protection heating is no longer provided. – The oil preheating is no longer active! • Shut down the main isolator.  The unit is now disconnected from the power supply. 86 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Operating Unit Danger due to electrical hazard which leads to serious injuries or death! • Check that all electrical control cables provided on-site are disconnected from the power supply. Depending on the contact, on-site potential may be necessary. • Also disconnect on-site control contacts from the power supply • Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. ATTENTION Damage to the unit! If the unit has been switched off for more than 3 hours, it must be energized through the main isolator for at least 8 hours before putting it back into operation. This preheats the oil in the compressors. The compressors can be damaged if the warm-up phase is not adhered to – refer to “Warm-up phase prior to operation" in chapter 10. 11.8 Draining water circuit Before draining the water circuit of the unit you must: Electrocution through hazardous voltage will lead to death or serious injury! • Disconnect the unit from the power supply and ensure the power cannot be switched back on. • Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. • Connect tubes to all drain valves to ensure controlled draining of water or water• • • • • • • glycol mixture. Ensure leak-free condition of the unit: oil, water-glycol mix must not be released to the environment. Properly collect all liquids and dispose of in an environmentally-friendly way in accordance with local codes and regulations. Open all hydraulic shut-off valves Open shut-off valves on the drain valves. Open air vent valves to ensure trouble-free water draining. Avoid negative pressure in unit and connected hydraulic circuit. Following draining of the hydraulic circuit, use compressed air to blow out the unit and connected hydraulic circuit to eliminate remaining water and water-glycol mix. PR-2013-0112-GB • Subject to modifications • R1-01/2016 87 Chillers & Heat Pumps GL Series Operating Unit ATTENTION Damage to the unit! – Residual water can freeze and destroy the unit. – If the unit is equipped with a pump enabling function (see chapter 9.3.4 pump enabling) pump block-up protection is activated. This function regularly activates pumps which are controlled by the main unit to prevent pump blockage during extensive shutdown periods. The pump block-up protection is also active even the unit is deactivated via keyboard or digital contact of external remote ON/OFF. – Evaporator trace heating and where available frost protection heating in the buffer tank can result in serious unit damage. – Therefore, before activating the main isolator check that the hydraulic network, evaporator and, where available, buffer tank are filled and air vented. – Before the hydraulic network is drained, ensure that the main isolator of the unit is deactivated, the unit is de-energised to prevent inadvertent activation. 11.9 What to do in case of alarm and error messages ATTENTION Damage to the unit! In case of alarms and faults, always make sure that the cause of the fault is identified. In particular, a manual reset of an alarm without first rectifying the cause can damage the unit and invalidate the warranty. Refer to chapter "Troubleshooting" for help in the event of alarm messages. 88 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting 12 Fault Finding and Troubleshooting ATTENTION Damage to the unit! If alarms occur, inform DencoHappel Service immediately! Reset an alarm only after detecting and eliminating the cause of failure. If alarms are reset without eliminating the fault, serious unit damage and expiration of the guarantee can be the consequence. The fault must not be reset manually without prior consent of DencoHappel Services. 12.1 Alarms What to do in case of alarms: 1. Inform DencoHappel Service. 2. Have DencoHappel Service eliminate the fault’s cause. 3. Only DencoHappel Service is allowed to reset the fault.  In case of an alarm the “ALARM” key lights up red. To read out the alarm messages, proceed as follows: • Press “ALARM” key.  If no alarms are pending, “No Alarm detected” is displayed; otherwise “AL...”is displayed together with the alarm code and a short description. • If several alarms are pending, you can scroll through the current alarm list with the arrow keys. • Press any key to exit the menu. • Inform DencoHappel Service. 12.1.1 Only for DencoHappel Service To reset the alarm: • Eliminate the cause of failure. • Hold the “ALARM” key pressed down until “No Alarm detected” appears.  If this is not displayed, the alarm is still active. 12.2 Overview of alarm messages • Read off the code of the alarm message "AL..." from the controller • • • • (refer to section 11.1). Find the alarm number in the „Alarm“ column. Column „Description“ contains short description of an alarm, the same that can be read off using the controller. Column „Details“* contains a detailed fault description and checkpoints for troubleshooting. Further explanations on column „RESET“ can be found at the end of the list. *Column „Details“ specifies default temperature and pressure values set in the controller by the factory. PR-2013-0112-GB • Subject to modifications • R1-01/2016 89 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 002 Phase sequence relay tripped and prevents unit start. Possible reasons to be investigated: Electrical system: – Incorrectly connected rotating field (clockwise rotating field is mandatory) – Malfunction of one or more phases – Power supply too low / too high – Phase asymmetry too high – Defective phase sequence relay – Defective input of controller PCB – Incorrect wiring – Loose cable connection – Cable failure Phase sequence/ voltage outside the allowable range RESET Action A U A/M U Water inlet temperature at evaporator fell below allowed limit. Too low water inlet temperature at evaporator causes the unit to operate outside its operating range and safe operation can not be ensured. System failure can be the consequence (refer to section 4.5 „Operating limits of unit“). This message is only active in heat pump mode. This message is a signal that does not deactivate the unit. If water inlet temperature returns to allowable range, the message is deactivated automatically. S-A -/U High water temperature at in- Water inlet temperature at evaporator exceeds allowed limit. let Too high water inlet temperature at evaporator causes the unit to operate outside its operating range and safe operation can not be ensured. System failure can be the consequence. In case of frequent problems with alarm 006, install a so-called soft start controller using e.g. a 3-way valve, that can keep water inlet temperature in evaporator below the maximum limit (refer to section 4.5 „Operating limits of unit“). This message is only active in chiller mode. This message is a signal that does not deactivate the unit. If water inlet temperature returns to allowable range, the message is deactivated automatically. S-A -/U Note: never change wiring in the unit switch box. In case of an incorrectly connected rotating field, the on site supply line must be checked anyway (refer to chapter 8 „Electrical Connection“). 003 Flow switch of evaporator Tripping of flow switch (by others) or internal water side differential pressure switch. Possible reasons for investigating alarm release: Water circuit: – Shut off valve(s) connected – Air in water circuit – Dirty water filter – Flow regulating valve closed too wide – Water pressure too low – 3-way valve fitted incorrectly (constant volume flow within unit must be ensured even with closed 3-way valve) – 2-way valves mounted instead of 3-way valves – Flow switch mechanically blocked – Faulty installation / flow direction of flow switch (refer to installation manual of flow switch) – Glycol concentration too high (more than 50 %) – No constant water flow rate across unit using e.g. speed-regulated pump – Pumping capacity too low – Dirty heat exchanger Electrical system: – Faulty wiring of flow switch – Defective coupler relay – Defective input on controller – Contacts C-D (if available) are not connected to a normally open contact of pump contactor – Incorrect wiring – Loose cable connection – Cable failure Alarm is reset twice within one hour automatically, if automatic resetting within operating time corresponds to parameter P23.34. Otherwise the resetting of alarm must be performed manually. 005 006 90 Low water temperature at inlet PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 010 Water outlet temperature of evaporator equals or lower than set frost protection value. Standard frost protection value ranges between 3 °C and 4 °C, i.e. if water outlet temperature from evaporator is lower or equals above values - frost protection alarm is activated. Possible reasons to be investigated: Water circuit: – Shut off valve(s) not completely open – Air in water circuit – Dirty water filter – Flow regulating valve closed too wide – Water pressure too low – Set chilled water setpoint too low – No constant water flow rate across unit using e.g. speed-regulated pump – Glycol concentration too high (more than 50 %) – Temperature difference evaporator inlet and outlet is too high – Pumping capacity too low – Dirty heat exchanger – Ambient temperature is lower than set frost protection value* Evaporator frost protection RESET Action M CI M U * Even with open external enabling contact unit can indicate frost protection alarm, e.g., if ambient temperature is lower than set frost protection value and thus medium temperature decreases to reach frost protection value. Besides, units with several evaporators also indicate in which evaporator an alarm is triggered. For frost protection alarm the relevant evaporator outlet sensor is important. By deactivating compressors or activating other compressors in units with more than one evaporator, it is attempted to prevent frost protection alarm and to keep unit in operation. This alarm is also indicated if prevention of frost protection using the above-mentioned measures is attempted more than five times within 8 operating hours. 014 Insufficient pressure in system If an external contact, which must be wired in the switch box of the unit, is open, error message is displayed „014 - insufficient pressure in system“. This external alarm contact can be used to connect e.g.: – Field-provided pressostat monitoring water pressure of hydraulic system. – Refrigerant leak detection system monitoring concentration of refrigerant in a plant room. After opening of contact the unit is switched off and general alarm contact is closed. -> Check what safety device is wired at the terminals and perform the troubleshooting (refer to section 8.3 "Electrical integration"). 017 Low outside air temperature Displays that outdoor air temperature fell below alarm value (P.35.51). Check operating limits of units (refer to section 4.5) and temperature conditions on site. S - 021 Low water content of system Water inlet temperature at evaporator changes too fast or falls too fast (change of temperature in water inlet of the unit by more than 6 °C within 1 minute). Possible reasons for investigating alarm release: – Water content in unit too low/standard minimum water content for unit is not fulfilled – Load reduction of consumers is too small – Installed cooling capacity is too great Remedy: – Install a suitable buffer tank – Reduce unit capacity by deactivating one compressor. S - Low water flow volume in sys- Temperature difference between evaporator inlet and outlet exceeds 8 K for more tem than 30 seconds. Possible reasons to be investigated: Water circuit: – Shut off valve(s) not completely open – Air in water circuit – Dirty water filter – Flow regulating valve closed too wide – Water pressure too low – Glycol concentration too high (more than 50 %) – No constant water flow rate within unit using e.g. speed-controlled pump – Pumping capacity too low – Dirty heat exchanger M U A/M U* A U* 022 045 046 Flow switch of condenser Flow switch recuperator See alarm 003 „Flow switch of evaporator“. This error message is, however, valid for condenser side (condenser in chilled water mode). Faulty connection of flow switch can lead to destruction of unit. Check if flow switch for consumer circuit is connected to terminals A-B in the switch box of unit (in cooling mode - evaporator, in heating mode - condenser). Flow switch must be connected to terminals A1-B1 for external heat source (in cooling mode - condenser, in heating mode - evaporator). This alarm message is only valid for water cooled heat pumps with a reversible circuit via an integrated 4-way valve. See alarm message 010 „Flow switch of evaporator“. This error message is only valid for water circuit of heat recovery system. PR-2013-0112-GB • Subject to modifications • R1-01/2016 91 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 051 Sum of operating hours exceeds maintenance interval stored in controller. With units fitted with a single pump - pump 1 is evaporator pump. General alarm contact is closed, but the unit continues to operate. Automatic notification about maintenance intervals can be deactivated using a service password. To rest an alarm the service password is required as well. S - Maintenance pump 1 RESET Action 052 Maintenance pump 2 See alarm message 051 „Maintenance pump 1“. (only for units with 2 pumps). S - 057 Maintenance of heat recovery See alarm message 051 „Maintenance pump 1“. pump (only for units with a pump for heat recovery). S - 058 Maintenance condenser pump S - 065 Low quantity of water in recu- Water inlet temperature of the heat recovery changes too fast or falls too fast perator circuit (change of temperature in water inlet of the unit by more than 6 °C within 1 minute). Possible reasons for investigating alarm release: – Water content in unit too low/standard minimum water content for unit is not fulfilled – Load reduction of consumers is too small – Installed unit capacity is too great S - A/M U* See alarm 010 „Evaporator frost protection”. This alarm message is only valid for frost protection failure of evaporator (heat source), when the unit is in heating mode. This alarm message is only valid for water cooled heat pumps with a reversible circuit via an integrated 4-way valve. M U* See alarm message 051 „Maintenance pump 1“. (only for units with a pump for condenser). Remedy: – Install a suitable buffer tank – Reduce unit capacity by deactivating one compressor temporarily via the demand limit contact (optional) 066 075 Low water mass flow in recu- Temperature difference between inlet and outlet of heat recovery exceeds 8 K for perator circuit more than 30 seconds. Possible reasons to be investigated: Water circuit: – Shut off valve(s) not completely open – Air in water circuit – Dirty water filter – Flow regulating valve closed too wide – Water pressure too low – Glycol concentration too high (more than 50 %) – No constant water flow rate within unit using e.g. speed-controlled pump – Pumping capacity too low – Dirty heat exchanger Condenser frost protection 076 Frost protection recuperator See alarm 010 „Evaporator frost protection”. This alarm message is only valid for frost protection failure of heat recovery. A U* 079 Control module of VPF system uncoupled Communication with controller on „variable water volume regulation“ is interrupted. Possible reasons for investigating alarm release: Electrical system: – Incorrect wiring – Loose cable connection – Cable failure – Defective control module – Defective output of controller PCB A U A U 080 92 Break-down of control module Controller failure for „variable water volume regulation“ of VPF system Check indication on display of VPF module. PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 081 Overload relay of pump 1 tripped and prevents pump start. With units fitted with a single pump - pump 1 is evaporator pump. Possible reasons to be investigated: General: – Motor mechanical blockage – Water flow rate too high* – Glycol concentration too high (more than 50 %) – Operation outside operating limits Overload protection, pump 1 Electrical system: – Malfunction of one or more phases – Power supply outside tolerance range – Phase asymmetry too high – Contact resistance of load contactor too high – Defective input of controller PCB – Defective overload relay – Incorrect wiring – Loose cable connection – Cable failure RESET Action M U *If water flow rate is too high, current consumption of pump rises. Through pressureside throttling of pump, the volume flow and at the same time current consumption are reduced. Consider the minimum and maximum temperature difference of 3 or 8 K at evaporator at 100% unit capacity. 