A - ATG - PR 2013 0112 GB - Chiller GL Serie - BA - K0 11 2013 - 150dpi

GEA GL Series
Chillers and Heat Pumps

Energy-efficient, compact, available in variety of designs
Operation Manual
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Table of Contents 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 Series ......................................................................................................... 6
3.2 Unit overview ............................................................................................. 6
3.3 Scope of supply ......................................................................................... 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 instructions ............................................................. 8
4.5 Safety-conscious work procedures ............................................................ 9
4.6 Modifications and changes ...................................................................... 11
4.7 Spare parts .............................................................................................. 11
4.8 Disposal ................................................................................................... 11
4.9 Selection and qualification of personnel .................................................. 11
5 Technical Description ............................................................... 12

5.1 Unit description ........................................................................................ 12
5.2 Technical specifications ........................................................................... 17
5.3 Operating limits ........................................................................................ 18
6 Shipping and storage ............................................................... 19

6.1 Delivery .................................................................................................... 19
6.2 Transport .................................................................................................. 19
6.3 Storage .................................................................................................... 20
7 Mounting .................................................................................... 21
7.1 Positioning the unit ................................................................................... 21
7.2 Assembling the unit .................................................................................. 22
7.3 Rubber anti-vibration isolators ................................................................. 24
7.4 Spring anti-vibration isolators ................................................................... 27
8 Medium Connections ................................................................ 28

8.1 Requirements ........................................................................................... 28
8.2 Connecting water circuit (chilled and warm water) .................................. 30
8.3 Connecting cooling water circuit (only GLWC and GLWH units) ............. 36
8.4 Connecting refrigeration circuit to an external condenser
(by others, only GLRC) 39
9 Electrical Connection ............................................................... 47

9.1 Requirements ........................................................................................... 47
9.2 Connect mains electrical supply .............................................................. 48
9.3 Connecting control contacts and controller .............................................. 49
10 Commissioning ......................................................................... 53
10.1 Requirements ........................................................................................... 53
10.2 Commissioning procedure ....................................................................... 53
2 PR-2013-0112-GB • Subject to modifications • K0-11/2013

GL Series Table of Contents
11 Operation ................................................................................... 59
11.1 Overview of operator elements ................................................................. 59
11.2 POWER OFF and ON ............................................................................... 59
11.3 Operating controller .................................................................................. 60
11.4 Overview of operator elements ................................................................. 62
11.5 POWER OFF and ON ............................................................................... 63
11.6 Draining water circuit ................................................................................ 70
11.7 What to do in case of alarm and error messages ..................................... 70
12 Fault Finding and Troubleshooting ......................................... 71

12.1 Alarms ....................................................................................................... 71
12.2 Overview of alarm messages ................................................................... 71
12.3 Resistance temperature sensor for GEA HVAC systems controller ......... 86
13 Servicing and maintenance ..................................................... 87

13.1 Servicing and cleaning .............................................................................. 87
13.2 Maintenance ............................................................................................ 87
14 Dismantling and Disposal ........................................................ 89

14.1 Dismantling ............................................................................................... 89
14.2 Disposal .................................................................................................... 89
15 Appendix .................................................................................... 90
15.1 Technical Requirements for Function Testing or Maintenance
of Chiller/Heat Pump 91
15.2 Commissioning Report ............................................................................. 92
15.3 Measuring Report ..................................................................................... 94
15.4 Generally accepted translation of diagrams, plans and drawings
in order-related documentation 126
15.1 Log Book for Chillers, Heat Pumps and Compressor/Condenser Units . 134
PR-2013-0112-GB • Subject to modifications • K0-11/2013 3

Unit identification plate GL Series
1 Unit identification plate

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. operating pressure on water side
Max. power consumption
Max. current consumption
Max. storage CE symbol with certification number

and shipping temperature
Drawing number of wiring diagram
Fig. 1-1

GL Series Unit Type Code
2 Unit Type Code

GEA GL Series G L A C 4 8 4 0 C A 2 .HE
GEA Chiller
No. of compressors
Operating mode
or
GEA GL Series
Supply voltage
Capacity stage
condensing
Refrigerant
GEA Heat Pumps
version
Design
Series
GL GEA Large
Air cooled
A (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 Chiller
H Heat pump
2 2 compressors
3 3 compressors
4 4 compressors
015 - 960 Unit capacity stage
C 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 version - Eurovent class A
.LT LT-Version: heating at low ambient temperatures, only for heat pumps
NOTICE!
For detailed planning please only use the order related documentation. Detailed
dimensional drawings can be obtained on request from your relevant GEA sales
office. Specifications and technical data are subject to regular updates. The manu-
facturer reserves the right to make necessary changes to information without prior
written notice.

Overview of units and packaged content GL Series
3 Overview of units and packaged content
3.1 Series
For detailed technical specifications on individual unit series refer to the Data&Facts
catalogue 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 Scope of supply

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
– order related wiring diagrams
– 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.geagroup.com) for chillers and heat pumps.

GL Series Safety and User Instructions
4 Safety and User Instructions

GEA GL unit series are constructed using the state-of-the-art technology and accord-
ing to recognized safety regulations.
Use the GEA unit in a technically sound condition for the intended purpose observing
the current operation manual, taking safety aspects and potential hazards into account.
It is important to appeciate that failure to follow the instructions in this manual may
result in danger to health and safety, material-only damage and incorrect unit opera-
tion. Have all faults repaired by an authorized specialist without delay!
DAMAGE TO THE UNIT!

In the case of alarms and faults always make sure that the cause of the fault is inves-
tigated. In particular, multiple resetting of alarms without 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 oper-
ation of the GEA 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.
9 This symbol indicates the result of an action.
NOTICE!
This symbol denotes additional instructions on using the GEA unit.
RECYCLING!
This symbol is used to highlight instructions for the proper recycling of packaging
material and assembly groups no longer in use (separated according to recyclable
materials).
PROPER BOOTS REQUIRED!

This symbol points out that you must wear proper protective boots.

Safety and User Instructions GL Series
WEAR GLOVES!
This symbol points out that you must wear proper gloves.
PROTECTIVE GOGGLES REQUIRED!

This symbol indicates that wearing protective goggles is obligatory.
4.4 Identification of safety instructions
PERSONAL INJURY!
This section specifies procedures and precautions for preventing personal injury.
DANGER OF ELECTRICAL CURRENT!

This symbol indicates a risk of electrical shock when working on the equipment.
DANGER OF HOT SURFACES!

This section specifies procedures and precautions for preventing personal injury
resulting from hot surfaces.
DANGER – SHARP CUTTING EDGES!

This section specifies procedures and precautions for preventing personal injury due
to cutting on thin metal fins.
HIGH PRESSURE HAZARD!

This section specifies procedures and precautions for the
prevention of personal injury due to high pressure.
DANGER DUE TO LOW TEMPERATURES!

This section specifies procedures and precautions for prevention of
personal injury due to escaping liquid refrigerants.
DANGER DUE TO OVERHEAD LOADS!

This symbol warns about personal injury and damage caused by overhead loads and
suspended heavy objects.
ENVIRONMENTAL DAMAGE!
This symbol warns you about damage to the environment and turns
your attention to all existing national environmental protection regulations.
DANGER DUE TO TOXIC SUBSTANCES!

This symbol warns you about dangers due to toxic substances.
DAMAGE TO THE UNIT!

This section specifies procedures and precautions regarding the
prevention of damage to the GEA unit.

4.5 Safety-conscious work procedures

When working within range of mains voltage:

Disconnect all electric power of the unit and ensure the power cannot be inadvert-
ently switched on, earth, short-circuit and block off all neighboring live parts. Non-
compliance can lead to death or serious injury.
When working with refrigerants:

Please consider section „4.5.1 Handling refrigerants“

Contact with a liquid refrigerant can result in skin burns or injury to other organs.
Exercise due caution and attention when carrying out jobs and avoid contact with a
refrigerant.
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, and exercise due care and attention when
carrying out the work.
SMOKING AND OPEN FLAMES ARE PROHIBITED!

Smoking and open flames at the installation site of the unit or during work with refrig-
erants are prohibited. Open fire or flames can lead to the disintegration of a refriger-
ant and release of toxic gases. Do not keep any inflammable liquids in close
proximity to the unit.
For all kinds of work:

PERSONAL INJURY!
Glycols and other antifreeze agents are harmful for humans and animals,
if swallowed. Consult a doctor immediately if swallowed by mistake.

When working on hydraulic or refrigeration circuits or in case of damage to the com-
ponents or piping, there is a risk of injury from fluids or gases escaping at high pres-
sure. Exercise due caution and attention when carrying out this work.
Do not pollute the environment with liquid products, refrigerants or oils.
Dispose of the latter in accordance with local laws and regulations by avoiding harm
to the environment.Ethylene glycol and propylene glycol are categorised as Water
Hazard Class 1 in accordance with the catalogue of water pollutants (mild water pol-
lutants). This also applies to mixtures with water.
• Please comply with the installation and shipping instructions for GEA units.
• Observe the pre-commissioning check points.
• Always make sure that the GEA 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 GEA Service or a specialist refrigeration company
immediately (refer to section 4.10).

Safety and User Instructions GL Series
• The safety sheet stating the type of refrigerant charged on the given unit must 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.
4.5.1 Handling refrigerants

According to DIN EN 378 Part 1 the R-134a and R-410A refrigerants belong to 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 842/2006.
Features of applicable refrigerant types:
– Non-combustible
– No direct toxic effect
– Colourless and odourless
– Heavier than air
– Contains fluorinated greenhouse gases as defined by the Kyoto protocol
– Ozone-depleting potential OPD: 0
– Greenhouse potential GWP: R-134a: 1300, R-410A: 1980
– 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.
4.5.2 Proper use

Units are only used to produce chilled water for air treatment units in comfort air con-
ditioning or to provide chilled water for process cooling in enclosed circuits of manufac-
turing facilities. Unit are partially equipped with a heat-pump cycle.
Proper use also includes observance of the operation manual and the inspection and
maintenance conditions stipulated by GEA.

Improper use Any use other than that described above is considered improper. The manufacturer/
supplier is not liable for damage arising from improper use. The user alone bears the
risk.
PERSONAL INJURY AND EQUIPMENT DAMAGE!

It is not allowed to operate GEA units:
– In areas subject to explosion risk,
– in environments with strong electromagnetic fields,
– in environments with high levels of air contamination,
– in environments with corrosive and/or aggressive air.
4.6 Modifications and changes

You are not allowed to change, add to or modify the GEA unit in any way.
Any changes or modifications to the GEA units will invalidate the
CE conformity certificate and render and all warranty claims null and void.
4.7 Spare parts

Only original GEA spare parts are allowed, since GEA is not liable if third-party spare
parts are used.
4.8 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".
4.9 Selection and qualification of personnel

It must be ensured that every person working on the GEA 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 842/2006 Article 5, 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, passed by the German
parliament.
All skilled staff must be able to assess the entrusted work and must be able to recog-
nize and avoid all associated dangers.

Technical Description GL Series
5 Technical Description
5.1 Unit description

These GEA 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 com-
pleted. Carry out a functional test as well.
The GEA 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 regulations:
– 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 cata-
logue or your quotation for the unit.
5.1.2 Control cabinet

For data on the switch cabinet refer to the Data&Facts catalogue or your quotation text
for the unit.
5.1.3 Electronic control system

For the data on electronic controls refer to supplied operation for the controller.
Fig. 1: Display
Alternative display for units with screw compressor and GLFC unit series
Fig. 2: Alternative display

GL Series Technical Description
5.1.4 Functional description of the unit
5.1.5 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).
4
5
1
Fig. 5-1
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.
5.1.6 GLAH - air cooled heat pumps

In cooling mode the unit operates as specified in chapter 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.

5.1.7 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. In such a way the water-side pressure drop
is reduced 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 chill-
ers for inside installation.
Fig. 5-2
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
Fig. 5-3
savings can be achieved.
Winter operation:
Only free-cooling heat exchanger is activated dur-
ing winter season. The temperature difference be-
tween 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. 5-4

5.1.8 GLRC - chiller without condenser for inside installation

In cooling mode the unit operates as specified in chapter 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 pro-
vided by others on site, the corresponding pipework has to be established by others as
well.
5.1.9 GLWC - water cooled chiller for inside installation
5
1
Fig. 5-5: 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.
energy in the water-cooled (4) condenser (2).
The necessary thermal energy, which this process requires, is removed from the
chilled water circuit (6) resulting in its cooling.

5.1.10 GLWH-BD2 - water cooled heat pumps for inside installation with integrated 4-way valve
5
1
energy in the water-cooled (4) condenser (2).
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.

5.1.11 GLWH-BA2/CA2 - water cooled heat pumps for inside installation
4
1
energy in the condensing water (5) of the water-cooled condenser (2).
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.
5.2 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.geagroup.com) for chillers and heat pumps.

5.3 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.geagroup.com) for
chillers and heat pumps.
NOTICE!
– Protect all water-conducting components from freezing at ambient temperatures
below 5°C. GEA 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 out-
let temperature refer to the Data&Facts catalogue of the relevant unit series or
web-based unit selection and layout software Aid@ (www.aida.geagroup.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.geagroup.com) for
chillers and heat pumps. (only for heat pumps).
– At low outside-air temperature 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 soft-
ware Aid@ (www.aida.geagroup.com) for chillers and heat pumps.
– The relative humidity during operation must not exceed 90 %.

