A DEH PR-2014-0112-GB Chiller-Hydraulik BR R3-03-2020 150dpi

Hydraulic Manual
CHILLERS AND HEAT PUMPS

APPLICATION BROCHURE
_0 From practical experience, for your practical needs....................................... 3
01 Chiller/heat pump with
single-circuit buffer tank and one consumer................................................... 4
02 Chiller/heat pump with plate heat exchanger for system separation,
single-circuit buffer tank and one consumer................................................... 9
03 Chiller/heat pump with dual circuit-buffer tank and extensive system
hydraulics ..................................................................................................... 14
04 Chiller/heat pump with plate heat exchanger for the system
separation, dual circuit buffer tank and extensive system hydraulics........... 19
05 Chiller/heat pump with single-circuit buffer tank and several different
consumers.................................................................................................... 24
06 Chiller/heat pump with single-circuit buffer tank and several consumers
of the same power rating.............................................................................. 29
07 Production of chilled/warm water with plate heat exchanger for system
separation and secondary-sided inverter pump ........................................... 34
08 Sequence control of chiller/heat pump with dual circuit buffer tank and
extensive system hydraulics......................................................................... 39
09 Chiller, water-cooled, integration of a heat-rejection system........................ 44
10 Chiller, water-cooled, integration in the heat-rejection system with
cold weather start control for all-year operation ........................................... 47
11 Chiller, water-cooled plant, with heat-rejection system and free cooling
function......................................................................................................... 51
12 Air-cooled chiller, integration of desuperheater for heat recovery................ 57
13 Water-cooled chiller, with heat recovery and heat-rejection system ............ 61
14 Chilled/warm water unit with variable-speed pump, single-circuit buffer
tank and 2-way valves (VPS A-Control) ....................................................... 65
15 Chilled/warm water unit with speed-controlled pumps in primary and
secondary circuit (VPS D-Control) ............................................................... 71
16 Chilled/warm water unit with variable-speed pump, single-circuit buffer
tank and 3-way valves (VPS E-Control) ....................................................... 77
17 Chilled/warm water unit with speed-controlled pump in primary and
secondary circuit wit system separation (VPS E-Control) ............................ 82
18 Reversible water-to-water heat pump with geothermal source and
heat-rejection system ................................................................................... 87
19 Reversible water-to-water heat pump with geothermal drilling as heat
source and sink ............................................................................................ 92
20 Non-reversible water-to-water heat pump with
geothermal energy source as heat source and heat-rejection plant as heat
sink ............................................................................................................... 97
_i Legend ....................................................................................................... 104
2 PR-2014-0112-GB_Hydraulik_PU_R3-2020-02 • Subject to change

_0
From practical experience, for your practical needs
This is the basic idea behind the creation of this manual. Engineers and technicians
should be optimally supported in their work when it concerns system integration of
chillers or heat pumps.
The following pages outline and explain the most common hydraulic circuits for inte-
grating these units in various application areas. This document presents recommenda-
tions and useful notices, which however do not replace individual system planning and
configuration of hydraulic components.
COPYRIGHT NOTE The reproduction, distribution and utilization of this document as well as the communi-
cation of its contents to others without express authorization is prohibited. Offenders
will be held liable for the payment of damages. All rights reserved in the event of the
grant of a patent, utility model or design.
PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 3

01
Chiller/heat pump with
single-circuit buffer tank and one consumer
Area of application
Generation of chilled or warm water for comfort air conditioning or for process applica-
tions.
The deployment of a single-circuit buffer tank system is a simple consumer network
condition, which however requires the satisfaction of important prerequisites.
unit Buffer tank Consumers
Functional principle of the hydraulics
For released units, the medium flows from the buffer tank to the water pump in the unit.
The medium is chilled or warmed up if a load request is present. The chilled/warm
water now flows to the consumer and is then warmed up or chilled down again there.
The 3-way valve in the position A – AB is fully opened at maximum capacity. The
bypass line B is closed. If the load request of the consumer drops, then the bypass line
B is opened. This ensures a constant water/volume flow across the unit, regardless of
the load request. The unit requires a constant water/volume flow for trouble-free oper-
ation. Therefore variable speed pumps must not be used.
If the bypass line B is completely opened because of the lack of load request, water no
longer circulates to the consumer. The water temperature approaches the unit setpoint
and the compressors gradually switch off. The water pump continuously remains in
operation in order to record the current water temperatures in the system. If the load
request increases again, the unit switches on the individual compressors again
depending on how far the temperature deviates from the setpoint.
It is important for the regulation of the unit that a constant water quantity is transported
over the evaporator / condenser at all times. Variable water quantities lead to discon-
tinuous heat transfers and thus to undefined fluctuating ratings of the heat exchanger.
This can lead to operational malfunctions, which are recorded with the unit controller.
4 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

01
The possible fault signals are:
– Insufficient evaporating pressure
– Low pressure
– Frost protection
– Flow switch
– Low water flow in the plant
For this reason, no 2-way valves can be employed for the depicted hydraulic system!
Important hydraulic components
Single circuit buffer tank: The buffer tank primarily serves to increase the water volume in the hydraulic system
in order to ensure a minimum runtime of the compressors and to prevent unnecessarily
frequent on and off switching of the compressors.
Water filters: Water filters must always be installed before the immediate entry of all water-side heat
exchangers in the system.
The water filter protects the heat exchanger from deposits and soiling of all kinds. For
reliable protection, only use dirt traps with a mesh width of maximum 1 mm. Water fil-
ters are a prerequisite for the reliable and faultless function of the unit.
Paddle-type flow switch: The paddle-type flow switch protects the unit evaporator if there is no or inadequate
water volume flow. The flow switch must be installed at the unit outlet and electrically
connected to the unit according to the wiring diagram. The flow switch acts as a safety
device and not as a regular control element of the unit. The unit's remote ON/OFF may
therefore not be switched with the flow switch.
The flow switch is a prerequisite for the reliable and faultless functioning of the unit.
Expansion tank: The expansion tank is mandatory, since this hydraulic system is a closed water circu-
lation system. The expansion tank provides a required hydraulic seal and compen-
sates temperature-related volume changes in the hydraulic system. The entire system
volume must be taken into consideration for the dimensioning of the expansion tank.
If the plant configuration unit is used with a pre-integrated hydraulic module, it often
contains pumps, single-circuit buffer tanks, and possibly (apart from other installations)
also expansion tanks. In most cases, however, these expansion tanks are only dimen-
sioned for the water volume of the unit and no longer suffice for the connected hydrau-
lic circuit. The volume of the required additional expansion tank must be harmonized
with the total water volume in the hydraulic system. The volume of the expansion tank
integrated in the unit usually must be supplemented with an additional expansion ves-
sel on-site.
The unit is very frequently mounted on the roof of the building and thereby at the high-
est point of the system. If an incorrect inlet pressure is the reason for the pressure fall
at the highest point of the plant, where the water pumps is often mounted, this leads to
cavitation on the suction side of the pump. If cavitation is not noticed in time, water
pumps and other plant components can be damaged.
Water system pressure If units and water pumps are mounted at the highest point of the plant, then the water
switch: pressure switch of the plant should be used at all times. All units are usually equipped
with with an electrical input that can process the floating contact of the water pressure
switch of the plant. The unit control system processes the falling system pressure,
stops the unit and the pump and prevents expensive plant failures.
Regulating valves: In order to ensure correct operating conditions for the entire plant, the pump and plant
characteristics curve have to be matched with one another. If a pump with a variable
pump characteristics curve is not available, regulating valves must be used. These
valves are used for rebalancing the water pumps and consumers with each other. In
plants with only one consumer, the water flow rate can be adjusted. Hydraulic rebal-
ancing is used in plants with multiple consumers for regulating different volume flows
or compensating different pressure drops in the pipework.
Ventilation: Vent valves and air collectors must be positioned in such a way to ensure correct vent-
ing of the hydraulic plant before the unit is commissioned for use. Air-vent valves are
not considered in the schematic diagram.

01
Charging and draining: Filling and drain valves must be positioned in such a way that the hydraulic plant can
be correctly filled and drained. Filling and drain valves are not taken into account in the
schematic diagram.
Control and regulation
External enabling device: The unit can be released with an external zero-voltage contact. The release/change-
over contact can be switched to outside temperature or be time-dependent. The
enabling contact may not be used to control capacity or temperature. The capacity of
the unit and the associated water temperature may only be controlled with the internal
unit controls. Otherwise the consequence is a cycle operation of the compressors with
too short runtimes as well as a considerably lower energy efficiency of the overall sys-
tem.
After successful release, the unit switches the pump on and checks the current with an
internal differential pressure switch and additionally with a paddle-type flow switch
mounted on-site. As soon as a stable water flow is ensured, the water temperature is
measured and compared with the preset setpoint. Depending on the extent of the devi-
ation, the individual compressors are switched on in order to chill the water to the set-
point. After reaching the setpoint, the first compressor switches off. Additional
compressors are switched off or on depending on the temperature change. The water
pumps remain in continuous operation so that the plant can perform readings of the
current water temperature in the system.
After switching the unit off with the remote ON/OFF contact, the compressors are
driven down and then switched off. The pump is switched off after the expiration of a
programmed delay period.
Pump enabling: The on-site pump must be enabled with the pump ON/OFF contacts on the unit. In case
the unit is not standardly supplied with pump ON/OFF contacts, then these can be pro-
vided as an option.
If the internal pump ON/OFF contact is used, the unit can embed the pumps into the
internal control system. The required pump leading and overrun times, as well as pump
switch-off when the unit is turned off, are taken into consideration by the internal regu-
lation. Furthermore, additional energy-saving functions can be used.
If the unit does not have an integrated water pump, no voltage supply is available at
the unit for the water pumps installed on-site. The on-site pumps must therefore be pro-
vided with voltage.
Alarm signal: A floating contact is available in the unit for monitoring the plant. The contact closes in
case of a service breakdown. Never switch the unit off with the external enabling signal,
since if a break-down is recorded via the floating contact, information on the cause of
the malfunction might no longer be displayed on the unit display. Furthermore, the
entire unit is thereby put out of commission, even though possibly only one of several
refrigeration circuits was affected.
Frost protection
If the pipework with circulating water is run in the outdoor area or if the pipework is not
protected against frost within the building, the relevant freeze protection must be
ensured. FläktGroup recommends to use at least 30% ethylene glycol.
Remember: If glycol is not used as an antifreeze agent, note that you must use trace heating for the
pipework and other components like expansion tank and pump that are subjected to
outside temperatures below 5°C. For the water-based components in the unit, suitable
options are available and provided by the factory.