082 Overload protection, pump 2 See alarm message 081 „Overload protection pump 1“ (only for units with 2 pumps). M U* 085 Overload protection, condenser See alarm message 081 „Overload protection pump 1“ (only for units with pump for condenser). M U* 086 Overload protection recuperator pump See alarm message 081 „Overload protection pump 1“ (units with pump for heat recovery). M U* 090 Separation "Slave" Communication with controller PCB "Slave"-controller PCB is interrupted. This alarm message is valid only for units with screw compressor and 3 or 4 refrigeration circuits. Circuit 3 and 4 are controlled by „Slave-PCB". Possible reasons to be investigated: Electrical system: – Missing power supply of master and/or „Slave-controller PCB“ – Defective safety mechanism on „Slave-controller PCB“ – Faulty address of Master or Slave controller circuit board address Master: "01"/address Slave: "11" – Defective controller PCB Master – Defective controller PCB Slave – Faulty cabling (check Master/Slave terminal block J11 Rx+/Tx+ & Rx-/Tx- on main PCB) – Loose cable connection – Cable failure A U Communication with extension card with address 1 is interrupted. In units with 3 or 4 refrigeration circuits „Master“ is additionally indicated on display. Possible reasons to be investigated: Electrical system: – Missing power supply of extension card – Defective safety mechanism of extension card – Faulty address of main PCB or extension card Address main PCB: 01 address extension card: address see error message – Faulty cabling (main PCB: terminal block J23: E+ & E-, extension card terminal block J3: T+ & T-) – Faulty settings of controller PCB – Faulty extension card – Faulty main PCB – Loose cable connection – Cable failure A U 091 Isolation expansion with address 1 092 Isolation Exp. address 2 See alarm message 091 „Isolation expansion with address 1“ only for extension 2 A U 093 Isolation Exp. address 3 See alarm message 091 „Isolation expansion with address 1“ only for extension 3 A U 094 Isolation Exp. address 4 See alarm message 091 „Isolation expansion with address 1“ only for extension 4 A U 095 Isolation Exp. address 5 See alarm message 091 „Isolation expansion with address 1“ only for extension 5 A U 101 Isolation expansion Slave with address 1 See alarm message 091 "Isolation expansion with address 1" only for extension 1 of Slave A U 102 Isolation expansion Slave with address 2 See alarm message 091 "Isolation expansion with address 1" only for extension 2 of Slave A U 103 Isolation expansion Slave with address 3 See alarm message 091 "Isolation expansion with address 1" only for extension 3 of Slave A U PR-2013-0112-GB • Subject to modifications • R1-01/2016 93 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details RESET Action 104 Isolation expansion Slave with address 4 See alarm message 091 "Isolation expansion with address 1" only for extension 4 of Slave A U 105 Isolation expansion Slave with address 5 See alarm message 091 "Isolation expansion with address 1" only for extension 5 of Slave A U 111 Oil compressor 1 Oil level of compressor Nr.1 too low. Following compressor start alarm message of oil level switch is bridged for 90 s. If oil level switch opens for more than 10 s following first 90 s of compressor operation, the compressor duty is raised to 100 % in order to ensure oil return. If in the following 80 s the oil level does not rise, the compressor is blocked and isolated. Possible reasons to be investigated: Refrigeration circuit – Insufficient oil due to leak – Insufficient refrigerant – Faulty expansion valve – Defective oil level switch – Defective solenoid valves of compressors – Defective input of controller PCB – Defective output of controller PCB for solenoid valve(s) – Incorrect wiring – Loose cable connection – Cable failure -> Before resetting alarm, it is absolutely mandatory to check oil level of corresponding compressor. -> Never reset alarm, if oil level did not reach the minimum mark. Destruction of compressor can be the consequence. -> Only charge oil specified on the unit identification plate. Excessive oil level should be avoided to prevent compressor from damage. This alarm message is valid only for units with screw compressors. M CO 112 Oil compressor 2 See alarm message 111 „Oil compressor 1“ only for compressor 2 M CO 113 Oil compressor 3 See alarm message 111 „Oil compressor 1“ only for compressor 3 M CO 114 Oil compressor 4 See alarm message 111 „Oil compressor 1“ only for compressor 4 M CO 121 High discharge temperature compressor 1 Discharge temperature of compressor Nr.1 is too high. Possible reasons to be investigated: Refrigeration circuit – Insufficient refrigerant – Insufficient oil – Faulty expansion valve – Operation outside operating limits – Icing on air cooled heat exchanger (only GLAH units in heating mode) M CO Electrical system: – Faulty discharge temperature sensor – Defective input on controller – Faulty compressor – Incorrect wiring – Loose cable connection – Cable failure Never reset alarm as long as the reason for failure is not established. Destruction of compressor can be the consequence. 122 High discharge temperature compressor 2 See alarm message 121 „High discharge temperature compressor 1“ only for compressor 2 M CO 123 High discharge temperature compressor 3 See alarm message 121 „High discharge temperature compressor 1“ only for compressor 3 M CO 124 High discharge temperature compressor 4 See alarm message 121 „High discharge temperature compressor 1“ only for compressor 4 M CO 125 High discharge temperature compressor 5 See alarm message 121 „High discharge temperature compressor 1“ only for compressor 5 M CO 126 High discharge temperature compressor 6 See alarm message 121 „High discharge temperature compressor 1“ only for compressor 6 M CO 127 High discharge temperature compressor 7 See alarm message 121 „High discharge temperature compressor 1“ only for compressor 7 M CO 128 High discharge temperature compressor 8 See alarm message 121 „High discharge temperature compressor 1“ only for compressor 8 M CO 94 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 131 Motor protection relay and/or automatic circuit breaker tripped for compressor 1. Possible reasons to be investigated: Refrigeration circuit – Insufficient refrigerant – Faulty expansion valve – Operation outside operating limits – Acidic oil – Faulty solenoid valve for liquid injection/missing liquid injection – Mechanical blockage of compressor – Faulty compressor Fault, compressor 1 Electrical system: – Malfunction of one or more phases – Power supply outside tolerance range – Phase asymmetry too high – Load contactor does not switch one or more phases – Contact resistance of load contactor too high – Coil short circuit of compressor motors -> perform oil acidity test a.s.a.p. – Winding short circuit of compressor motor -> perform oil acidity test a.s.a.p. – Earth fault of compressor motors -> perform oil acidity test a.s.a.p. – Faulty compressor – Defective input on controller – Incorrect wiring – Loose cable connection – Cable failure RESET Action M - A/M CO Never reset alarm as long as the reason for failure is not established. Destruction of compressor can be the consequence. 132 Fault, compressor 2 See alarm message 131 „Fault compressor 1“ only for compressor 2 M - A/M CO 133 Fault, compressor 3 See alarm message 131 „Fault compressor 1“ only for compressor 3 M - A/M CO 134 Fault, compressor 4 See alarm message 131 „Fault compressor 1“ only for compressor 4 M - A/M CO 135 Fault, compressor 5 See alarm message 131 „Fault compressor 1“ only for compressor 5 M - A/M CO 136 Fault, compressor 6 See alarm message 131 „Fault compressor 1“ only for compressor 6 M - A/M CO 137 Fault, compressor 7 See alarm message 131 „Fault compressor 1“ only for compressor 7 M - A/M CO 138 Fault, compressor 8 See alarm message 131 „Fault compressor 1“ only for compressor 8 M - A/M CO 151 Maintenance, compressor 1 Sum of operating hours exceeds maintenance interval stored in controller. General alarm contact is closed, but unit is operated further on. Automatic notification about maintenance intervals can be deactivated using a service password. To rest an alarm the service password is required as well. S - 152 Maintenance, compressor 2 See alarm message 151 „Maintenance compressor 1“ (only for units with 2 compressors). S - 153 Maintenance, compressor 3 See alarm message 151 „Maintenance compressor 1“ (only for units with 3 compressors). S - 154 Maintenance, compressor 4 See alarm message 151 „Maintenance compressor 1“ (only for units with 4 compressors). S - 155 Maintenance, compressor 5 See alarm message 151 „Maintenance compressor 1“ (only for units with 5 compressors). S - 156 Maintenance, compressor 6 See alarm message 151 „Maintenance compressor 1“ (only for units with 6 compressors). S - 157 Maintenance, compressor 7 See alarm message 151 „Maintenance compressor 1“ (only for units with 7 compressors). S - 158 Maintenance, compressor 8 See alarm message 151 „Maintenance compressor 1“ (only for units with 8 compressors). S - 201 Alarm circuit 1 Please contact DencoHappel Service a.s.a.p. S - 202 Alarm circuit 2 Please contact DencoHappel Service a.s.a.p. S - 203 Alarm circuit 3 Please contact DencoHappel Service a.s.a.p. S - 204 Alarm circuit 4 Please contact DencoHappel Service a.s.a.p. S - PR-2013-0112-GB • Subject to modifications • R1-01/2016 95 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 211 High pressure switch of refrigeration circuit 1 tripped because of too high pressure. Possible reasons to be investigated: General/Water circuit: – Operation outside operating limits – Dirty condenser High pressure, circuit 1 RESET Action Additionally for air cooled units: – Clearances around the unit are too small, there is not enough air supply – Air short circuit (warm discharge air is sucked in again) – Ambient temperature too high (refer to operating limits) – Water inlet temperature in the evaporator too high (refer to operating limits) – In units with axial fans air duct is mounted at unit inlet and/or air outlet (because of required pressure, volume flow of fans and thus operating limits are reduced). – In units with centrifugal fans the actually required external pressure did not match the external pressure specified in the order -> gear ratio of V-belt pulley is not suitable and/or fan motors are of too small size. Additionally for water cooled units: – Dirty heat-rejection unit – Shut off valve(s) not completely open – Air in water circuit – Dirty water filter – Water pressure too low – Flow regulating valve closed too wide – Pumping capacity too low – Water inlet or outlet temperature in condenser is too high – Temperature difference between condenser water inlet and outlet too low/high – Glycol concentration too high (more than 50 %) Refrigeration circuit – Overcharge of refrigerant Electrical system: – One or more fans not in operation – Fan does not operate at full speed – Faulty high pressure switch – Defective input of controller PCB – Incorrect wiring – Loose cable connection – Cable failure M CI Electronic expansion valve: Due to a missing battery - overheated high-pressure faulty operation may occur on units with an electronic expansion valve. The battery is required for correct closing of the valve. Connect the battery of the electronic expansion valve as specified in the order-related wiring diagram. The required cable for connecting the battery is already included into the switch cabinet of the unit. Then confirm displayed high pressure fault. Disconnect the cable from the battery of electronic expansion valve in case of extended downtime of the unit in order to avoid damage to the battery. 212 High pressure, circuit 2 See alarm message 211 „High pressure circuit 1“, but for refrigeration circuit 2 M CI 213 High pressure, circuit 3 See alarm message 211 „High pressure circuit 1“, but for refrigeration circuit 3 M CI 214 High pressure, circuit 4 See alarm message 211 „High pressure circuit 1“, but for refrigeration circuit 4 M CI 221 Overload protection, fan circuit 1 At least one overload relay and/or automatic circuit breaker tripped for fans in circuit 1. Possible reasons to be investigated: General: – Fan is mechanically blocked M CI M CI M CI Electrical system: – Malfunction of one or more phases – Power supply outside tolerance range – Phase asymmetry too high – Load contactor does not switch one or more phases – Contact resistance of load contactor too high – Coil short circuit of fan motor – Winding short circuit of compressor motor – Earth fault of fan motor – Defective input on controller – Incorrect wiring – Loose cable connection – Cable failure Never reset alarm as long as the reason for failure is not established. Destruction of fan can be the consequence. 222 Overload protection, fan circuit 2 See message 221 „Overload protection fans circuit 1“, only for fans in circuit 2 223 Overload protection, fan circuit 3 See message 221 „Overload protection fans circuit 1“, only for fans in circuit 3 96 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 224 Overload protection, fan circuit 4 See message 221 „Overload protection fans circuit 1“, only for fans in circuit 4 231 Low pressure, circuit 1 Low pressure sensor or low pressure switch of refrigeration circuit 1 is deactivated because of too low pressure. Possible reasons to be investigated: Refrigeration circuit – Insufficient refrigerant (sight glass must be without bubbles following around 10 min of operation) – Shut off valve(s) closed/not completely open – Faulty expansion valve (measure overheat, 5 to 10 K following 15 min of operation) – Faulty solenoid valve for liquid line – Operation outside operating limits Water circuit: – Air in water circuit – Dirty water filter – Water pressure too low – Temperature difference between evaporator water inlet and outlet too low/high (min/max 3 to 8 K) – Pumping capacity too low – Flow regulating valve closed too wide – Water inlet or outlet temperature at evaporator is too low – Glycol concentration too high (more than 50 %) – Dirty heat exchanger RESET Action M CI A/M CI Additionally for air cooled units: – Too low air inlet temperature – Condenser is not wind protected at ambient temperature < -10 °C (refer to operating limits) Additionally for water cooled units: – Water temperature at condenser is too low (refer to operating limits) Electrical system: – Faulty low pressure sensor -> Check pressure displayed in controller against the actual pressure (measured by pressure gauge) -> Use a 4-20 mA encoder by others to simulate the corresponding signal and evaluate the result displayed by the controller. – Faulty low pressure switch – Defective input on controller – Incorrect wiring – Loose cable connection – Cable failure In the course of relevant circuit start, low pressure alarm is bridged for 120 s for regulating cold weather start. Alarm is automatically reset twice an hour. In case of third alarm within an hour the resetting must be performed manually. 232 Low pressure, circuit 2 See alarm message 231 „Low pressure circuit 1“, but for refrigeration circuit 2 A/M CI 233 Low pressure, circuit 3 See alarm message 231 „Low pressure circuit 1“, but for refrigeration circuit 3 A/M CI 234 Low pressure, circuit 4 See alarm message 231 „Low pressure circuit 1“, but for refrigeration circuit 4 A/M CI PR-2013-0112-GB • Subject to modifications • R1-01/2016 97 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 241 High pressure sensor of refrigeration circuit 1 tripped because of too high pressure. Possible reasons to be investigated: General/Water circuit: – Operation outside operating limits – Dirty condenser High pressure through Converter 1 RESET Action Additionally for air cooled units: – Clearances around the unit are too small, there is not enough air supply – Air short circuit (warm discharge air is sucked in again) – Ambient temperature too high (refer to operating limits) – Water inlet temperature in the evaporator too high (refer to operating limits) – In units with axial fans air duct is mounted at unit inlet and/or air outlet (because of required pressure, volume flow of fans and thus operating limits are reduced). – In units with centrifugal fans the actually required external pressure did not match the external pressure specified in the order -> gear ratio of V-belt pulley is not suitable and/or fan motors are of too small size. Additionally for water cooled units: – Dirty heat-rejection unit – Shut off valve(s) not completely open – Air in water circuit – Dirty water filter – Water pressure too low – Flow regulating valve closed too wide – Pumping capacity too low – Water inlet or outlet temperature in condenser is too high – Too low/high temperature difference between water inlet and outlet of condenser – Glycol concentration too high (more than 50 %) M CI Refrigeration circuit – Overcharge of refrigerant Electrical system: – One or more fans not in operation – Fan does not operate at full speed Faulty high pressure sensor -> Check pressure displayed in controller against the actual pressure (measured by pressure gauge) -> Use a 4-20 mA encoder by others to simulate the corresponding signal and evaluate the result displayed by the controller. – Defective input of controller PCB – Incorrect wiring – Loose cable connection – Cable failure As standard alarm value of the high-pressure sensor is set higher than the trigger value of the high-pressure switch. If "Alarm 241" is active check the corresponding high-pressure switch. 242 High pressure converter 2 See alarm message 241 „High pressure through converter 1“, but for refrigeration circuit 2 M CI 243 High pressure converter 3 See alarm message 241 „High pressure through converter 1“, but for refrigeration circuit 3 M CI 244 High pressure converter 4 See alarm message 241 „High pressure through converter 1“, but for refrigeration circuit 4 M CI 251 Timeout start of circuit 1 If low pressure reading with requested but not yet activated compressor lower or equals value of low pressure alarm, the unit switches in error mode. Possible reasons to be investigated: Refrigeration circuit – Insufficient refrigerant – Faulty expansion valve – Faulty solenoid valve for liquid line A CI Electrical system: – Faulty low pressure sensor -> Check pressure displayed in controller against the actual pressure measured by pressure gauge. -> Use a 4-20 mA encoder by others to simulate the corresponding signal and evaluate the result displayed by the controller. – Deactivated low pressure sensor – Defective input on controller – Incorrect wiring – Loose cable connection – Cable failure This alarm is valid only for units with a low pressure sensor. 