GL Series Shipping and storage
6 Shipping and storage
6.1 Delivery
Upon receipt of the GEA unit and prior to unloading, inspect the unit 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
PERSONAL INJURY!
In order to prevent injury, damage and ensure safety, 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.
For unit weight - refer to the order-related documentation and the unit identification
plate.
• Only transport the GEA units using the transport lugs or lifting points provided by
the manufacturer. For locating lifting points refer to the order-related dimensional
drawing or strickers on the unit.
• Never attach lifting hooks or similar gear directly to the unit construction - only
proper lifting gear must be used (refer to Fig. 6-1).
• When handling and shipping, do not tilt the unit by more than 15°.
• For your own safety wear gloves and safety footwear when lifting or shipping the
unit.
DANGER DUE TO OVERHEAD LOADS!

Never stand beneath suspended loads, 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.
• 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. 6-1) (provided by others).
• Move the unit carefully without jerky movements.
• Always set the unit down gently, without bumping it.
• If necessary, use a specialist company to transport the unit.

Shipping and storage GL Series
LIFTING USE N°4 LIFTING ROPES WITH EQUAL LENGHT ONLY (min.3000)
c1 C2
Fig. 6-1: Example of unit shipment procedure - air cooled chiller for outdoor installation For exact positioning refer to the order-
related dimensional drawing.
NOTICE!
Use only supplied documentation and enclosed detailed dimensional drawings when
transporting the unit.
6.3 Storage
Allowable storage conditions / allowable air condition for non-installed units
Air temperature: -20 °C to +46 °C
Air humidity: up to 85 % (relative humidity with no condensation)

GL Series Mounting
7 Mounting
NOTE ON UNIT ASSEMBLY AND INSTALLATION!
Here you will find information on how to assemble 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 rel-
evant accident prevention regulations, as well as other generally recognized safety
and occupational health codes.
NOTICE ON MOVING THE UNIT!
If the GEA units have been moved from one plant/location to another, repeated com-
missioning is required, refer to the description in chapter "Commissioning".
7.1 Positioning the unit
NOTICE!
Use only supplied order related documentation and enclosed detailed dimensional
drawings when transporting the unit.
The unit must be installed at a location that fulfils the following requirements:
– Ensure that the site is level and that it can support the weight of the equipment, so
that no vibrations or operating noise occur when the unit is operating.
– The unit should 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.
– Sufficient clearance around the unit to carry out maintenance or repair work must
be ensured. For required clearances refer to the Data&Facts catalogue for your unit
or order-related dimensional drawing.
– If two or more units are installed next to each other, the relevant clearances must
be kept for each unit. (see Fig. 7-1) Overlapping of clearances is not allowed!
– 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.
– Choose the installation location so that operating noise does not cause a distur-
bance.
– Check if requirements for the installation site
defined by EN 378-3 are fulfilled (refrigerating
systems and heat pumps - safety and environ-
mental requirements Part 3: installation site and
personal protection). These requirements es-
pecially apply to units for indoor installation.
– There must be sufficient clearance around the
unit to carry out maintenance or repair work.
A B
R2 R1 R2 R1
Clearances Clearances Clearances
Fig. 7-1

Mounting GL Series
Further notices on air cooled units GLAC, GLAH, GLFC and GLCU series:
Clearances for air supply!
R2 – Unit must freely discharge air to top. Air short-
circuiting must be impossible!
– The necessary clearances near and over the
unit may exceed the depicted maintenance
R3 R4 clearance by many times.
R1
Fig. 7-2: Clearances
– At low outside-air temperature install the unit in

Wind protection Wind protection a wind-protected area with wind velocity below
0.5 m/s. For exact temperatur refer to the Da-
ta&Facts catalogue of unit. For this purpose
take appropriate measures. Make sure that the
air flow is not obstructed and consider the clear-
ances of the unit.
R2 R1
Clearances Clearances
Fig. 7-3
Notices on ambient condition such as ice and snow.

– Due to static and operational reasons the unit must be protected from snow. Make
sure that unit operation is not impaired by snow. This problem can exemplified by
an air cooled heat exchanger 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 build-
up of snow around the unit.
DAMAGE TO THE UNIT!
Buildup of snow and ice around the unit can lead to unit damage. Irrepairable dam-
age to unit and refrigerant leak can be the consequence.
Additional notice for GLAH units:

– Ensure well-arranged and free water drainage for air cooled heat pumps in heating
mode to divert collected water during defrosting. At low outside temperatures pro-
vide a heated tray and condensate drainage.
PERSONAL INJURY
Frozen surfaces around the unit as a result of random or irregular condensate drain-
age during defrosting can lead to personal injuries.
7.2 Assembling the unit

In order to reduce the transmission of vibration and avoid unit damage, anti-vibration
isolators must be fitted:
– Under all circumstances anti-vibration isolators must be used to separate the unit
from the foundation when installing the unit in a location where no special require-
ments for the neutralisation of structure-borne noise apply.
– For very special acoustic requirements please consult an acoustic engineer to se-
lect the most suitable method for neutralising structure-borne noise.
To install the unit, proceed as follows:

GL Series Mounting
DAMAGE TO THE UNIT!

Please consider that suitable anti-vibration mounts must be installed
below the unit as well as pipework compensators on water inlet and outlet
of the unit. The anti-vibration mounts 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 in such a way this requirement 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
W2 W4
R1
Fig. 7-4: Example for mounting position

For exact positioning refer to the order-related dimensional drawing

Mounting GL Series
7.3 Rubber anti-vibration isolators

For exact type of rubber anti-vibration isolators necessary for each unit refer to the unit-
related Data&Facts catalogue.
BOLT
BASEMENT BASEMENT
LITTLE PLANE WASHER
ANTIVIBRATING MOUNTING FIXING BRACKET
45
66
LITTLE PLANE WASHER
GROVER ELASTIC WASHER
NUT
BASEMENT
OF NUT
OH
E
GROVER ELASTIC WASHER

A
BIG PLANE WASHER
D C D BIG PLANE WASHER

RUBBER TYPE ANTIVIBRATING MOUNTING
D
NUT
C
B
OG
D
B
Fig. 7-5: Mounting rubber anti-vibration isolators
Type A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) G (mm) H

FZ 100-57 56 80 67 6.5 60 25 6.5 M12
FZ 200-51 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
FZ 400-57 95 155 125 15 60 70 12.5 M16
FZ 600-51 95 175 140 17.5 60 75 14 M18
FZ 600-57 95 175 140 17.5 60 100 14 M20
FZ 1000-57 95 205 162 21.5 60 80 16 M20
Tab. 7-1

GL Series Mounting
Fig. 7-6: Installation of anti-vibration isolators
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. 8- Size in [mm]

Mounting GL Series
Fig. 7-7: Installation of anti-vibration isolators
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. 9- Size in [mm]

GL Series Mounting
7.4 Spring anti-vibration isolators

Refer to the order-related unit documentation to select the correct type of spring anti-
vibration isolators to be installed below the relevant points W1 to Wn.
45
66
ØA
75 Fz
Li
f
DH L Ø C
50
F
A
140
f [mm] = F/k
50
F [kg]: refer to weight

100
k [kg]: see below

12
50
12 116 12
Fig. 7-8
Type 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
Tab. 10- Size of anti-vibration isolators
* applies to unit feet with 10 mm thick carrying frame

Medium Connections GL Series
8 Medium Connections
Medium connections must only be carried out by qualified licensed staff or other indi-
viduals with proper professional training and experience in the relevant accident pre-
vention 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
Keep in mind:
• The entire chilled water system must be designed and implemented in accordance
with the current standards and guidelines.
Components • 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
PERSONAL INJURY!
Glycols and other antifreeze agents are harmful for humans and animals,
if swallowed. Contact a doctor immediately if ingested by mistake.
Ethylene glycol and propylene glycol are in Water Hazard Class 1 (slightly water
endangering) of the catalogue of water-endangering substances. This also applies
to mixtures with water.
• 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.

GL Series Medium Connections
• 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 %.
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
Effects in case of
Description Icon Values
difference
Hydrogen ion concentration pH 7.5 – 9 < 7.5 Corrosion

>9 Incrustation
Calcium and magnesium content Hardness 4 – 8,5 °D > 8.5 Incrustation

(Ca/Mg)
Chlorine ions Cl– < 50 ppm Corrosion
Iron ions Fe³+ < 0.5 ppm Corrosion
+
Magnesium ions Mg² < 0.05 ppm Corrosion
Carbon dioxide CO2 < 10 ppm Corrosion
Hydrogen sulphide H2S < 50 ppb Corrosion
Oxygen O2 < 0.1 ppm Corrosion
Chlorine Cl2 < 0.5 ppm Corrosion
Ammonia NH3 < 0.5 ppm Corrosion
- -
Bicarbonate/sulphate ratio HCO3 /SO4² >1 <1 Corrosion
Tab. 1- 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)

8.2 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.
• 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 should also be protected against corrosion using
protective paint.
DAMAGE TO THE UNIT!

The GEA 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".
DAMAGE TO THE UNIT!

When connecting the chilled water system, counter hold the connecting spigots with
a pipe wrench to prevent damage.
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 on heat exchangers.The water filter can be optionally ordered and is a
requirement for safe and trouble-free operation of the unit and in such a way this
requirement constitutes an integral part for the validity of the warranty.
DAMAGE TO THE UNIT!

The heat exchangers in the unit must be protected against ice formation during sys-
tem shutdown or if the ambient temperatures fall below freezing. Use an 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“).
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.
• Connect the pipe system by others to the 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 Chapter 15.4
"Generally accepted translation of diagrams, plans and drawings in order-related
documentation" on page 126
• Contact your GEA 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 not sealing 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 ["] flexible joint: rated diameter (also known as „Victaulic®“ trade mark)
coupling
Tab. 8-1
NOTICE!
For detailed planning please only use the order related documentation. Detailed
dimensional drawings can be obtained on request from your relevant GEA sales
office. Specifications and technical data are subject to regular updates. The manu-
facturer 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".
8.2.2 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 cat-
alogue or unit quotation text.
When charging the unit with water or a water-glycol mixture, the initial pressure in ex-
pansion tank of hydraulic or pump module must be checked and adjusted. Only cor-
rectly 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.
[ m ] + 0, 3
Inlet pressure (estimated): Pv = H
-------------
10, 2
Plant filling pressure min. (estimated): PA min = Pv + 0, 3
Plant filling pressure max.: PA max = Psv – 0, 3
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

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.
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.
D. 1
2,5
Initial pressure of expansion tank Pv [bar]
1,5
0,5
0
0 5 10 15 20 25
Height of water column over expansion tank H [m]
8.2.3 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 allow all air escape when charging the water circuit.
DAMAGE TO THE UNIT!
The unit may only be operated with excessive pressure. The suction side pump pres-
sure 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.
8.2.4 Schematic representation of various hydraulic circuits (examples)

The following two hydraulic circuits are presented as examples for conceptual knowl-
edge and do not substitute proper planning and layout of the entire system.
8.2.5 Single circuit buffer tank with one pump for the entire system
GEA unit
Fig. 8-1: Hydraulic circuit of single circuit buffer tank

1 Pressure gauge 10 Expansion tank
2 Shut off 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 GEA 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 GEA 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.
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 sys-
tem 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 Depending on unit configuration and the selected accessories, the unit can also be
modules: supplied with one or two water pumps, a buffer tank and other hydraulic components
(see the available accessories).
8.2.6 Dual circuit buffer tank with multiple pumps for the entire system
GEA unit
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 duct fixing point 14 Pump – secondary circuit
6 Water filter (maximum mesh size 1 mm2) 15 GEA unit
7 Drain valve Hydraulic switch/buffer tank suitable for chilled and warm
16
8 Pump – primary circuit water systems
9 Safety valve 17 Consumer
Items 4, 5, 6 and 12 are also specified by GEA 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 guar-
antees the compressor's minimum running time, it also achieves proper thermal layer-
ing 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 reg-
ulated 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-reg-
ulated 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 second-
ary 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 second-
ary pumps. The cooled water flows back to the buffer tank from below.
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-cir-
cuit 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 tem-
peratures of the secondary circuit do not influence the inlet temperatures of the sec-
ondary 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 tempera-
tures in the system. If the load reduction increases again, the unit switches on the indi-
vidual 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
in the buffer tank is not permitted, as this would prevent the unit from automatically reg-
ulating the capacity to optimise energy consumption. This would cause an undesirable
cycle operation. The compressor's capacity is controlled depending on the tempera-
ture difference (setpoint and actual value) from the unit. Depending on the unit config-
uration, the water pump control function can be withdrawn from the unit. The
consumers and the secondary pumps are controlled by others.
Hydraulic or pump Depending on unit configuration and the selected accessories, the unit can also be
modules: supplied with one or two water pumps, a buffer tank and other hydraulic components
(see the available accessories).
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 on heat exchangers. The water filter can be optionally ordered and is a
requirement for safe and trouble-free operation of the unit and in such a way this
requirement constitutes an integral part for the validity of the warranty.

DAMAGE TO THE UNIT!

Consider that a constant water volume flow must be secured in the evaporator/con-
denser during unit operation. Refer to the "Planning Manual on Chillers" for further
instructions on hydraulic integration of chillers and heat pumps.
8.3 Connecting cooling water circuit (only GLWC and GLWH units)
For connecting cooling water 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
The following two hydraulic circuits are presented as examples for conceptual knowledge and do not substitute proper
planning and layout of the entire system.
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
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 oper-
ation of the unit and in therefore is covered by the warranty.
Freeze protection The GEA 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 GEA recommends to use ethylene glycol.
Dimensioning Dimension the GEA heat rejection unit in such a way that the cooling water tempera-
ture 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 To ensure safe operation of the unit, operator must maintain minimum cooling water
temperature 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.geagroup.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.
Possibility 1: – Option 1 enables control the fan speed depending on the cooling water outlet tem-
perature. For all circumstances GEA recommends to control the fan speed in order
to ensure continuous operation of the unit under constant conditions.
Possibility 2: – 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 36). The cooling water pump is regulated by the cooling water
outlet temperature.
Possibility 3: – Option 3 can also be used in order to provide for the minimum cool water outlet tem-
perature of the unit. In this case a 3-way valve is installed in cooling water inlet addi-
tionally to the fan speed control to provide valve regulation depending on the
cooling water outlet temperature (refer to Fig. 8-4 on page 37).
Observe the unit operating limits when switching between heating and cooling mode
of a heat pump.
8.3.1 Operation of a 3-way valve (by others)

Ensure a minimum cooling water outlet temperature after compressor start. For mini-
mum cooling water 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.geagroup.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
8.3.2 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, how-
ever they can accordingly be applied for the heating operation.
Using a 3-way valve in heating mode is reasonable as integrated microprocessor con-
trol of a 3-way valve enables to regulate unit operation at constant water temperature
and ensure safe and trouble-free unit performance.

