FläktGroup FG Series User manual

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

Chillers & Heat Pumps
FG/GL Series
2FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
Table of Contents
1 Unit Identification Plate .............................................................. 4
2 Unit Type Code ............................................................................ 5
3 Overview of Units and Packaged Content ................................ 6
3.1 Series ......................................................................................................... 6
3.2 Unit overview ............................................................................................. 6
3.3 Packaged content ...................................................................................... 6
3.4 Accessories and special equipment ........................................................... 6
4 Safety and User Instructions ..................................................... 7
4.1 Availability of the operation manual ........................................................... 7
4.2 Scope of the operation manual .................................................................. 7
4.3 Symbols used ............................................................................................ 7
4.4 Identification of safety information ............................................................. 8
4.5 Used safety symbols .................................................................................. 9
4.6 Safety-conscious work procedures .......................................................... 10
4.7 Modifications and changes ...................................................................... 13
4.8 Spare parts .............................................................................................. 13
4.9 Disposal ................................................................................................... 13
4.10 Selection and qualification of personnel .................................................. 13
5 Technical Description ............................................................... 14
5.1 Description of the unit .............................................................................. 14
5.2 Functional description .............................................................................. 15
5.3 Technical Specifications .......................................................................... 19
5.4 Operating limits ........................................................................................ 20
6 Shipping and Storage ............................................................... 21
6.1 Delivery .................................................................................................... 21
6.2 Transport .................................................................................................. 21
6.3 Storage .................................................................................................... 23
7 Assembly ................................................................................... 24
7.1 Positioning the unit ................................................................................... 24
7.2 Assembling the unit .................................................................................. 28
7.3 Installing accessories ............................................................................... 30
7.4 Installation of unit accessories ................................................................. 34
8 Medium Connections ................................................................ 40
8.1 Requirements ........................................................................................... 40
8.2 Connecting water circuit (chilled and warm water) .................................. 43
8.3 Check and adjust inlet pressure in expansion tank (for units with
installed hydraulic or pump module with expansion tank) ........................ 44
8.4 Charging water circuit .............................................................................. 46
8.5 Connecting cooling water circuit (only GLWC and GLWH units) ............. 50
8.6 Connecting refrigeration circuit to an external condenser
(by others, only GLRC) ............................................................................ 54
8.7 Connect Desuperheater/Heat Recovery Circuit ....................................... 62

Chillers & Heat Pumps
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 3
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 Overview of operator elements ................................................................. 76
11.2 POWER OFF and ON ............................................................................... 76
11.3 Operating controller .................................................................................. 78
11.4 Overview of operator elements ................................................................. 80
11.5 POWER OFF and ON ............................................................................... 80
11.6 Operating controller .................................................................................. 81
11.7 Disconnecting from power supply ............................................................. 86
11.8 Draining water circuit ................................................................................ 87
11.9 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 FläktGroup HVAC
systems controller ...................................................................................105
13 Servicing and Maintenance .................................................... 106
13.1 Statutory limit values of leakage checks on refrigeration systems ......... 106
13.2 Overview of maintenance intervals ......................................................... 107
13.3 Maintenance of air-cooled heat exchangers ........................................... 108
13.4 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 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.

Unit Identification Plate Chillers & Heat Pumps
FG/GL Series
4FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
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.
Fig. 1-1
FläktGroup Deutschland GmbH
FläktGroup Deutschland GmbH
Company name
Max. operating pressure
high and low pressure side
Max. operating pressure on water side
CE symbol with certification number
Drawing number of wiring diagram
Company logo
Unit type
Item number
Serial Number
Year of manufacture
Operating weight
Refrigerant
Refrigerant charge volume
Oil type
Power supply
Max. power consumption
Max. current consumption
Max. storage
and shipping temperature