252 Timeout start of circuit 2 See alarm message 251 „Timeout start of circuit 1“, but for refrigeration circuit 2 A CI 253 Timeout start of circuit 3 See alarm message 251 „Timeout start of circuit 1“, but for refrigeration circuit 3 A CI 254 Timeout start of circuit 4 See alarm message 251 „Timeout start of circuit 1“, but for refrigeration circuit 4 A CI 98 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series ALARM DESCRIPTION Fault Finding and Troubleshooting Details RESET Action 261 Missing freon in circuit 1 If alarm 251 has been active for more than 8 hours, alarm message 261 is displayed A CI 262 Missing freon in circuit 2 If alarm 252 has been active for more than 8 hours, alarm message 262 is displayed A CI 263 Missing freon in circuit 3 If alarm 253 has been active for more than 8 hours, alarm message 263 is displayed A CI 264 Missing freon in circuit 4 If alarm 254 has been active for more than 8 hours, alarm message 264 is displayed A CI 271 Finned tube battery circuit 1 If forced defrosting cycle is activated three times an hour because of insufficient low pressure, alarm message 271 is displayed. Possible reasons to be investigated: General: – Dirty air cooled heat exchanger – Air cooled heat exchanger with incomplete defrosting due to: - insufficient clearances around unit - air short circuit – Snow on/around air cooled heat exchanger – Air inlet temperature of unit is too low, unit running outside operating limits A/M CI Refrigeration circuit – Insufficient refrigerant 272 Finned tube battery circuit 2 See alarm message 271 „Finned tube battery circuit 1“, but for refrigeration circuit 2 A/M CI 273 Finned tube battery circuit 3 See alarm message 271 „Finned tube battery circuit 1“, but for refrigeration circuit 3 A/M CI A/M CI M CI 274 Finned tube battery circuit 4 See alarm message 271 „Finned tube battery circuit 1“, but for refrigeration circuit 4 281 Evaporating pressure insufficient in circuit 1 Alarm indicates that low pressure during operation is below expected pressure. If 300 s following start of circuit low pressure remains below the set alarm value for more than 30 s, the circuit is isolated due to error. Possible reasons to be investigated: Refrigeration circuit – Insufficient refrigerant (sight glass must be without bubbles following around 10 min of operation) – Shut off valve(s) closed/not completely open – Faulty expansion valve (measure overheat, 5 to 10 K following 10 min of operation) – Operation outside operating limits Water circuit: – Air in water circuit – Dirty water filter – Water pressure too low – Flow regulating valve closed too wide – Water inlet or outlet temperature at evaporator is too low – Temperature difference between evaporator water inlet and outlet too low/high (min/max 3 to 8 K) – Pumping capacity too low – Glycol concentration too high (more than 50 %) – Dirty heat exchanger Additionally for air cooled units: – Too low air inlet temperature – Condenser is not wind protected at ambient temperature < -10 °C (refer to operating limits) Additionally for water cooled units: – Water temperature at condenser is too low (refer to operating limits) Electrical system: – Faulty low pressure sensor -> Check pressure displayed in controller against the actual pressure measured by pressure gauge. -> Use a 4-20 mA encoder by others to simulate the corresponding signal and evaluate the result displayed by the controller. – Defective input on controller – Incorrect wiring – Loose cable connection – Cable failure 282 Evaporating pressure insufficient in circuit 2 See alarm message 281 "Insufficient evaporating pressure circuit 1", only for refrigeration circuit 2 M CI 283 Evaporating pressure insufficient in circuit 3 See alarm message 281 "Insufficient evaporating pressure circuit 1", only for refrigeration circuit 3 M CI 284 Evaporating pressure insufficient in circuit 4 See alarm message 281 "Insufficient evaporating pressure circuit 1", only for refrigeration circuit 4 M CI PR-2013-0112-GB • Subject to modifications • R1-01/2016 99 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 400 Received readings for sensor 10 on the main PCB (Master) are outside limiting values. Use the wiring diagram to establish if a temperature or pressure sensor is connected to terminal B10 on the main PCB (Master). Possible reasons to be investigated: Electrical system: – Check if temperature/pressure sensor readings indicated through in/output menu of controller correspond to those measured by thermometer/pressure gauge. -> Temperature sensor - Establish resistance value of temperature sensor. - Compare measured reading with theoretical value from table/figure 12.3. If the difference between setpoint and actual value is too great, it is probable that the temperature sensor is faulty. -> pressure sensor - Read off the pressure measure range of pressure sensor. - Measure current using a pressure sensor (4-20 mA signal). - Check if measured current corresponds to actual pressure value measured by pressure sensor (4 mA - lower pressure reading, 20 mA - upper pressure reading, other pressure/current readings belong linearly in-between). – Faulty pressure sensor – Faulty temperature sensor – Defective input on controller – Non-available analog input signal, as e.g. 4-20 mA signal for setpoint shift – Incorrect configuration of controller (e.g. if setpoint shift is registered via 4-20 mA signal, but the latter is not available). – Incorrect wiring – Loose cable connection – Cable failure A * Fault, sensor 10 RESET Action 401 Fault, sensor 1 See message 400, but for sensor B1 of main PCB (Master) A * 402 Fault, sensor 2 See message 400, but for sensor B2 of main PCB (Master) A * 403 Fault, sensor 3 See message 400, but for sensor B3 of main PCB (Master) A * 404 Fault, sensor 4 See message 400, but for sensor B4 of main PCB (Master) A * 405 Fault, sensor 5 See message 400, but for sensor B5 of main PCB (Master) A * 406 Fault, sensor 6 See message 400, but for sensor B6 of main PCB (Master) A * 407 Fault, sensor 7 See message 400, but for sensor B7 of main PCB (Master) A * 408 Fault, sensor 8 See message 400, but for sensor B8 of main PCB (Master) A * 409 Fault, sensor 9 See message 400, but for sensor B9 of main PCB (Master) A * 411 Exp 1 faulty sensor 1 See message 400, but for sensor B1 of extension address 1 A * 412 Exp 1 faulty sensor 2 See message 400, but for sensor B2 of extension address 1 A * 413 Exp 1 faulty sensor 3 See message 400, but for sensor B3 of extension address 1 A * 414 Exp 1 faulty sensor 4 See message 400, but for sensor B4 of extension address 1 A * 421 Exp 2 faulty sensor 1 See message 400, but for sensor B1 of extension address 2 A * 422 Exp 2 faulty sensor 2 See message 400, but for sensor B2 of extension address 2 A * 423 Exp 2 faulty sensor 3 See message 400, but for sensor B3 of extension address 2 A * 424 Exp 2 faulty sensor 4 See message 400, but for sensor B4 of extension address 2 A * 425 Exp 2 faulty sensor 5 See message 400, but for sensor B5 of extension address 2 A * 426 Exp 2 faulty sensor 6 See message 400, but for sensor B6 of extension address 2 A * 427 Exp 2 faulty sensor 7 See message 400, but for sensor B7 of extension address 2 A * 428 Exp 2 faulty sensor 8 See message 400, but for sensor B8 of extension address 2 A * 431 Exp 3 faulty sensor 1 See message 400, but for sensor B1 of extension address 3 A * 432 Exp 3 faulty sensor 2 See message 400, but for sensor B2 of extension address 3 A * 433 Exp 3 faulty sensor 3 See message 400, but for sensor B3 of extension address 3 A * 434 Exp 3 faulty sensor 4 See message 400, but for sensor B4 of extension address 3 A * 441 Exp 4 faulty sensor 1 See message 400, but for sensor B1 of extension address 4 A * 442 Exp 4 faulty sensor 2 See message 400, but for sensor B2 of extension address 4 A * 443 Exp 4 faulty sensor 3 See message 400, but for sensor B3 of extension address 4 A * 444 Exp 4 faulty sensor 4 See message 400, but for sensor B4 of extension address 4 A * 451 Exp 5 faulty sensor 1 See message 400, but for sensor B1 of extension address 5 A * 452 Exp 5 faulty sensor 2 See message 400, but for sensor B2 of extension address 5 A * 453 Exp 5 faulty sensor 3 See message 400, but for sensor B3 of extension address 5 A * 454 Exp 5 faulty sensor 4 See message 400, but for sensor B4 of extension address 5 A * 100 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series ALARM DESCRIPTION Fault Finding and Troubleshooting Details RESET Action 500 Slave faulty sensor 10 See message 400, but for sensor B10 of main PCB (Slave) A * 501 Slave faulty sensor 1 See message 400, but for sensor B1 of main PCB (Slave) A * 502 Slave faulty sensor 2 See message 400, but for sensor B2 of main PCB (Slave) A * 503 Slave faulty sensor 3 See message 400, but for sensor B3 of main PCB (Slave) A * 504 Slave faulty sensor 4 See message 400, but for sensor B4 of main PCB (Slave) A * 505 Slave faulty sensor 5 See message 400, but for sensor B5 of main PCB (Slave) A * 506 Slave faulty sensor 6 See message 400, but for sensor B6 of main PCB (Slave) A * 507 Slave faulty sensor 7 See message 400, but for sensor B7 of main PCB (Slave) A * 508 Slave faulty sensor 8 See message 400, but for sensor B8 of main PCB (Slave) A * 509 Slave faulty sensor 9 See message 400, but for sensor B9 of main PCB (Slave) A * 511 Exp 1 Slave faulty sensor 1 See message 400, but for sensor B1 of extension address 1 (Slave) A * 512 Exp 1 Slave faulty sensor 2 See message 400, but for sensor B2 of extension address 1 (Slave) A * 513 Exp 1 Slave faulty sensor 3 See message 400, but for sensor B3 of extension address 1 (Slave) A * 514 Exp 1 Slave faulty sensor 4 See message 400, but for sensor B4 of extension address 1 (Slave) A * 521 Exp 2 Slave faulty sensor 1 See message 400, but for sensor B1 of extension address 2 (Slave) A * 522 Exp 2 Slave faulty sensor 2 See message 400, but for sensor B2 of extension address 2 (Slave) A * 523 Exp 2 Slave faulty sensor 3 See message 400, but for sensor B3 of extension address 2 (Slave) A * 524 Exp 2 Slave faulty sensor 4 See message 400, but for sensor B4 of extension address 2 (Slave) A * 525 Exp 2 Slave faulty sensor 5 See message 400, but for sensor B5 of extension address 2 (Slave) A * 526 Exp 2 Slave faulty sensor 6 See message 400, but for sensor B6 of extension address 2 (Slave) A * 527 Exp 2 Slave faulty sensor 7 See message 400, but for sensor B7 of extension address 2 (Slave) A * 528 Exp 2 Slave faulty sensor 8 See message 400, but for sensor B8 of extension address 2 (Slave) A * 531 Exp 3 Slave faulty sensor 1 See message 400, but for sensor B1 of extension address 3 (Slave) A * 532 Exp 3 Slave faulty sensor 2 See message 400, but for sensor B2 of extension address 3 (Slave) A * 533 Exp 3 Slave faulty sensor 3 See message 400, but for sensor B3 of extension address 3 (Slave) A * 534 Exp 3 Slave faulty sensor 4 See message 400, but for sensor B4 of extension address 3 (Slave) A * 551 Exp 5 Slave faulty sensor 1 See message 400, but for sensor B1 of extension address 5 (Slave) A * 552 Exp 5 Slave faulty sensor 2 See message 400, but for sensor B2 of extension address 5 (Slave) A * 553 Exp 5 Slave faulty sensor 3 See message 400, but for sensor B3 of extension address 5 (Slave) A * 554 Exp 5 Slave faulty sensor 4 See message 400, but for sensor B4 of extension address 5 (Slave) A * 611 Pre-alarm frost protection for evaporator 1 Pre-alarm is a signal message transmitted to building management system Unit continues to operate and informs beforehand about expected fault message. General alarm contact is not closed. Pre-alarm must activated in controller menu and the corresponding signal value must be entered as a positive difference to alarm value. As a remedy for „Pre-alarm frosts protection evaporator 1“ see alarm message 010 „Evaporator frost protection“ S - 612 Pre-alarm frost protection for evaporator 2 See alarm message 611 „Pre-alarm frost protection evaporator 1“, but for evaporator 2 S - 613 Pre-alarm frost protection for evaporator 3 See alarm message 611 „Pre-alarm frost protection evaporator 1“, but for evaporator 3 S - 614 Pre-alarm frost protection for evaporator 4 See alarm message 611 „Pre-alarm frost protection evaporator 1“, but for evaporator 4 S - 631 Pre-alarm low pressure Circuit 1 Pre-alarm is a signal message transmitted to building management system Unit continues to operate and informs beforehand about expected fault message. General alarm contact is not closed. Pre-alarm must activated in controller menu and the corresponding signal value must be entered as a positive difference to alarm value. As a remedy for „Pre-alarm low pressure circuit 1“ see alarm message 231 „Low pressure circuit 1“. For displaying pre-alarm 631 only measured value of low pressure sensor is evaluated. S - 632 Pre-alarm low pressure Circuit 2 See alarm message 631 „Pre-alarm low pressure circuit 1“, but for refrigeration circuit 2 S - 633 Pre-alarm low pressure Circuit 3 See alarm message 631 „Pre-alarm low pressure circuit 1“, but for refrigeration circuit 3 S - 634 Pre-alarm low pressure Circuit 4 See alarm message 631 „Pre-alarm low pressure circuit 1“, but for refrigeration circuit 4 S - PR-2013-0112-GB • Subject to modifications • R1-01/2016 101 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 641 Pre-alarm is a signal message transmitted to building management system Unit continues to operate and informs beforehand about expected fault message. General alarm contact is not closed. Pre-alarm must activated in controller menu and the corresponding signal value must be entered as a positive difference to alarm value. As a remedy for „Pre-alarm high pressure circuit 1“ see alarm message 241 „High pressure via converter 1“. For displaying pre-alarm 641 only measured value of high pressure sensor is evaluated. S - Pre-alarm high pressure Circuit 1 RESET Action 642 Pre-alarm high pressure Circuit 2 See alarm message 641 „Pre-alarm high pressure circuit 1“, but for refrigeration circuit 2 S - 643 Pre-alarm high pressure Circuit 3 See alarm message 641 „Pre-alarm high pressure circuit 1“, but for refrigeration circuit 3 S - 644 Pre-alarm high pressure Circuit 4 See alarm message 641 „Pre-alarm high pressure circuit 1“, but for refrigeration circuit 4 S - 651 Checking operating range: discharge temperature too low for circuit 1 Alarm indicates that discharge temperature fell below minimum allowed discharge temperature while operation. Setpoint for the minimum discharge temperature is determined at the compressor depending on the pressure condition. If the discharge temperature remains below the set alarm value 120 s following compressor start or deactivation or 30 s during the operation, the refrigeration circuit is deactivated as a result of a fault. The bridging time of 120 s also applies after the changeover of operating mode, during pump downtime or defrost cycle. Possible reasons to be investigated: Refrigeration circuit: – Overcharge of refrigerant – Faulty expansion valve (measure overheat, 5 to 10 K following 10 min of operation) – Operation outside operating limits Additionally for air cooled units: – Too low air inlet temperature – Condenser is not installed in a wind protected location (refer to operating limits) Additionally for water cooled units: - Water temperature at condenser is too low (refer to operating limits) Electrical system: - Faulty temperature sensor -> Check temperature displayed in controller against the actual temperature measured by thermometer. - Establish resistance value of temperature sensor. - Compare measured reading with theoretical value from table/figure 12.3 If the difference between setpoint and actual value is too great, the temperature sensor is faulty. - Defective input of controller - Incorrect wiring - Loose cable connection - Cable break M CI This alarm only applies for units with screw compressors and requires high and low pressure sensors per each refrigeration circuit as well as a discharge temperature sensor. 