8.4 Connecting refrigeration circuit to an external condenser (by others, only GLRC)
Contact with a liquid refrigerant can result in skin burns or injury to other organs.
Exercise due caution and attention when carrying out jobs and avoid contact with a
refrigerant.

When working on hydraulic or refrigeration circuits or in case of damage to the com-
ponents or piping, there is a risk of injury from fluids or gases escaping at high pres-
sure. Exercise due caution and attention when carrying out this work.
8.4.1 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 temperature- The larger difference between condensing temperature and ambient temperature in
difference... the layout stage, the smaller condenser can be selected. Disadvantages of a smaller-
dimensioned 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 The smaller difference between condensing temperature and ambient temperature in
difference... the layout stage, the larger condenser should be dimensioned. Through a large-dimen-
sioned 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 require-
ments.
Depending on the region, practical values for temperature difference between con-
densing temperature and ambient temperature in the layout stage amount to 10 to
15 K, i.e. condensing temperature exceeds the layout parameters of ambient temper-
ature by 10 to 15 Kelvin.
Fan regulation and control Under all circumstances the condenser must be selected at least with the correspond-
ing fan regulation or optimally with a fan speed control in order to ensure constant con-
densing 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 catalogue, unit quotation text or order-related dimen-
sional 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 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.
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 must 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 Chapter 8.4.2 for the
maximum distance and height difference between chiller and field-provided con-
denser.
Oil transportation must be When dimensioning pipes it must be considered that oil transportation is ensured
ensured under all operating conditions. Oil transportation must be ensured using the corre-
sponding pipe dimensioning and pipe routing.
As low pressure drop as It is also important that the pressure drop in the pipework is minimized with a purpose
possible to avoid unnecessary decreases in capacity.The greater the selected pipe diameter,
the lower speed in the pipe and more difficult the oil return.The smaller the selected
pipe diameter, the higher speed and greater pressure drop in the pipe. Capacity and
energy efficiency of the unit drop.
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 Chapter 8.4.2 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 com-
pressor running times it is reasonable to install an oil separator in the field-provided dis-
charge 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 mini-
mum 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 trou-
ble-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.

8.4.2 Placement and installation examples
Example 1
GLRC chiller and condenser at the same vertical level with horizontal pipe routing.
GLRC chiller
Discharge line Condensers

 1 % slope (1 cm/m)
Liquid line
Circuit 2
Fig. 8-6: 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)

Circuit 2
max. 10 vertical meters
Condensers
Discharge line
1 % slope (1 cm/m)
Liquid line
Fig. 8-7: GLRC chiller above the condenser

Example 3
GLRC chiller below the condenser at different vertical levels.
Condensers
Discharge line

1 % slope (1 cm/m)
max. 10 vertical meters

per 5 vertical meters
GLRC chiller 
Discharge line
1 % slope (1 cm/m)

Liquid line
Circuit 2
Fig. 8-8: GLRC chiller below the condenser
 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.
8.4.3 Connecting refrigerating circuit

• Connect the field-provided piping system to the liquid and discharge line. The exact
positions of the connections can be taken from the documentation supplied with the
unit, the dimensional drawings and diagrams.
NOTICE!
To find out if the unit is equipped with one or two refrigeration circuits, refer to the unit
description in the Data&Facts catalogue, unit quotation text or order-related dimen-
sional drawing.
Two refrigeration circuits must be performed 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. For dimensioning of piping refer to Chapter 8.4.1.

Routing refrigerant lines

NOTICE!
During routing of pipes always consider that the pipe ends are sealed. Even if the unit
setup is incomplete, seal all pipe ends after the job is finished. Only in such a way
penetration of dirt and humidity can be prevented.
• Pipes should always be routed with a slight slope to the flow direction.
9 Thus, the refrigerant oil return to the compressor is facilitated. The refrigerant flows
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.
• Consider temperature-related changes in length!
Cutting To cut pipes use a pipe cutter, apply slow cutting method to avoid copper pipe defor-
mation.
Deburring Cut surfaces must be deburred. Ensure that copper chips do not penetrate into the
pipe.
Soldering and brazing

Brazing is the connection technique and is performed as hard-soldering method
defined according to DIN EN 1044. If necessary, use a flux 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 heat must be as high as necessary.
brazing – 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 should therefore be performed at appro-
priately low brazing temperature and the smallest possible surface should be heat-
ed.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 humid 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 braz-
ing 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 avail-
able antioxidants can be purchased. These antioxydants can contain different ag-
gressive components, that attack pipe material and can adversely affect
refrigerants or refrigerator oil, and should be used with extreme care.
GEA recommendation: use nitrogen!

Avoid oxidation during • Connect a pressure reducing valve at the nitrogen bottle.
brazing • 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.
9 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 to a manual-contact temperature.
• After brazing/soldering completely remove the remaining flux.
Drying systems
NOTICE!
When replacing components within the refrigeration circuit, the drier must
always be replaced too!
At the same time the drier must always be replaced last. The new drier is vacuum-
packed. After opening the vacuum packing, commence with brazing as soon as pos-
sible. Evacuation must be performed within 2 hours.
The drier must also be replaced, if the entire refrigerant escaped because of a leak.
Insulation
Insulation for the liquid line is not mandatory. Proper thermal insulation for the dis-
charge line must be provided, in order to prevent scalding risk posed by hot refrigera-
tion 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.
8.4.4 Leak testing

• Before leak testing, check the pressure gauge indication.
9 Indicated pressure must be within the overpressure range.
• In this is the case, keep the liquid shut off valve and suction gas shut off valve
closed for leak testing.
9 If overpressure is no longer measured in the refrigeration circuit of the unit, it should
be assumed that the unit refrigeration circuit is possibly leaking.
• In this case, open the liquid shut off valve and discharge line shut off valve for leak
testing.
For leak testing, the system must be depressurized with dry nitrogen, 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.
• After that overpressure in the system can be reduced.
8.4.5 Evacuation
Reasons for evacuation Before charging the system with a refrigerant, the refrigeration circuit must be evacu-
ated 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 tem-
peratures.
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 vapour 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 order-
related 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 vapour 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. 8-2
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.

Pressure rise after evacuation

0,018
1
0,016
Humid and leaking
Absolute pressure [bar]

0,014
2
0,012 Humid and leak-free
at Ta = +10 °C
0,01
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
8.4.6 Charging
DANGER OF LOW TEMPERATURE AND HIGH PRESSURE!
When charging a refrigeration system with a refrigerant, there is a risk of injury from
contacting liquid refrigerant or fluids/gases escaping at high pressure. Contact with
a liquid refrigerant can result in skin burns or injury to other organs.Exercise due cau-
tion and attention when carrying out jobs on the unit and avoid contact with the refrig-
erant.
R-410A The system is certified to be operated with a R-410A refrigerant. 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. For refrigerant volume for charging or its approximate calculation
refer to the Data&Facts catalogue of the relevant unit series.To avoid overcharging,
first charge around 80% of the calculated volume. Use the liquid refrigerant to fill
into 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!

GL Series Electrical Connection
9 Electrical Connection
Electrical 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 occupa-
tional health codes.
Ensure and observe protective measures!
When installing and connecting the unit, observe all protective measures for low-volt-
age systems according to the EU Directive as well as regulations and codes of the
local utility provider.
Ensure potential equalization and the earthing of the unit with all connected compo-
nents.

Disconnect all electric power and ensure the power cannot be inadvertently ener-
gized; earth, short-circuit and block off all neighbouring live parts. Non-compliance
can lead to death or serious injury.
NOTICE!
The cabling must be carried out according to the enclosed unit-specific wiring dia-
grams.
Only separate mains power cable may be used. Never connect other units to this
mains power cable.
9.1 Requirements
Before you start setting up the unit’s electrical connections, check the following:
– The properties of the mains power supply must comply with EN 60204-1 regulations
and the power requirements of the unit.
– 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 inval-
idate the warranty. To check, use the following formula (see example).
max. voltage imbalance from average value
Voltage imbalance [%] Δ U max = ------------------------------------------------------------------------------------------------------- × 100
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 by others – never change the wiring in the unit switch box.

Electrical Connection GL Series
EXAMPLE
Input data ➯ Result
Requirements Rated voltage ➔ 400 V/50 Hz/3 phases
Calculate and determine specific in- Voltage between ➔ L1/L2 = 409 V; L2/L3 = 398 V; L1/L3 = 396 V
put data and measurements before- phases
hand.
1. Step Average voltage ➔ ΣU

U m = -------
Determine averagevoltage Um 3
( 409 + 398 + 396 ) = 401 V

-----------------------------------------------
3 ➔ Um = 401 V
2. Step Voltage imbalance ΔU- ➔ max. voltage imbalance

max in %? Δ U max = -------------------------------------------------------- × 100
Determine the maximum Um
voltage imbalance ΔUmax Umax = 409 V
( 409 – 401 )V
----------------------------------- × 100 = 2 %
Um = 401 V 401 V ➔ ΔUmax = 2 % ✓
9.2 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 unit by a qualified licensed electrician – for maximum cable cross-sections
and fuses refer to Data&Facts catalogue.
For the supply cable grommets refer to the enclosed order-related documentation and
electrical wiring diagram.
• The cable grommet in the switch box 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 box !
• 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.

Fig. 9-1: Connection of mains isolator for unit with

L1 L2 L3 N PE
supply-voltage code 1
1 Q S1
L1 L2 L3 N PE
400V / 3 / 50Hz
Fig. 9-2: Connection of mains isolator for unit with

L1 L2 L3 PE
supply-voltage code 2
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 field-
provided supply lines of 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 field-provided 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 box !
• The cable grommet in the switch box 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.

9.3.2 Integrating common fault signal

DAMAGE TO THE UNIT!
Do not open the remote on/off contact, e.g. via the changeover contact of the
relay by others, if the system is faulty.
– In such a way the fault can be reset.
– The cause of the malfunction cannot be determined.
– The entire unit stops operating although only one refrigeration circuit is possibly
affected.
GEA unit • Connect the cable for common fault signal

(volt free dry contact, suitable for 230 V AC / 50
Hz / 2 A). See the electrical wiring diagram sup-
E F A B X Y
plied with unit, terminals X-Y.
Contact 230V/50Hz/2A
Remote On/Off* Flow
switch Relay by others
By others
Relay Common
fault signal
Fig. 9-3: Electric integration of error message

Terminals: A - B: Connecting flow switch by others
E - F: Remote contact for switching the unit on and off using the NOC by others
X - Y: 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

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.
GEA unit • Connect the external flow switch. See the

electrical wiring diagram enclosed with the unit,
terminals A/B. Cable specification: terminals
E F A B X Y
under voltage for wiring a volt-free contact by
others. Maximum cable length 100 m, minimum
230V/50Hz/2A cable cross-section 1.5 mm².
Contact
Flow
Remote On/Off*
switch Relay by others
Flow
switch Common
fault signal
Fig. 9-4: Electrical integration of flow switch

Terminals: 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 in such a way this requirement constitutes an
integral part for the validity of the warranty.

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 In units with an integrated hydraulic or pump module the cabling for pump controls is
pump module already done as standard and therefore no additional work is required on site. The con-
tacts 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 dry contact by others. 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 seconds

of the pump lead time.
Upon opening the external enabling contact (contact E-F) the compressors are con-
secutively switched off and the contact P1-P2 (pump enabling contact) opens 60 sec-
onds 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 oper-
ated 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 ena-
bling and deactivated compressors.
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.

GL Series Commissioning
10 Commissioning
This information applies to initial commissioning of the GEA units as well as re-com-
missioning after an extended shut-down period.
All commissioning work must only be entrusted to qualified licensed staff or other
individuals with proper professional training and experience in the relevant regula-
tions and codes of practice!
10.1 Requirements
Specific requirements for unit commissioning must be met. The function test must be
carried out by GEA Service or specialist refrigeration company (see section 4.10) and
the commissioning report must be drawn up and sent to GEA.
We recommend that the checklist “Technical requirements for commissioning report/
Recommendation! client witness test or maintenance of chillers/heat pumps” is used to ensure that the on-
Pre-Commissioning site requirements for drawing up the commissioning report are met. This can also save
Checklist additional work and costs because GEA 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! The commissioning report must be drawn up by GEA Service or a specialist refrigera-
Send Commissioning report tion company (see section 4.10). You must send the commissioning report to GEA
to GEA - for exact form - see Appendix II.If you do not send the commissioning report to
GEA, the warranty for your GEA unit will be rendered null and void!
Obligatory! With refrigeration units / chillers / heat pumps with a refrigerant charge exceeding 3 kg,
Create a unit report the owner or operator must draw up and continuously update the unit report after the
system is commissioned.
10.2 Commissioning procedure

Once the electric supply is energised 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, e.g.:
– 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.