01
Additional notices for planning
Every unit is subject to relevant operating limits.

The following points must be considered:
– minimum and maximum ambient temperatures
– minimum and maximum water temperatures for evaporator and condenser
To ensure a trouble-free operation, it is necessary to maintain the required operating
limits. Technical documentation (technical data sheets) of the individual unit contains
diagrams with the application limits. These limits must be strictly observed.

01
Consumers
Buffer Tank
unit

02
Chiller/heat pump with plate heat exchanger for system separation,
single-circuit buffer tank and one consumer
Area of application
tions.
By using a single-circuit buffer tank system and a plate heat exchanger for system sep-
aration, a simple consumer network is conditioned, where however important prereq-
uisites must be satisfied.
Plate heat
unit Buffer tank Consumers
exchanger
Primary side Secondary side
A plate heat exchanger creates a system separation in this hydraulic scheme in order
to ensure freeze resistance for low outside temperatures without requiring the entire
plant to be filled with a water-glycol mixture. The buffer tank is fitted in the secondary
circuit of the plate heat exchanger in order to reduce the quantity of glycol required and
thereby to reduce costs. In order to be able to make use of the entire system content,
primary and secondary side, it is mandatory to always operate both pumps together.
The entire plant can thereby be employed to guarantee the minimum system contents,
especially because the buffet tank is in the secondary circuit. The minimum system
content is required to guarantee the minimum runtime of the compressors.
For the released unit, the medium flows to the secondary side of the buffer tank through
the water pump in the secondary side of the plate heat exchanger of the system sep-
aration, which provides the primary side of the unit with the chilled/heated water-glycol
mixture. The medium is chilled or warmed up for the required load request. The chilled/
warm water now flows to the consumer and is once again warmed up or cooled down.
For maximum capacity, the 3-way valve is fully opened to the position A – AB. The
bypass line B is closed. If the load request of the consumer drops, then the bypass line
B is opened. This ensures that, independent of the load request, a constant water vol-
ume flow over the plate heat exchanger is present. Abrupt temperature variations on
the primary part of the plate heat exchanger are thereby avoided.

02
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 completely opened because of the lack of load request, water no longer circulates
to the consumer. The water temperature approaches the unit setpoint and the com-
pressors gradually switch off. Both water pumps remain continuously in operation in
order to record the current water temperatures in the system. If the load request
increases again, the unit switches on the individual compressors again depending on
how far the temperature deviates from the setpoint.
in the unit over the evaporator / condenser at all times. Variable water quantities lead
to discontinuous heat transfers and thus to undefined fluctuating ratings of the heat ex-
changer. This can lead to operational malfunctions, which are recorded with the unit
controller.
– Low pressure
– Flow switch
Expansion tank: The expansion tanks are obligatory, as this hydraulic system requires to have two
closed water circuits. The expansion tanks provide a required water supply and com-
pensate the temperature-related volume changes of the hydraulic system. When
dimensioning the expansion tanks, the respective system volume (primary side or sec-
ondary side) must be taken into account. If for the plant configuration units with a pre-
integrated hydraulic module are used, these often contains pumps, single-circuit buffer
tanks, and possibly (apart from other installations) also expansion tanks. In most
cases, however, these expansion tanks are only dimensioned for the water volume of
the unit and no longer suffice for the connected hydraulic circuit. The volume of the
additional expansion tank to be installed for the primary circuit must be matched to the
water volume of the primary circuit in the hydraulic system. The volume of the expan-
sion tank integrated in the unit usually must be supplemented with an additional expan-
sion vessel on-site.

02
schematic diagram.
Plate Heat Exchangers: The plate heat exchanger is used in a hydraulic plant as system separation. Reasons
for the use of a plate heat exchanger could be:
– Separation between water-glycol circuit and water circuit
– Different temperature ranges and protection of a circuit against too high or too low
temperatures
– Different pressure ranges and protection of a circuit against too high pressure
– Functioning as hydraulic switch
tem.
ation, the individual compressors are switched on in order to chill or heat the water to
the setpoint. After reaching the setpoint, the first compressor switches off. Additional
vided as an option. Both the water pump in the primary as well as in the secondary cir-
cuit must be operated with the enabling contact. Both pumps must always be
simultaneously in operation.

02
vided with voltage.
Frost protection
ensured. FläktGroup recommends the use of at least 30% ethylene glycol.
All components installed outdoors are, in this case, protected from freezing with a
water-glycol mixture. Since a plate heat exchanger was employed as a system sepa-
ration, filling the entire plant with anti-freeze is not required.


PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change
Plate heat
unit exchanger Buffer tank Consumers
13
02
03
Chiller/heat pump with dual circuit-buffer tank and extensive system
hydraulics
Area of application
tions.
The consumer network can take on complex forms with the deployment of a dual circuit
buffer tank system, where however important prerequisites must be satisfied.
Consumers
Buffer tank
unit
Plant circuit Consumer circuit
The medium is chilled or warmed up for the required load. The chilled/warm water now
once again flows into the buffer tank. In case there are no requirements on chilled/
warm water, the buffer tank guarantees the minimum runtime of the compressors. A
constant water volume flow through the unit is guaranteed with the dual circuit buffer
tank.
The consumer circuit can be designed in any number of complex forms.
This includes e.g.:
– Use of speed-regulated pumps
– Use of 2-way or 3-way valves
– Consumer circuits in different temperature ranges.
– Consumer circuits with various power capacities and water/volume flows
No influence on the plant circuit can arise and a constant water quantity to the unit is
guaranteed at all times.

03
Dual circuit buffer tank The dual circuit buffer tank fulfills the following functions:
– Assurance of the entire minimum system contents.
The minimum runtimes of the compressors are observed and unnecessarily fre-
quent compressor switch on and off is prevented.
– Hydraulic switch for the separation of plant and consumer circuits
– Guarantee of a thermal stratification within the container
Standing buffer tanks must be used for this purpose. The chilled water supply in the
plant circuit and the chilled water inlet in the consumer circuit must be attached at
the lower connections of the buffer tank.
In order to determine the minimum system content of the unit, only the volume of the
buffer tank and the volume of the piping between device and buffer tank may be used.
However, the volume of the consumer circuit is not taken into account.
Dual circuit buffer tanks for chillers are characterized by their special design whose
structure favors chilled-water stratification. Perforated perfusion pipes or perforated
separation plates are used in the upper and lower area of the tank.
sel on-site.

03
schematic diagram.
tem.
vided as an option.
vided with voltage.

03
Frost protection


03 Consumers
Consumer circuit
Buffer tank
Plant circuit
unit

04
Chiller/heat pump with plate heat exchanger for the system
separation, dual circuit buffer tank and extensive system hydraulics
Area of application
tions.
Chilled/warm water generator with plate heat exchanger for the system separation,
dual circuit buffer tank and extensive system hydraulics
Consumers
unit Plate heat Buffer tank

exchanger
Primary side Secondary side Plant circuit Consumer circuit
A plate heat exchanger creates a system separation in this hydraulic scheme in order
to ensure freeze resistance for low outside temperatures without requiring the entire
plant to be filled with a water-glycol mixture. The buffer tank is fitted in the secondary
circuit of the plate heat exchanger in order to reduce the quantity of glycol required and
thereby to reduce costs. In order to be able to employ the buffer tank correctly, it is
absolutely required that the pumps on the primary and secondary side of the plate heat
exchanger are always operated together.
The dual circuit buffer tank can thereby be employed to guarantee the minimum sys-
tem contents, especially because these are in the secondary circuit.
The minimum system content is required to guarantee the minimum runtime of the
compressors.
For a released unit, the medium of the buffer tank flows through the water pump to the
secondary side of the plate heat exchanger of the system separation, which provides
the primary side of the unit with chilled/heated water glycol mixture. The medium is
chilled or warmed up for the required load. The chilled/warm water now once again
flows into the buffer tank. In case there are no requirements on
chilled/warm water, the buffer tank guarantees the minimum runtime of the compres-
sors.
A constant water volume flow in the unit is guaranteed because of the plate heat
exchanger for the system separation. The minimum system content is guaranteed by
the parallel operation of the primary and secondary pump as well as the dual circuit buf-
fer tank.

04
This includes e.g.:
No influence on the generator circuit can arise and a constant water quantity to the unit
is guaranteed at all times.
In order to determine the minimum system content of the unit, in this case only the vol-
ume of the buffer tank, the plate heat exchanger, and the piping on the primary and
secondary side may be employed. However, the volume of the consumer circuit is not
taken into account.
ondary side) must be taken into account. If the plant configuration unit is used with a
pre-integrated hydraulic module, it often contains pumps, single-circuit buffer tanks,
and possibly (apart from other installations) also expansion tanks. In most cases, how-
ever, these expansion tanks are only dimensioned for the water volume of the unit and
no longer suffice for the connected hydraulic circuit. The volume of the additional
expansion tank to be installed for the primary circuit must be matched to the water vol-
ume of the primary circuit in the hydraulic system. The volume of the expansion tank
sel on-site.
Water system pressure The unit is very frequently mounted on the roof of the building and thereby at the high-
switch: est point of the system. If an incorrect inlet pressure is the reason for the pressure fall
pumps and other plant components can be damaged. Water system pressure switch:

04
If units and water pumps are mounted at the highest point of the plant, then the water
pressure switch of the plant should be used at all times. All units are usually equipped
schematic diagram.
Plate Heat Exchangers: The plate heat exchanger is used in a hydraulic plant as system separation. Reasons
temperatures
tem.
cuit must be operated with the enabling contact. Both pumps must always be
simultaneously in operation.

04
vided with voltage.
Frost protection
ensured. FläktGroup recommends the use of at least 30% ethylene glycol.
water-glycol mixture. Since a plate heat exchanger was employed as a system sepa-
ration, filling the entire plant with anti-freeze is not required.


Consumers

Plate heat
unit exchanger Buffer tank
Primary side Secondary side Plant circuit Consumer circuit
23
04
05
Chiller/heat pump with single-circuit buffer tank and several different
consumers
Area of application
tions.
Geko® Geko® Geko® Geko® Geko® Geko® Geko®
unit Buffer tank
flows through the consumer and is once again warmed up or cooled down.
In this case the consumers can have the same or unequal power consumption at iden-
tical water temperatures. The required water quantity must be adjusted individually for
every consumer with balancing valves.
The use of 3-way valves regulates the consumer's capacity and ensures a constant
volume flow through the unit. For maximum capacity, the 3-way valve is fully opened
to the position A – AB. The bypass line B is closed. If the load request of the consumer
drops, then the bypass line B is opened. This ensures a constant water/volume flow
across the unit, regardless of the load request. The unit requires a constant water/vol-
ume flow for trouble-free operation. Therefore variable speed pumps must not be used.
If the bypass line B is completely opened because of the lack of load request, water no
longer circulates to the consumer. The water temperature approaches the unit setpoint
and the compressors gradually switch off. The water pump continuously remains in
operation in order to record the current water temperatures in the system. If the load
request increases again, the unit switches on the individual compressors again
depending on how far the temperature deviates from the setpoint.
Since a constant water volume flow is required for the fault-free operation of the unit,
no variable-speed pumps may be used.
05
– Low pressure
– Flow switch
sel on-site.