652 Checking operating range: discharge temperature too low for circuit 2 Refer to alarm message 651 „Checking operating range: discharge temperature too low in circuit 1“, only for refrigeration circuit 2 M CI 653 Checking operating range: discharge temperature too low for circuit 3 Refer to alarm message 651 „Checking operating range: discharge temperature too low in circuit 1“, only for refrigeration circuit 3 M CI 654 Checking operating range: discharge temperature too low for circuit 4 Refer to alarm message 651 „Checking operating range: discharge temperature too low in circuit 1“, only for refrigeration circuit 4 M CI 102 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details 661 Alarm indicates that discharge temperature exceeded maximum allowed discharge temperature while in operation. Setpoint for the minimum discharge temperature is determined at the compressor depending on the pressure condition. If the discharge temperature remains above the set alarm value 120 s following compressor start or deactivation or 30 s during the operation, the refrigeration circuit is deactivated as a result of a fault. The bridging time of 120 s also applies after the changeover of operating mode, during pump downtime or defrost cycle. Possible reasons to be investigated: Refrigeration circuit: – Insufficient refrigerant (sight glass must be without bubbles following around 10 min of operation) – Faulty expansion valve (measure overheat, 5 to 10 K following 10 min of operation) – Operation outside operating limits Water circuit: – Water temperature at condenser is too high (refer to operating limits) Additionally for air cooled units: – Air inlet temperature too low (refer to operating limits) Additionally for water cooled units: – Water temperature at condenser is too high (refer to operating limits) Electrical system: - Faulty temperature sensor -> Check temperature displayed in controller against the actual temperature measured by thermometer. - Establish resistance value of temperature sensor. - Compare measured reading with theoretical value from table/figure 12.3 If the difference between setpoint and actual value is too great, the temperature sensor is faulty. – Defective input on controller – Incorrect wiring – Loose cable connection – Cable failure Checking operating range: discharge temperature too high for circuit 1 RESET Action M CI This alarm only applies for units with screw compressors and requires high and low pressure sensors per each refrigeration circuit as well as a discharge temperature sensor. 662 Checking operating range: discharge temperature too high for circuit 2 Refer to alarm message 661 „Checking operating range: discharge temperature too high in circuit 1“, only for refrigeration circuit 2 M CI 663 Checking operating range: discharge temperature too high for circuit 3 Refer to alarm message 661 „Checking operating range: discharge temperature too high in circuit 1“, only for refrigeration circuit 3 M CI 664 Checking operating range: discharge temperature too high for circuit 4 Refer to alarm message 661 „Checking operating range: discharge temperature too high in circuit 1“, only for refrigeration circuit 4 M CI 671 Checking operating range: high pressure too low for circuit 1 Alarm indicates that high pressure fell below minimum allowed high pressure while in operation. If the high pressure remains below the set alarm value 120 s following compressor start or deactivation or 30 s during the operation, the refrigeration circuit is deactivated as a result of a fault. The bridging time of 120 s also applies after the changeover of operating mode, during pump downtime or defrost cycle. Possible reasons to be investigated: Refrigeration circuit: – Insufficient refrigerant (sight glass must be without bubbles following around 10 min of operation) – Faulty expansion valve (measure overheat, 5 to 10 K following 10 min of operation) – Operation outside operating limits Additionally for air cooled units: – Too low air inlet temperature – Condenser is not installed in a wind protected location (refer to operating limits) Additionally for water cooled units: – Water temperature at condenser is too low (refer to operating limits) Electrical system: – Faulty low pressure sensor -> Check pressure displayed in controller against the actual pressure measured by pressure gauge. -> Use a 4-20 mA encoder by others to simulate the corresponding signal and evaluate the result displayed by the controller. – Defective input on controller – Incorrect wiring – Loose cable connection – Cable failure M CI This alarm requires high and low pressure sensors per each refrigeration circuit. PR-2013-0112-GB • Subject to modifications • R1-01/2016 103 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting ALARM DESCRIPTION Details RESET Action 672 Checking operating range: high pressure too low for circuit 2 Refer to alarm message 671 „Checking operating range: discharge temperature too low in circuit 1“, only for refrigeration circuit 2 M CI 673 Checking operating range: high pressure too low for circuit 3 Refer to alarm message 671 „Checking operating range: discharge temperature too low in circuit 1“, only for refrigeration circuit 3 M CI 674 Checking operating range: high pressure too low for circuit 4 Refer to alarm message 671 „Checking operating range: discharge temperature too low in circuit 1“, only for refrigeration circuit 4 M CI Legend for column „RESET“ M= Alarm with manual reset (after the cause that triggered alarm is eliminated, the alarm must be reset using the keyboard). A= Alarm with automatic reset (after the cause that triggered alarm is eliminated, the alarm is reset automatically). A/M = Alarm automatically reset following the first "n" alarms of this type, after that manual reset is needed. S= Display instruction. S-A= Note (does not affect unit operation) or alarm with automatic reset. The required operating mode can be selected via parameters. M - A/M = Alarm with manual reset (with scroll and screw compressors), automatic reset for the first „n“ alarms of this type, then manual reset is needed (with turbocompressors). B= Stop function, that cannot be reset using display; enable "alarm recording". To delete an alarm, the power supply of the relevant compressor has to be interrupted for a short time. Legend for column „Action“ -= Unit does not switch off U= Unit switches off. -/U = Depending on parameter settings unit does not switch off or switches off. U* = In automatic mode the unit does not switch off, operating mode is selected in which the error is not displayed. With an externally selected operating mode the unit is deactivated. CI = The refrigeration circuit with an error is deactivated. CO = The compressor with an error is deactivated. *= Depending on the temperature or pressure sensor, which triggered the alarm, the corresponding compressor, refrigeration circuit or entire unit is either deactivated or not, if the temperature/pressure sensor fulfils a subordinate function. Tab. 12-1 104 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Fault Finding and Troubleshooting 12.3 Resistance temperature sensor for DencoHappel HVAC systems controller Temperature Resistance Temperature Resistance Temperature Resistance [°C] [kOhm] [°C] [kOhm] [°C] [kOhm] -50 32.92 -15 53.39 40 5.83 -47 27.70 -10 42.25 45 4.91 -45 24.75 -5 33.89 50 4.16 -42 20.98 0 27.28 55 3.54 -40 18.84 5 22.05 60 3.02 -37 16.01 10 17.96 65 2.59 -35 14.40 15 14.68 70 2.23 -32 12.32 20 12.09 75 1.92 -30 11.13 25 10 80 1.67 -25 8.64 30 8.313 85 1.45 -20 6.77 35 6.941 90 1.27 Tab. 12-2 60 50 Resistance [kOhm] 40 30 20 10 0 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 Temperature [°C] Fig. 12-1: Diagram for temperature resistance of DencoHappel HVAC systems controller PR-2013-0112-GB • Subject to modifications • R1-01/2016 105 Chillers & Heat Pumps GL Series Servicing and Maintenance 13 Servicing and Maintenance For a safe and energy efficient operation, a maintenance of the unit is necessary at regular intervals. In the Appendix of this operation manual you can find a logbook for chillers, heat pumps and compressor/condenser units. All work performed on this unit must be documented in the logbook. Logbook For refrigeration systems/chillers/heat pumps with CO2 equivalent ? 5 t the owner or operator must keep a logbook of the plant. According to the EG 517/2014 standard, the logbook must be updated following the unit maintenance or service. You can find the logbook in Appendix IV "Log book for chillers, heat pumps and compressor/condenser units". Enter the data specified on the unit code plate in chapter 1. This establishes a clear relationship between the unit, the current operation manual, and the logbook. Keep the logbook for at least 5 years after the last recording. Upon request, this inspection logbook is to be submitted to the competent authorities. Maintenance Unit maintenance must only be carried out by DencoHappel Service or a licensed refrigeration company! Consider the instructions specified in section 4.10 "Personnel selection and qualification". During maintenance work all safety-relevant codes and practices must be observed. Mandatory! A minimum 1 annual maintenance Have the system serviced at least once a year! Depending on the refrigerant charge, legal codes and regulations require to have this maintenance conducted, at the same time the latter also constitutes the condition for the validity of the warranty. 13.1 Statutory limit values of leakage checks on refrigeration systems Because of the current F-Gas Regulation 517/2015, the limit values to check tightness on refrigeration systems are regulated by law. The limit values do not depend on the filled weight of the plant in kg anymore but on the CO2 equivalent. The CO2 equivalent is calculated through the multiplication of charge in kg and GWP value. Example: A unit contains 100 kg refrigerant R134a. With a GWP of 1430, this corresponds to a CO2 equivalent of 143.000 t CO2. For the GWP values refer to section 4.6.1 Handling refrigerants. Based on the Regulation 517/2014 Article 4, the following test intervals for the refrigerants used in the unit are prescribed: Amount of refrigerant in CO2 equivalent Mandatory inspection starting from: Filling quantity Testing interval < 3 kg but < 5 t CO2 equivalent R134a: to 3.5 kg Does not have to be checked by an inR410A: to 2.4 kg spector until 31.12.2016 R407C: to 2.8 kg 01.01.2017 if CO2 equivalent ? 5 t ? 5 t bis < 50 t CO2 Equivalent At least every 12 months, when using a leakage detection system (EU 517/ 2014 Article 2): at least every 24 months R134a: to 35 kg R410A: to 24 kg R407C: to 28 kg 2015-01-01 ? 50 t to < 500 t CO2 Equivalent At least every 6 months, when using a leakage detection system (EU 517/ 2014 Article 2): at least every 12 months R134a: to 349 kg R410A: to 239 kg R407C: to 281 kg 2015-01-01 ? 500 t CO2 equivalent At least every 3 months, when using a R134a: from 349 kg leakage detection system (EU 517/ R410A: from 239 kg 2014 Article 2): at least every 6 months R407C: from 281 kg 2015-01-01 Tab. 13-1 Operator of units with a CO2 equivalent ≥ 500 t must install a leckage detection system which must be checked for proper function every 12 months. 106 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Servicing and Maintenance 13.2 Overview of maintenance intervals In the following list you can find the general maintenance intervals for all units. For documenting the maintenance, use the relevant measuring report in Appendix III. Action Interval in months 3 6 12 24 Note General Check the unit for dirt X Control frost protection heating of the heat exchangers X Control frost protection heating of the pipework X Check functional principle of the solenoid valves X Check functional principle of the pressure switch X Check condition and voltage of the belts for centrifugal fans X Check the unit for damage X Measure outdoor-air temperature X Check fans for unbalanced condition and noise in bearings X General cleaning of the unit X Clean air-cooled heat exchangers Refer to chapter 13.3 Clean shell and tube heat exchanger X Check horizontal installation of the unit X Check the unit for corrosion X Change and check safety valves X Electric and regulation Check electrical connections and tighten if necessary X Check supply voltage of the unit X Check supply voltage of the compressors X Check supply voltage of the fans X Check supply voltage of the water pump X Check contactor of the compressors for wear X Check contactor of the fans for wear X Check contactor of the water pump for wear X Measure current consumption of the compressors X Measure current consumption of the fans X Measure current consumption of the water pump X Check functional principle of the pressure sensors and calibrate if necessary X Check functional principle of the temperature sensors and calibrate if necessary X Check functional principle of the crankcase heating X Refrigeration circuit at full load Test for leakage on refrigeration circuit Refer to chapter 13.1 Check oil level X Check sight glass for absence of bubbles and humidity X Measure high pressure X Measure low pressure X Measure suction gas overheating X Measure liquid subcooling X Measure hot gas overheating X Check cleanliness of the oil X Carry out oleic acid test X Check temperature difference on the heat exchangers X Check oil level switch X Check filter dryer in the liquid line X Tab. 13-2 PR-2013-0112-GB • Subject to modifications • R1-01/2016 107 Chillers & Heat Pumps GL Series Servicing and Maintenance Action Interval in months 3 6 12 24 Note Hydraulics Check functional principle of the flow switch X Check functional principle of the water differential pressure switch X Check rotation direction of the water pump X Air vent hydraulic circuit X Fill hydraulic circuit, if necessary X Clean water filter X Check water-side pressure drop of the heat exchangers X Check glycol concentration X Check water pump for tightness X Check initial pressure in expansion tank X Check hydraulic circuit for tightness X Check condition of the glycol (corrosion protection) X Tab. 13-2 13.3 Maintenance of air-cooled heat exchangers To ensure an energy efficient operation of the unit and to protect air-cooled heat exchangers against corrosion, these heat exchangers must be cleaned and serviced regularly and correctly. Air-cooled heat exchangers must be cleaned and serviced at least once a year. Depending on the installation site, shorter maintenance intervals may be required, especially when heavily soiled or with aggressive weather conditions. Refer to the contract documents to obtain data on the heat exchanger and its coating. Electrocution through hazardous voltage will lead to death or serious injury! • Disconnect the unit from the power supply and ensure the power cannot be switched back on. • Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. Sharp edges can cause injuries! Observe precaution when cleaning due to risk of cuts on thin and sharp edges. (Only GLAC, GLAH, GLFC and GLDC) • Wear chemical resistant gloves. Before you start with cleaning or maintenance work, disconnect the power from the unit and wait until the fans stop. Removal of dirt on the surface: • Dirt in the form of leaves, dust, pollen or similar must be removed carefully with a • • 108 vacuum cleaner, a brush or a similar device. Make sure that the fins and pipes of the heat exchangers remain undamaged and do not deform. When cleaning with compressed air, the air jet must be placed vertically on the surface of the tab to not bend the aluminium fins. PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Servicing and Maintenance Regular Cleaning: ATTENTION Damage to the unit! Cleaning of the heat exchanger with a high pressure cleaner is not allowed. The high pressure cleaner can cause permanent damage on the fins and the pipes. • Rinse the heat exchanger with water. • Special cleaning agents which are suitable for the heat exchanger and perhaps the heat exchanger coating may be used as long as it is not explicitly excluded in this chapter. Notice! Damages caused by using inappropriate cleaning agents invalidate the warranty. • Rinse the individual fins from the inside to the outside until the fins are completely clean. • When cleaning with water, the water jet must be placed vertically on the surface of • the tab to not bend the aluminium fins. Do not use a brush nozzle on the water hose to avoid damage on the fins and pipes of the heat exchanger. 13.3.1 Additional information for Cu/Al heat exchangers with coatings at least twice a year: For air-cooled heat exchangers with copper pipes and aluminium fins there are different coatings to protect the heat exchanger from corrosion in the long term. For coated heat exchangers, maintenance and cleaning must be carried out at least twice a year. For particularly critical installations, e.g. in coastal areas, maintenance and cleaning may be necessary at shorter intervals. After cleaning, the heat exchanger must be completely checked to ensure that no damages, erosions or corrosion symptoms have occured. Every damage, erosion or corrosion symptom must be reported to the DencoHappel Service. 