Commissioning GL Series
• 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 unit
– Wiring diagram
– Refrigeration circuit diagram
– Hydraulic circuit diagram (if available)
– Installation manual for accessories (once ordered and enclosed)
Ensure the following before the mains isolator is applied to the unit and after all nec-
essary 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,
GLCU 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 summed up, i.e. are doubled
(refer to section 7.1 „Unit placement“).
• With air cooled units (GLAC, GLAH, GLCU and GLFC) ensure that fans can freely
discharge air in up-flow direction.
• 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. GEA strainer, GEA
flow switch) is properly installed in accordance with the specifications and condi-
tions specified in chapter 8 "Medium Connections".
• Check if the connected chilled water circuit is properly charged and vented cor-
rectly and that entire pipework and all pipe connections are leak-free and insulat-
ed.
• Check that all filling valves and vent cocks are closed.
• Check that 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 „In-
tegration of flow switch“).

• 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“).
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 GLCU
Installation Outside Inside Inside Inside Outside Outside

Evaporator ✓ 1) ✗ 3) ✗ 3) ✗ 3) ✓ 2) ✗
Condensers ✗ ✓1) ✗ ✗ ✗ ✗
1) Alternatively, charging glycol is not necessary, if e.g. a pipework trace heating is provided or the pipe-
work 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

Disconnect all electric power and ensure the power cannot be inadvertently ener-
gized; earth, short-circuit and block off all neighbouring live parts. Non-compliance
can lead to death or serious injury.
• Disconnect the unit from the power supply. Re-tighten all electrical connections in
the switch box and in terminal board of 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 box for damaged components.
• Ensure that wiring by others is carried out in accordance with the instructions and
requirements specified in chapter "Electrical Connection". This chapter stipulates
observing 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 field-provided
potential.
– 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

Once the electric supply is energised to the unit, beware of electric shock during
checking and commissioning the unit. For this job - due caution and attention are
required.
For the following steps refer to chapter 9 „Electrical Connection“.
DAMAGE TO THE UNIT!

If the unit is equipped with a pump enabling function (see chapter 9.3.6 pump ena-
bling) 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 deac-
tivated 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.

9 The background lighting of the display and keyboard of the control panel is
activated.
9 The oil heating is in operation.
• Operating control panel is not necessary at this point!
Warm-up phase before operation
DAMAGE TO THE UNIT!

Before commissioning, the unit must be supplied with electricity for at least 8 hours
with main isolator switched on.This preheats the oil in the compressors. The com-
pressors can be damaged if this warm-up phase is not carried out. Use a measuring
device to check the operation of oil heating.
• Check supply voltage. The voltage must match the details on the nameplate/
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 box.
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 cabi-
net.
Checks in the course 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 GEA Service.
Dispose of any escaping media or oil immediately in an environmentally-friendly
manner and in compliance with local laws and regulations.
NOTE FOR REFRIGERATION COMPANY.

• Make sure that all manually operated shut-off valves in the refrigeration circuit are
open. These checks must only be carried out by 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 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 (AL003, AL045, 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.
Calibration
8 hours of uninterrupted oil heater operation will ensure that there is no more refriger-
ant in the oil. The unit can now be put into operation and calibrated.
DANGER OF HOT SURFACES!

Certain components and surfaces of the unit and media can get hot during operation.
There is a risk that burns may be inflicted when taking measurements.
• 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 opera-
tion of the unit. A stable operating state is reached approximately 0.5 h following the
unit activation. Only then calibration can 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 exchanger

• 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
– Setpoints
– External enabling (ON/OFF)
– Notification of maintenance intervals
– Alarm readings including frost protection
– etc.
if necessary, perform corresponding adjustments (refer to chapter 11).
• Activate all compressors and fill in the commissioning report in the Appendix II.
• For complete and full documenting of commissioning, it is recommended to fill in the
Measuring Report in Appendix III.
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.geagroup.com) for specific unit data.
Water circuit:
Inlet: min. -5 °C – max. 23 °C
Evaporator: Outlet: min. -8 °C – max. 15 °C
ΔT: min. 3 K – max. 8 K
Inlet: min. 10 °C – max. 47-51 °C
Condenser (GLWC/GLWH) Outlet: min. 26 °C – max. 51-55 °C
ΔT: min. 4 K – max. 16 K
Outside air/
See unit operating range (compare chapter 5.4)
condensation temperature
Superheating: 5 - 10 K
Subcooling: 3-5K
Refrigeration circuit:
Discharge temperature: Max. 120°C
Suction pressure Economiser: 1.5 - 2 bar > suction pressure
Tab. 10-1
NOTICE!
You must send the commissioning report to GEA! If you do not send the commission-
ing report to GEA, the warranty for your GEA unit will be rendered null and void!

GL Series Operation
11 Operation
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“ are carried out.
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 GEA HVAC systems - Step I and GEA HVAC systems
- Step II, excluding units of the GLFC series:
Operator ele-
Description
ment
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 pa-
rameters that need to be changed.
Is used to navigate the screens and to enter/change parameter values down-

wards.
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.
Priorities of various options:
Highest priority: – Activation/deactivation by entering parameters (Com.: ON/ Com.: OFF)
– Activation/deactivation via digital input (refer to „External enabling through digital
input“ refer to section 11.3.1)
– Activation/deactivation using integrated timer programme (only GEA HVAC sys-
tems Step II and Step III)
Lowest priority: – Activation/deactivation using Building Management System
9 The first line of GEA 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.

Operation GL Series
11.2.1 Switching on
ATTENTION!
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.
9 The first character of the “OFF” parameter flashes.
• Select “ON” using the “Up” or “Down” key.
• Confirm the setting with the “Enter” key.
9 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.
9 The first character of the “ON” parameter flashes
• Select “OFF” using the “Up” or “Down” key.
• Confirm the setting with the “Enter” key.
9 If “OFF” remains displayed - the unit is switched off.

NOTICE!
The oil preheating remains active!
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 box 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.

GL Series Operation
• Press the “Enter” key to confirm.
• Enter the password "1234" using the arrow keys.
• In the “User” menu use the arrow keys to set “Ing. dig. enabled: on/off ” Set
enable via Dig.Input: on/off“).
• With the arrow key change “N” to “Y”.
• Press the "Esc" key to return to the start screen.
9 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 the water inlet and outlet temperature controls

If you change the control mode 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.
• Select the “Setpoint” menu with the arrow keys.
9 Use the arrow keys to adjust the parameter “Chiller setpoint”.
• Change the parameter using the arrow keys.

Operation GL Series
– "by steps" With GEA HVAC systems Step II controller, the standard setpoint of
"INPUT": 7°C is displayed here, which in the preset proportional band corre-
sponds to the actual setpoint of 12°C (7.0°C + 5.0°C P-band = 12.0°C).
With GEA HVAC systems Step I controller, the standard setpoint of
9.5°C is displayed here, which in the preset proportional band corre-
sponds 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
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)
11.4 Overview of operator elements

Operator and display elements GEA HVAC systems - Step III
and units of the GLFC series:
Operator
Description
element
Enables unit switching on and off.
Serves to display and reset alarms.
Fig. 11-2: Alternative display of unit 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 pa-

rameter values downwards.
Used to navigate the screens and to enter/change pa-

rameter values upwards.
Use the Enter key to confirm the selection and to place

the cursor below parameters that need to be changed.
Display LED
element colour Description
If the LED is permanently on, the compressor is switched. If the LED is flash-
Green ing - the compressor is requested to switch, however, it is blocked due to the
internal safety time.
Red 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

GL Series Operation
Green The circuit is in free-cooling mode
LED on: The circuit is in heat recovery mode

Green
LED flashes: The circuit has an alarm in heat recovery mode
LED on: The circuit is in defrost mode
Green
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.
Priorities of various options:
Highest priority: – 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 "GEA HVAC systems
controller")
Lowest priority: – on/off using monitoring protocol (see operation manual "GEA HVAC systems con-
troller")
9 The first line of GEA 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.
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.
9 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.
9 If “off” remains displayed - the unit is switched off.
NOTICE!
The oil preheating remains active!

Operation GL Series
11.5.3 Operating controller
11.5.4 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.
11.5.5 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”.
• Change the parameter using the arrow keys.

– "by steps" As a control system type
"INPUT": 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“ as control mode
„OUTPUT“: standard setpoint 7.0 °C is displayed here
• 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 evapo-
rator water outlet).
For further controller settings refer to controller operation manual.
11.5.6 Temperature regulation

The GEA 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

GL Series Operation
Proportional control via chilled water inlet temperature - unit with 2 capacity stages
Example cooling:
Capacity
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 run-
ning (setpoint 9.5 °C + proportional band 2.5 K = 12.0 °C). If the water temperature
entering the evaporator makes up 12.0 °C, the 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
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.

Operation GL Series
Example cooling:
Capacity
Setpoint Water inlet
Setpoint
Proportional band 5 K
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.
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:
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 compres-
sors. 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 temper-
ature control and assuming continuous operation, the water outlet temperature will
fluctuate between 5.75 °C and 8.25 °C.

GL Series Operation
Example heating:
Capacity
Water inlet
Setpoint
Proportional band 2.5 K

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.
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:

If the water inlet temperature amounts to 40.0 °C or less, both compressors will be run-
ning (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 compres-
sor 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.

Operation GL Series
Example heating:
Capacity
Water inlet
Setpoint
Setpoint
Proportional band 5 K
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 con-
tent of the unit is sufficient.
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:
If the water inlet temperature amounts to 37.5 °C or less, all compressors will be run-
ning (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 contin-
ued.
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 + propor-
tional 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.

GL Series Operation
Auto-adaptive control with neutral range via water outlet or inlet temperature
Capacity reduced Capacity increased
Setpoint cooling/heating
Capacity ↓ Capacity↑
Neutral zone
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 auto-
matically 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 tempera-
ture 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 algo-
rithm is able to determine the dynamics of the system. The neutral range is calculated
so that the compressor switching times and the max. permissible start-up frequency
(e.g. 8 times per hour) only cause very small temperature deviations from the setpoint.
Other implemented functions reduce the compressors’ start-up frequency at low loads.
Capacity stages are activated and deactivated not only as a result of wide setpoint var-
iances, but also in relation to the temperature change-over time, which allows to make
conclusions about the output.
Disconnecting the unit from the power supply
DAMAGE TO THE UNIT!
– Frost protection using internal frost protection heating is not provided.
– The oil preheating is no longer active.
• Shut down the main isolator.

9 The unit is now disconnected from the power supply.
ELECTRICAL HAZARD!
Check that all electrical control cables by others are disconnected from the power
supply. Depending on the contact, potential by others on site may be necessary.
Also disconnect control contacts by others from the power supply.
DAMAGE TO THE UNIT!

If the unit has been switched off for more than 3 hours, it must be energised through
the main isolator for at least 8 hours before putting it back into operation. This pre-
heats 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.

Operation GL Series
11.6 Draining water circuit

HAZARDOUS VOLTAGE!
Before draining the water circuit of the unit, disconnect all power supply connections,
ensure the power cannot be inadvertently energised and verify that electric lines
have been disconnected. Earth and short-circuit them, block off or otherwise isolate
all live components. Non-compliance can lead to death or serious injury.
• 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.
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 buff-
er 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.
11.7 What to do in case of alarm and error messages
DAMAGE TO THE UNIT!

In the case of alarms and faults always make sure that the cause of the fault is inves-
tigated. In particular, multiple resetting of alarms without rectifying the cause can
damage the unit and invalidate the warranty.
Refer to chapter "Troubleshooting" for help in the event of alarm messages.

GL Series Fault Finding and Troubleshooting
12 Fault Finding and Troubleshooting

DAMAGE TO THE UNIT!
If alarms are reset several times without eliminating the fault, serious unit damage
can be the consequence. The fault must not be reset manually
without prior consent of the licensed refrigeration company or GEA
12.1 Alarms
What to do in case of alarms:
1. Inform GEA Service.
2. Have GEA Service attend to the cause of failure.
3. Only GEA Service is allowed to reset the fault.
9 In case of an alarm the “ALARM” key lights up red.

To read out the alarm messages, proceed as follows:
• Press “ALARM” key.
9 If no alarms are pending, “No Alarm detected” is displayed; otherwise “AL...”is

displayed together with the alarm code and a short description.
• If several alarms are pending, you can scroll through the current alarm list with the
arrow keys.
• Press any key to exit the menu.
• Inform GEA Service.
12.1.1 Only for GEA service

To reset the alarm:
• Eliminate the cause of failure.

• Hold the “ALARM” key pressed down until “No Alarm detected” appears.
9 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.

Fault Finding and Troubleshooting GL Series
ALARM DESCRIPTION Details RESET Action

002 Phase sequence/ Phase sequence relay tripped and prevents unit start.
voltage outside the allowable Possible reasons to be investigated:
range 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 A U
– Defective input of controller PCB
– Incorrect wiring
– Loose cable connection
– Cable failure
Note: never change wiring in the unit switch box. In case of an incorrectly connect-
ed 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 A/M U
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
– Cable failure
Alarm is reset twice within one hour automatically, if automatic resetting within op-
erating time corresponds to parameter P23.34. Otherwise the resetting of alarm
must be performed manually.
005 Low water temperature at in- Water inlet temperature at evaporator fell below allowed limit.
let 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“). S-A -/U
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.
006 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 S-A -/U
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.