05
schematic diagram.
tem.
vided as an option.
vided with voltage.

05
Frost protection


05
Geko®
Geko®
Buffer tank
Geko®
Geko®
Geko®
Geko®
unit
Geko®

06
Chiller/heat pump with single-circuit buffer tank and several
consumers of the same power rating
Area of application
tions.
unit Buffer tank
flows through the consumer and is once again warmed up or cooled down.
This applies for consumers with the same power rating, who in this case are connected
according to the Tichelmann principle to ensure an almost equal water quantity at full
load via every individual consumer. Balancing valves are not needed for this reason.
The use of 3-way valves regulates the consumer's capacity and ensures a constant
volume flow through the unit.
Since a constant water volume flow is required for the fault-free operation of the unit,
no variable-speed pumps may be used. For maximum capacity, the 3-way valve is fully
opened to the position A – AB. The bypass line B is closed. If the load request of the
consumer drops, then the bypass line B is opened. This ensures a constant water/vol-
ume flow across the unit, regardless of the load request. The unit requires a constant
water/volume flow for trouble-free operation. Therefore variable speed pumps must not
be used. If the bypass line B is completely opened because of the lack of load request,
water no longer circulates to the consumer. The water temperature approaches the
unit setpoint and the compressors gradually switch off. The water pump continuously
remains in operation in order to record the current water temperatures in the system.
If the load request increases again, the unit switches on the individual compressors
again depending on how far the temperature deviates from the setpoint.

06
– Low pressure
– Flow switch
sel on-site.

06
schematic diagram.
tem.
vided as an option.
vided with voltage.

06
Frost protection


06
Geko®
Geko®
Buffer tank
Geko®
Geko®
Geko®
Geko®
unit
Geko®

07
Production of chilled/warm water with plate heat exchanger for
system separation and secondary-sided inverter pump
Area of application
tions.
The consumers are primarily equipped with straight-way valves for regulation. The sec-
ondary-sided consumer network therefore has a variable plant characteristics curve.
To optimize energy consumption and flow pattern, a speed-regulated pump is used as
a secondary pump.
unit Buffer tank Plate heat exchanger
The secondary side is equipped with a speed-regulated pump. The unit requires a con-
stant water flow-rate for trouble-free operation, therefore a system separation is cre-
ated using a plate heat exchanger. Thus, the primary circuit has a constant water flow
and the secondary circuit has a variable water flow. Due to the variable water flow in
the secondary circuit, the necessary buffer tank must be arranged in the primary circuit
to guarantee the minimum system contents. To ensure freeze resistance, the primary
circuit is operated with a water-glycol mixture.
For the released unit, pump P1 is in operation and provides the unit with a constant
water-glycol mass flow. Via the plate heat exchanger, a heat exchange with the sec-
ondary-sided consumer network takes place, depending on the operation of the sec-
ondary-sided speed-regulated pump.
The secondary-sided consumer network can be freely designed. By using a speed-reg-
ulated pump, straight-way regulating valves can be used. The secondary pump can
adjust the pump characteristics of a variable plant characteristics curve within the vari-
able pump characteristics range and can set an optimal operating point.

07
therefore not be switched with the flow switch. The flow switch is a prerequisite for the
reliable and faultless functioning of the unit.
ondary side) must be taken into account. If the plant configuration unit is used with a
pre-integrated hydraulic module, it often contains pumps, single-circuit buffer tanks,
and possibly (apart from other installations) also expansion tanks. In most cases, how-
ever, these expansion tanks are only dimensioned for the water volume of the unit and
no longer suffice for the connected hydraulic circuit. The volume of the additional
expansion tank to be installed for the primary circuit must be matched to the water vol-
ume of the primary circuit in the hydraulic system. The volume of the expansion tank
sel on-site.
schematic diagram.
Plate heat exchanger The plate heat exchanger is used in a hydraulic plant as system separation. Reasons
temperatures

07
tem.
Pump release: The on-site pump must be enabled with the pump ON/OFF contacts on the unit. In case
cuit can be operated with the enabling contact. Both pumps do not have to be in
operation simultaneously.
If the internal pump ON/OFF contact is employed, the unit can embed the pumps in the
vided with voltage.
Error message: A floating contact is available in the unit for monitoring the plant. The contact closes in

07
Frost protection
water-glycol mixture. Since a plate heat exchanger is employed as a system separa-
tion, filling the entire plant with anti-freeze is not required.


38
07
unit Buffer tank Plate heat exchanger

08
Sequence control of chiller/heat pump with dual circuit buffer tank
and extensive system hydraulics
Area of application
tions.
The consumer network and the plant network can take on complex forms with the
deployment of a dual circuit buffer tank system, where however important prerequisites
must be satisfied.
Sequencer
Unit n
Consumers
Unit 2
Unit 1 Buffer tank
In this case, several units are switched in sequence in order to render the required total
performance or to build a redundant system. The units can have various different
power ratings. Every unit must have its own pump.
once again flows into the buffer tank. In case there are no requirements on chilled/
warm water, the buffer tank guarantees the minimum runtime of the compressors. A
tank.
This includes e.g.:
No influence on the plant circuit can arise and a constant water quantity to the unit is
guaranteed at all times.

08
sel on-site.

08
Non-return valves: The deployment of several pumps may require the use of non-return valves in order to
guarantee the correct flow direction of the heat transfer medium. This is the only way
to guarantee the faultless functioning of the hydraulic system in all operating states.
schematic diagram.
Sequential switching: In order to ensure an optimal management of the units relatively easily, a sequence
control unit (sequencer) is available for such applications. Up to five units can be oper-
ated with this unit. The water inlet and water outlet temperature serves as the con-
trolled variable that is measured in the common collecting pipe line of all units. In order
for the sequencer to communicate with the units, every unit must be furnished with a
modbus interface. Now only the sequencer is accessed for all additional management
activities. It is not necessary to control every unit individually.
External enabling of the unit: The unit must be enabled with the external floating contact of the sequencer. After
being enabled with the remote ON/OFF contact of the sequencer, a data exchange
with the connected units takes place with a bus signal. The unit with the fewest oper-
ating hours is given priority. As soon as a unit receives a command from the
sequencer, the unit switches on the water pump assigned to it. After the expiration of
the pump lead time, the first compressor of the unit goes into operation.
Depending on the requirements and the associated setpoint deviation from the preset
water temperature, additional compressors of the same unit or of the next unit go into
operation, depending on the settings in the sequencer. If the compressor of the next
unit is requested, it also switches its pump on beforehand.
When the water temperature drops, the compressor and the pumps successively
switch off. Only the pump of the last still running unit continues to operate in order to
continually provide the temperature sensor of the sequencer with the current water
temperature.
vided as an option.
vided with voltage.

08
Frost protection


Sequencer
Unit n
Consumers

Unit 2
Buffer tank
Unit 1
43
08
09
Chiller, water-cooled, integration of a heat-rejection system
Area of application
Heat-rejection circuits for water-cooled units that are exclusively employed in the warm
season for generating chilled water for comfort air conditioning or for process applica-
tions.
Heat-rejection system
Unit
Chilled-water circuit
When the unit is enabled, the medium flows to the water pump into the unit. At the
required load, the medium takes up the waste heat and flows on to the heat-rejection
system where the heat is returned to the ambient air.
Expansion vessel: The expansion tank is mandatory, since this hydraulic system is a closed water circu-
schematic diagram.
44 PR-2014-0112-EN_Hydraulics_PU_R3-2020-02 - Subject to alterations

09
For water-cooled units, it is necessary to dissipate unwanted heat from the cooling pro-
cess and conduct it to the outdoor air. The operating limits must be observed for the
reliable operation of the unit. The corresponding operating limits are provided in the
technical documentation of the unit.
It is necessary to regulate the power of the dry cooler in order to observe the operating
limits of the unit. It is recommended to regulate the speed of the fan motor depending
on the dry cooler water discharge temperatures from the dry cooler. This ensures opti-
mal heat-rejection water temperatures and constant operating conditions throughout
the year. In order to achieve an optimal energy efficiency of the unit, the cooling water
temperature must be kept as low as possible within the operating limits.
vided as an option.
internal control system. The required pump leading and overrun times, as well as the
pump switch-off when turning off the compressors, is taken into consideration by the
internal regulation. Furthermore, additional energy-saving functions can be used.
vided with voltage.
Antifreeze protection
In order to protect the heat-rejection circuit from frost, the employment of a water-glycol
mixture is definitely required. FläktGroup recommends the use of at least 30% ethylene
glycol.

PR-2014-0112-EN_Hydraulics_PU_R3-2020-02 - Subject to alterations 45

09
unit
46 PR-2014-0112-EN_Hydraulics_PU_R3-2020-02 - Subject to alterations

10
Chiller, water-cooled, integration in the heat-rejection system with
cold weather start control for all-year operation
Area of application
Heat-rejection circuit for water-cooled units that is employed throughout the year for
the generation of chilled water for comfort air conditioning or for process applications.
Unit
When the unit is enabled, the medium flows to the water pump into the unit. At the
required load, the medium takes up the waste heat and flows on to the heat-rejection
system where the heat is returned to the ambient air. When the condensation pressure
is too low, the 3-way valve conducts the medium once again into the condenser to
increase the condensation pressure. Operation within the permissible condensation
pressure is thereby guaranteed throughout the year.
Expansion vessel: The expansion tank is mandatory, since this hydraulic system is a closed water circu-

10
schematic diagram.
For water-cooled units, it is necessary to dissipate unwanted heat from the cooling pro-
cess and conduct it to the outdoor air. The operating limits must be observed for the
reliable operation of the unit. The corresponding operating limits are provided in the
technical documentation of the unit.
The pump P2 is activated in parallel for requested compressor operation. As soon as
the setpoint temperature is achieved and all compressors are disabled, the pump P2
is also switched off. All-year operating mode is required for this version. For this rea-
son, the heat-rejection circuit is furnished with a cold-weather start control in the form
of a 3-way valve (MV1). The 3-way valve is actuated by a 0-10 V signal directly from
the unit, depending on the condensation pressure. This method ensures the obser-
vance of the minimum water temperature also at very low outdoor air temperatures.
When the condensation pressure is too low, connection B of the 3-way valve (MV1)
opens. The temperature of the inlet medium thereby increases in the condenser of the
unit and the condensation pressure rises. The unit works within the range of applica-
tion. As soon as the condensing pressure of the unit has reached the required limit
value, port B of the 3-way valve is slowly closed again. When the heat-rejection circuit
has achieved a required high temperature, as a rule the system is regulated only via
the fan control of the heat-rejection system. The power of the heat-rejection system is
additionally controlled by the speed of the fan motor, depending on the cooling water
discharge temperatures from the dry cooler. This ensures optimal heat-rejection water
temperatures and constant operating conditions throughout the year. In order to
achieve an optimal energy efficiency of the unit, the cooling water temperature must be
kept as low as possible within the operating limits.
vided as an option.
vided with voltage.