13.3.2 Additional information on MicroChannel Heat Exchangers (MCHX) every three months For MicroChannel heat exchangers, dirt is more likely to accumulate on the surface due to the tight structure. As a result, these heat exchangers are easier to clean than Cu/Al heat exchangers. MicroChannel heat exchangers must be cleaned and serviced at least every three months. Depending on the installation site, shorter maintenance intervals may be required, especially when heavily soiled or with aggressive weather conditions. Rinsing: • Rinse the heat exchanger only with water. Chemical cleaning agents are not allowed as they can cause corrosion. • After cleaning, the remaining water must be removed by blowing out. 13.3.3 Additional information on MicroChannel Heat Exchangers (MCHX) with epoxid polymer coating: Document all maintenance and cleaning procedures on the heat exchanger to maintain the requirement for warranty claims of the protective coating. PR-2013-0112-GB • Subject to modifications • R1-01/2016 109 Chillers & Heat Pumps GL Series Servicing and Maintenance Regular Cleaning: monthly: • When installing near coastal and industrial areas, it is compulsory to clean the heat exchangers of salt, dirt and other residues once a month. • Rinse the heat exchanger only with water. Chemical cleaning agents are not allowed quarterly: as they can cause corrosion. • Make sure the water temperature is below 45 °C. Clean the heat exchangers every three months to maintain the service life as well as the requirement for warranty claims of the protective coating. • In the first step, clean the tabs with the following agents. These agents remove mold, dust, soot, grease residues, fibres and other particles. Consider the relevant instructions of the manufacturer for proper use and the correct mixing ratio. Product Code Enviro-Coil Concentrate H-ECO1 Enviro-Coil Universal Coil Cleaner • In the second step, the heat exchanger must be cleaned from salts. Use the agent chlorine * RID DTSTM for this purpose. This way, soluble salts are removed and the heat exchanger is thoroughly cleaned. The product must come in contact with the salts which can be underneath a layer of fat and dirt. Therefore, the cleaning mentioned in step one is a necessary requirement. Chlorine * RID DTSTM must be applied evenly on the heat exchanger in a sufficiently large quantity. After the salts are dissolved, rinse the heat exchanger with clear water as described above. 13.4 Recommendation: Two services per year Depending on operating hours and ambient temperature, it can become necessary to perform unit maintenance several times a year. DencoHappel Service can draw up an individual maintenance plan for you. For each maintenance of DencoHappel unit the Measuring report, enclosed in Appendix III, must be filled in by the DencoHappel Service or a licensed refrigeration company (refer to section 4.10). You should be provided with a copy of this report (or the original) listing all maintenance jobs carried out and recorded measured values. Use this report to verify whether all specified maintenance jobs and measurements have been carried out. Also consider legal requirements regarding maintenance of refrigeration chillers/heat pumps and connected systems apply in addition to previously mentioned regulations. We recommend that you have your unit serviced at least twice a year. Notice! If case of leaking refrigerant, liquids or oil - switch off the unit immediately and inform DencoHappel Service. ATTENTION Environmental damage! All leaking media must be disposed of in accordance with the current regulations, local codes and practices. 110 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Dismantling and Disposal 14 Dismantling and Disposal ATTENTION Risk of environmental damage! Have qualified licensed staff dismantle and dispose of the unit! 14.1 Dismantling To dismantle the units proceed as follows: Electrocution through hazardous voltage will lead to death or serious injury! When carrying out decommissioning and dismantling work on the unit you must: • Disconnect the unit from the power supply and ensure the power cannot be switched back on. • Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. Warning of high pressure! When carrying out decommissioning and dismantling work on the unit you must: • shut off and empty all connected pipework until the system pressure has equalized with the ambient air pressure. • Wear protective clothing and safety glasses • Close all hydraulic shut-off valves. • Isolate all connections and ensure there are no leaking materials such as oil, refrigerant or water-glycol mix. • Release the fixing to the floor. Danger due to high loads! Inappropriate handling with high loads can lead to death or serious injuries. For unit weight, refer to the order-related documentation and the unit identification plate. • Use proper lifting gear (crane equipment) for lifting and handling. • Never use a fork lift truck or pallet truck, as there is a risk of the unit toppling over. • Secure the unit against slipping.  The unit is ready for transport. • Consider all instructions on shipping (refer to chapter 6). PR-2013-0112-GB • Subject to modifications • R1-01/2016 111 Chillers & Heat Pumps GL Series Dismantling and Disposal 14.2 Disposal Notice! The operator of the refrigeration unit is responsible for taking all necessary precautionary measures and ensures that only certified and licensed staff properly recovers, recycles, processes and disposes of fluorinated refrigerants containing greenhouse gases (F-Gases). An authorized appointed contractor specializing in waste processing must dispose of the unit or its individual components. This appointed contractor must ensure that: – the components are separated according to material types – the used operating materials are sorted and separated according to their respective properties. – fluorinated greenhouse gases are properly recycled or disposed ATTENTION Environmental damage! Dispose of all components and materials (such as oil, refrigerants and water-glycol mixture) in an environmentally friendly manner in accordance with the local codes, practices and environmental regulations. 112 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Appendix 15 Appendix The following pages contain check lists and reports: On 15.1 Appendix I 15.1 Technical Requirements for Function Testing or Maintenance of Chiller/Heat Pump See Appendix I For commissioning: We recommend to use the checklist “Technical requirements for commissioning report/ client witness test of chiller/heat pump” to ensure that the on-site requirements for drawing up the commissioning report are fulfilled ("Commissioning report" in Appendix II). This can also save additional work and costs because DencoHappel Service will possibly have to visit your unit again, if the on-site requirements were not met beforehand. Pre-maintenance jobs: Prior to maintenance jobs and creation of Maintenance and Measuring Report (Appendix III), “Technical requirements for maintenance of chiller/heat pump” must be fulfilled as well. On 15.2 Appendix II 15.2 Commissioning Report Refer to Appendix II Fill out the report in the course of the client witness test. The function test must be carried out by DencoHappel Service or a specialist refrigeration company (see section 4.10) and the commissioning report must be drawn up and sent to DencoHappel. Notice! You must send the commissioning report to DencoHappel! If you do not send the commissioning report to DencoHappel, the warranty for your DencoHappel unit will be rendered null and void! See “Schematic representation of various hydraulic circuits (examples)” on page 47. On 15.3 Appendix III Measuring Report Refer to Appendix III Have the system serviced at least once a year! This condition must be met for the warranty to remain valid! Staff of the contractor company authorized to perform maintenance must draw up a “Measuring Report“. You should be provided with a copy of this report (or the original) listing all maintenance jobs carried out and recorded measured values. This report contains all maintenance procedures that must be carried out according to DencoHappel. Use this report to verify if your authorized appointed contractor has carried out all specified maintenance jobs and measurements. Also consider legal requirements regarding maintenance of refrigeration chillers/heat pumps and connected systems apply in addition to previously mentioned regulations. PR-2013-0112-GB • Subject to modifications • R1-01/2016 113 Chillers & Heat Pumps GL Series Appendix Appendix I 15.1 Technical Requirements for Function Testing or Maintenance of Chiller/Heat Pump Technical Requirements for Function Testing or Maintenance of Chiller/Heat Pump Customer: Address: Tel./Fax.: Contact person Contact person on site: GEA Order Nr.: Construction site: Address: Tel./Fax.: Contact person: Can be reached tel.: Serial-Nr. Unit type: Design data: Setpoint temperature water in: Setpoint temperature water out: Glycol concentration: Freeze point: Chilled water charge: Glycol type: Glycol charged on: Glycol added/checked by: °C °C % °C m³/h Cool water setpoint temp. in1) Cool water setpoint temp. out1) Glycol concentration in cool water1): Freeze point1): Cool water charge1): Glycol type used1): Glycol charged on1): Glycol added/checked by1): °C °C % °C m³/h 1) only GLWC/GLWH; 2) only with GLRC Requirements to be met by others prior to function test 1. Electrical connections according to the local utility guidelines incl. necessary fusing 2. On site fusing 3. On site supply piping 4. Electrical cabling between the components - On site chilled and cool water pump - Flow switch - Remote On/Off contact (if available) - Common fault signal - External air cooled heat rejection units1) / condenser2) 5. Water connection and pipe network filled and bled according to local and national codes. 6. Strainer/water filter fitted directly before the water-side inlet to the unit. 7. Flow switch fitted directly after the water-side outlet of the unit. 8. Water-side safety device installed and tested for correct function, fixtures such as thermometer, differential pressure gauge fitted above the heat exchanger. 9. Pipe system by others rinsed clean before connection to the unit. Cleaning report present. 10. Output discharge (at least 50%) continually guaranteed 11. 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: Date: 114 Name: Place: Checked ____A ___mm2 Company: Signature customer/operator PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps Appendix GL Series II 15.2 Appendix Commissioning Report Commissioning Report DencoHappel Company name: Customer / Operator name: Customer / Operator name: Company: Street: City: Witnessed by: Commissioning requested by: Cond. fan current L1 Cond. fan current L2 Cond. fan current L3 T out [°C] @100 % Control Voltage: [V] Compressor N° Evaporating press. bar Condesing press. bar Discharge temp. °C Suction line temp. °C Liquid line temp. °C Current consump. L1 A Current consump. L2 A Current consump. L3 A Capacity unit @measurem. Measure. @working mode A A A Unit data: Type: Serial Number: Buffer tank S.N.: Condenser S.N.: Phone: Operating data: T in [°C] @100 % Evaporator: Condenser: Outside temp.: [°C] Installer´s name: deltaT [K] @100 % Power supply: [V] / 1 2 % Chiller Circuit 1 % Hydraulic system check (see OM): 1. Pressure gauge Yes 2. Shut off valve press. gauge Yes 3. Autom. Air venting Yes 4 Vibration damping point Yes 6. Water filter Yes 7. Drain valve Yes 8. Pump (Unit circuit) Yes 9 Safety valve: bar Yes 10. Expansion vessel Yes 11. Filling valve Yes 12. Flow switch (Paddle type) Yes 13. Regulation valve Yes 14. 2nd Pump / 3-way-valve Yes 16. Buffer tank: litre Yes Pump operation contact Yes Shut-Off valve (Evaporator) Yes Hydraulic circuit finished Yes Anti Vibration rubbers installed below the unit Notes: 4 % Heat pump Circuit 2 No No No No No No No No No No No No No No No No No Chilled water Pump / 5 % 6 Low press. switch bar High press. switch bar Anti freeze value °C Set point Unit °C Hydr. diff. press. switch bar Check funct. & setting Free space around the unit R1 R 3 R 4 R2 No 7 8 % % % Chiller- and Heat pump mode Circuit 3 Circuit 4 Unit check: Electric connections checked: Yes / Type Glycol % / 3 Type: Current: Order: % Yes No Yes Yes Yes Yes Yes Yes No No No No No No R1: cm R2: cm R3: cm R4: cm N° of AV rubbers Date: Technician´s name: Signature: Date: Customer / Operator name: Signature: V1.11/2015 by DH PRM CH PR-2013-0112-GB • Subject to modifications • R1-01/2016 115 Chillers & Heat Pumps GL Series Appendix Commissioning Report Sketch of the unit´s hydraulic circuit Legend: Pump Unit Buffer tank (vertical) Buffer tank (horizontal) Hydraulic switch Water filter Installation position of 3-wayvalve Shut-off valve Safety valve Flow switch Temperature sensor Flow regulating valve No return valve Pressure gauge 2-way-valve Expansion vessel Consumer Dry cooler/ condenser Air vent valve 3-way-valvel Charge and drain valve Vibration damping point V1.11/2015 by DH PRM CH 116 PR-2013-0112-GB • Subject to modifications • R1-01/2016 15.3 Measuring Report GLAC Chiller Appendix III Measuring Report Chiller: GLAC – GLFC – GLDC Service engineer Cost Date DH Order Nr. Service-Nr. DH Order No (bottom of unit type plate) Plant operator Contact person Tel. Address Fax. Postal code / City E-Mail Plant manufacturer Contact person Tel. Address Fax. Postal code / City E-Mail Function check Maintenance Chiller Type Hydraulic module yes Year of no Serial Nr. Refrigerant G. Repairs R 407C R 134a R 410A Measured values Unit electrical features L1 - L2 G.1 R L2 - L3 L1 - L3 Mains voltage Unit V L1 - N L2 - N L3 - N V G.2 Mains voltage V G.3 Control voltage V Checking G.4 Phase sequence relay O.K. Not O.K. G.5 Contactor O.K. Not O.K. G.6 Control contactor O.K. Not O.K. G.7 Relay O.K. Not O.K. G.8 Thermostats O.K. Not O.K. G.9 Sensors O.K. Not O.K. G.10 Pressure sensor O.K. Not O.K. G.11 Solenoid valves O.K. Not O.K. G.12 Capacity regulation O.K. Not O.K. G.13 Paddle flow switch O.K. Not O.K. G.14 Anti-freeze protection O.K. Not O.K. Value °C G.15 Evaporator heating O.K. Not O.K. Current [A] G.16 Anti-freeze heater O.K. Not O.K. Current [A] Vers.1.1 11/2015 by DH PRM CHI PR-2013-0112-GB • Subject to modifications • R1-01/2016 117 R. Refrigeration circuit Date Serial Nr. unit: Measured unit Measured values 1 Refrigeration circuit 2 3 4 Unit Values at load R.1 Condensing pressure R.2 Condensing temp. °C R.3 Liquid temp. °C R.4 Sub cooling K R.5 Discharge temperature R.6 Suction pressure R.7 Evaporation temp. °C R.8 Suction gas temp. °C R.9 Superheating R.10 Safety valve bar R.11 Tested HP switch point bar R.12 Tested LP switch point bar R.13 Oil level R.14 Oleic acid test Ok? R.15 Sight glass Ok? R.16 Indicator Ok? R.17 Filter drier Ok? R.18 Leakage test Ok? Compressor Compressor at 100 % 118 % bar °C bar K 1 2 3 4 5 6 7 8 Current consumption R.19 L1 A R.19 L2 A R.19 L3 A R.22 Crankcase heating A R.23 MV - compress. cooling A R.24 Compressor type 1 Serial Nr. R.25 Compressor type 2 Serial Nr. R.26 Compressor type 3 Serial Nr. R.27 Compressor type 4 Serial Nr. R.24 Compressor type 5 Serial Nr. R.25 Compressor type 6 Serial Nr. R.26 Compressor type 7 Serial Nr. R.27 Compressor type 8 Serial Nr. PR-2013-0112-GB • Subject to modifications • R1-01/2016 EW. Evaporator Serial Nr. unit: Type Date Serial number of evaporator Medium Glycol %/ °C Glycol type Measured unit Values at full load (100%) Water Measured values Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit EW.1 Medium inlet temperature °C EW.2 Medium outlet temperature °C EW.3 T EW.4 Inlet water pressure bar EW.5 Outlet water pressure bar EW.6 p bar EW.7 GLHM / GLPE available EW.8 Type of hydraulic module EW.9 Buffer tank available / size K yes no by others Serial Nr. litre Single circuit tank Dual circuit tank EW.10 Strainer available yes no Cleaned yes no EW.11 Flow switch available yes no Function ok not ok EW.12 Pressure gauge available yes no EW.13 Shut off valves available yes no EW.14 Expansion tank available yes no EW.15 Safety valve available yes no EW.16 Current consumption of pumps L1 L2 Pressure bar L3 EW.17 Chilled water pump 1 A EW.18 Chilled water pump 2 A EW.19 Chilled water pump type 1 Serial Nr. EW.20 Chilled water pump type 2 Serial Nr. Notes R1 mm R2 mm R3 mm R4 mm PR-2013-0112-GB • Subject to modifications • R1-01/2016 119 CA. Condenser Serial Nr. unit: Type Date Serial number Measured unit Measured values Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit CA.1 Cleaning of fins necessary Yes / No CA.2 Cleaning of fins done Yes / No CA.3 Air heat exchanger inlet °C CA.4 Air heat exchanger outlet °C CA.5 T CA.6 Condensing temp. °C CA.7 Refrigerant outlet temperature °C CA.8 Difference CA.7 zu CA.3 CA.9 Current consumption of motors CA.10 Fan motor 1 A CA.11 Fan motor 2 A CA.12 Fan motor 3 A CA.13 Fan motor 4 A CA.14 Fan motor 5 A CA.15 Fan motor 6 A CA.16 Fan motor 7 A CA.17 Fan motor 8 A CA.18 Fan motor 9 A CA.19 Fan motor 10 A CA.20 Fan motor 11 A CA.21 Fan motor 12 A K K L1 L2 L3 Speed control CA.22 Start speed min. bar Speed % CA.23 Start speed max. bar Speed % Speed regulation CA.24 Start fan speed 1 bar Difference bar CA.25 Start fan speed 2 bar Difference bar CA.26 Start fan speed 3 bar Difference bar CA.27 Start fan speed 4 bar Difference bar Notes 120 PR-2013-0112-GB • Subject to modifications • R1-01/2016 C. Controller and Settings Date Serial Nr. unit: Used controller Software version Set parameters Note C.1 External ON/OFF used yes no C.2 Common fault signal used yes no C.3 Locked gen. fault remote ON/OFF yes no C.4 Pump lead time sec. by controller By others C.5 Pump overrun time sec By others C.6 Type of temperature regulation Proportional regulation Quick Mind C.7 Temperature regulation by Inlet Outlet C.8 Setpoint value, design value C.9 2nd setpoint yes no C.10 Setpoint variation 4-20 mA yes no C.11 Load shedding switch yes no C.12 Connection to BMS yes no C.13 Anti-freeze set point °C Dif. °C C.14 Start value evaporator heating °C Dif. °C C.15 Operating hours compressor 1 h Maintenance interval x h C.16 Operating hours compressor 2 h Maintenance interval x h C.17 Operating hours compressor 3 h Maintenance interval x h C.18 Operating hours compressor 4 h Maintenance interval x h C.19 Operating hours compressor 5 h Maintenance interval x h C.20 Operating hours compressor 6 h Maintenance interval x h C.21 Operating hours compressor 7 h Maintenance interval x h C.22 Operating hours compressor 8 h Maintenance interval x h C.23 Operating hours chill water pump 1 h Maintenance