010 Evaporator frost protection Water outlet temperature of evaporator equals or lower than set frost protection val-
ue.
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
– 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 %) M CI
– Temperature difference evaporator inlet and outlet is too high
– Ambient temperature is lower than set frost protection value*
* 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 im-
portant.
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-men-
tioned measures is attempted more than five times within 8 operating hours.
014 Insufficient pressure in sys- If an external contact, which must be wired in the switch box of the unit, is open,
tem 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 M U
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 S -
site.
021 Low water content of system Water inlet temperature at evaporator changes too fast or falls too fast.
Possible reasons for investigating alarm release:
– Water content in unit too low/standard minimum water content for unit is not ful-
filled
– Load reduction of consumers is too small S -
– Installed cooling capacity is too great
Remedy:
– Install a suitable buffer tank
– Reduce unit capacity by deactivating one compressor.
022 Low water flow volume in sys- Temperature difference between evaporator inlet and outlet exceeds 8 K for more
tem than 30 seconds.
Water circuit:
– Flow regulating valve closed too wide M U
– No constant water flow rate across unit using e.g. speed-regulated
pump
045 Flow switch of condenser 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). A/M U*
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.
046 Flow switch See alarm message 010 „Flow switch of evaporator“. This error message is only
A U*
recuperator valid for water circuit of heat recovery system.


051 Maintenance pump 1 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. S -
Automatic notification about maintenance intervals can be deactivated using a serv-
ice password.
To rest an alarm the service password is required as well.
052 Maintenance pump 2 See alarm message 051 „Maintenance pump 1“.
S -
(only for units with 2 pumps).
057 Maintenance of heat recovery See alarm message 051 „Maintenance pump 1“.
pump S -
(only for units with a pump for heat recovery).
058 Maintenance condenser See alarm message 051 „Maintenance pump 1“.
pump S -
(only for units with a pump for condenser).
075 Condenser frost protection 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. M U*
This alarm message is only valid for water cooled heat pumps with a reversible cir-
cuit via an integrated 4-way valve.
076 Frost protection recuperator See alarm 010 „Evaporator frost protection”.
A U*
This alarm message is only valid for frost protection failure of heat recovery.
079 Control module of VPF sys- Communication with controller on „variable water volume regulation“ is interrupted.
tem uncoupled Possible reasons for investigating alarm release:
Electrical system:
– Loose cable connection A U
– Cable failure
– Defective control module
– Defective output of controller PCB
080 Break-down of control module Controller failure for „variable water volume regulation“
of VPF system A U
Check indication on display of VPF module.
081 Overload protection, pump 1 Overload relay of pump 1 tripped and prevents pump start.
With units fitted with a single pump - pump 1 is evaporator pump.
General:
– Motor mechanical blockage
– Water flow rate too high*
– Operation outside operating limits
Electrical system:
– Power supply outside tolerance range
– Phase asymmetry too high M U
– Contact resistance of load contactor too high
– Defective overload relay
– Cable failure
*If water flow rate is too high, current consumption of pump rises. Through pressure-
side 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 evapo-
rator 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, con- See alarm message 081 „Overload protection pump 1“ (only for units with pump for
M U*
denser condenser).
086 Overload protection recuper- See alarm message 081 „Overload protection pump 1“ (units with pump for heat re- M U*
ator pump covery).
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 refrig-
eration circuits. Circuit 3 and 4 are controlled by „Slave-PCB".
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 A U
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)
– Cable failure


091 Isolation expansion with ad- Communication with extension card with address 1 is interrupted.
dress 1 In units with 3 or 4 refrigeration circuits „Master“ is additionally indicated on display.
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 A U
– 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
– Cable failure
092 Isolation Exp. address 2 See alarm message 091 „Isolation expansion with address 1“ only for extension 2 A U
101 Isolation expansion See alarm message 091 "Isolation expansion with address 1" only for extension 1
A U
Slave with address 1 of Slave
102 Isolation expansion See alarm message 091 "Isolation expansion with address 1" only for extension 2 A U
Slave with address 3 of Slave A U
A U
105 Isolation expansion See alarm message 091 "Isolation expansion with address 1" only for extension 5 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 opera-
tion, 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.
Refrigeration circuit
– Insufficient oil due to leak
– Insufficient refrigerant
– Faulty expansion valve
– Defective oil level switch
– Defective solenoid valves of compressors
M CO
– Defective output of controller PCB for solenoid valve(s)
– 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 com-
pressor 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.
112 Oil compressor 2 See alarm message 111 „Oil compressor 1“ only for compressor 2 M CO


121 High discharge temperature Discharge temperature of compressor Nr.1 is too high.
compressor 1 Possible reasons to be investigated:
– Insufficient oil
– Icing on air cooled heat exchanger (only GLAH units in heating mode)
Electrical system: M CO
– Faulty discharge temperature sensor
– Faulty compressor
– 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 See alarm message 121 „High discharge temperature compressor 1“ only for com-
compressor 2 pressor 2 M CO
M CO
compressor 3 pressor 3
124 High discharge temperature See alarm message 121 „High discharge temperature compressor 1“ only for com- M CO
M CO
127 High discharge temperature See alarm message 121 „High discharge temperature compressor 1“ only for com- M CO
131 Fault, compressor 1 Motor protection relay and/or automatic circuit breaker tripped for compressor 1.
– Acidic oil
– Faulty solenoid valve for liquid injection/missing liquid injection
– Mechanical blockage of compressor
Electrical system:
M - A/M CO
– 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.
– Cable failure
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
151 Maintenance, compressor 1 Sum of operating hours exceeds maintenance interval stored in controller.
General alarm contact is closed, but the unit continues to operate.
Automatic notification about maintenance intervals can be deactivated using a serv- S -
ice password.
To rest an alarm the service password is required as well.


152 Maintenance, compressor 2 See alarm message 151 „Maintenance compressor 1“ (only for units with 2 com- S -
pressors).
153 Maintenance, compressor 3 See alarm message 151 „Maintenance compressor 1“ (only for units with 3 com-
pressors). S -
S -
pressors).
pressors).
S -
pressors).
pressors).
pressors). S -
201 Alarm circuit 1 Please contact GEA Service a.s.a.p. S -

211 High pressure, circuit 1 High pressure switch of refrigeration circuit 1 tripped because of too high pressure.
General/Water circuit:
– Dirty condenser
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
– Pumping capacity too low M CI
– Water inlet or outlet temperature in condenser is too high
– Temperature difference between condenser water inlet and outlet too low/high
– Overcharge of refrigerant
Electrical system:
– One or more fans not in operation
– Fan does not operate at full speed
– Faulty high pressure switch
– Cable failure
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 dam-
age to the battery.
212 High pressure, circuit 2 See alarm message 211 „High pressure circuit 1“, but for refrigeration circuit 2 M CI


221 Overload protection, fan cir- At least one overload relay and/or automatic circuit breaker tripped for fans in circuit
cuit 1 1.
General:
– Fan is mechanically blocked
Electrical system:
– Load contactor does not switch one or more phases
– Contact resistance of load contactor too high M CI
– Coil short circuit of fan motor
– Winding short circuit of compressor motor
– Earth fault of fan motor
– Cable failure
of fan can be the consequence.
222 Overload protection, fan cir- See message 221 „Overload protection fans circuit 1“, only for fans in circuit 2
cuit 2 M CI
223 Overload protection, fan cir- See message 221 „Overload protection fans circuit 1“, only for fans in circuit 3
M CI
cuit 3
224 Overload protection, fan cir- See message 221 „Overload protection fans circuit 1“, only for fans in circuit 4 M CI
cuit 4
231 Low pressure, circuit 1 Low pressure sensor or low pressure switch of refrigeration circuit 1 is deactivated
because of too low pressure.
– 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 opera-
tion)
– Faulty solenoid valve for liquid line
Water circuit:
– Temperature difference between evaporator water inlet and outlet too low/high
(min/max 3 to 8 K)
– Water inlet or outlet temperature at evaporator is too low
A/M CI
– Too low air inlet temperature
– Condenser is not wind protected at ambient temperature < -10 °C (refer to oper-
ating
limits)
– Water temperature at condenser is too low (refer to operating limits)
Electrical system:
– Faulty low pressure sensor
-> Check pressure value 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 the controller.
– Faulty low pressure switch
– Cable failure
In the course of relevant circuit start, low pressure alarm is bridged for 120 s for reg-
ulating 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


241 High pressure through High pressure sensor of refrigeration circuit 1 tripped because of too high pressure.
Converter 1 Possible reasons to be investigated:
General/Water circuit:
– Dirty condenser
– 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.
– Dirty heat-rejection unit
M CI
– Water inlet or outlet temperature in condenser is too high
– Too low/high temperature difference between water inlet and outlet of condenser
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
– 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
M CI
circuit 3
244 High pressure converter 4 See alarm message 241 „High pressure through converter 1“, but for refrigeration M CI
circuit 4
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.
– Faulty solenoid valve for liquid line
Electrical system:
-> Check indicated pressure in controller with actual A CI
pressure measured by pressure gauge.
– Deactivated low pressure sensor
– 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


261 Missing freon in circuit 1 If alarm 251 has been active for more than 8 hours, alarm message 261 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.
General:
– Dirty air cooled heat exchanger
– Air cooled heat exchanger with incomplete defrosting due to:
- insufficient clearances around unit A/M CI
- air short circuit
– Snow on/around air cooled heat exchanger
– Air inlet temperature of unit is too low, unit running outside operating limits
272 Finned tube battery circuit 2 See alarm message 271 „Finned tube battery circuit 1“, but for refrigeration circuit 2 A/M CI
281 Evaporating pressure insuffi- Alarm indicates that low pressure during operation is below expected pressure.
cient in circuit 1 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.
min of operation)
– Shut off valve(s) closed/not completely open
tion)
Water circuit:
– 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 M CI
– Condenser is not wind protected at ambient temperature < -10 °C (refer to oper-
ating limits)
Electrical system:
-> Check pressure displayed in controller against the actual pressure measured by
pressure gauge.
– Cable failure
282 Evaporating pressure See alarm message 281 "Insufficient evaporating pressure circuit 1", only for
M CI
insufficient in circuit 2 refrigeration circuit 2
insufficient in circuit 3 refrigeration circuit 3 M CI
M CI
insufficient in circuit 4 refrigeration circuit 4


400 Fault, sensor 10 Received readings for sensor 10 on the main PCB (Master) are outside limiting val-
ues.
Use the wiring diagram to establish if a temperature or pressure sensor is connect-
ed to terminal B10 on the main PCB (Master).
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 dif-
ference 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. A *
- 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 read-
ing, other pressure/current readings belong linearly in-between).
– Faulty pressure sensor
– Faulty temperature sensor
– Non-available analogue 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).
– Cable failure
401 Fault, sensor 1 See message 400, but for sensor B1 of main PCB (Master) A *
411 Exp 1 faulty sensor 1 See message 400, but for sensor B1 of extension address 1 A *


500 Slave faulty sensor 10 See message 400, but for sensor B10 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 *
611 Pre-alarm frost protection for Pre-alarm is a signal message transmitted to building management system Unit
evaporator 1 continues to operate and informs beforehand about expected fault message. Gen-
eral alarm contact is not closed.
Pre-alarm must activated in controller menu and the corresponding signal value S -
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“
612 Pre-alarm frost protection for See alarm message 611 „Pre-alarm frost protection evaporator 1“, but for evapora-
S -
evaporator 2 tor 2
613 Pre-alarm frost protection for See alarm message 611 „Pre-alarm frost protection evaporator 1“, but for evapora- S -
evaporator 3 tor 3
614 Pre-alarm frost protection for See alarm message 611 „Pre-alarm frost protection evaporator 1“, but for evapora-
evaporator 4 tor 4 S -
631 Pre-alarm low pressure Pre-alarm is a signal message transmitted to building management system Unit
Circuit 1 continues to operate and informs beforehand about expected fault message. Gen-
Pre-alarm must activated in controller menu and the corresponding signal value
must be entered as a positive difference to alarm value. S -
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 evalu-
ated.
632 Pre-alarm low pressure See alarm message 631 „Pre-alarm low pressure circuit 1“, but for refrigeration cir-
cuit 2 S -
Circuit 2
cuit 3 S -
Circuit 3
cuit 4 S -
Circuit 4


641 Pre-alarm high pressure Pre-alarm is a signal message transmitted to building management system Unit
Circuit 1 continues to operate and informs beforehand about expected fault message. Gen-
Pre-alarm must activated in controller menu and the corresponding signal value
must be entered as a positive difference to alarm value. S -
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 eval-
uated.
642 Pre-alarm high pressure See alarm message 641 „Pre-alarm high pressure circuit 1“, but for refrigeration cir-
cuit 2 S -
Circuit 2
cuit 3 S -
Circuit 3
cuit 4 S -
Circuit 4
651 Checking operating range: Alarm indicates that discharge temperature fell below minimum allowed discharge
discharge temperature too temperature while operation.
low for circuit 1 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, dur-
ing pump downtime or defrost cycle.
tion)
– Condenser is not installed in a wind protected location (refer to operating limits) M CI
- 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 meas-
ured by thermometer.
ference between setpoint and actual value is too great, the temperature sensor
is faulty.
- Defective input of controller
- Incorrect wiring
- Loose cable connection
- Cable break
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: Refer to alarm message 651 „Checking operating range: discharge temperature too
discharge temperature too low in circuit 1“, only for refrigeration circuit 2 M CI
low for circuit 2
low for circuit 3
low for circuit 4


661 Checking operating range: Alarm indicates that discharge temperature exceeded maximum allowed discharge
discharge temperature too temperature while in operation.
high for circuit 1 Setpoint for the maximum 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.
- 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 opera-
tion)
- Operation outside operating limits
Water circuit:
- Water temperature at condenser is too high (refer to operating limits)
- Air inlet temperature too low (refer to operating limits) M CI
- 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 meas-
ured by thermometer.
ference between setpoint and actual value is too great, the temperature sensor
is faulty.
- Defective input of controller
- Incorrect wiring
- Loose cable connection
- Cable break
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.
discharge temperature too high in circuit 1“, only for refrigeration circuit 2 M CI
high for circuit 2
high for circuit 3
high for circuit 4
671 Checking operating range: Alarm indicates that high pressure fell below minimum allowed high pressure while
high pressure too low for cir- in operation.
cuit 1 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 deacti-
vated as a result of a fault.
min of operation)
tion)
– Too low air inlet temperature M CI
– Condenser is not installed in a wind protected location (refer to operating limits)
Electrical system:
-> 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.
– Cable failure
This alarm requires high and low pressure sensors per each refrigeration circuit.