Chillers & Heat Pumps Unit Type Code
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 5
2 Unit Type Code
FläktGroup FG/GL Series G L A C 4 8 4 0 C A 2 .HE
FläktGroup chiller
or
FläktGroup heat pumps
FläktGroup FG/GL Series Condensation Operating mode No. of compressors Capacity stage Series Refrigerant Supply voltage Design version
FG/GL FläktGroup/Global Large Series
AAir cooled
(outdoor installation)
DAir cooled (indoor installation)
FAir cooled with free-cooling function (outdoor installation)
Rwithout condenser (indoor installation)
WWater cooled (indoor installation)
CChillers
HHeat Pump
22 compressors
33 compressors
44 compressors
55 compressors
66 compressors
88 compressors
015 - 960 Unit capacity stage
#Unit series, continued
AR-134a and Bitzer screw compressor
DR-410A and scroll compressor
1400 Volt/3 Ph~/ 50 Hz/+N/+PE
2400 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
Notice!
For detailed planning please only use the order-related documentation. Detailed
dimensional drawings can be obtained on request from your responsible FläktGroup
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

Overview of Units and Packaged Content Chillers & Heat Pumps
FG/GL Series
6FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
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 order-
related 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.
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.FläktGroup.com) for chillers and heat pumps.
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.

Chillers & Heat Pumps Safety and User Instructions
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 7
4 Safety and User Instructions
FläktGroup FG/GL units are constructed using state-of-the-art technology and accord-
ing to recognized safety regulations.
Use the FläktGroup units in a technically sound condition for the intended purpose
observing the operation manual, taking safety aspects and potential hazards into
account. 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!
4.1 Availability of the operation manual
This operation manual contains important instructions regarding safe and correct oper-
ation of the FläktGroup 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 air-
conditioning 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.
ATTENTION
Damage to the unit!
In case of alarms and faults, always make sure that the cause of the fault is iden-
tified. In particular, a manual reset of an alarm without first rectifying the cause can
damage the unit and invalidate the warranty.
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.

Safety and User Instructions Chillers & Heat Pumps
FG/GL Series
8FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
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 irre-
versible injury, if the safety instruction is not followed.
Example:
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:
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:
4.4.4 ATTENTION – Environmental or material damage
Indicates actions that can result in equipment or property-damage only accidents.
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.
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.
Sharp edges can cause injuries!
Observe precaution when cleaning due to risk of cuts on thin and sharp edges.
•Wear chemical resistant gloves.
ATTENTION

Chillers & Heat Pumps Safety and User Instructions
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 9
Examples:
4.5 Used safety symbols
ATTENTION
Risk of environmental damage!
Heavily contaminated filters can have a negative impact on production processes.
Depending on the filtered-out materials, contaminated filters are therefore classi-
fied as hazardous waste and must be properly disposed of according to the pre-
vailing guidelines and laws.
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 com-
ponents.
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

Safety and User Instructions Chillers & Heat Pumps
FG/GL Series
10 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
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:
– 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“
For all kinds of work:
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.
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 suf-
focation 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.

Chillers & Heat Pumps Safety and User Instructions
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 11
•Please comply with the installation and shipping instructions for FläktGroup units.
•Observe the pre-commissioning check points.
•Always make sure that the FläktGroup 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 FläktGroup 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.
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 swal-
lowed.
•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.

Safety and User Instructions Chillers & Heat Pumps
FG/GL Series
12 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
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 Pro-
tocol 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 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.
Inhalation 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.