interval x h C.24 Operating hours chill water pump 2 h Maintenance interval x h C.25 Minimum idle time of compressor sec. C.26 Minimum time 2 compressor starts sec. C.27 Compressor min. oper. time sec. C.28 Max. compressor starts per hour /h °C by controller Proportional band °C °C Min. / Max. / °C % Report Notes PR-2013-0112-GB • Subject to modifications • R1-01/2016 121 G Check / visual inspection o. k. G.1 Compressor G.1.1 Check for debris, damage and corrosion G.1.2 Check if secured and for operating noise G.1.3 Check for air-tightness G.2 Condenser G.2.1 Check for debris, damage and corrosion G.2.2 Check for air-tightness G.3 Evap. G.3.1 Check for debris, damage and corrosion G.3.2 Check for air-tightness G.3 Fans Check for secured position, debris, damage and corrosion. G.3.1 G.3.2 Check for unbalanced impeller G.3.3 Check bearings for noise G.3.4 Check function of anti-vibration isolators G.4 Electric motors G.4.1 Check for dirt and damage Check for corrosion and secured position G.4.2 Check direction of rotation G.4.3 Check bearings for noise G.4.4 Check protective devices for proper function G.5 System components G.5.1 Visual check of insulation for damage G.5.2 G.5.3 G.5.4 G.6 G.6.1 G.6.2. Date Serial Nr. unit: Not O.K. Comment / action required Check for damage Refrigerant conducting unit components to be checks for leaks, visual inspection Visual check of compensators for damage Electrical devices Check optical and acoustical regulation for proper function Check connecting terminals for tightness, tighten, if necessary Notes Date 122 Name Signature PR-2013-0112-GB • Subject to modifications • R1-01/2016 Appendix III Measuring Report air cooled Heat Pumps: GLAH Service engineer Cost Date DH Order Nr. Service-Nr. DH Order No (bottom of unit type plate) Plant operator Contact person Tel. Address Fax. Postal code / City E-Mail Plant manufacturer Contact person Tel. Address Fax. Postal code / City E-Mail Function check Maintenance Unit Type Hydraulic module yes no Refrigerant G. Repairs Year of Serial N° R 407C R 134a R 410A Measured values Unit electrical features L1 - L2 G.1 R L2 - L3 L1 - L3 Mains voltage Unit V L1 - N L2 - N L3 - N V G.2 Mains voltage V G.3 Control voltage V Checking G.4 Phase sequence relay O.K. Not O.K. G.5 Contactor O.K. Not O.K. G.6 Control contactor O.K. Not O.K. G.7 Relay O.K. Not O.K. G.8 Thermostats O.K. Not O.K. G.9 Sensors O.K. Not O.K. G.10 Pressure sensor O.K. Not O.K. G.11 Solenoid valves O.K. Not O.K. G.12 Capacity regulation O.K. Not O.K. G.13 Paddle flow switch O.K. Not O.K. G.14 Anti-freeze protection O.K. Not O.K. Value °C G.15 Evaporator heating O.K. Not O.K. Current [A] G.16 Anti-freeze heater O.K. Not O.K. Current [A] G.17 4-way-valve o. K. nicht o. k. Vers.1.1 11/2015 by DH PRM CHI PR-2013-0112-GB • Subject to modifications • R1-01/2016 123 R. Ref. circuit cooling Date: Serial Nr. unit: Measured unit Measured values 1 Refrigeration circuit 2 3 4 Unit Values at load R.1 Condensing pressure R.2 Condensing temp. °C R.3 Liquid temp. °C R.4 Subcooling K R.5 Discharge temperature R.6 Suction pressure R.7 Evaporation temp. °C R.8 Suction gas temp. °C R.9 Superheating R.10 Safety valve bar R.11 Tested HP switch point bar R.12 Tested LP switch point bar R.13 Oil level R.14 Oleic acid test Ok? R.15 Sight glass Ok? R.16 Indicator Ok? R.17 Filter drier Ok? R.18 Leakage test Ok? Compressor Compressor at 100 % 124 % bar °C bar K 1 2 3 4 5 6 7 8 Current consumption R.19 L1 A R.19 L2 A R.19 L3 A R.22 Crankcase heating A R.23 MV - compress. cooling A R.24 Compressor type 1 Serial Nr. R.25 Compressor type 2 Serial Nr. R.26 Compressor type 3 Serial Nr. R.27 Compressor type 4 Serial Nr. R.24 Compressor type 5 Serial Nr. R.25 Compressor type 6 Serial Nr. R.26 Compressor type 7 Serial Nr. R.27 Compressor type 8 Serial Nr. PR-2013-0112-GB • Subject to modifications • R1-01/2016 EW. Evaporator in cooling mode Serial Nr. unit: Type: Date: Serial number of evaporator: Medium Glycol %/ °C Glycol type: Measured unit Values at full load (100%) Water Measured values Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit EW.1 Medium inlet temperature °C EW.2 Medium outlet temperature °C EW.3 T EW.4 Inlet water pressure bar EW.5 Outlet water pressure bar EW.6 p bar EW.7 GLHM available EW.8 Type of hydraulic module EW.9 Buffer tank available / size K yes no by others Serial Nr. litre Single circuit tank Dual circuit tank EW.10 Strainer available yes no Cleaned yes EW.11 Flow switch available yes no Function ok EW.12 Pressure gauge available yes no EW.13 Shut off valves available yes no EW.14 Expansion tank available yes no EW.15 Safety valve available yes no EW.16 Current consumption of pumps L1 L2 Pressure no not ok bar L3 EW.17 Water pump 1 A EW.18 Water pump 2 A EW.19 Water pump type 1 Serial Nr. EW.20 Water pump type 2 Serial Nr. Notes R1 mm R2 mm R3 mm R4 mm PR-2013-0112-GB • Subject to modifications • R1-01/2016 125 CA. Condenser in cooling mode Serial Nr. unit: Type: Date: Serial number: Measured unit Measured values Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit CA.1 Cleaning of fins necessary Yes / No CA.2 Cleaning of fins done Yes / No CA.3 Air heat exchanger inlet °C CA.4 Air heat exchanger outlet °C CA.5 T CA.6 Condensing temp. °C CA.7 Refrigerant outlet temperature °C CA.8 Difference CA.7 to CA.3 CA.9 Current consumption of motors CA.10 Fan motor 1 A CA.11 Fan motor 2 A CA.12 Fan motor 3 A CA.13 Fan motor 4 A CA.14 Fan motor 5 A CA.15 Fan motor 6 A CA.16 Fan motor 7 A CA.17 Fan motor 8 A CA.18 Fan motor 9 A CA.19 Fan motor 10 A CA.20 Fan motor 11 A CA.21 Fan motor 12 A K K L1 L2 L3 Speed control CA.22 Start speed min. bar Speed % CA.23 Start speed max. bar Speed % Speed regulation CA.24 Start fan speed 1 bar Difference bar CA.25 Start fan speed 2 bar Difference bar CA.26 Start fan speed 3 bar Difference bar CA.27 Start fan speed 4 bar Difference bar Notes 126 PR-2013-0112-GB • Subject to modifications • R1-01/2016 R. Ref. circuit heating Measured unit Refrigeration circuit Measured values 1 2 3 4 Unit Values at load % R.28 Condensing pressure R.29 Condensing temp. °C R.30 Liquid temp. °C R.31 Subcooling K R.32 Discharge temperature R.33 Suction pressure R.34 Evaporation temp. °C R.35 Suction gas temp. °C R.36 Superheating CW. bar °C bar K Condenser in heating operation Measured unit Measured values Values at full load (100%) Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit CW.1 Medium inlet temperature °C CW.2 Medium outlet temperature °C CW.3 T CW.4 Inlet water pressure bar CW.5 Outlet water pressure bar CW.6 p bar CW.7 Current consumption of pumps CW.8 Chilled water pump 1 A CW.9 Chilled water pump 2 A EA. Evaporator in cooling mode K L1 Type L2 L3 Serial number Measured unit Measured values Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit EA.1 Air heat exchanger inlet °C EA.2 Air heat exchanger outlet °C EA.3 T EA.4 Refrigerant inlet temperature °C EA.5 Refrigerant outlet temperature °C EA.6 Difference 4.7 to 4.3 PR-2013-0112-GB • Subject to modifications • R1-01/2016 K K 127 C. Controller and Settings Date Serial Nr. unit: Used controller Software version Set parameters Note C.1 External ON/OFF used yes no C.2 Common fault signal used yes no C.3 Locked gen. fault remote ON/OFF yes no C.4 Pump lead time sec. by controller By others C.5 Pump overrun time sec By others C.6 Type of temperature regulation Proportional regulation Quick Mind C.7 Temperature regulation by Inlet Outlet by controller C.8.1 Setpoint cooling °C Proportional band °C C.8.2 Setpoint heating °C Proportional band °C C.9.1 2nd setpoint cooling yes no °C C.9.2 2nd setpoint heating yes no °C C.10 Setpoint shift 4-20 mA yes no C.11 Load shedding switch yes no C.12 Connection to BMS yes no C.13 Set frost protection switch °C Dif. °C C.14 Start value evaporator heating °C Dif. °C C.15 Operating hours compressor 1 h Maintenance interval x h C.16 Operating hours compressor 2 h Maintenance interval x h C.17 Operating hours compressor 3 h Maintenance interval x h C.18 Operating hours compressor 4 h Maintenance interval x h C.19 Operating hours compressor 5 h Maintenance interval x h C.20 Operating hours compressor 6 h Maintenance interval x h C.21 Operating hours compressor 7 h Maintenance interval x h C.22 Operating hours compressor 8 h Maintenance interval x h C.23 Operating hours chill water pump 1 h Maintenance interval x h C.24 Operating hours chill water pump 2 h Maintenance interval x h C.25 Minimum idle time of compressor sec. C.26 Minimum time 2 compressor starts sec. C.27 Comp. minimum operating time sec. C.28 Max. compressor starts per hour /h Min. / Max. / °C % Report Notes 128 PR-2013-0112-GB • Subject to modifications • R1-01/2016 G Check / visual inspection Serial Nr. unit: o. k. G.1 Compressor G.1.1 Check for debris, damage and corrosion G.1.2 Check if secured and for operating noise G.1.3 Check for air-tightness G.2 Condenser G.2.1 Check for debris, damage and corrosion G.2.2 Check for air-tightness G.3 Evaporator G.3.1 Check for debris, damage and corrosion G.3.2 Check for air-tightness G.3 Fans Check for secured position, debris, damage and corrosion. G.3.1 G.3.2 Check for unbalanced impeller G.3.3 Check bearings for noise G.3.4 Check function of anti-vibration mounts G.4 Electric motors G.4.1 Check for dirt and damage Check for corrosion and secured position G.4.2 Check direction of rotation G.4.3 Check bearings for noise G.4.4 Check protective devices for proper function G.5 System components G.5.1 Visual check of insulation for damage G.5.2 Check for damage G.5.3 G.5.4 G.6 G.6.1 G.6.2. Not O.K. Date Comment / action required Refrigerant conducting unit components to be checks for leaks, visual inspection Visual check of compensators for damage Electrical devices Check optical and acoustical regulation for proper function Check connecting terminals for tightness, tighten, if necessary Notes Date Name PR-2013-0112-GB • Subject to modifications • R1-01/2016 Signature 129 Appendix III Measuring Report Chiller: GLRC Service engineer Cost Date DH Order Nr. Service-Nr. DH Order No (bottom of unit type plate) Plant operator Contact person Tel. Address Fax. Postal code / City E-Mail Plant manufacturer Contact person Tel. Address Fax. Postal code / City E-Mail Function check Maintenance Chiller Type GLPE Pump Module: yes Man. year no Serial Nr. Refrigerant G. Repairs R 407C R 134a R 410A Measured values Unit electrical features L1 - L2 G.1 R L2 - L3 L1 - L3 Mains voltage Unit V L1 - N L2 - N L3 - N V G.2 Mains voltage V G.3 Control voltage V Check G.4 Phase sequence relay O.K. Not O.K. G.5 Contactor O.K. Not O.K. G.6 Control contactor O.K. Not O.K. G.7 Relay O.K. Not O.K. G.8 Thermostats O.K. Not O.K. G.9 Sensors O.K. Not O.K. G.10 Pressure sensor O.K. Not O.K. G.11 Solenoid valves O.K. Not O.K. G.12 Capacity regulation O.K. Not O.K. G.13 Flow switch O.K. Not O.K. G.14 Freeze protection O.K. Not O.K. Value °C Notes  Vers.1.1 11/2015 by DH PRM CHI 130 PR-2013-0112-GB • Subject to modifications • R1-01/2016 R. Refrigeration Circuit Date Serial Nr. Measured unit Measured values Refrigeration circuit Compressor Values at load 1 2 1 2 3 4 100 100 100 100 Unit % R.1 Condensing pressure bar R.2 Condensing temperature °C R.3 Fluid temperature °C R.4 Subcooling (Bubble Point) R.5 Discharge temperature R.6 Suction pressure R.7 Evaporation temperature °C R.8 Suction gas temperature °C R.9 Overheating (dew point) K R.10 Blow off pressure safety valve bar R.11 Tested HP switch point bar R.12 Tested LP switch point bar R.13 Oil level R.14 Crankcase heating K °C bar ok / nok A Compressor at 100 % Current consumption R.15 L1 A R.16 L2 A R.17 L3 A R.18 Oleic acid test Ok / Nok R.19 Sight glass Ok / Nok R.20 Indicator Ok / Nok R.21 Filter drier Ok / Nok R.22 Leakage test Ok / Nok R.23 Compressor type 1 Serial Nr. R.24 Compressor type 2 Serial Nr. R.25 Compressor type 3 Serial Nr. R.26 Compressor type 4 Serial Nr. Notes  PR-2013-0112-GB • Subject to modifications • R1-01/2016 131 EW. Evaporator Serial Nr. Type Date Serial number of evaporator Medium Glycol %/ °C Glycol type Measured unit Water Measured values Values at full load (100%) Circuit 1 Circuit 2 Unit EW.1 Medium inlet temperature °C EW.2 Medium outlet temperature °C EW.3 T EW.4 Inlet water pressure bar EW.5 Outlet water pressure bar EW.6 p bar EW.7 GLPE available EW.8 Type GLPE pump module EW.9 Buffer tank available / size K yes no by others Serial Nr. Litre Single circuit tank Dual circuit tank EW.10 Strainer available yes no Cleaned yes EW.11 Flow switch available yes no Function ok EW.12 Pressure gauge available yes no EW.13 Shut off valves available yes no EW.14 Expansion tank available yes no EW.15 Safety valve available yes no EW.16 Current consumption of pumps L1 Pressure L2 no not ok bar L3 EW.17 Chilled water pump 1 A EW.18 Chilled water pump 2 A EW.19 Chilled water pump type 1 Serial Nr. EW.20 Chilled water pump type 2 Serial Nr. Notes 132 R1 mm R2 mm R3 mm R4 mm PR-2013-0112-GB • Subject to modifications • R1-01/2016 !!! BY OTHERS !!! CA. Air Cooled Condenser Serial Nr. Type Date Serial number Measured unit Measured values Refrigeration circuit 1 Refrigeration circuit 2 Unit CA.1 Cleaning of fins necessary Yes / No CA.2 Cleaning of fins done Yes / No CA.3 Air heat exchanger inlet °C CA.4 Air heat exchanger outlet °C CA.5 T CA.6 Condensing temperature °C CA.7 Refrigerant outlet temperature °C CA.8 Difference CA.7 to CA.3 CA.9 Current consumption of motors CA.10 Fan motor 1 A CA.11 Fan motor 2 A CA.12 Fan motor 3 A CA.13 Fan motor 4 A CA.14 Fan motor 5 A CA.15 Fan motor 6 A CA.16 Fan motor 7 A CA.17 Fan motor 8 A CA.18 Fan motor 9 A CA.19 Fan motor 10 A CA.20 Fan motor 11 A CA.21 Fan motor 12 A K K L1 L2 L3 Speed control CA.22 Start speed min. bar Speed % CA.23 Start speed max. bar Speed % Speed regulation CA.24 Start fan speed 1 bar Difference bar CA.25 Start fan speed 2 bar Difference bar CA.26 Start fan speed 3 bar Difference bar CA.27 Start fan speed 4 bar Difference bar Notes PR-2013-0112-GB • Subject to modifications • R1-01/2016 133 C. Controller and Settings Date Serial Nr. Used controller Software version Set parameters Note C.1 External ON/OFF used yes no C.2 Common fault signal used yes no C.3 Fault signal lock remote ON/OFF yes no C.4 Pump lead time sec. by controller By others C.5 Pump overrun time sec by controller By others C.6 Type of temperature regulation Proportional regulation Quick Mind C.7 Temperature regulation by Inlet Outlet C.8 Setpoint value, design value C.9 2nd setpoint yes no C.10 Setpoint shift 4-20 mA yes no C.11 Load shedding switch yes no C.12 Connection to BMS yes no C.13 Set frost protection switch C.15 Operating hours compressor 1 h C.16 Operating hours compressor 2 C.17 °C Proportional band °C °C / °C Maintenance interval x h h Maintenance interval x h Operating hours compressor 3 h Maintenance interval x h C.18 Operating hours compressor 4 h Maintenance interval x h C.19 Operat. hours chilled water pump 1 h Maintenance interval x h C.20 Operat. hours chilled water pump 2 h Maintenance interval x h C.21 Minimum idle time of compressor sec. (if readable) C.22 Min. time between 2 comp. starts sec. (if readable) C.23 Comp. min. operating time sec. (if readable) C.24 Max. compressor starts per hour /h (if readable) °C Min. / Max. Dif. % Report °C Notes 134 PR-2013-0112-GB • Subject to modifications • R1-01/2016 G Check / visual inspection o. k. G.1 Compressor G.1.1 Check for debris, damage and corrosion G.1.2 Check if secured and for operating noise G.1.3 Check for air-tightness G.2 Condenser G.2.1 Check for debris, damage and corrosion G.2.2 Check for air-tightness G.3 Evaporator G.3.1 Check for debris, damage and corrosion G.3.2 Check for air-tightness G.3 Fans Check for secured position, debris, damage and corrosion. G.3.1 G.3.2 Check for unbalanced impeller G.3.3 Check bearings for noise G.3.4 Check function of anti-vibration mounts G.4 Electric motors G.4.1 Check for dirt and damage Check for corrosion and secured position G.4.2 Check direction of rotation G.4.3 Check bearings for noise G.4.4 Check protective devices for proper function G.5 System components G.5.1 Visual check of insulation for damage G.5.2 Check for damage G.5.3 G.5.4 G.6 G.6.1 G.6.2. Date Serial Nr. Not O.K. Comment / action required Refrigerant conducting unit components to be checks for leaks, visual inspection Visual check of compensators for damage Electrical devices Check optical and acoustical regulation for proper function Check connecting terminals for tightness, tighten, if necessary Notes Date Name PR-2013-0112-GB • Subject to modifications • R1-01/2016 Signature 135 Appendix III Measuring Report GLWC Chiller Service engineer Cost Date DH Order Nr. Service-Nr. DH Order No (bottom of unit type plate) Plant operator Contact person Tel. Address Fax. Postal code / City E-Mail Plant manufacturer Contact person Tel. Address Fax. Postal code / City E-Mail Function check Maintenance Unit Type Hydraulic module yes Year of noSerial Nr. Refrigerant G. Repairs R 407C R 134a R 410A Measured values Unit electrical features L1 - L2 G.1 R L2 - L3 L1 - L3 Mains supply voltage Unit V L1 - N L2 - N L3 - N V G.2 Mains supply voltage V G.3 Control voltage V Checking G.4 Phase sequence relay O.K. Not O.K. G.5 Contactor O.K. Not O.K. G.6 Control contactor O.K. Not O.K. G.7 Relay O.K. Not O.K. G.8 Thermostats O.K. Not O.K. G.9 Sensors O.K. Not O.K. G.10 Pressure sensor O.K. Not O.K. G.11 Solenoid valves O.K. Not O.K. G.12 Capacity regulation O.K. Not