high pressure too low for cir- low in circuit 1“, only for refrigeration circuit 2 M CI
cuit 2
cuit 3
cuit 4
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

12.3 Resistance temperature sensor for GEA 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
40
Resistance [kOhm]
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 GEA HVAC systems controller

GL Series Servicing and maintenance
13 Servicing and maintenance
13.1 Servicing and cleaning

DANGER – SHARP CUTTING EDGES!
Exercise due care when cleaning the unit due to risk of injury caused by sharp fins
(only GLAC, GLAH, GLCU, GLFC and GLDC).
13.2 Maintenance
Unit report With refrigeration units / chillers / heat pumps with a refrigerant charge exceeding 3 kg
the owner or operator has to create and continuously update the unit report. According
to the EN 378-4 standard, the unit report must be updated following the unit mainte-
nance or service. You can find the unit report 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. In such a way a clear relationship is established between the unit,
the current operation manual and the unit report.
Maintenance Unit maintenance must only be carried out by GEA 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! Have the system serviced at least once a year!
A minimum Depending on the refrigerant charge, legal codes and regulations require to have this
1 annual maintenance maintenance conducted, at the same time the latter also constitutes the condition for
the validity of the warranty.
Moreover, the following legally mandatory maintenance intervals must be observed:
Maintenance
Maintenance Condition Responsible
frequency
Refrigerant Leakage detec-

charge tion system
over 300 kg yes

every 6 months Check that the entire system is tight
30-300 kg no
Perform maintenance on the entire system! - -
30-300 kg yes
Check that the entire system is tight
GEA Service or li-
3-30 kg - censed refrigeration
every 12 months company
Check proper function of the leakage detection - -
system (if available)
Always check glycol content of the unit if the liquid - -

is topped up!
every 24 months
Check water glycol mixture for corrosion protec-
- -
tion properties
For exact refrigerant charge volume - refer to the unit identification plate.
Depending on operating hours and ambient temperature, it can become necessary to

perform unit maintenance several times a year. GEA Service can draw up an individual
maintenance plan for you.
For each maintenance of GEA unit the Measuring report, enclosed in Appendix III,
must be filled in by the GEA Service or a licensed refrigeration company (refer to sec-
tion 4.10). They should provide you with a copy of this report (or the original) listing all
maintenance jobs carried out and recorded measured values.

Servicing and maintenance GL Series
Use this report to verify whether all specified maintenance jobs and measurements
have been carried out.
Also consider legal requirements regarding maintenance of refrigeration chill-
ers/heat pumps and connected systems apply in addition to previously men-
tioned regulations.
Recommendation! We recommend that you have your unit serviced twice a year.
2 maintenance services per
year
NOTICE!
If case of leaking refrigerant, liquids or oil - switch off the unit immediately and inform
GEA Service.
All leaking media must be disposed of in accordance with the current regulations,
local codes and practices.

GL Series Dismantling and Disposal
14 Dismantling and Disposal
Have qualified licensed staff dismantle and dispose of the unit!
14.1 Dismantling
To dismantle the units proceed as follows:
When carrying out decommissioning and dismantling work on the unit, disconnect all
power supply connections, ensure the power cannot be inadvertently energized and
verify that electric lines have been disconnected. Earth and short-circuit them, and
cover or otherwise isolate any neighboring live parts. Non-compliance can lead to
death or serious injury.

When carrying out decommissioning and dismantling jobs on the unit, shut off and
empty all connected pipework until the system pressure has equalized with the ambi-
ent air pressure. Failure to follow safety precautions can result in serious injury.
• 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.
PERSONAL INJURY
Secure the unit against slipping.
9 The unit is ready for transport.

• Consider all instructions on shipping (refer to chapter 6).
14.2 Disposal
NOTICE!
The operator of the refrigeration unit is responsible for taking all necessary precau-
tionary measures and ensures that only certified and licensed staff properly recov-
ers, 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.
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.

Appendix GL Series
15 Appendix
The following pages contain check lists and reports:
On 15.1 Appendix I 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 GEA 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 Commissioning Report

Refer to Appendix II Fill out the report in the course of the client witness test.GEA Service or a licensed spe-
cialist refrigeration company must carry out a Client witness test (see section 4.10)
then fill out Commissioning Report and sent it to GEA.
NOTICE!
You must send the commissioning report to GEA!If you do not send the commission-
ing report to GEA, the warranty for your GEA unit will be rendered null and void!
Siehe “Schematic representation of various hydraulic circuits (examples)” auf Seite 33.
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“. They should provide you with a copy of this report (or the origi-
nal) listing all maintenance jobs carried out and recorded measured values.
This report contains all maintenance procedures that must be carried out according to
GEA. 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 chill-
ers/heat pumps and connected systems apply in addition to previously men-
tioned regulations.

Appendix
15.1 I Requirements for Function Testing or Maintenance of Chiller/Heat Pump
Technical
Technical Requirements for Function Testing

Technical
Technische Requirements
Voraussetzung zur for Function Testing
or Maintenance
Funktionsprüfung
or Maintenance
of
oder Chiller/Heat
ofWartung
Pump.
Kaltwassererzeuger
Chiller/Heat Pump / Wärmepumpe
Customer: Construction site:
Customer: Construction site:
Address:
Address: Address:
Address:
Kunde:
Tel./Fax.: Baustelle:
Tel./Fax.:
Tel./Fax.:
Anschrift: Tel./Fax.:
Anschrift:
Contact
Contact
Tel.:
person
/ Fax.: person
Contact
Contact
Tel.:
person:
/ Fax.: person:
Contact person
Contact person
Ansprechpartner: onon
site:
site: Can
Can be reached tel.:
be reached
Ansprechpartner:
GEAGEA Order
AnsprechpartnerNr.:
Order vor
Nr.:Ort: Unit
Unittype:
type: zu erreichen unter Serial-Nr.
Tel.:
GEA-Auftrags-Nr.: Gerätetyp: Serien-Nr.:
Design
Design data:
data:
Auslegungsdaten: 1)
Setpoint
Setpoint temperature
temperature water
water in:in: °C°C Coolwater
Cool water setpoint
setpoint temp. temp. in in1)1)1) °C
°C
Sollwerttemperatur water out:
Wasser Eintritt: °C
°C Cool water setpoint temp.
Kühlwassersollwerttemp. out
Eintritt : 1) °C°C
Sollwerttemperatur
water out:
Wasser Austritt:
°C°C
Cool water setpoint temp.
Kühlwassersollwerttemp. Austritt
out1)
: 1) °C %
°C
Glycol concentration: % Glycol concentration in cool water
1) cool water1):
:
Glycol concentration:
Glykol-Anteil %% Glycol concentration
Glykol-Anteil Kühlwasser
1) in : % °C%
Freeze point: °C Freeze point :
Freeze point:
Gefrierpunkt: °C°C Freeze
Gefrierpunkt :1):
point1)charge 1) °C °C
Chilled water charge:
Kaltwassermenge:
m³/h
m³/h
Cool water
Kühlwassermenge
1)
: 1): m³/h
m³/h
Chilled water
type:charge: m³/h Cool water charge 1) : m³/h
TypGlycol Glycol
Typ destype used1) : Glykols 1)
des eingesetzten Glykols: eingesetzten :
Glycol
Glykol type:
Glycol charged
gefüllt am: on: Glycol
Glycol type
charged
Glykol gefüllt used
am :on :
1) :
1)
Glycol
Glykol charged
Glycol on: von: by:
added/checked
eingefüllt / geprüft Glycol
Glycol charged
added/checked
Glykol eingefüllt on1): von
/ geprüft by1)1)::
Glycol added/checked by: Glycol added/checked by1):
Pos.: Bauseitige Voraussetzungen

Requirements für die Funktionsprüfung
to be met by others prior to function test Geprüft
Checked
1. Elektroanschlüsse gemäß örtlicher
Requirements EVU-Vorschriften
to be metlocal
by others inkl.
priorerforderlicher
to function Absicherung
test fusing Checked
1. Electrical connections according to the utility guidelines incl. necessary
2. 2. Electrical
1. Bauseitige Absicherungaccording to the local utility guidelines incl. necessary fusing
On siteconnections
fusing _____
____AA
2
3. 3. On On
sitesite supply piping ___mm 2
2. fusing
Bauseitige Zuleitung ____A
_____ mm
4. Electrical cabling between the components
3.
4. On site supply piping
Elektroverdrahtung zwischen den Komponenten: ___mm2
- On site chilled and cool water pump
-
Bauseitige
4. - Flow
Electrical
- cablingKalt-/Kühlwasserpumpe
switch between the components
Strömungswächter
- Remote On/Off
- On
- site chilled andcontact (if available)
cool water pump
Fern Ein/Aus
- Common Kontakt (sofern gewünscht)
fault signal
- Flow
- switch
Allgemeine Störmeldung 1)
- External air cooled heat rejection units / condenser2)2)
- Remote
- On/Off
externen contact (if available)
luftgekühlten
1)
Rückkühler / Verflüssiger
5. - Common fault signal
Water connection and pipe network filled and bled according to local and national codes.
5. Wasseranschluss und Rohrnetz nach 1)
örtlichen 2)
und behördlich definierten Richtlinien
- External
6. gefüllt,
air cooled
Strainer/water
heat
filter
rejection
fitted
units
directly geprüft.
/ condenser
before the water-side inlet to the unit.
entlüftet und auf Dichtigkeit
5. 7. Water
Flowconnection
switch and
fitted pipe network
directly filled and bled according to local and national codes.
6. Wasserfilter unmittelbar vor after
dem the water-side
wasserseitigen outlet of in
Eintritt thedas
unit.
Gerät installiert.
6. 8. Strainer/water filter fitted
Water-side safety devicedirectly before
installed and the water-side
tested for correctinlet to the unit.
function, fixtures such as
7. Strömungswächter unmittelbar nach dem wasserseitigen Austritt aus dem Gerät installiert.
thermometer, differential pressure gauge fitted above the heat exchanger.
7.
8. Flow switch fitted
Wasserseitige directly after the water-side
Sicherheitseinrichtung installiertoutlet of the
und auf unit. geprüft, Armaturen, wie
Funktion
9. Thermometer,
Pipe systemDifferenzdruckmanometer
by others rinsed clean before
überconnection
dencorrectto the unit. Cleaning
Wärmetauscher report present.
montiert.
8. Water-side safety device installed and tested for function, fixtures such as
9. 10. thermometer,
Output discharge
Bauseitiges (at least
differential
Rohrsystem 50%)
wurde vorcontinually
pressure gauge guaranteed
fitted
Anschluss anabove the heat sauber
die Maschine exchanger.
gespült.
Spülprotokoll liegt vor.
9. 11. Pipe
The system
system by must be rinsed
others powered withbefore
clean electricity for at least
connection 8 hours
to the unit.before the report
Cleaning function test
present.
and the main switch must be switched on (preheating of oil in compressor)
10. Lastabnahme (mindestens 50 %) kontinuierlich gewährleistet
10. Output discharge (at least 50%) continually guaranteed 1) only GLWC/GLWH; 2) only with GLRC
11. Die Anlage muss mindestens 8 Stunden vor der Funktionsprüfung elektrisch gespeist und
11. The system must be powered with electricity for at least 8 hours before
der Hauptschalter muss eingeschaltet werden (Vorwärmen des Öls im Verdichter) the function test
To be instructed:
and Name:
the main switch must be switched on (preheating ofCompany:
oil in compressor)
Date: Place: Signature1)customer/operator
nur bei GLWC / GLWH; 2) nur bei GLRC
1) only GLWC/GLWH; 2) only with GLRC
Eingewiesen werden soll: Name: Firma:
To be instructed: Name: Company:
Date:
Datum: Place: Ort: SignatureAuftraggeber
Unterschrift customer/operator
/ Betreiber
91
15.2 Appendix II Report
Commissioning
Commissioning Report
Funktionsprüfungsprotokoll
GEA Company name: Customer / Operator name: Installer´s name:
Name GEA Firma Name Kunde / Betreiber: Name Anlagenbauer:
Customer / Operator name: Unit data:
Kunden-
Company: / Betreiber Daten Gerätedaten
Type: Order:
Firma:
Street: Typ: Number:
Serial A.-Nr.:
Straße:
City: SerienNummer:
Buffer tank S.N.:
Stadt:
Witnessed by: Phone: Pufferspeicher
Condenser S.N.:
S.N.:
Vertreter:
Commissioning requested by: Telefone: Verflüssiger S.N.:
Funktionsprüfung angefordert von
Operating data:
Betriebsdaten: T in [°C] @100 % T out [°C] @100 % deltaT [K] @100 % Chilled water Pump
Evaporator: T in [°C] @100 % T aus [°C] @100 % deltaT [K] @100 % Type: Kalt-/Warmwasserpumpe
Verdampfer: Typ:
Condenser: Current: / /
Verflüssiger: Stromaufn.: / /
Outside temp.: Control Voltage: Power supply: Type Glycol
Außentemperatur: Steuerspannung: Spannungsversorgung: Typ Glykol
[°C] [V] [V] / / %
[°C] [V] [V] / / %
Compressor N°N° 11 22 33 44 5
5
6
6
7
7
8
8
Verdichter
Evaporating press. bar
Verdampfungsdruck bar
Condesing press.
Verflüssigungsdruck bar
bar
Discharge temp.
Heißgastemperatur °C°C
Suction line temp.
Sauggastemperatur °C°C
Liquid line temp.
Flüssigkeitstemperatur °C°C
Current consump.
Stromaufnahme L1 L1 AA
Current consump.
Current consump.
CapacityGerät
Leistung unit @measurem.
bei Messung %% %
% %
% %
% %
% %
% %
% %
%
Measure.
Werte @working mode
bei Betriebsart: Chiller
Kaltwasser Heat pump
Wärmepumpe Chiller- and Heat pump mode
Kalt- und Warmwasserbetrieb
Circuit 1 1
Kreislauf Circuit 2 2
Kreislauf Circuit 33
Kreislauf Circuit 44
Kreislauf
Cond. fanLüfter
Stromauf. current
L1 L1 AA
Cond. fanLüfter
Stromauf. current
L2 L2 AA
Cond. fanLüfter
Stromauf. current
L3 L3 AA
Hydraulic system
Überprüfung check (see(Nr.
Wasserkreislauf OM): siehe BA): Unit check:
Geräteprüfung:
1. Manometer
1. Pressure gauge Yes
Ja No
Nein Electric connectionsgeprüft:
Kabelverbindungen checked: JaYes No
Nein
2. Absperrventile
2. Shut off valveManometer
press. gauge Yes
Ja No
Nein Wert: Prüfung:
3.
3. Automatische Entlüftung
Autom. Air venting Ja
Yes Nein Low
No Niederdruckschalter
press. switch bar
bar JaYes Nein
No
4 Rohrleitungskompensatoren
Vibration damping point Ja
Yes Nein High
No Hochdruckschalter
press. switch bar
bar JaYes Nein
No
6.
6. Wasserfilter
Water filter Ja
Yes Nein Anti
No Frostschutz
freeze value °C°C JaYes Nein
No
7.
7. Entleerungsventil
Drain valve Ja
Yes Nein Set
No Sollwert
pointGeräte
Unit °C°C JaYes Nein
No
8.
8. Pumpe
Pump (Gerätekreislauf)
(Unit circuit) Ja
Yes Nein Hydr.
No Hydr.Diff.drucksch.
diff. press. switch bar
bar JaYes Nein
No
9
9 Sicherheitsventil
Safety valve: : barbar Ja
Yes Nein
No Einstellungen geprüft
Check funct. & setting JaYes Nein
No
10.
10. Ausdehnungsgefäß
Expansion vessel Ja
Yes Nein Free
No Freiraum
spaceum das Gerät:
around the unit
11.
11. Füllventil
Filling valve Ja
Yes Nein
No R1:
R1: cm
cm
12. Paddelströmungswächter
12. Flow switch (Paddle type) Ja
Yes Nein
No R1
13. R1
13. Durchflussregulierventil
Regulation valve Ja
Yes Nein
No R2:
R2: cm
cm
14. R
R R
R
14. 2.2Pumpe
nd
Pump/ 3-Wege-Ventil
/ 3-way-valve Ja
Yes Nein
No 3 4
16.
15. Pufferspeicher:
Buffer tank: Liter
litre Ja
Yes Nein
No 3 4 R3:
R3: cm
cm
- - Pumpenkontakt
Pump operation contact Ja
Yes Nein
No R2
R2
- - Absperrventil
Shut-Off valve (Verdampfer)
(Evaporator) Ja
Yes Nein
No R4:
R4: cm
cm
- - Hydraulikkreislauf fertig
Hydraulic circuit finished Ja
Yes Nein
No
Schwingungsdämpfer
Anti Vibration rubbersunter Gerätbelow
installed lt. Maßzeichnung
the unit installiert:Yes Ja No Nein N°Anzahl Schw.dämpfer
of AV rubbers
Kommentar:
Notes:
Datum: Servicetechniker: Unterschrift:

Date: Technician´s name: Signature:
Datum: Kunde / Betreiber: Unterschrift:
Date: Customer / Operator name: Signature:
For Warranty: Sent a copy to E-Mail address: [email protected] V1.4 05/2012 by

TK V1.4 05/2011 by TK
92
Appendix II
Commissioning Report
Sketch of the unit´s hydraulic circuit
Legend:
Installation
Buffer tank Water filter position of 3-way-
Pump (vertical) Flow switch
valve
Shut-off valve Safety valve
Buffer tank Temperature sensor
(horizontal) Flow regulating
Unit valve
Pressure gauge
No return valve
Hydraulic
switch 2-way-valve
Consumer Expansion vessel

Air vent valve
Dry cooler/ 3-way-valvel
condenser
Charge and Vibration damping
drain valve point
For Warranty: Sent a copy to E-Mail address: [email protected] V1.4 05/2012 by

TK
93
Anhang III A
15.3 Measuring Report GLAC Chiller
Measuring Report Chiller: GLAC – GLFC – GLDC

Service engineer Cost Date
GEA Order Nr. Service-Nr.
GEA 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.
Function check Maintenance Repairs
Chiller Type Year of

Hydraulic module yes no Serial Nr.
Refrigerant R 407C R 134a R 410A R
G. Unit electrical features Measured values

L1 - L2 L2 - L3 L1 - L3 Unit
G.1 Mains voltage 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.11/2013-1 by ATG PRM CHI
Page 1 of 6
94
R. Refrigeration circuit Serial Nr. unit: Date
Measured unit Measured values
Refrigeration circuit 1 2 3 4 Unit
Values at load %
R.1 Condensing pressure bar
R.2 Condensing temp. °C
R.3 Liquid temp. °C
R.4 Sub cooling K
R.5 Discharge temperature °C
R.6 Suction pressure bar
R.7 Evaporation temp. °C
R.8 Suction gas temp. °C
R.9 Superheating K
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 1 2 3 4 5 6 7 8
Compressor at 100 % 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.
Page 2 of 6
95
EW. Evaporator Serial Nr. unit: Date
Type Serial number of evaporator
Medium Glycol %/ °C Glycol type Water
Values at full load (100%) Circuit 1 Circuit 2 Circuit 3 Circuit 4 Unit
EW.1 Medium inlet temperature °C
EW.2 Medium outlet temperature °C
EW.3 ǻT K
EW.4 Inlet water pressure bar
EW.5 Outlet water pressure bar
EW.6 ǻp bar
EW.7 GEA GLHM / GLPE available yes no by others
EW.8 Type of hydraulic module Serial Nr.
EW.9 Buffer tank available / size 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 Pressure bar
EW.16 Current consumption of pumps L1 L2 L3
EW.17 Chilled water pump 1 A
EW.19 Chilled water pump type 1 Serial Nr.
Notes
R1 mm
R2 mm
R3 mm
R4 mm
Page 3 of 6
96
CA. Condenser Serial Nr. unit: Date
Type Serial number
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 ǻT K
CA.6 Condensing temp. °C
CA.7 Refrigerant outlet temperature °C
CA.8 Difference CA.7 zu CA.3 K
CA.9 Current consumption of motors L1 L2 L3
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
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
Notes
Page 4 of 6
97
C. Controller and Settings Serial Nr. unit: Date
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 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 Proportional band °C
C.9 2nd setpoint yes no °C
C.10 Setpoint variation 4-20 mA yes no Min. / Max. / °C
C.11 Load shedding switch yes no %
C.12 Connection to BMS yes no Report
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.23 Operating hours chill water pump 1 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
Notes
Page 5 of 6
98
G Check / visual inspection Serial Nr. unit: Date
o. k. Not O.K. Comment / action required
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.3 Evap.
G.3 Fans
Check for secured position, debris, damage
G.3.1
and corrosion.
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

Check for dirt and damage
G.4.1
Check for corrosion and secured position
G.4.2 Check direction of rotation
G.4.4 Check protective devices for proper function
G.5 System components

Visual check of insulation for
G.5.1
damage
G.5.2 Check for damage
Refrigerant conducting unit components
G.5.3
to be checks for leaks, visual inspection
Visual check of compensators for
G.5.4
damage
G.6 Electrical devices
Check optical and acoustical regulation for
G.6.1
proper function
Check connecting terminals for
G.6.2.
tightness, tighten, if necessary
Notes
Date Name Signature
Page 6 of 6
99
Measuring Report air cooled Heat Pumps: GLAH
Plant operator
Contact person Tel.
Address Fax.
Plant manufacturer
Contact person Tel.
Address Fax.
Unit Type Year of

Hydraulic module yes no Serial N°

L1 - L2 L2 - L3 L1 - L3 Unit
G.1 Mains voltage V
L1 - N L2 - N L3 - N V
G.2 Mains voltage V
Checking
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.
Page 1 of 7
100
R. Ref. circuit cooling Serial Nr. unit: Date:
Values at load %
R.4 Subcooling K
R.9 Superheating K
R.13 Oil level
R.14 Oleic acid test Ok?

R.16 Indicator Ok?
Compressor 1 2 3 4 5 6 7 8
R.19 L1 A
R.19 L2 A
R.19 L3 A
R.23 MV - compress. cooling A
Page 2 of 7
101
EW. Evaporator in cooling mode Serial Nr. unit: Date:
Type: Serial number of evaporator:
Medium Glycol %/ °C Glycol type: Water
EW.3 ǻT K
EW.6 ǻp bar
EW.7 GEA GLHM available yes no by others
EW.8 Type of hydraulic module Serial Nr.
EW.9 Buffer tank available / size litre Single circuit tank Dual circuit tank
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
Page 3 of 7
102
CA. Condenser in cooling mode Serial Nr. unit: Date:
Type: Serial number:
CA.5 ǻT K
CA.6 Condensing temp. °C
CA.8 Difference CA.7 to CA.3 K
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
Speed control
Speed regulation
Notes
Page 4 of 7
103
R. Ref. circuit heating
Values at load %
R.31 Subcooling K
R.36 Superheating K
CW. Condenser in heating operation

CW.1 Medium inlet temperature °C
CW.2 Medium outlet temperature °C
CW.3 ǻT K
CW.4 Inlet water pressure bar
CW.5 Outlet water pressure bar
CW.6 ǻp bar
CW.7 Current consumption of pumps L1 L2 L3
CW.8 Chilled water pump 1 A
CW.9 Chilled water pump 2 A
EA. Evaporator in cooling mode

Type Serial number
EA.1 Air heat exchanger inlet °C
EA.2 Air heat exchanger outlet °C
EA.3 ǻT K
EA.4 Refrigerant inlet temperature °C
EA.5 Refrigerant outlet temperature °C
EA.6 Difference 4.7 to 4.3 K
Page 5 of 7
104
Set parameters Note

C.3 Locked gen. fault remote ON/OFF yes no
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 Min. / Max. / °C
C.13 Set frost protection switch °C Dif. °C
C.27 Comp. minimum operating time sec.
Notes
Page 6 of 7
105
G.1 Compressor
G.2 Condenser
G.3 Evaporator
G.3 Fans
G.3.1
and corrosion.
G.3.4 Check function of anti-vibration mounts
G.4 Electric motors

G.4.1

Check protective devices for proper
G.4.4
function
G.5.1
damage
G.5.3
G.5.4
damage
G.6.1
proper function
G.6.2.
Notes
Date Name Signature
Page 7 of 7
106
Measuring Report Chiller: GLRC
Plant operator
Contact person Tel.
Address Fax.
Plant manufacturer
Contact person Tel.
Address Fax.
Chiller Type Man. year

GLPE Pump Module: yes no Serial Nr.

L1 - L2 L2 - L3 L1 - L3 Unit
G.1 Mains voltage V
L1 - N L2 - N L3 - N V
G.2 Mains voltage V
Check
G.13 Flow switch O.K. Not O.K.
G.14 Freeze protection O.K. Not O.K. Value °C
Notes
page 1 of 6
107
R. Refrigeration Circuit Serial Nr. Date
Refrigeration circuit 1 2
Compressor 1 2 3 4 Unit
Values at load 100 100 100 100 %
R.2 Condensing temperature °C
R.3 Fluid temperature °C
R.4 Subcooling (Bubble Point) K
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.13 Oil level ok / nok

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
Notes

page 2 of 6
108
EW. Evaporator Serial Nr. Date
Type Serial number of evaporator
Medium Glycol %/ °C Glycol type Water
Values at full load (100%) Circuit 1 Circuit 2 Unit
EW.3 ǻT K
EW.6 ǻp bar
EW.7 GEA GLPE available yes no by others
EW.8 Type GLPE pump module Serial Nr.
EW.9 Buffer tank available / size Litre Single circuit tank Dual circuit tank
Notes
R1 mm
R2 mm
R3 mm
R4 mm
page 3 of 6
109
!!! BY OTHERS !!!
CA. Air Cooled Condenser Serial Nr. Date
Type Serial number
Refrigeration circuit 1 Refrigeration circuit 2 Unit
CA.5 ǻT K
CA.6 Condensing temperature °C
CA.8 Difference CA.7 to CA.3 K
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
Speed control
Speed regulation
Notes
page 4 of 6
110
C. Controller and Settings Serial Nr. Date
Set parameters Note

C.3 Fault signal lock remote ON/OFF yes no
C.8 Setpoint value, design value °C Proportional band °C
C.9 2nd setpoint yes no °C
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)
Notes
page 5 of 6
111
G Check / visual inspection Serial Nr. Date
G.1 Compressor
G.2 Condenser
G.3 Evaporator
G.3 Fans
G.3.1
and corrosion.
G.4 Electric motors

G.4.1

G.4.4
function
G.5.1
damage
G.5.3
G.5.4
damage
G.6.1
proper function
G.6.2.
Notes
Date Name Signature
page 6 of 6
112
Measuring Report GLWC Chiller
Plant operator
Contact person Tel.
Address Fax.
Plant manufacturer
Contact person Tel.
Address Fax.
Unit Type Year of

Hydraulic module yes noSerial Nr.