10
glycol.


10
unit

11
Chiller, water-cooled, with heat-rejection system and free cooling
function
Area of application
Generation of chilled water for comfort air conditioning or process applications.

In this case, the chilling unit is water-cooled and must be set up within a building. A
heat-rejection system is employed for heat dissipation to achieve a free cooling func-
tion at low outside temperatures. This provides an energy-saving operation for year-
round cooling demands.
Plate heat exchanger
unit
Heat-rejection circuit
Producer Consumer
circuit circuit
The following operating modes are possible for this plant system:
– Unit operation (as water-cooled chiller)
– Free cooling operation
Unit operation in connection with the pumps P1 and P2

When the unit is enabled, the pump P1 supplies the medium from the buffer tank in the
unit. The medium is cooled down in the evaporator and then once again flows back into
the buffer tank.
If there is no chilled water requirement from the consumer, the buffer tank ensures a
minimum runtime of the compressors. The dual circuit buffer tank maintains a constant
water volume flow into the unit.
This includes e.g.:

11
The plant circuit is not influenced and the water quantity through the unit is constant at
all times.
A water-glycol mixture must be employed as the medium in the heat-rejection circuit.
When enabled, pump P2 supplies the medium through the condenser of the unit where
the waste heat is taken up. At sufficiently high condensation pressure, the medium
continues to be transported to the heat-rejection system in order for the waste heat to
be conducted into the ambient air.
The 3-way valve MV1 ensures the observance of the operating limits of the unit in the
heat-rejection circuit. When the condensation pressure is too low, the 3-way valve MV1
conducts the medium via a bypass once again into the condenser. The temperature of
the medium thereby continues to rise, which in turn also continues to increase the con-
densation pressure. Operation within the permissible condensation pressure is thereby
guaranteed throughout the year.
The 3-way valve MV1 is likewise necessary for the switchover from free cooling oper-
ation to unit operation, because the medium temperature lies below the application
range of the unit. Without a 3-way valve, the unit would break down.
Free cooling operation with a heat-rejection system in connection with the

pumps P3 and P4
For free cooling operation, the pump P3 supplies the medium from the buffer tank
through the secondary side of the plate heat exchanger. The medium is cooled down
there and then once again flows back in the buffer tank.
The pump P4 supplies the medium through the primary side of the plate heat
exchanger where the heat is taken up from the cooling process. The heated medium
continues to flow to the heat-rejection system in order to deliver the waste heat into the
ambient air.

11
dimensioning the expansion tanks, the respective system volume (chilled water side or
cooling water side) must be taken into account.
The unit is very frequently mounted on the top floor of the building and thereby at the
highest point of the system. If an incorrect inlet pressure is the reason for the pressure
fall at the highest point of the plant, where the water pumps is often mounted, this leads
to cavitation on the suction side of the pump. If cavitation is not noticed in time, water
Non-return valves: The deployment of several pumps may require the use of non-return valves in order to
guarantee the correct flow direction of the heat transfer medium. This is the only way
to guarantee the faultless functioning of the hydraulic system in all operating states.
schematic diagram.
Plate heat exchangers: The plate heat exchanger is used in a hydraulic plant as system separation. Reasons
temperatures
Unit operation in connection with the pumps P1 and P2

The unit can be released with an external zero-voltage contact. The release/change-
tem.
After successful release, the unit switches the pump P1 on and checks the current with
an internal differential pressure switch and additionally with a paddle-type flow switch
measured and compared with the preset setpoint. Depending on setpoint deviation, the
individual compressors are switched on or off.
The pump P2 is activated in parallel for requested compressor operation. As soon as
the setpoint temperature is achieved and all compressors are disabled, the pump P2
11
is also switched off. On continued active unit release, the water pump P1 continuously
remains in operation to record the water temperatures in the system. The pumps P3
and P4 for the free cooling operation remain OFF.
The heat removed from the cooling process in the heat-rejection circuit is conducted
off into the outdoor air. The operating limits must be observed for the reliable operation
of the unit. These are provided in the technical documentation of the unit.
The heat-rejection circuit is furnished with a cold weather start control, in the form of a
3-way valve (MV1). The 3-way valve is actuated by a 0-10 V signal directly from the
unit, depending on the condensation pressure. The water temperature in the heat-
rejection circuit can thereby be ensured even after switchover between free cooling
operation and unit operation.
When the condensation pressure is too low, connection B of the 3-way valve (MV1)
opens. The temperature of the inlet medium thereby increases in the condenser of the
unit and the condensation pressure rises. The unit works within the range of applica-
tion. As soon as the condensing pressure of the unit has reached the required limit
value, port B of the 3-way valve is slowly closed again. When the heat-rejection circuit
has achieved a required high temperature, as a rule the system is regulated only via
the fan control of the heat-rejection system.
The power of the heat-rejection system is additionally controlled by the speed of the
fan motor, depending on the cooling water discharge temperatures from the heat-rejec-
tion unit. This ensures optimal heat-rejection water temperatures and constant operat-
ing conditions throughout the year.
In order to achieve an optimal energy efficiency of the unit, the cooling water tempera-
ture must be kept as low as possible within the operating limits.
After unit switch-off or switchover to the free cooling operation, the compressor is
driven down and switched off. The pumps are switched off after the expiration of a pro-
grammed delay period.
vided as an option.
If the internal pump ON/OFF contact is employed, the unit can embed the pumps in the
vided with voltage.
Free cooling operation with a heat-rejection system in connection with the

pumps P3 and P4
An external control with the following requirements is needed for the management of
free-cooling operation:
– Switch-off of unit operation
– Actuation of the pumps P3 and P4
– Actuation of the fans of the heat-rejection unit with a changed setpoint
– Actuation of the 3-way valve MV2
The change-over point between free cooling operation and unit operation must be pre-
cisely determined on the basis of the system configuration, in order to guarantee the
required cooling needs in free cooling operation. Frequently switching between unit
operation and free cooling operation should be especially avoided in seasons with
strongly fluctuating daily temperatures. The switching hysteresis must be set accord-
ingly high.
The delay period of the pump P1 must be taken into consideration for the switchover
from unit operation to free cooling operation.

11
After release of the pumps P3 and P4, the fans of the heat-rejection system must be
controlled depending on the medium outlet temperature of the heat-rejection unit.
Make sure that the chilled water temperature is controlled for free cooling operation,
for instance between +4 to +10 °C, whereas for unit operation the heat-rejection water
temperature must be regulated between +25 to +30 °C.
In order to avoid frost damages at very low outside temperatures on the secondary side
of the plate heat exchanger, the 3-way valve MV2 must be installed. The control must
ensure that the primary side inlet temperatures in the plate heat exchanger do not fall
below +2°C.
Frost protection
mixture is definitely required. FläktGroup recommends to use at least 30% ethylene
glycol.


56
11
Buffer tank
unit
Heat-rejection circuit
Producer Consumer
circuit circuit

12
Air-cooled chiller, integration of desuperheater for heat recovery
Area of application
If emphasis is also put on heat recovery in addition to the generation of chilled water,
a unit with integrated desuperheater is a good opportunity to reduce operating costs
for the production of warm water.
unit
Fresh water outlet
Auxiliary heating
E heating
Desuperheater circuit
Fresh water inlet
Combination
storage tank
As soon as at least one compressor of the unit is running for the generation of chilled
water, warm water can be produced for comfort or process applications via the desu-
perheater which is integrated in the unit. Consequently, the pump P1 should only be
enabled with an activated compressor to avoid causing unnecessary energy costs.
For the released pump P1, the medium flows through the water pump to the desuper-
heater of the unit. If the compressor is running, the medium is heated and can be made
available for a heating process. For the desuperheater there are operating limits which
must be maintained. The medium discharge temperature from the desuperheater must
not fall below 30 °C. In order to ensure this, a 3-way valve must be used.

12
Ventilation: Vent valves and air collector must be positioned in such a way to ensure correct vent-
schematic diagram.
Combi storage tank: The combi storage tank is a drinking water heater for which different heat sources can
be used to heat up drinking water. Since the maximum attainable discharge tempera-
ture from the desuperheater does not exceed 60 °, only combi storage tanks with a
large internal heat exchanger should be used to operate the system as efficiently as
possible. To ensure drinking water hygiene, the relevant basic standards and national
supplementary standards must be considered and strictly adhered to. Therefore, it
must also be possible to thermally desinfect the combi storage tank through corre-
sponding heating.
For this purpose the following components can be used:
– Additional heat exchanger, heater supported
– Electric heating rod
As soon as one of the compressors is running, the desuperheater can be used for heat
recovery. The enabling of pump P1 should be performed via the operating status con-
tact of the compressors and via an enabling contact of the heating request on-site.
To ensure an operation within the operating limits, a 3-way valve is used which ensures
a minimum discharge temperature of 30 °C from the desuperheater.
As alternative, an inverter controlled pump can be used which regulates the medium
volume flow via the desuperheater in such a way that this requirement is observed.

12
Frost protection


60
12
unit
Fresh water inlet
Auxilary heating
E heating
Desuperheater circuit
Fresh water outlet
Combi storage tank

13
Water-cooled chiller, with heat recovery and heat-rejection system
Area of application
Heat-rejection circuit with heat recovery for water-cooled units which are used for gen-
erating chilled or warm water for comfort air conditioning or for process applications.
Unit
Buffer tank
If a compressor is operating and produces waste heat, the pump P1 is also operating
and transports the water-glycol mixture through the condenser of the unit where the
waste heat is taken in. The heated water-glycol mixture is directed through the primary
side of a plate heat exchanger. If necessary, the heat is transferred to a secondary sid-
ed water circuit and stored in a buffer tank.
When the temperature of the water-glycol mixture is too low, the 3-way valve MV1 con-
ducts the water-glycol mixture back into the condenser which causes another rise in
temperature.
If the allowable temperature of the water-glycol mixture is reached, the 3-way valve
MV1 opens, adds chilled water-glycol mixture from the heat-rejection system and
achieves an operation within the allowable operating limits.
dimensioning the expansion tanks, the respective system volume (chilled water side or
warm water side) must be taken into account.