O.K. G.13 Flow switch O.K. Not O.K. G.14 Frost protection O.K. Not O.K. Value °C Notes Vers.1.1 11/2015 by DH PRM CHI 136 PR-2013-0112-GB • Subject to modifications • R1-01/2016 R. Refrigeration circuit Date: Serial Nr. unit: Measured unit Measured values 1 Refrigeration circuit 2 3 4 Unit Values at load % R.1 Condensing pressure R.2 Condensing temp. °C R.3 Liquid temp. °C R.4 Subcooling K R.5 Discharge temperature R.6 Suction pressure R.7 Evaporation temp. °C R.8 Suction gas temp. °C R.9 Superheating R.10 Safety valve bar R.11 Tested HP switch point bar R.12 Tested LP switch point bar R.13 Oil level R.14 Oil acid test Ok? R.15 Sight glass Ok? R.16 Indicator Ok? R.17 Filter drier Ok? R.18 Leakage test Ok? Compressor bar °C bar K 1 2 Compressor at 100 % 3 4 5 6 7 8 Current consumption R.19 L1 A R.19 L2 A R.19 L3 A R.22 Crankcase heating A R.23 MV – comp. cooling A R.24 Compressor type 1 Serial Nr. R.25 Compressor type 2 Serial Nr. R.26 Compressor type 3 Serial Nr. R.27 Compressor type 4 Serial Nr. Notes PR-2013-0112-GB • Subject to modifications • R1-01/2016 137 EW. Eva aporator in cooling c mod de Serial Nr. unit: Type: Daate: Serial number of evaporator: e Medium G Glycol %/ °C C Glyco ol type: Measu ured unit Values at full loa ad (100%) Water W Measu ured values Circcuit 1 Cirrcuit 2 Circuit 3 C Circuit 4 Unit EW.1 Med dium inlet temperature °C EW.2 Med dium outlet temperature °C EW.3 T EW.4 Inle et water pressure bar EW.5 Outtlet water pre essure bar EW.6 p bar EW.7 GLP PE available e EW.8 Pum mp module tyype EW.9 Bufffer tank avaiilable / size K yes no by others Serrial Nr. Liter Single S circuit tank k Dual circuit tank EW.10 Stra ainer availab ble yes no Cle eaned yess EW.11 Flow w switch ava ailable yes no Fun nction okk EW.12 Pre essure gauge e available yes no EW.13 Shu ut off valves available yes no EW.14 Exp pansion tankk available yes no EW.15 Saffety valve ava ailable yes no EW.16 Currrent consum mption of pum mps L1 L2 Pre essure no o no ot ok bar L3 EW.17 Wa ater pump 1 A EW.18 Wa ater pump 2 A EW.19 Typ pe of water pump p 1 Serrial Nr. EW.20 Typ pe of water pump p 2 Serrial Nr. Notes 138 R1 mm R2 mm R3 mm R4 mm PR-2013-0112-GB • Subject to modifications • R1-01/2016 CW. Condenser in cooling mode Serial Nr. unit: Type: Date: Serial number: Measured unit Measured values Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit CW.1 Medium inlet temperature °C CW.2 Medium outlet temperature °C CW.3 T: CW.4 Inlet water pressure bar CW.5 Outlet water pressure bar CW.6 p bar CW.7 Difference R.3 to CW.2 CW.8 GLPC available CW.9 Type of hydraulic module: K K yes no by others Serial Nr.: CW.10 Strainer available yes no Cleaned: yes CW.11 Flow switch available yes no Function: O.K. CW.12 Pressure gauge available yes no CW.13 Shut off valves available yes no CW.14 Expansion tank available yes no CW.15 Safety valve available yes no CW.16 Current consumption of pumps L1 L2 Press. no Not O.K. bar L3 CW.17 Cool water pump 1 A CW.18 Cool water pump 2 A CW.19 Type of cool water pump 1 Serial Nr. CW.20 Type of cool water pump 2 Serial Nr. CW.21 3-way valve available yes no DencoHappel by others CW.22 Regulation of 3-way valve yes no DencoHappel by others CW.23 Fan control of dry-cooler yes CW.24 Inverter-regulated pump yes no no Notes PR-2013-0112-GB • Subject to modifications • R1-01/2016 139 C. Controller and Settings Date Serial Nr. unit: Used controller Software version Set parameters Comment C.1 External ON/OFF used yes no C.2 Common fault signal used yes no C.3 Does common fault signal lock remote ON/OFF yes no C.4 Pump lead time sec. by controller By others C.5 Pump overrun time sec By others C.6 Type of temperature regulation Proportional control Quick Mind C.7 Temperature regulation by Inlet Outlet by controller C.8.1 Setpoint cooling °C Proportional band °C C.8.2 Setpoint heating °C Proportional band °C C.9.1 2. Sollwert Kühlen yes no °C C.9.2 2. Sollwert Heizen yes no °C C.10 Setpoint shift 4-20 mA yes no C.11 Load shedding switch yes no C.12 Connection to BMS yes no C.13 Set frost protection switch °C Dif. °C C.14 Start value evaporator heating °C Dif. °C C.15 Operating hours compressor 1 h Maintenance interval x h C.16 Operating hours compressor 2 h Maintenance interval x h C.17 Operating hours compressor 3 h Maintenance interval x h C.18 Operating hours compressor 4 h Maintenance interval x h C.19 Operating hours compressor 5 h Maintenance interval x h C.20 Operating hours compressor 6 h Maintenance interval x h C.21 Operating hours compressor 7 h Maintenance interval x h C.22 Operating hours compressor 8 h Maintenance interval x h C.23 Operating hours Water pump 1 h Maintenance interval x h C.24 Operating hours Water pump 2 h Maintenance interval x h C.25 Minimum idle time of compressor sec. C.26 Minimum time 2 compressor starts sec. C.27 Comp. minimum operating time sec. C.28 Max. compressor starts per hour /h Min. / Max. / °C % Report Notes 140 PR-2013-0112-GB • Subject to modifications • R1-01/2016 G Check / visual inspection Serial Nr. unit: o. k. G.1 Compressor G.1.1 Check for debris, damage and corrosion G.1.2 Check if secured and for operating noise G.1.3 Check for air-tightness G.2 Condenser G.2.1 Check for debris, damage and corrosion G.2.2 Check for air-tightness G.3 Evaporator G.3.1 Check for debris, damage and corrosion G.3.2 Check for air-tightness G.3 Fans Check for secured position, debris, damage and corrosion. G.3.1 G.3.2 Check for unbalanced impeller G.3.3 Check bearings for noise G.3.4 Check function of anti-vibration mounts G.4 Electric motors Check for dirt and damage Check for corrosion and secured position G.4.1 G.4.2 Check direction of rotation G.4.3 Check bearings for noise Check protective devices for proper function G.4.4 G.5 System components G.5.1 Visual check of insulation for damage G.5.2 Check for damage G.5.3 G.5.4 G.6 G.6.1 G.6.2. Not O.K. Date Comment / action required Refrigerant conducting unit components to be checks for leaks, visual inspection Visual check of compensators for damage Electrical devices Check optical and acoustical regulation for proper function Check connecting terminals for tightness, tighten, if necessary Notes Date Name PR-2013-0112-GB • Subject to modifications • R1-01/2016 Signature 141 Appendix III Measuring Report GLWH Chiller / Heat Pump Service engineer Cost Date DH Order Nr. Service-Nr. DH Order No (bottom of unit type plate) Plant operator Contact person Tel. Address Fax. Postal code / City E-Mail Plant manufacturer Contact person Tel. Address Fax. Postal code / City E-Mail Function check Maintenance Unit Type Hydraulic module yes Year of noSerial Nr. Refrigerant G. Repairs R 407C R 134a R 410A Measured values Unit electrical features L1 - L2 G.1 R L2 - L3 L1 - L3 Mains supply voltage Unit V L1 - N L2 - N L3 - N V G.2 Mains supply voltage V G.3 Control voltage V Checking G.4 Phase sequence relay O.K. Not O.K. G.5 Contactor O.K. Not O.K. G.6 Control contactor O.K. Not O.K. G.7 Relay O.K. Not O.K. G.8 Thermostats O.K. Not O.K. G.9 Sensors O.K. Not O.K. G.10 Pressure sensor O.K. Not O.K. G.11 Solenoid valves O.K. Not O.K. G.12 Capacity regulation O.K. Not O.K. G.13 Flow switch O.K. Not O.K. G.14 Frost protection O.K. Not O.K. G.14 4-way valve O.K. Not O.K. Value °C Notes Vers 1.1 11/2015 by DH PRM CHI 142 PR-2013-0112-GB • Subject to modifications • R1-01/2016 R. Refrigeration circuit Date: Serial Nr. unit: Measured unit Measured values 1 Refrigeration circuit 2 3 4 Unit Values at load % R.1 Condensing pressure R.2 Condensing temp. °C R.3 Liquid temp. °C R.4 Subcooling K R.5 Discharge temperature R.6 Suction pressure R.7 Evaporation temp. °C R.8 Suction gas temp. °C R.9 Superheating R.10 Safety valve bar R.11 Tested HP switch point bar R.12 Tested LP switch point bar R.13 Oil level R.14 Oil acid test Ok? R.15 Sight glass Ok? R.16 Indicator Ok? R.17 Filter drier Ok? R.18 Leakage test Ok? Compressor bar °C bar K 1 2 Compressor at 100 % 3 4 5 6 7 8 Current consumption R.19 L1 A R.19 L2 A R.19 L3 A R.22 Crankcase heating A R.23 MV – comp. cooling A R.24 Compressor type 1 Serial Nr. R.25 Compressor type 2 Serial Nr. R.26 Compressor type 3 Serial Nr. R.27 Compressor type 4 Serial Nr. Notes PR-2013-0112-GB • Subject to modifications • R1-01/2016 143 EW. Eva aporator in cooling c mod de Serial Nr. unit: Type: Daate: Serial number of evaporator: e Medium G Glycol %/ °C C Glyco ol type: Measu ured unit Values at full loa ad (100%) Water W Measu ured values Circcuit 1 Cirrcuit 2 Circuit 3 C Circuit 4 Unit EW.1 Med dium inlet temperature °C EW.2 Med dium outlet temperature °C EW.3 T EW.4 Inle et water pressure bar EW.5 Outtlet water pre essure bar EW.6 p bar EW.7 GLP PE available e EW.8 Pum mp module tyype EW.9 Bufffer tank avaiilable / size K yes no by others Serrial Nr. Liter Single S circ. ta ank Dual circuit tank EW.10 Stra ainer availab ble yes no Cle eaned yess EW.11 Flow w switch ava ailable yes no Fun nction okk EW.12 Pre essure gauge e available yes no EW.13 Shu ut off valves available yes no EW.14 Exp pansion tankk available yes no EW.15 Saffety valve ava ailable yes no EW.16 Currrent consum mption of pum mps L1 L2 Pre essure no o no ot ok bar L3 EW.17 Wa ater pump 1 A EW.18 Wa ater pump 2 A EW.19 Typ pe of water pump p 1 Serrial Nr. EW.20 Typ pe of water pump p 2 Serrial Nr. Notes 144 R1 mm R2 mm R3 mm R4 mm PR-2013-0112-GB • Subject to modifications • R1-01/2016 CW. Condenser in cooling mode Serial Nr. unit: Type: Date: Serial number: Measured unit Measured values Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit CW.1 Medium inlet temperature °C CW.2 Medium outlet temperature °C CW.3 T: CW.4 Inlet water pressure bar CW.5 Outlet water pressure bar CW.6 p bar CW.7 Difference R.3 to CW.2 CW.8 GLPC available CW.9 Type of hydraulic module: K K yes no by others Serial Nr.: CW.10 Strainer available yes no Cleaned: yes CW.11 Flow switch available yes no Function: O.K. CW.12 Pressure gauge available yes no CW.13 Shut off valves available yes no CW.14 Expansion tank available yes no CW.15 Safety valve available yes no CW.16 Current consumption of pumps L1 L2 Press. no Not O.K. bar L3 CW.17 Cool water pump 1 A CW.18 Cool water pump 2 A CW.19 Type of cool water pump 1 Serial Nr. CW.20 Type of cool water pump 2 Serial Nr. CW.21 3-way valve available yes no DencoHappel by others CW.22 Regulation of 3-way valve yes no DencoHappel by others CW.23 Fan control of dry-cooler yes no CW.24 Inverter-regulated pump yes no Notes PR-2013-0112-GB • Subject to modifications • R1-01/2016 145 R. Circuit in heating mode Serial Nr.: Date: Measured unit Refrigeration circuit Measured values 1 2 3 4 Values under load Unit % R.28 Condensation pressure: bar R.29 Condensing temperature: °C R.30 Fluid temperature: °C R.31 Subcooling (Bubble Point): R.32 Discharge temperature R.33 Suction pressure: R.34 Evaporating temperature: °C R.35 Suction gas temperature: °C R.36 Overheating (dew point): K CW. Condenser in heating mode K °C bar Measured unit Values at full load (100%) Measured values Circuit 1: Circuit 2: Circuit 3: Circuit 4: Unit CW.25 Medium inlet temperature °C CW.26 Medium outlet temperature °C CW.27 T: K CW.28 Inlet water pressure bar CW.29 Outlet water pressure bar CW.30  p bar EW. Evaporator in heating mode Measured unit Values at full load (100%) Measured values Circuit 1: Circuit 2: Circuit 3: Circuit 4: Unit EW.21 Medium inlet temperature °C EW.22 Medium outlet temperature °C EW.23 T: K EW.24 Inlet water pressure bar EW.25 Outlet water pressure bar EW.26  p bar Notes: 146 PR-2013-0112-GB • Subject to modifications • R1-01/2016 C. Controller and Settings Date Serial Nr. unit: Used controller Software version Set parameters Comment C.1 External ON/OFF used yes no C.2 Common fault signal used yes no C.3 Does common fault signal lock remote ON/OFF yes no C.4 Pump lead time sec. by controller By others C.5 Pump overrun time sec By others C.6 Type of temperature regulation Proportional control Quick Mind C.7 Temperature regulation by Inlet Outlet by controller C.8.1 Setpoint cooling °C Proportional band °C C.8.2 Setpoint heating °C Proportional band °C C.9.1 2. Sollwert Kühlen yes no °C C.9.2 2. Sollwert Heizen yes no °C C.10 Setpoint shift 4-20 mA yes no C.11 Load shedding switch yes no C.12 Connection to BMS yes no C.13 Set frost protection switch °C Dif. °C C.14 Start value evaporator heating °C Dif. °C C.15 Operating hours compressor 1 h Maintenance interval x h C.16 Operating hours compressor 2 h Maintenance interval x h C.17 Operating hours compressor 3 h Maintenance interval x h C.18 Operating hours compressor 4 h Maintenance interval x h C.19 Operating hours compressor 5 h Maintenance interval x h C.20 Operating hours compressor 6 h Maintenance interval x h C.21 Operating hours compressor 7 h Maintenance interval x h C.22 Operating hours compressor 8 h Maintenance interval x h C.23 Operating hours water pump 1 h Maintenance interval x h C.24 Operating hours water pump 2 h Maintenance interval x h C.25 Minimum idle time of compressor sec. C.26 Minimum time 2 compressor starts sec. C.27 Comp. minimum operating time sec. C.28 Max. compressor starts per hour /h Min. / Max. / °C % Report Notes PR-2013-0112-GB • Subject to modifications • R1-01/2016 147 G Check / visual inspection o. k. G.1 Compressor G.1.1 Check for debris, damage and corrosion G.1.2 Check if secured and for operating noise G.1.3 Check for air-tightness G.2 Condenser G.2.1 Check for debris, damage and corrosion G.2.2 Check for air-tightness G.3 Evaporator G.3.1 Check for debris, damage and corrosion G.3.2 Check for air-tightness G.3 Fans Check for secured position, debris, damage and corrosion. G.3.1 G.3.2 Check for unbalanced impeller G.3.3 Check bearings for noise G.3.4 Check function of anti-vibration mounts G.4 Electric motors Check for dirt and damage Check for corrosion and secured position G.4.1 G.4.2 Check direction of rotation G.4.3 Check bearings for noise Check protective devices for proper function G.4.4 G.5 System components G.5.1 Visual check of insulation for damage G.5.2 Check for damage G.5.3 G.5.4 G.6 G.6.1 G.6.2. Date Serial Nr. unit: Not O.K. Comment / action required Refrigerant conducting unit components to be checks for leaks, visual inspection Visual check of compensators for damage Electrical devices Check optical and acoustical regulation for proper function Check connecting terminals for tightness, tighten, if necessary Notes Date 148 Name Signature PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Appendix 15.4 Generally accepted translation of diagrams, plans and drawings in order-related documentation 15.4.1 Terminology used in dimensional drawings English German Air inlet Luft Eintritt Air outlet Luft Austritt Anti vibration mounts Gummischwingungsdämpfer ATTN: Use N° X Lifting ropes with equal length only Achtung: Verwenden Sie X Trageseile mit gleicher Länge Centre of Gravity Gewichtsschwerpunkt Compressor Verdichter Condenser connections Anschluss Verflüssiger Condenser water inlet Verflüssiger Eintritt Condenser water outlet Verflüssiger Austritt Condensing side Verflüssigerseite Connection Verbindung Desuperheater connection(s) Anschluss Enthitzer Desuperheater water inlet Enthitzer Wassereintritt Desuperheater water outlet Enthitzer Wasseraustritt Discharge line connection Anschluss Heißgasleitung Electrical board side Schaltschrankseite Evaporator Verdampfer Evaporator (water) inlet Verdampfer (Wasser) Eintritt Evaporator (water) outlet Verdampfer (Wasser) Austritt Evaporator side Verdampferseite Flanged connection Flansch Anschluss Groovelock connection Victaulic Anschluss H.P. relief valve Sicherheitsventil Hochdruckseite High pressure head Verstärkte Förderhöhe der Pumpe L.P. relief valve Sicherheitsventil Niederdruckseite Lifting Hebepunkte/Transport Lifting holes Hebepunkte Liquid line connection Anschluss Flüssigkeitsleitung Low pressure head Standard Förderhöhe der Pumpe Main isolator (handle) Hauptschalter minimum clearance minimale Freifläche N° X Holes X Bohrungen insgesamt Only for nur für Only for shipping nur für den Transport Optional Option/Zubehör Optional evaporator (water) inlet optionaler Verdampfer (Wasser) Eintritt Optional evaporator (water) outlet optionaler Verdampfer (Wasser) Austritt Optional external water connection außenliegende Wasseranschlüsse (optional) Optional flanged connections Flansch Anschluss (optional) Optional groovelock connection Victaulic Anschluss (optional) Pallet Palette Power Inlet Spannungsversorgung Eingang Power Inlet (Hole pre-cut) Spannungsversorgung Eingang (Loch vorgestanzt) Removable abnehmbar Removable lifting brackets abnehmbare Hebehalterungen Shipping weight Transportgewicht Size/Version Größe/Version Suction line connection Anschluss Sauggasleitung Supplied loose only for evap. lose geliefert - nur für Verdampfer Supporting Basement Grundrahmen/Aufstellungsfläche PR-2013-0112-GB • Subject to modifications • R1-01/2016 149 Chillers & Heat Pumps GL Series Appendix English German Total gesamt Type Typ User water inlet Wasser für Verbraucher-/Gebäudeseite Eintritt User water outlet Wasser für Verbraucher-/Gebäudeseite Austritt Version Ausführung View table beachte Tabelle Weight distribution Gewichtsverteilung Weight for unit with Copper/Copper coils Gewichte für Geräte mit Cu/Cu Verflüssiger Well/Tower water inlet Brunnenwasser/Rückkühlerwasser Eintritt Well/Tower water outlet Brunnenwasser/Rückkühlerwasser Austritt with mit without ohne Working weight for unit with copper/copper finned coils