Chillers & Heat Pumps Safety and User Instructions
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 13
4.6.2 Proper use
FG/GL units are only used to produce chilled water for air treatment units in comfort air
conditioning or to provide chilled water for process cooling in enclosed circuits of man-
ufacturing facilities. Unit are partially equipped with a heat-pump cycle.
Proper use also requires adherence to the operation manual for the controller and suit-
able and regular inspection and maintenance,
following guidelines specified by FläktGroup.
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.
4.7 Modifications and changes
You are not allowed to change, add to or modify the FläktGroup units in any way. Any
changes or modifications to the FläktGroup units will invalidate the CE conformity cer-
tificate and render and all warranty claims null and void.
4.8 Spare parts
Only original FläktGroup spare parts are allowed, since FläktGroup 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.
Personal injury and equipment damage!
It is not allowed to operate FläktGroup 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,

Technical Description Chillers & Heat Pumps
FG/GL Series
14 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
5 Technical Description
5.1 Description of the unit
These FläktGroup units are performed as chillers or heat pumps. In the factory
units are filled with refrigerator oil and refrigerant and a test run is performed, so that
when the units are installed on site only chilled water and electrical connections have
to be completed. Carry out a functional test as well.
The FläktGroup 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 con-
troller (also refer to chapter "11.1").
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).
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. 5-1: Display
Fig. 5-2: Alternative display
Fig. 5-3: Alternative display

Chillers & Heat Pumps Technical Description
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 15
5.2 Functional description
5.2.1 FGAC/GLAC – air cooled chillers designed for outside installation and
Refrigeration circuit The refrigeration system generates a refrigeration output in a thermodynamic cycle by
means of heat removal, this is used to cool a water circuit (indirect cooling).
Fig. 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 FGAH/GLAH – air cooled heat pumps
In cooling mode the unit operates as specified in chapter 5.2.1 FGAC/GLAC – air
cooled chillers designed for outside installation and.
Heating circuit - FGAH/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.
1
2
3
4
5

Technical Description Chillers & Heat Pumps
FG/GL Series
16 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
5.2.3 GLFC - air cooled chillers with a free-cooling function for outside installation
Summer operation:
During summer operation a 3-way valve directs
water for cooling not through an additional air
cooled heat exchanger but directly into the evapo-
rator. 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 de-
activated and the unit operates as a chiller - refer
to chapter FGAC/GLAC - air cooled chillers for out-
side installation and GLDC - air cooled chillers for
inside installation.
Transition time:
During transition seasons in spring and autumn the
unit operates with an additional air-cooled free-
cooling heat exchanger as well as using usual
evaporative cooling. As soon as outdoor air tem-
perature falls 1 °C below the set return tempera-
ture 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 associ-
ated electric power consumption. Now water pass-
es through both heat exchangers. Missing cooling
energy, which is not recovered by free cooling, is
provided by the one or multiple compressors. Al-
ready 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. 5-5
Fig. 5-6
Fig. 5-7

Chillers & Heat Pumps Technical Description
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 17
5.2.4 GLRC - chiller without condenser for inside installation
In cooling mode the unit operates as specified in chapter 5.2.1 FGAC/GLAC – air
cooled chillers designed for outside installation and.
With this configuration the condenser is not located in the unit itself and must be pro-
vided by others on site, the corresponding pipework has to be established by others as
well.
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).
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.
1
2
3
4
5
6

Technical Description Chillers & Heat Pumps
FG/GL Series
18 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
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).
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 con-
nected water or water/glycol circuit. Thus a chiller turns into a heat pump.
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Chillers & Heat Pumps Technical Description
FG/GL Series
FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications 19
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).
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 auto-
matically. 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 acti-
vates 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.FläktGroup.com) for chillers and heat pumps.
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Technical Description Chillers & Heat Pumps
FG/GL Series
20 FläktGroup DC-2013-0112-GB 2018-09/R3 • Subject to modifications
5.4 Operating limits
For unit operating limits refer to Data&Facts catalogue of the relevant unit series or
web-based unit selection and layout software Aid@ (www.aida.FläktGroup.com) for
chillers and heat pumps.
Notice!
– Protect all water-conducting components from freezing at ambient tempera-
tures below 5°C. FläktGroup recommends to use at least 30 % ethylene gly-
col.
– 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.Fläkt-
Group.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.Fläkt-
Group.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.FläktGroup.com) for chillers and heat
pumps.
– The relative humidity during operation must not exceed 90 %.