13
The unit is very frequently mounted on the top floor of the building and thereby at the
highest point of the system. If an incorrect inlet pressure is the reason for the pressure
fall at the highest point of the plant, where the water pumps is often mounted, this leads
to cavitation on the suction side of the pump. If cavitation is not noticed in time, water
schematic diagram.
Buffer tank In the field of heat recovery it is recommended to use a buffer tank. Thus, transition
of heat recovery: periods in which heat is required during inactive heat recovery are well compensated.
Plate heat exchangers: The plate heat exchanger is used in a hydraulic plant as system separation. Reasons
temperatures
For water-cooled units, it is necessary to remove heat from the cooling process. The
heat coming from the condenser of the unit can be used for other processes or can be
given off to the outside air.
The operating limits must be observed for the reliable operation of the unit. The corre-
sponding operating limits are provided in the technical documentation of the unit.
In this case, heat recovery is possible and therefore a distinction is made between:
– Cooling operation without heat recovery
– Cooling operation with heat recovery
Cooling operation without heat recovery

In this operating mode, heat recovery is not required. The unit is to be operated as effi-
ciently as possible. In order to achieve this, the 3-way valve MV1 is to be regulated so
that the lowest possible cooling water inlet temperature T1 is ensured in the con-
denser, within the operating limit.
The pump P1 is activated in parallel for requested compressor operation. The
3-way valve MV1 controls the minimum medium inlet temperature T1 in the condenser,
depending on the water volume flow. Thus, the minimum medium discharge tempera-
ture from the condenser can be ensured and optimal conditions for an economic com-
pressor operation are created.
If the medium inlet temperature T1 exceeds the minimum allowable temperature, the
3-way valve MV1 opens the connection A and uses the heat-rejection system to dissi-
pate excessive heat.
The power of the heat-rejection system is controlled by the speed of the fan motor,
depending on the medium discharge temperature T4 from the heat-rejection unit. This
ensures optimal heat-rejection water temperatures and constant operating conditions
within the operating limits of the unit. The setpoint of the medium discharge tempera-
ture T4 corresponds to the minimum medium discharge temperature in the condenser,
considering the water volume flow.

13
Cooling operation with heat recovery
In this operating mode, the heat recovery is required and the transmission of heat via
the plate heat exchanger should be as efficient as possible. In order to achieve this,
the 3-way valve MV1 is to be regulated so that the highest possible cooling water inlet
temperature T1 is ensured in the condenser, within the operating limit.
The pump P1 is activated in parallel for requested compressor operation. The
3-way valve MV1 controls the maximum medium inlet temperature T1 in the con-
denser, depending on the water volume flow. Therefore, optimal conditions for the heat
recovery are created.
If the water temperature T3, measured in the buffer tank, is lower than the medium tem-
perature T2 coming from the condenser, pump P2 is activated and heat recovery takes
place. The pump P2 is deactivated as soon as the water temperature T3 in the buffer
tank exceeds the water/glycol temperature T2 coming from the condenser. This can be
the case if the load request of the unit decreases.
If the medium inlet temperature T1 exceeds the maximum allowable temperature,
since the heat demand of the heat recovery is reduced, the 3-way valve MV1 opens
the connection A and ensures a release of the non-required heat via the heat-rejection
system.
The power of the heat-rejection system is controlled by the speed of the fan motor,
depending on the medium discharge temperature T4 from the heat-rejection unit. This
ensures optimal heat-rejection water temperatures for heat recovery and constant
operating conditions within the operating limits of the unit. The setpoint of the medium
discharge temperature T4 corresponds in this operating mode with heat recovery to the
maximum medium discharge temperature in the condenser, considering the water vol-
ume flow.
glycol.


64
13
unit
Plate heat exchanger Buffer tank

14
Chilled/warm water unit with variable-speed pump, single-circuit
buffer tank and 2-way valves (VPS A-Control)
Area of application
Generation of chilled or hot water for comfort air conditioning or for process applica-
tions. The consumer network is easily designed and the consumers are equipped with
2-way valves.
By using a variable-speed pump, the hydraulic system can be planned securely with
energy-saving features.
DP2
p
unit Buffer tank

P P P P
DP1 V1
p P
FL T
Advantages of a variable-speed pump
Using variable-speed pumps with the correct hydraulic integration of the unit results in
many crucial advantages compared to pumps without speed control:
– The maximum rotational speed of the pump adjusts to pressure loss in the hydraulic
network. This practically precludes an oversized pump with fixed rotational speed
and the associated high power consumption. It is important to create an exact com-
putation of the piping in order to adapt the speed-controlled pump to the plant char-
acteristic curve and to ensure a correct control system.
– Costly and energy-destroying control valves are unnecessary.
– Constant control of the water outlet temperature in stationary operation
– High energy-saving potential at full and partial load operation as well as also in
stand-by operation
– Longer pump lifetime
– Lower noise emission
In full-load operation, an energy saving potential results, since the pump adapts the
rotational speed to the actual demand and the pressure loss in the system.
In partial-load mode, the reduced rotational speed lowers the water flow, since the
maximum water flow is not required in partial-load mode. Depending on the applica-
tion, the partial-load mode of the unit reflects the largest portion the operating time with
up to 99%.

14
If the system temperature is achieved during stand-by operation, the pump automati-
cally reduces to the minimum possible rotational speed. The water flow is reduced to
50% of the maximum volume of water. The system temperatures are still recorded in
a reliable and energy-saving manner. For systems without speed control, the pump
also works during stand-by operation at maximum rotational speed and power con-
sumption.
The theoretical pump characteristics change when there is a change in speed as fol-
lows:
– The pump feed rate is proportional to the change in pump speed. A reduction of the
rotational speed by 50% therefore leads to halving the pump feed rate.
– The discharge head is proportional to the square of the change of the pump speed.
This means a reduction of 50% in rotational speed results in a reduction of the dis-
charge head by 25%.
– The power demand of the pump is proportional to the third potential of the change
in the pump speed. This means a reduction of 50% in rotational speed results in a
reduction of the power consumption by 12.5%.
The energy-saving potential decisively depends on the following factors:
– Design and pressure losses of the hydraulic network
– Load of the consumer
– Operating and stand-by time of the unit
– Design of the unit for the required demand
The medium is chilled or warmed up for the required load request. The chilled/hot water
now flows over the consumers and is warmed or cooled down once again.
tical water temperatures. The required volume of water must be individually adjusted
with control valves for every consumer; this is the only way to ensure the respective
performance at full load. The capacity control of every consumer is regulated by 2-way
valves. At partial load, the changing pressure losses are compensated by the speed-
controlled pump.
For fault-free operation of the unit, a minimum water flow through the heat exchanger
of the unit is required. To ensure this, the bypass valve V1 is employed. If the minimum
water flow over the heat exchanger is not achieved, the bypass valve V1 opens and
ensures fault-free operation.
One cycle buffer tank The buffer tank primarily serves to increase the water volume in the hydraulic system
frequent switching on and off of the compressors.
Paddle-type flow switch The paddle-type flow switch protects the unit evaporator if there is no or inadequate
therefore not be switched with the flow switch. The switch-on point of the flow monitor
must be at approx. 35 % of the nominal volume flow according to the technical design,
as the pumps can reduce the water volume flow to 50 % in regular operation. If neces-

14
sary, reduce the piping in the area of the flow monitor including the required inlet and
outlet sections. The flow switch is a prerequisite for the reliable and faultless function-
ing of the unit.
volume must be taken into consideration for the dimensioning of the expansion tank. If
the plant configuration unit is used with a pre-integrated hydraulic module, it often con-
tains pumps, single-circuit buffer tanks, and possibly (apart from other installations)
sel on-site. The unit is very frequently mounted on the roof of the building and thereby
at the highest point of the system. If an incorrect inlet pressure is the reason for the
pressure fall at the highest point of the plant, where the water pumps is often mounted,
this leads to cavitation on the suction side of the pump. If cavitation is not noticed in
time, water pumps and other plant components can be damaged.
switch of the plant. A falling system pressure is processed in the control system of the
unit, which in the event of this malfunction stops both the unit as well as the pump, and
prevents costly plant breakdowns.
Regulating valves: Hydraulic rebalancing is used in plants with multiple consumers of different power rat-
ings for regulating different volume flows or compensating different pressure drops in
the pipework.
schematic diagram.
over contact can be switched to outside temperature or be time-dependent. The en-
abling contact may not be used to control capacity or temperature. The capacity control
of the unit and the associated control system of the water temperature may only be im-
plemented with the internal control of the unit. Otherwise the consequence is a cycle
operation of the compressors with too short runtimes as well as a considerably lower
energy efficiency of the overall system.
Pump release: After completed release, the unit switches the speed-controlled pump P1 with a spec-
ified start rotational speed, checks the water flow with the internal differential pressure
switch and additionally with the on-site mounted paddle-type flow switch. As soon as a
stable water flow is ensured, the water outlet temperature is recorded and compared
with the preset setpoint. Depending on the extent of the deviation, the individual com-
pressors are switched on in order to chill or heat the water to the setpoint.
In addition, the unit controller continually records the differential pressure over the most
unfavorable consumer (pressure transducer DP2) and also the differential pressure
over the heat exchanger of the unit (pressure transducer DP1) in order to regulate the
rotational speed of the pump or control the bypass valve V1. The position of the most
unfavorable consumer should be determined by the computation of piping.

14
Differential pressure over As control variable for the speed control of the pump, the differential pressure of the
consumers (pressure sensor consumer lying farthest away and in the most unfavorable pipe section is used. Exactly
DP2): which pipe section and which consumer can be taken from the piping computation.
The differential pressure of the consumer network minimum and maximum limit values
must be entered in the unit controller. Within these limit values, the rotational speed of
the pump remains unchanged.
If the differential pressure increases above the maximum limit value because individual
consumers close their valves, the rotational speed of the pump is reduced so that the
differential pressure is once again within the limit values.
If the differential pressure decreases below the minimum limit value because individual
consumers open their valves, the rotational speed of the pump is increased so that the
differential pressure is once again within the limit values.
Differential pressure over the Since the plant characteristics are variable within certain limits due to the 2-way valves
heat exchanger of the unit to the consumers and the speed-controlled pump, the differential pressure over the
(pressure sensor DP1): heat exchanger of the unit is monitored by the pressure differential sensor DP1. In
order to avoid operational breakdowns of the unit, it is important to always promote a
minimum water flow over the heat exchanger.
As soon as the limit value for the minimum water flow is undershot, the rotational speed
the pump increases and a bypass valve is opened in order to increase the differential
pressure and thereby the water flow over the exchanger of the unit.
If the differential pressure over the heat exchanger is once again within the required
limit value, the rotational speed of the pump is reduced. The bypass valve is slowly
closed.
Bypass valve V1: The bypass valve serves to ensure a minimum water volumetric flow over the heat
exchanger of the unit when there is only little or no load and a large number of 2-valves
are closed. In order to make a correct adjustment of the bypass line, it is important to
only use the bypass valve in connection with a regulating valve. This is the only possi-
bility of regulating the bypass water flow for an energy-saving operating mode.