L1 - L2 L2 - L3 L1 - L3 Unit
G.1 Mains supply voltage V
L1 - N L2 - N L3 - N V
Checking
G.14 Frost protection O.K. Not O.K. Value °C
Notes
Vers.02/2012-1 by TK
Page 1 of 6
113
R. Refrigeration circuit Serial Nr. unit: Date:
Values at load %
R.4 Subcooling K
R.9 Superheating K
R.13 Oil level
R.14 Oil acid test Ok?

R.16 Indicator Ok?
Compressor 1 2 3 4 5 6 7 8
R.19 L1 A
R.19 L2 A
R.19 L3 A
R.23 MV – comp. cooling A
Notes
Page 2 of 6
114
EW. aporator in cooling
Eva c mod
de Serial Nr. unit: Daate:
e
Medium G
Glycol %/ °C
C Glyco
ol type: Water
W
Measu
ured unit Measu
ured values
Values at full loa
ad (100%) 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 ǻT K
EW.4 Inle
et water pressure bar
EW.5 Outtlet water pre
essure bar
EW.6 ǻp bar
EW.7 GEA
A GLPE ava
ailable yes no by others
EW.8 mp module tyype
Pum Serrial Nr.
EW.9 Bufffer tank avaiilable / size Liter Single
S circuit Dual circuit tank
tank
k
EW.10 Stra
ainer availab
ble yes no Cle
eaned yess no
o
EW.11 Flow
w switch ava
ailable yes no Fun
nction okk no
ot ok
EW.12 Pre
essure gauge
e available yes no
EW.13 Shu
ut off valves available yes no
pansion tankk available
EW.14 Exp yes no
EW.15 Saffety valve ava
ailable yes no essure
Pre bar
EW.16 Currrent consum
mption of pum
mps L1 L2 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
R1 mm
R2 mm
R3 mm
R4 mm
Page 3 of 6
115
CW. Condenser in cooling mode Serial Nr. unit: Date:
CW.3 ǻT: K
CW.6 ǻp bar
CW.7 Difference R.3 to CW.2 K
CW.8 GEA GLPC available yes no by others
CW.9 Type of hydraulic module: Serial Nr.:
CW.10 Strainer available yes no Cleaned: yes no
CW.11 Flow switch available yes no Function: O.K. Not 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 Press. bar
CW.17 Cool water pump 1 A
CW.19 Type of cool water pump 1 Serial Nr.
CW.21 3-way valve available yes no GEA by others
CW.22 Regulation of 3-way valve yes no GEA by others
CW.23 Fan control of dry-cooler yes no
CW.24 Inverter-regulated pump yes no
Notes
Page 4 of 6
116
Set parameters Comment

C.3 Does common fault signal lock yes no
remote ON/OFF
C.6 Type of temperature regulation Proportional control Quick Mind
C.9.1 2. Sollwert Kühlen yes no °C
C.9.2 2. Sollwert Heizen yes no °C
C.23 Operating hours Water pump 1 h Maintenance interval x h
C.24 Operating hours Water pump 2 h Maintenance interval x h
Notes
Page 5 of 6
117
G.1 Compressor
G.2 Condenser
G.3 Evaporator
G.3 Fans
G.3.1
and corrosion.
G.4 Electric motors

G.4.1

G.4.4
function
G.5.1
damage
G.5.3
G.5.4
damage
G.6.1
proper function
G.6.2.
Notes
Date Name Signature
Page 6 of 6
118
Measuring Report GLWH Chiller / Heat Pump
Plant operator
Contact person Tel.
Address Fax.
Plant manufacturer
Contact person Tel.
Address Fax.
Unit Type Year of

Hydraulic module yes noSerial Nr.

L1 - L2 L2 - L3 L1 - L3 Unit
L1 - N L2 - N L3 - N V
Checking
G.14 Frost protection O.K. Not O.K. Value °C
G.14 4-way valve O.K. Not O.K.
Notes
Vers.02/2012-1 by TK
Page 1 of 7
119
R. Refrigeration circuit Serial Nr. unit: Date:
Values at load %
R.4 Subcooling K
R.9 Superheating K
R.13 Oil level
R.14 Oil acid test Ok?

R.16 Indicator Ok?
Compressor 1 2 3 4 5 6 7 8
R.19 L1 A
R.19 L2 A
R.19 L3 A
R.23 MV – comp. cooling A
Notes
Page 2 of 7
120
EW. aporator in cooling
Eva c mod
de Serial Nr. unit: Daate:
e
Medium G
Glycol %/ °C
C Glyco
ol type: Water
W
Measu
ured unit Measu
ured values
Values at full loa
ad (100%) 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 ǻT K
EW.4 Inle
et water pressure bar
EW.5 Outtlet water pre
essure bar
EW.6 ǻp bar
EW.7 GEA
A GLPE ava
ailable yes no by others
EW.8 mp module tyype
Pum Serrial Nr.
EW.9 Bufffer tank avaiilable / size Liter Single
S circ. ta
ank Dual circuit tank
EW.10 Stra
ainer availab
ble yes no Cle
eaned yess no
o
EW.11 Flow
w switch ava
ailable yes no Fun
nction okk no
ot ok
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 essure
Pre bar
EW.16 Currrent consum
mption of pum
mps L1 L2 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
R1 mm
R2 mm
R3 mm
R4 mm
Page 3 of 7
121
CW. Condenser in cooling mode Serial Nr. unit: Date:
CW.3 ǻT: K
CW.6 ǻp bar
CW.7 Difference R.3 to CW.2 K
CW.8 GEA GLPC available yes no by others
CW.9 Type of hydraulic module: Serial Nr.:
CW.10 Strainer available yes no Cleaned: yes no
CW.11 Flow switch available yes no Function: O.K. Not 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 Press. bar
CW.21 3-way valve available yes no GEA by others
CW.22 Regulation of 3-way valve yes no GEA by others
CW.23 Fan control of dry-cooler yes no
CW.24 Inverter-regulated pump yes no
Notes
Page 4 of 7
122
R. Circuit in heating mode Serial Nr.: Date:
Values under load %
R.28 Condensation pressure: bar
R.29 Condensing temperature: °C
R.30 Fluid temperature: °C
R.31 Subcooling (Bubble Point): K
R.33 Suction pressure: bar
R.34 Evaporating temperature: °C
R.35 Suction gas temperature: °C
R.36 Overheating (dew point): K
CW. Condenser in heating mode

Values at full load (100%) Circuit 1: Circuit 2: Circuit 3: Circuit 4: Unit
CW.27 ǻT: K
CW.30 ǻ p bar
EW. Evaporator in heating mode

Values at full load (100%) Circuit 1: Circuit 2: Circuit 3: Circuit 4: Unit
EW.23 ǻT: K
EW.26 ǻ p bar
Notes:
Page 5 of 7
123
Set parameters Comment

C.3 Does common fault signal lock yes no
remote ON/OFF
C.6 Type of temperature regulation Proportional control Quick Mind
C.9.1 2. Sollwert Kühlen yes no °C
C.9.2 2. Sollwert Heizen yes no °C
C.23 Operating hours water pump 1 h Maintenance interval x h
C.24 Operating hours water pump 2 h Maintenance interval x h
Notes
Page 6 of 7
124
G.1 Compressor
G.2 Condenser
G.3 Evaporator
G.3 Fans
G.3.1
and corrosion.
G.4 Electric motors

G.4.1

G.4.4
function
G.5.1
damage
G.5.3
G.5.4
damage
G.6.1
proper function
G.6.2.
Notes
Date Name Signature
Page 7 of 7
125
Appendix GL Series
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
Tab. 15-1

GL Series Appendix
English German
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
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
Tab. 15-1
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
Tab. 15-2

Appendix GL Series

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
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 Filter 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
Tab. 15-2

GL Series Appendix

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+
- R-/T- Serial card 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
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
Tab. 15-2
15.4.3 Terminology in wiring diagrams
English German
Black Schwarz
Blue Blau
Brown Braun
Tab. 15-3

Appendix GL Series
English German
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
Summer / Winter (remote) Umschaltung Heizen / Kühlen
Thermal Compr. Motorvollschutz Verdichter
Two pumps Zwei Pumpen
Unit Gerät
Ventilation circuit Lüfter Kreislauf
White Weiß
Yellow Gelb
Tab. 15-3

GL Series Appendix
15.4.4 Terminology in legends and refrigeration circuit diagrams

&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
VP Pilot valve Pilotventil
Tab. 15-4

Appendix GL Series

VR Check valve / no return valve Rückschlagventil
VS Sight glass Schauglas
Tab. 15-4
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
Tab. 15-5
15.4.6 Terminology in legends for hydraulic circuit diagrams

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 Filter 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
Tab. 15-6

GL Series Appendix

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
V3V 3-way valve 3-Wege-Ventil
VA(H) Safety valve Sicherheitsventil
VE Expansion tank Ausdehnungsgefäß
VR(H) Check valve / No return valve Rückschlagventil
Tab. 15-6
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
Tab. 15-7

15.1 Log Book
Anhang IV for Chillers, Heat Pumps and Compressor/Condenser Units
Log Book for Chillers, Heat Pumps and Compressor/Condenser Units
System Data
Producer Refrigerant
Type Refrigerant charge kg
Serial number Oil type
Year of manufacture Oil charge volume kg
Type of system Chiller Heat pump Comp./condenser unit
Max. allowed pressure High pressure side bar Low pressure side bar
Power supply V/Ph/Hz Max. current A
Leak test without leakage detection system Once a year from 3 kg refrigerant charge weight
Twice a year at 30 to 299 kg refrigerant charge
4 times a year from 300 kg refrigerant charge
Leakage detection system is available yes no

Leak test with leakage detection system Once a year at 30 to 299 kg refrigerant charge
Twice times a year from 300 kg refrigerant charge
Plant operator
Contact person Tel.
Address Fax.
Service company
Contact person Tel.
Address Fax.
Certification number
Date of commissioning
Commissioning by Service technician Certificate Nr.:
Service through Service technician Certificate Nr.:
Notes
Vers. 08/2010-1 by TK
134
Date / Visit Nr. Company: Certificate Nr.:
/ Service technician: Certificate Nr.:
Leak testing yes / Result:
Refrigerant charged yes / Reason:
Refrigerant evacuated yes / Reason:
Leak system test yes / Result:
Repairs
Required measures
Units leak tested, safety devices checked and function test passed.
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
135
Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
136
Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
137
Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
138
Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
139
Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
140
Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
141
Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
142
Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature

Repairs
Required measures
Name Signature
143
We live our values.
Excellence r Passion r Integrity r Responsibility r)'#XGTUKV[
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
|EQWPVTKGU(QWPFGFKPVJGEQORCP[KUQPGQHVJGNCTIGUVRTQXKFGTUQHKPPQXCVKXGGSWKROGPVCPF
process technology. GEA Group is listed in the STOXX® Europe 600 Index.
www.gea-airtreatment.com

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GEA GL Series

Chillers and Heat Pumps

1 Unit identification plate .............................................................. 4

4 Safety and User Instructions ..................................................... 7

5 Technical Description ............................................................... 12

6 Shipping and storage ............................................................... 19

8 Medium Connections ................................................................ 28

9 Electrical Connection ............................................................... 47

2 PR-2013-0112-GB • Subject to modifications • K0-11/2013

12 Fault Finding and Troubleshooting ......................................... 71

13 Servicing and maintenance ..................................................... 87

14 Dismantling and Disposal ........................................................ 89

PR-2013-0112-GB • Subject to modifications • K0-11/2013 3

1 Unit identification plate

Company logo Company name

Refrigerant charge volume

Max. operating pressure

Max. storage CE symbol with certification number

Drawing number of wiring diagram

4 PR-2013-0112-GB • Subject to modifications • K0-11/2013

2 Unit Type Code

015 - 960 Unit capacity stage

C Unit series, continued

A R-134a and Bitzer screw compressor

1 400 Volt / 3 Ph~/ 50 Hz / +N / +PE

PR-2013-0112-GB • Subject to modifications • K0-11/2013 5

3 Overview of units and packaged content

3.2 Unit overview

3.3 Scope of supply

3.4 Accessories and special Equipment

6 PR-2013-0112-GB • Subject to modifications • K0-11/2013

4 Safety and User Instructions

DAMAGE TO THE UNIT!

4.1 Availability of the operation manual

4.2 Scope of the operation manual

4.3 Symbols used

PROPER BOOTS REQUIRED!

PR-2013-0112-GB • Subject to modifications • K0-11/2013 7

PROTECTIVE GOGGLES REQUIRED!

4.4 Identification of safety instructions

DANGER OF ELECTRICAL CURRENT!

DANGER OF HOT SURFACES!

DANGER – SHARP CUTTING EDGES!

HIGH PRESSURE HAZARD!

DANGER DUE TO LOW TEMPERATURES!

DANGER DUE TO OVERHEAD LOADS!

DANGER DUE TO TOXIC SUBSTANCES!

DAMAGE TO THE UNIT!

8 PR-2013-0112-GB • Subject to modifications • K0-11/2013

4.5 Safety-conscious work procedures

DANGER OF ELECTRICAL CURRENT!

When working with refrigerants:

DANGER DUE TO LOW TEMPERATURES!

DANGER DUE TO TOXIC SUBSTANCES!

SMOKING AND OPEN FLAMES ARE PROHIBITED!

For all kinds of work:

HIGH PRESSURE HAZARD!

PR-2013-0112-GB • Subject to modifications • K0-11/2013 9

4.5.1 Handling refrigerants