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