14
Frost protection


14
V1
Buffer Tank
P
P
P
P
T
FL
DP1
p
Unit
DP2
p

15
Chilled/warm water unit with speed-controlled pumps in primary and
secondary circuit (VPS D-Control)
Area of application
Generation of chilled or hot water for comfort air conditioning or for process applica-
tions. The consumer network can be made as complex as you want. Both on the pri-
mary as well as the secondary side, speed-controlled pumps are employed.
The use of variable speed pumps enables primary and secondary circuits to be
planned reliably in an energy-saving manner.
Consumers
T T T
T T T P P P
P P P
P2-P4
AB
B
A
T2
unit Buffer tank

P P P P T1
T
DT P
P1
FL T
stand-by operation
In full-load operation, an energy saving potential results, since the pump adapts the
rotational speed to the actual demand and the pressure loss in the system. For pumps
without speed control, the excessive energy must be compensated by regulating
valves.

15
up to 99%.
sumption.
lows:
charge head by 25%.
– Load request of the consumer
By the use of a bypass line in the secondary side consumer circuits, this hydraulic sys-
tem is separated from the primary side generator circuit. Since the unit is in the position
to demand-dependently regulate the rotational speed of the primary pump P1, speed-
controlled pumps can also be employed for the on-site secondary pumps.
On load request, the medium is refrigerated or warmed and therefore available to the
secondary network with the pumps P2 to P4. If there is only a small or no cooling/heat-
ing requirement and the volume of water was thereby reduced over the secondary side
consumers, the water is again supplied to the primary circuit via a bypass line between
supply line and return flow distributer. A minimum volume of water is thereby ensured
with the unit.
The consumer circuit can be designed in any number of complex forms. These include
e.g.
The volume of water of the primarily circuit must always be greater than the volume of
water of the secondary circuit over the consumers.

15
sary, reduce the pipeline in the area of the flow monitor including the required inlet and
ing of the unit.
with an electrical input that can process the floating contact of the water pressure
schematic diagram.
Bypass line If there is little or no cooling / heating demand and the water quantity has thereby been
reduced or is zero via the secondary consumers, the minimum water quantity of 50%
is fed back into the primary circuit via a bypass line between the inlet and outlet mani-

15
folds. When dimensioning the bypass line, minimum cross sections must therefore be
taken into account. Please also observe the notes in the operation manual.
As already mentioned as the functional principle the hydraulic system, the control of
the secondary circuit separated from the primary circuit must be observed. Since the
unit does not perform the actuation and control of the secondary pumps P2-P4, this
must be regulated on-site with the load.
The control system of the primary circuit is taken over by the unit with the pump P1.
ified start rotational speed, checks the water flow with an internal differential pressure
pressors are switched on in order to chill or heat the water to the setpoint. In addition,
the unit controller continually records the values of the temperature sensors T1 and T2
and also the temperature difference with the heat exchanger of the device. The rota-
tional speed of the primary pump is determined with the values of this parameter.
Temperature sensor The sensor T1 must be assembled on-site in the water outlet line and the sensor T2 in
T1 and T2: the bypass line between the supply and return flow distributer. The rotational speed of
pump P1 is corrected by analysis of this temperature sensor, so that the volume of
water of the primary circuit is never less than the volume of water of the secondary cir-
cuit. This presupposes that the on-site secondary pumps are designed or limited for
this purpose.
The speed of the primary pump P1 is regulated according to the following criteria:
T1=T2 The rotational speed of the primary pump remains constant and is not
corrected
T1<T2 This means that the secondary volume of water is greater than the pri-
mary volume of water. The rotational speed of the primary pump is slowly increased
until T1 and T2 have the same values. For units in heat pump operation, the logic is
vice versa (T1 > T2)
Temperature difference over The actual speed control of pump P1 takes place with the water-side temperature dif-
the heat exchanger of the ference over the heat exchanger of the device. The temperature difference 'T over the
unit (DT): evaporator is compared with a reference value at regular intervals. The rotational
speed of the primary pump P1 is regulated according to the following criteria:
DT HEAT EXCHANGER > reference value speed of pump P1 is slowly increased
DT HEAT EXCHANGER > reference value speed of pump P1 is slowly decreased
Especially in the partial load mode of the unit, the performance of pump P1 can be
adapted and energy saved.

15
Frost protection


15
P2-P4
T
P
T
T1
T
P
AB A
Consumers
T2
P
T
P
T
P
T
Buffer Tank
P
P
P1
P
P
P
T
T
FL
DT
unit

16
Chilled/warm water unit with variable-speed pump, single-circuit
buffer tank and 3-way valves (VPS E-Control)
Area of application
Generation of chilled or warm water for comfort air conditioning. The consumer net-
work is easily designed and the consumers are equipped with 3-way valves.
By the use of a variable speed pump, the hydraulic system can be planned securely
and to save energy.
With the proposed hydraulics, it should be noted that if some consumers are switched
off, the maximum achievable output of the remaining consumers may drop due to the
reduced water volume flow. Therefore, this hydraulic system is only recommended if
all consumers are used in the same manner or if, contrary to the following illustration,
only one consumer is present. In process applications, this hydraulic system is only
suitable for systems with only one consumer.
A
A
B
B
AB
AB
AB
AB
AB
AB
AB
unit Buffer tank

P P P P
DT P
FL T
stand-by operation

16
In full-load operation there is a potential for energy savings, as the maximum speed of
the pump can be adjusted according to the actual demand or the pressure drop of the
system.
maximum flow is not required in partial-load mode. Depending on the application, the
partial-load mode of the unit reflects the largest portion the operating time with up to
99%.
sumption.
lows:
charge head by 25%.
The medium is chilled or warmed up for the load request. The chilled/hot water now
flows over the consumers and is warmed or cooled down once again.
tical water temperatures. The required volume of water must be individually adjusted
with control valves for every consumer; this is the only way to ensure the respective
performance at full load. The power control of every consumer takes place by 3-way
valves.
16
ing of the unit.
the pipework.
schematic diagram.

16
Temperature difference over The actual speed control of pump P1 takes place with the water-side temperature dif-
the heat exchanger of the ference over the heat exchanger of the device. The temperature difference 'T over the
unit (DT): evaporator is compared with a reference value at regular intervals. The rotational
Frost protection


16
A AB
Buffer Tank
B
A AB
A AB
P
P
B
A AB
P
P
B
T
A AB
T
FL
B
DT
A AB
Unit
A AB

17
Chilled/warm water unit with speed-controlled pump in primary and
secondary circuit wit system separation (VPS E-Control)
Area of application
tions. The consumers are primarily equipped with straight-way valves for regulation.
The secondary-sided consumer network therefore has a variable plant characteristics
curve. Speed-controlled pumps are used as primary and secondary pumps to optimize
energy consumption and flow behavior. The primary circuit pump is controlled accord-
ing to Delta T.
dP
Unit Buffer tank

Gerät Pufferspeicher Plate heat
exchanger P
P P P P
T
WT
T P
P1
FL T
– Costly and energy-destroying control valves are unnecessary in the primary circuit.
stand-by operation
In full-load operation there is a potential for energy savings, as the maximum speed of
the pump can be adjusted according to the actual demand or the pressure drop of the
system. For pumps without speed control, the excess energy must be compensated by
regulating valves.

17
up to 99%.
sumption.
lows:
charge head by 25%.
The medium is cooled or heated to maintain the plate-type heat exchanger at the
required temperature level when load request is required.
This hydraulic system uses a speed-regulated pump on the primary side which,
depending on the load requirement, regulates the speed in the range of 50-100% in
order to keep the Delta T in the primary circuit constant over a wide working range. The
plate-type heat exchanger separates the primary system from the secondary system.
If there is only a low or no cooling / heating requirement and the quantity of water via
the secondary consumers has thereby been reduced or is equal to zero, the flow
through the plate heat exchanger on the secondary side is only low or no longer suffi-
cient. In the generator circuit, the flow of the minimum water quantity of 50 % is still
ensured at all times.
On the secondary side, various temperature zones, mixing circuits, speed-regulated
pumps, 2- or 3-way valves can be used on-site. The buffer tank is used to increase the
volume in the primary circuit to ensure the minimum running time of the compressors
and to prevent the unit from being switched on and off unnecessarily frequently.
17
ing of the unit.
Expansion vessels: The expansion tanks are obligatory, as this hydraulic system requires to have two
ondary side) must be taken into account. If for the plant configuration units with a pre-
integrated hydraulic module are used, these often contains pumps, single-circuit buffer
tanks, and possibly (apart from other installations) also expansion tanks. In most
cases, however, these expansion tanks are only dimensioned for the water volume of
the unit and no longer suffice for the connected hydraulic circuit. The volume of the
additional expansion tank to be installed for the primary circuit must be matched to the
water volume of the primary circuit in the hydraulic system. The volume of the expan-
sion tank integrated in the unit usually must be supplemented with an additional expan-
sion vessel on-site.
the pipework.
schematic diagram.
External enabling device: The unit can be released with an external zero-voltage contact. The enable/change-
over contact can be switched depending on the outside temperature or time. The en-
stable water flow is ensured, the water outlet temperature is measured and compared
with the setpoint value. Depending on the extent of the deviation, the individual com-

17
Temperature difference The actual speed control of pump P1 takes place with the water-side temperature dif-
across the heat exchanger ference over the heat exchanger of the device. The temperature difference ΔT across
of unit (DT): the evaporator is compared with a reference value at regular intervals. The rotational
The generator circuit, in which the medium partly circulates outside, is operated with a
water-glycol mixture in this hydraulic system to protect against frost. FläktGroup rec-
ommends to use at least 30% ethylene glycol. The plate heat exchanger serves as a
system separation so that it is not necessary to fill the consumer circuit with glycol.
Remember: In winter, the frost protection heating of the unit must ensure that the medium tempera-
ture does not drop below freezing point, otherwise there is a risk of frost on the sec-
ondary side of the plate heat exchanger.