Betriebsgewicht für Geräte mit Cu/Cu Verflüssigern 15.4.2 Terminology in legends and wiring diagrams Acronym English German A Actuators Motor für elektronisches Expansionsventil R Antifreeze heater Frostschutzheizung QF Automatic circuit breaker(s) Sicherungsautomat(en) TM Autotransformer Transformator QM Autotransformer automatic circuit breaker Sicherungsautomat für Transformator QF Auxiliary (automatic) circuit breakers Steuersicherung QF Auxiliary/Sequence phase automatic circuit breakers Schutzschalter für Phasenfolgerelais KA Auxiliary relay(s) Hilfsrelais TC Auxiliary transformer Transformator für Steuerspannung KM Coil electric contactor Lastschütz Heizung Wärmetauscher QM Coil electrical (automatic) circuit breakers Sicherungsautomat für Heizung Wärmetauscher R Coil electrical heater Elektrische Heizung Wärmetauscher A Compr. control module Regler für Verdichter M Compressor Verdichter QM Compressor (automatic) circuit breakers Motorschutzschalter Verdichter KM Compressor contactors Lastschütz Verdichter F Compressor controls oil level Öllevelschalter Verdichter R Compressor crankcase heater Ölheizung Verdichter S Compressor faulty/protection reset Reset-Taster für Verdichteralarm XX - XX Compressor operating contacts Betriebsmeldung Verdichter A Compressor thermal overload relay Motorvollschutz Verdichter C Condenser fans Betriebskondensator Lüftermotoren F Condenser pressure control Verflüssigerdruckregelung A Connector T-Verbinder KM Contactor compressor Lastschütz Verdichter KM Contactor pump Lastschütz Pumpe A Converter pwm/0-10 V 0 - 10 V PWM Konverter XX - XX Cumulative alarm block Sammelstörmeldung R -S Demand limit Leistungsbegrenzung R Desuperheater anti freeze heater Frostschutzheizung Enthitzer F Differential pressure switch wasserseitiger Differenzdruckschalter F Discharge compr. thermostat Heißgastemperaturfühler Y Economizer solenoid valves Magnetventil für Economiserbetrieb A Elaboration module Reglerplatine M Electric board fan Schaltschranklüfter R Electric board heater Heizung Schaltschrank KP Evap. pump contact Kontakt zur Pumpenfreigabe R Evaporator/desuperheater antifreeze heater Verdampfer/Enthitzer Frostschutzheizung 150 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Acronym English Appendix German R Evaporator anti freeze heater Frostschutzheizung Verdampfer BT Evaporator inlet temperature probe Temperaturfühler Verdampfer Eintritt BT Evaporator outlet temperature probe Temperaturfühler Verdampfer Austritt A Exp. module Erweiterungskarte A Expansion module Erweiterungskarte BT External Air probe Temperaturfühler Außenluft KM Fan (speed) contactors Lastschütze für Ventilatormotoren QM Fan speed regulation (automatic) circuit breakers Sicherungsautomaten für Lüfterregelung M Fan(s) Lüftermotor(en) QM Fan(s) (automatic) circuit breakers Motorschutzschalter Lüftermotor(en) C Fan(s) capacitor Betriebskondensator Lüftermotor(en) QM Fan(s) circuit breaker Motorschutzschalter Lüftermotor(en) A Fan(s) speed regulation Drehzahlregelung der Lüftermotor(en) A Filters Netzfilter F Flow switch Strömungswächter QS General isolating switch Hauptschalter KA High/low speed fans relay Relais für hohe/niedrige Drehzahlstufe der Lüfter F High pressure (control) Hochdruckschalter BP High pressure transducer Druckaufnehmer Hochdruck F High safety pressure (control) Hochdrucksicherheitsschalter QM High speed fans automatic circuit breakers Motorschutzschalter Lüftermotoren - hohe Drehzahl KM High speed fans contactor Lastschütz hohe Drehzahlstufe Lüfter XX - XX In pressure plant pressostat (on field) Druckschalter zur Überwachung des Anlagensystemdrucks (bauseits) Y Liquid injection solenoid valves Magnetventil zur Flüssigkeitseinspritzung Y Liquid line solenoid valve(s) Magnetventil(e) Flüssigkeitsleitung Y Liquid line valves Magnetventil(e) Flüssigkeitsleitung F Low pressure control Niederdruckschalter BP Low pressure transducer Druckaufnehmer Niederdruck KM Low speed fans contactor Lastschütz niedrige Drehzahlstufe Lüfter FU Main fuse (on site) Hauptsicherungen (bauseits) QS Main isolator Hauptschalter XX - XX Main power input Elektrische Zuleitung F Oil control level Öllevelschalter Verdichter C Phase advancing condenser compressor Kondensatoren zur Blindstromkompensation F Pressure condenser control Druckschalter zur Druckregelung Y Pressure oil solenoid valves Magnetventil für Öldruck (zur Leistungsregulierung) BP Pressure transducers Druckaufnehmer M/XX - XX Pump Kaltwasserpumpe/Pumpenkontakt QM Pump (automatic) circuit breakers Sicherungsautomat Pumpe KM Pump contactors Lastschütz Wasserpumpe A Remote Keyboard Fernbedienung E-F Remote on/off Externe Betriebsfreigabe G -H Remote summer/winter Umschaltung Heizen/Kühlen A Remote visual display Fernbedienung Y Reversing valves 4-Wege-Ventil A Sequence failure/phase relay Phasenfolgerelais QF Sequence phase relay circuit breaker Sicherungsautomat für Phasenfolgerelais GND - R+/T+ Serial card - R-/T- Serielle Karte XX - XX Set point variation 4-20 mA Sollwertverschiebung über 4-20mA Signal Y Solenoid capacity valves Magnetventile zur Leistungsregelung Y Solenoid valve Magnetventil A Switches Schalter/T-Verbinder XX - XX System pressurised Kontakt für bauseitige Störabschaltung BT Temperature probe Temperaturfühler FS Thermal fans low speed Überstromrelais Lüfter niedrige Drehzahlstufe PR-2013-0112-GB • Subject to modifications • R1-01/2016 151 Chillers & Heat Pumps GL Series Appendix Acronym English German A Thermostatic controller Treiber für elektronisches Expansionsventil Y Thermostatic equalisation valves Magnetventile für äußeren Druckausgleich am Expansionsventil C Three phase capacitors Kondensatoren zur Blindstromkompensation QM Three phase capacitors automatic circuit breakers Sicherungsautomaten Kondensatoren KM Three phase capacitors contactors Lastschütz zur Blindstromkompensation KT Time delay relay Zeitrelais BP Transducer Druckaufnehmer Y Unloading start valves Magnetventile für Verdichteranlauf A Visual display (unit) Bediendisplay (am Gerät) Y water (modulating) valve 3-Wege-Ventil, Wasserkreislauf R Water tank heater Heizstab Pufferspeicher KM Water tank heater contactor Lastschütz Heizstab Pufferspeicher 15.4.3 Terminology in wiring diagrams English German Black Schwarz Blue Blau Brown Braun Circuit Kreislauf Coil electrical heater Elektrische Heizung Wärmetauscher Compr. Verdichter Condenser circuit Kreislauf Verflüssiger Connection Delta Anschluss Dreieckschaltung Connection Star Anschluss Sternschaltung Description Beschreibung Discharge temp. compr. Heißgastemperaturfühler Verdichter EV driver Treiber für elektronisches Expansionsventil Evap. inlet probe Temperaturfühler Verdampfer Eintritt Evap. outlet probe Temperaturfühler Verdampfer Austritt Evaporator circuit Kreislauf Verdampfer Fault vent. circuit Fehler Lüfter Kreislauf Field card Interne Kommunikationskarte (Feldkarte) For Remote start unit Externer Betriebsfreigabekontakt General fault Allgemeine Störmeldung Green Grün H2O valve Wasserventil High pressure circuit Druckaufnehmer/Druckschalter Hochdruck Identifying symbol of device Eindeutige Bezeichnung des Bauteils Low pressure circuit Druckaufnehmer/Druckschalter Niederdruck Modulating valve two or three way Modulierendes 2 oder 3-Wege Ventil One pump Eine Pumpe Only for tank Nur für den Pufferspeicher Operating Compr. Betriebsmeldung Verdichter OPT. 1 Pump Option mit 1 Pumpe OPT. 2 Pumps Option mit 2 Pumpe Optional Zubehör Piping anti freeze heater Rohrbegleitheizung Remote set point Externe Sollwertverschiebung Reversing valve 4-Wege Ventil Secondary set (point) 2. Sollwert Sequence phase relay Phasenfolgerelais Standard Standard Standard without pump Standard ohne Pumpe Start rely pump Pumpenstartrelais 152 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Appendix English German Summer/Winter (remote) Umschaltung Heizen/Kühlen Thermal Compr. Motorvollschutz Verdichter Two pumps Zwei Pumpen Unit Gerät Ventilation circuit Lüfter Kreislauf White Weiß Yellow Gelb 15.4.4 Terminology in legends and refrigeration circuit diagrams Acronym English German A1 Suction line connection Anschluss Sauggasleitung B1 Discharge line connection Anschluss Heißgasleitung C1 Liquid line connection Anschluss Flüssigkeitsleitung BC Condenser/condensing coil Verflüssiger BCE Cond./Evap. coil (finned exchanger) Verflüssiger/Verdampfer (je nach Betriebsart) BCR Condenser/cooling coil (finned exchanger) Free Cooling Wärmetauscher C Compressor Verdichter CD Condenser Verflüssiger (wassergekühlt) CD/EV Condenser/Evaporator Verflüssiger/Verdampfer (je nach Betriebsart) DS Desuperheater Enthitzer EC Eco plate exchanger Plattenwärmetauscher Economizer EEV Electronic expansion valve Elektronisches Expansionsventil ES(X) Solenoid valve Magnetventil EV Evaporator Verdampfer EV/CD Evaporator/Condenser Verdampfer/Verflüssiger FE Filter dryer Filtertrockner LR Liquid receiver Kältemittelsammler MA High pressure gauge Hochdruckmanometer MB Low pressure gauge Niederdruckmanometer Pd Differential pressure switch wasserseitiger Differenzdruckschalter Pmax High pressure control Hochdruckschalter Pmin Low pressure control Niederdruckschalter PP Schrader pressure top Schrader-/Serviceventil RA(S) Suction valve Absperrventil Saugseite RL Liquid valve Absperrventil Flüssigkeitsleitung RM(S) Discharge valve Absperrventil Druckseite RM1 Discharge valve Hochdruckregulierventil S1 Evaporator inlet probe Temperaturfühler Verdampfereintritt S1/2 Evap./Cond. inlet/outlet probe Verdampfer/Verflüssiger Ein-/Austrittsfühler S2 Evaporator inlet probe Temperaturfühler Verdampferaustritt S3 Condenser inlet probe Temperaturfühler Verflüssigereintritt S4 Condenser outlet probe Temperaturfühler Verflüssigeraustritt SL Liquid separator Flüssigkeitsabscheider T Thermostat/Pressure transducer Thermostat/Druckaufnehmer Teev Electronic expansion valve transducer Druckaufnehmer für elektronisches Expansionsventil THP High pressure transducer Druckaufnehmer für Niederdruckseite TLP Low pressure transducer Druckaufnehmer für Hochdruckseite TS Liquid injection thermostat Thermostat zur Flüssigkeitseinspritzung V4V 4-way reversing valve 4-Wege Umkehrventil VA(1) High pressure (H.P.) relief valve Sicherheitsventil Hochdruckseite VB Low pressure (L.P.) relief valve Sicherheitsventil Niederdruckseite VE(H) Thermostatic valve Thermostatisches Expansionsventil VEE Economizer expansion valve Expansionsventil für Economiserbetrieb VL Axial fans Axialventilatoren PR-2013-0112-GB • Subject to modifications • R1-01/2016 153 Chillers & Heat Pumps GL Series Appendix Acronym English German VP Pilot valve Pilotventil VR Check valve/no return valve Rückschlagventil VS Sight glass Schauglas 15.4.5 Terminology in refrigeration circuit diagrams English German Chiller Betrieb Kaltwassererzeuger Discharge to refrigerant system Austritt Gerät zum externen Kältekreislauf H2O Wasser Heat pump Betrieb Wärmepumpe In Eintritt Legend Legende Off Aus On Ein Out Austritt Return from refrigerant system Eintritt Gerät vom externen Kältekreislauf 15.4.6 Terminology in legends for hydraulic circuit diagrams Acronym English German AC Water tank Pufferspeicher BC Condenser coil Verflüssiger BCR Condenser/cooling coil (finned exchanger) Freikühl Wärmetauscher BR Water coil Freikühl Wärmetauscher CD Condenser Verflüssiger EV Evaporator Verdampfer EV/CD Evaporator/Condenser Verdampfer/Verflüssiger F Flow Switch Strömungswächter FI Filters Wasserfilter/Schmutzfänger MA Water pressure gauge Manometer für Wasserdruck P (Water) pump Pumpe Pc Condenser available pressure pump Kühlwasserpumpe (Verflüssiger) Pd Differential pressure switch wasserseitiger Differenzdruckschalter Pe Evaporator available pressure pump Kaltwasserpumpe (Verdampfer) RA(H) Pump suction valve Absperrventil Saugseite Pumpe RM(H) Pump discharge valve Absperrventil Druckseite Pumpe RR Filling valve Füllventil RT Flow control valve Durchflussregulierventil S1 Exchanger water inlet probe Temperaturfühler Wassereintritt S1 Evaporator/Condenser water inlet probe Temperaturfühler Wassereintritt Verdampfer/Verflüssiger S2 Exchanger water inlet probe Temperaturfühler Wassereintritt S2 Evaporator/Condenser water outlet probe Temperaturfühler Wasseraustritt Verdampfer/Verflüssiger S3 Return water probe Temperaturfühler gemeinsamer Wassereintritt S3 Common evaporator outlet probe Temperaturfühler gemeinsamer Wasseraustritt S4 Condensers water inlet probe Temperaturfühler Verflüssiger Eintritt S4/SAE External air probe Temperaturfühler Außenluft S5 Condensers water outlet probe Temperaturfühler Verflüssiger Austritt SC Drain valve Ablassventil Sc1 Evaporator/Condenser drain valve Ablassventil Verdampfer/Verflüssiger Sc2 Water tank drain valve Ablassventil Pufferspeicher SF Purge valve/Breather valve Entlüftungsventil Sf1 Evaporator/Condenser breather valve Entlüftungsventil Verdampfer/Verflüssiger Sf2 (Water) tank breather valve Entlüftungsventil Pufferspeicher TP Drain plug Ablassventil Pumpe 154 PR-2013-0112-GB • Subject to modifications • R1-01/2016 Chillers & Heat Pumps GL Series Appendix Acronym English German V3V 3-way valve 3-Wege-Ventil VA(H) Safety valve Sicherheitsventil VE Expansion tank Ausdehnungsgefäß VR(H) Check valve/No return valve Rückschlagventil 15.4.7 Terminology in hydraulic circuit diagrams English German Discharge to hydraulic system Wasseraustritt Gerät Legend Legende Only with 2 pumps nur bei 2 Pumpen Optional 2 pumps circuit Optional: Kreislauf mit 2 Pumpen Return from hydraulic system Wassereintritt Gerät Tube Rohrbündelwärmetauscher PR-2013-0112-GB • Subject to modifications • R1-01/2016 155 15 Log Book for Chiller, Heat Pumps and Compressor/Condenser Units  Log Book for Chillers, Heat Pumps and Compressor/Condenser Units  System Data Producer Type Serial number Year of manufacture     Type of system Power supply Refrigerant charge kg  Oil type Oil charge volume Chiller Max. allowed pressure  Refrigerant High pressure side  kg Heat pump bar V/Ph/Hz Comp./condenser unit Low pressure side bar Max. current A  Leak test without leakage detection system Once a year  5 t to <50 t of CO2 equivalent   Twice a  50 t to <500 t of CO2 equivalent 4 times a year  500 of CO2 equivalent  Leakage detection system is available   yes no If a suitable leakage detection system is used, the above check intervals are doubled.  Plant operator Contact person Address Postal code / City      Tel. Fax. E-Mail   Contact person  Address  Postal code / City  Certification number Date of commissioning     Service company Tel. Fax. E-Mail     Commissioning by Service technician  Certificate Nr.: Service through Service technician  Certificate Nr.: Service through Service technician  Certificate Nr.: Service through Service technician  Certificate Nr.:   Notes         Vers. 01/2016-2 by TK 156 PR-2013-0112-GB • Subject to modifications • R1-01/2016   Date / Visit Nr. / Company: Service technician: Certificate Nr.: Certificate Nr.: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: yes / no Result: Leak system test Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name PR-2013-0112-GB • Subject to modifications • R1-01/2016 Signature 157   Date / Visit Nr. / Company: Service technician: Certificate Nr.: Certificate Nr.: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: yes / no Result: Leak system test Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name 158 Signature PR-2013-0112-GB • Subject to modifications • R1-01/2016   Date / Visit Nr. / Company: Service technician: Certificate Nr.: Certificate Nr.: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: yes / no Result: Leak system test Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name PR-2013-0112-GB • Subject to modifications • R1-01/2016 Signature 159   Date / Visit Nr. / Company: Service technician: Certificate Nr.: Certificate Nr.: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: yes / no Result: Leak system test Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name 160 Signature PR-2013-0112-GB • Subject to modifications • R1-01/2016   Date / Visit Nr. / Company: Service technician: Certificate Nr.: Certificate Nr.: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: yes / no Result: Leak system test Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name PR-2013-0112-GB • Subject to modifications • R1-01/2016 Signature 161   Date / Visit Nr. / Company: Service technician: Certificate Nr.: Certificate Nr.: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: yes / no Result: Leak system test Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name 162 Signature PR-2013-0112-GB • Subject to modifications • R1-01/2016   Date / Visit Nr. / Company: Service technician: Certificate Nr.: Certificate Nr.: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: yes / no Result: Leak system test Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name Signature  Date / Visit Nr. / Company: Service technician: Leak testing yes / no Result: Refrigerant charged yes / no Reason: Refrigerant evacuated yes / no Reason: Leak system test yes / no Result: Repairs  Required measures  Certificate Nr.: Certificate Nr.: Units leak tested, safety devices checked and function test passed. Name PR-2013-0112-GB • Subject to modifications • R1-01/2016 Signature 163 DencoHappel is a global company with expertise in air treatment, air conditioning and air filtration. Our nearest sales and service teams will be glad to discuss ideas and develop creative and effective solutions with you. www.dencohappel.com