86
17
dP
Unit
Gerät Buffer tank
Pufferspeicher Plate heat
P
exchanger
P P P P
T
WT
T P
P1
FL T

18
Reversible water-to-water heat pump with geothermal source and
heat-rejection system
Area of application
Reversible water-to-water heat pump for cooling or heating with seasonal switching.
These units are suitable for 2-pipe change-over systems. A geothermal energy source
is used as the heat source for heating. A heat-rejection unit is used for heat dissipation
in cooling mode.
Heat-rejection unit for cooling operation
Unit
Source Source Consumer-

Circuit heat exchanger heat exchanger
Producer Consumer
circuit circuit
Geothermal source for heating operation
Cooling operation
During the summer months, the unit is switched to cooling mode via the building
management system or a potential-free contact. A customer-side control unit is used
to move the customer-side change-over valve MV2 for summer operation to position A
→ AB. The unit contains an integrated 4-valve in the refrigeration circuit, so it has a
fixed source heat exchanger and a fixed consumer heat exchanger. In cooling mode
the source heat exchanger acts as a condenser and the consumer heat exchanger as
an evaporator. In connection with 2-pipe change-over systems, the advantage is that
no switching devices are required on the consumer side. Furthermore, a buffer tank is
only required on the consumer side.
When the unit is enabled, the pumps on the source side and consumer side start. In
summer or in cooling mode, the consumer circuit is cooled at the required load request.
The medium in the source circuit absorbs the waste heat and flows on to the heat-
rejection unit, where the heat is released to the ambient air.
Heating operation
During the winter months, the unit is switched to heating mode via the building man-
agement system or a potential-free contact. A customer-supplied control unit is used
to move the customer change-over valve MV2 to position B → AB for winter operation.

18
The unit contains an integrated 4-valve in the refrigeration circuit, so it has a fixed
source heat exchanger and a fixed consumer heat exchanger. In heating mode, the
source heat exchanger acts as an evaporator and the consumer heat exchanger as a
condenser. In connection with 2-pipe change-over systems, the advantage is that no
switching devices are required on the consumer side. Furthermore, a buffer tank is only
required on the consumer side. Contrary to common practice, the buffer tank is filled
with heat from below during heating operation. This means that the effect of thermal
stratification cannot be used. This technical compromise has the advantage that the
same buffer tank with identical connection positions can be used for cooling and heat-
ing operation.
winter or in heating mode, the consumer circuit is heated. In heating mode it is neces-
sary to extract the energy required for the refrigeration process from the geothermal
source. It should be noted that the water temperatures in the source circuit are not con-
trolled by the unit. Rather, these result thermodynamically from the evaporator capac-
ity, the ground temperature and the heat transfer processes in the geothermal source.
The operating limits must be observed for the reliable operation of the unit. The geo-
thermal energy source must be designed by the expert planner according to the
extraction capacity and the extraction work over the heating period. The corresponding
limits of use of the unit can be found in the technical documentation of the unit.
Heat-rejection plants are not suitable as a source for heating operation, as condensate
from the ambient air would freeze in winter.
– Ensuring the entire minimum system content. The minimum runtimes of the com-
pressors are observed and unnecessarily frequent compressor switch on and off is
prevented.
– Guarantee of temperature stratification within the container in cooling mode. Stand-
ing buffers must be used for this. The chilled water supply in the plant circuit and the
chilled water inlet in the consumer circuit must be attached at the lower connections
of the buffer tank. In heating mode, the same connection points are used so that a
layering effect cannot be used. The connection positions are optimized for cooling
operation.
Paddle-type flow switch The paddle flow monitors protect both heat exchangers, which can each act as evap-
orators depending on the operating mode, in the event of no or insufficient water vol-
ume flow. The flow monitor must be installed at each unit outlet and wired electrically
- according to the wiring diagram - to the unit. The flow switch acts as a safety device
and not as a regular control element of the unit. The unit's remote ON/OFF may there-
fore not be switched with the flow switch. The flow switch is a prerequisite for the reli-
able and faultless functioning of the unit.
dimensioning the expansion tanks, the respective system volume (source side or con-
sumer side) must be taken into account.

18
If necessary, units are installed on the top floor of the building and thus at the highest
point of the system. If an incorrect inlet pressure is the reason for the pressure fall at
the highest point of the plant, where the water pumps is often mounted, this leads to
characteristics curve have to be matched with one another. If no pumps with variable
pump characteristics are selected, control valves must be used. These are used for the
important alignment of water pumps and hydraulic network with each other. In plants
with only one consumer, the water flow rate can be adjusted. Hydraulic rebalancing is
used in plants with multiple consumers for regulating different volume flows or compen-
sating different pressure drops in the pipework. On the source side, different pressure
drops of the geothermal source and the heat-rejection plant must be balanced.
3-way valve MV1 Shortly after compressor start the operating limits must be observed. For this reason,
the heat-rejection circuit is furnished with a cold-weather start control in the form of a
3-way valve (MV1). The valve is controlled by the unit.
3-way valve MV2 The on-site valve MV2 should be designed as a change-over valve, for example as a
ball valve with a 90° bore. The advantage is a significantly lower pressure drop com-
pared to a spindle valve. Together with the switching of the unit between heating and
cooling, the MV2 valve must be moved to position A → AB for summer operation or
to position B → AB for winter operation.
schematic diagram.
Cooling operation
Before the start of the seasonal cooling phase, the on-site valve MV2 must be moved
to position A → AB by an on-site controller. When the unit is enabled, pumps P1 and
P2 are activated by the control of the unit. Depending on the water temperature, the
compressors are switched on gradually.
Cold weather start control for cooling operation

Shortly after compressor start the operating limits must be observed. For this reason,
3-way valve (MV1). The 3-way valve is controlled directly by the unit, depending on the
condensing pressure, via a 0-10 V signal. This method ensures the observance of the
minimum water temperature also at very low outdoor air temperatures. When the con-
densation pressure is too low, connection B of the 3-way valve (MV1) opens. The tem-
perature of the inlet medium thereby increases in the condenser of the unit and the
condensation pressure rises. The unit works within the range of application. As soon
as the condensing pressure of the unit has reached the required limit value, port B of
the 3-way valve is slowly closed again. When the heat-rejection circuit has achieved a
required high temperature, as a rule the system is regulated only via the fan control of
the heat-rejection system. The power of the heat-rejection system is additionally con-
trolled by the speed of the fan motor, depending on the cooling water discharge tem-
peratures from the dry cooler. This ensures optimal heat-rejection water temperatures
and constant operating conditions throughout the year. In order to achieve an optimal

18
energy efficiency of the unit, the cooling water temperature must be kept as low as pos-
sible within the operating limits.
Heating operation
Before the start of the seasonal heating phase, the on-site valve MV2 must be moved
to position B → AB by an on-site control unit. When the unit is enabled, pumps P1 and
compressors are switched on gradually. Shortly after compressor start the operating
limits must be observed. For heating operation, it is recommended for energy saving
reasons to use an outdoor temperature-dependent supply temperature. For this pur-
pose, the unit must be equipped with an optional outdoor temperature sensor, which
must be installed by the customer.
Heating mode/cooling mode changeover

Switching between heating and cooling must be carried out when the unit is at a stand-
still (no unit enabling). It is recommended to provide a sufficiently long downtime
between heating and cooling operation or vice versa to allow the water temperatures
of both circuits to approximate each other, thus allowing a safe start in the other oper-
ating mode.
vided as an option.
vided with voltage.
the malfunction might no longer be displayed on the unit display.
To protect the source circuit from frost, it is absolutely necessary to use a water-glycol
mixture. FläktGroup recommends to use at least 30% ethylene glycol.


Heat-rejection unit
for cooling operation

Buffer Tank
Unit

Circuit heat exchanger heat exchanger Producer Consumer
circuit circuit
Geothermal source
for heating operation
91
18
19
Reversible water-to-water heat pump with geothermal drilling as heat
source and sink
Area of application
Reversible water-to-water heat pump for cooling or heating with seasonal switching.
These units are suitable for 2-pipe change-over systems. A geothermal energy source
is used as a heat source for heating operation or a heat sink for cooling operation.
Buffer tank
Unit
MV2

Circuit heat exchanger heat exchanger
Producer Consumer
circuit circuit
Geothermal energy source
Cooling operation
During the summer months, the unit is switched to cooling mode via the building
management system or a potential-free contact. The unit contains an integrated 4-
valve in the refrigeration circuit, so it has a fixed source heat exchanger and a fixed
consumer heat exchanger. In cooling mode the source heat exchanger acts as a con-
denser and the consumer heat exchanger as an evaporator. In connection with 2-pipe
change-over systems, the advantage is that no switching devices are required on the
consumer side. Furthermore, a buffer tank is only required on the consumer side.
summer or in cooling mode, the consumer circuit is cooled at the required load request.
The medium in the source circuit absorbs the waste heat and flows on to the geother-
mal borehole, where the heat is transferred to the ground. The geothermal source must
be designed by the specialist planner according to the heat output and the heat quan-
tity over the cooling period. Furthermore, the geothermal source must also be designed
for heating operation (see below). The corresponding application limits of the unit must
be observed. These are specified in the technical documentation of the unit.
Heating operation
During the winter months, the unit is switched to heating mode via the building control
system or a potential-free contact. The unit contains an integrated 4-valve in the refrig-
eration circuit, so it has a fixed source heat exchanger and a fixed consumer heat
exchanger. In heating mode, the source heat exchanger acts as an evaporator and the
consumer heat exchanger as a condenser. In connection with 2-pipe change-over sys-
19
tems, the advantage is that no switching devices are required on the consumer side.
Furthermore, a buffer tank is only required on the consumer side. Contrary to common
practice, the buffer tank is filled with heat from below during heating operation. This
means that the effect of thermal stratification cannot be used. This technical compro-
mise has the advantage that the same buffer tank with identical connection positions
can be used for cooling and heating operation.
winter or in heating mode, the consumer circuit is heated. In heating mode it is neces-
sary to extract the energy required for the refrigeration process from the geothermal
source. It should be noted that the water temperatures in the source circuit are not con-
trolled by the unit. Rather, these result thermodynamically from the evaporator capac-
ity, the ground temperature and the heat transfer processes in the geothermal source.
The operating limits must be observed for the reliable operation of the unit. The geo-
thermal energy source must be designed by the expert planner according to the
Heat-rejection plants are not suitable as a source for heating operation, as condensate
from the ambient air would freeze in winter.
– Ensuring the entire minimum system content. The minimum runtimes of the com-
pressors are observed and unnecessarily frequent compressor switch on and off is
prevented.
– Guarantee of temperature stratification within the container in cooling mode. Stand-
ing buffers must be used for this. The chilled water supply in the plant circuit and the
chilled water inlet in the consumer circuit must be attached at the lower connections
of the buffer tank. In heating mode, the same connection points are used so that a
layering effect cannot be used. The connection positions are optimized for cooling
operation.
Paddle-type flow switch The paddle flow monitors protect both heat exchangers, which can each act as evap-
orators depending on the operating mode, in the event of no or insufficient water vol-
ume flow. The flow monitor must be installed at each unit outlet and wired electrically
- according to the wiring diagram - to the unit. The flow switch acts as a safety device
and not as a regular control element of the unit. The unit's remote ON/OFF may there-
fore not be switched with the flow switch. The flow switch is a prerequisite for the reli-
able and faultless functioning of the unit.
Expansion vessels: The expansion tanks are obligatory, as this hydraulic system requires to have two
dimensioning the expansion tanks, the respective system volume (source side or con-
sumer side) must be taken into account.

19
characteristics curve have to be matched with one another. If no pumps with variable
pump characteristics are selected, control valves must be used. These are used for the
important alignment of water pumps and hydraulic network with each other. In plants
with only one consumer, the water flow rate can be adjusted. Hydraulic rebalancing is
used in plants with multiple consumers for regulating different volume flows or compen-
sating different pressure drops in the pipework. If no speed-controlled pump has been
selected on the source side, the pressure drop in the circuit must also be throttled by
means of a control valve according to the design.
schematic diagram.
Cooling operation
When the unit is enabled, pumps P1 and P2 are activated by the control of the unit.
Depending on the water temperature, the compressors are switched on gradually.

Shortly after compressor start the operating limits must be observed. For this reason
the source circuit is equipped with a 3-way valve (MV1). The 3-way valve is actuated
by a 0-10 V signal directly from the unit, depending on the condensation pressure. This
method ensures that the minimum water temperature can be maintained even at very
low ground temperatures. When the condensation pressure is too low, connection B of
the 3-way valve (MV1) opens. The temperature of the inlet medium thereby increases
in the condenser of the unit and the condensation pressure rises. The unit works within
the range of application. As soon as the condensing pressure of the unit has reached
the required limit value, port B of the 3-way valve is slowly closed again.
As an alternative to the 3-way valve, a speed-controlled pump can be selected. In this
case the high pressure control is realized by adjusting the flow rate. The speed of the
pump is controlled by the unit controller.
Heating operation
When the unit is enabled, pumps P1 and P2 are activated by the control of the unit.
Depending on the water temperature, the compressors are switched on gradually.
Shortly after compressor start the operating limits must be observed. For heating oper-
ation, it is recommended for energy saving reasons to use an outdoor temperature-
dependent supply temperature. For this purpose, the unit must be equipped with an
optional outdoor temperature sensor, which must be installed by the customer.

19
still (no unit enabling). It is recommended to provide a sufficiently long downtime
between heating and cooling operation or vice versa to allow the water temperatures
of both circuits to approximate each other, thus allowing a safe start in the other oper-
ating mode.
vided as an option.
vided with voltage.
the malfunction might no longer be displayed on the unit display.
To protect the source circuit from frost, it is absolutely necessary to use a water-glycol
mixture. FläktGroup recommends to use at least 30% ethylene glycol.


96
19
Buffer tank
Unit
MV2
Source Source Consumer

Circuit heat exchanger heat exchanger Producer Consumer
circuit circuit
Geothermal energy source

20
Non-reversible water-to-water heat pump with
geothermal energy source as heat source and heat-rejection plant as
heat sink
Area of application
Non-reversible water-to-water heat pump for cooling or heating with seasonal switch-
ing. These units are ideal for separate consumers for cooling and heating. A geother-
mal energy source is used as the heat source for heating. A heat-rejection plant is used
for heat dissipation in cooling mode. The advantage over reversible water-to-water
heat pumps is that it is possible to switch between heating and cooling more frequently.
However, a more complicated hydraulic system and two buffer storage tanks are
required. All pumps must be provided by the customer.
Heat-rejection unit for cooling operation
Chilled water-
Buffer storage
Unit
Warm water Chilled water P3

Hot Water-
Buffer tank Water-glycol Water-glycol mixture Producer Consum-
mixture circuit er
circuit
P5 3
Heating Climate system

Water Water glycol
Geothermal source for

heating operation
Cooling operation
The unit is switched to cooling mode via the building management system or a poten-
tial-free contact. The customer's changeover valve MV2 is moved to position B → AB
for summer operation via a customer-side control unit. The unit is equipped with a fixed
evaporator for the cold side and a fixed condenser for the warm side. In the cooling
operating mode, the chilled water temperature is controlled at the evaporator. The hot
water temperature, which in this case is also called the cooling water temperature,
remains unregulated and results thermodynamically.
When the unit is enabled, the customer's pumps start on the evaporator side P1 and
condenser side P2.
The water-glycol mixture used as chilled water medium flows via pump P1 into the
evaporator of the unit. It is cooled when the load request is present. From there it flows
to the lower inlet into the 2-circuit chilled water buffer tank. If there is no demand for
chilled water, the buffer tank ensures the minimum running time of the compressors. A
tank. The chilled water medium flows from the upper outlet of the chilled water buffer
tank back to pump P1. Pump P3 is switched off in cooling mode, so that no medium

20
flows from the chilled water buffer tank to the geothermal source. Pump P5 and the
temperature control valve MV3 are activated by the customer's control system so that
the chilled water glycol mixture flows from the lower outlet of the chilled water buffer
tank to the consumers of the air-conditioning system and from there back to the upper
inlet of the chilled water buffer tank. The MV3 mixing valve ensures that the setpoint
value for the chilled water supply temperature of the consumers in the air-conditioning
system is maintained.
In cooling mode, it is necessary to dissipate the unwanted heat generated by the cool-
ing process to the outside air. The water-glycol mixture in the condenser circuit used
as the hot water medium flows from pump P2 into the condenser of the unit, where it
absorbs the waste heat from the refrigeration process. From there, the medium flows
through the pipeline to the heat-rejection unit, where the heat is transferred to the ambi-
ent air. The cooled medium flows back through valve MV1, which is normally open in
direction A → AB. In addition, the medium flows through port B of valve MV2 to its out-
let AB back to pump P2. Due to the position of the MV2 valve, there is no flow through
the plate exchanger for the heating system in cooling mode. The valve MV1, which is
controlled by the chiller, serves as a cold weather start control. For heat pumps with
seasonal switching, it is possible that at the beginning or end of the annual cooling sea-
son, e.g. in the morning, the outside temperatures are still very cold, so that the cooling
water temperature must be raised by opening the bypass B → AB in order to maintain
the operating limits (see " Cold weather start control for cooling operation").
Heating operation
During the winter months, the unit is switched to heating mode via the building
management system or a potential-free contact. Via a customer-side control unit, the
customer-side changeover valve MV2 is moved to position A → AB for winter opera-
tion. The unit is equipped with a fixed evaporator for the cold side and a fixed con-
denser for the warm side.
When the unit is enabled, the customer's pumps start on the evaporator side P1 and
condenser side P2. The water-glycol mixture used as the hot water medium in the con-
denser circuit flows from pump P2 into the condenser of the unit and is heated there at
the actual load request depending on the hot water setpoint. From there the medium
flows through the piping to the plate heat exchanger, which transfers the heat to a sec-
ondary heating circuit with water as the medium. Furthermore, the medium flows to the
hot water single-circuit buffer tank, which increases the system volume in heating
mode and thus ensures the minimum running time of the compressors. The water-gly-
col mixture flows back to pump P2 through valve MV2. Pump P4 must be activated by
the customer's control system in heating mode so that the medium of the secondary
circuit circulates between the consumers of the heating system and the plate heat
exchanger.
Heat pumps require a heat source for heating. The heat source is the connected geo-
thermal energy source, which extracts energy from the ground. The water-glycol mix-
ture used as chilled water medium flows via pump P1 into the evaporator of the unit.
During compressor operation it is cooled down uncontrolled. From there it flows to the
lower inlet into the 2-circuit chilled water buffer tank. The chilled water medium flows
from the upper outlet of the chilled water buffer tank back to pump P1. In heating mode,
pump P3 must be controlled by the customer's control system when the compressor is
running, so that the energy from the geothermal source is available to the chilled water
buffer storage tank.
Please note that in heating mode the water temperature in the chilled water circuit is
not controlled by the unit. Rather, these result thermodynamically from the evaporator
capacity, the ground temperature and the heat transfer processes in the geothermal
source. The operating limits must be observed for the reliable operation of the unit. The
geothermal energy source must be designed by the expert planner according to the

20
Dual circuit buffer tank The dual-circuit buffer tank (chilled water circuit) fulfils the following functions:
– Ensuring the entire minimum system content for the chilled water side. The minimum
runtimes of the compressors are observed and unnecessarily frequent compressor
switch on and off is prevented.
– Ensure temperature stratification within the container. Standing buffers must be
used for this. The inlet of the chilled water buffer tank in the generator circuit and the
chilled water supply for the consumer circuit must be connected to the lower con-
nections of the chilled water buffer tank.
To determine the system content of the cold side system, in this case only the volume
of the buffer tank and the volume of the pipe between the unit and the buffer tank may
be used. The volume of the consumer circuits or the geothermal borehole, on the other
hand, are not taken into account. The system content must be greater than the mini-
mum system content for the cold side specified in the data sheets.
One cycle buffer tank The single circuit buffer tank (hot water circuit) fulfils the following function:
– Ensuring the minimum system content for the hot water side. The minimum runtimes
of the compressors are observed and unnecessarily frequent compressor switch on
and off is prevented.
To determine the system content of the system for the hot side, in this case only the
volume of the buffer tank, the plate heat exchanger and the volume of the piping
between the unit, buffer tank and plate heat exchanger may be used. The volume of
the consumer circuits or that of the recooling plant, on the other hand, are not taken
into account. The system content must be greater than the minimum system content
specified in the data sheets for the warm side.
Paddle-type flow switch The paddle flow monitor protects the evaporator in case of no or insufficient water flow.
The flow monitor must be installed at the outlet of the evaporator and electrically wired
to the unit according to the wiring diagram. The flow switch acts as a safety device and
not as a regular control element of the unit. The unit's remote ON/OFF may therefore
not be switched with the flow switch. The flow switch is a prerequisite for the reliable
and faultless functioning of the unit. No flow monitor is required in the hot water circuit.
Expansion vessels: The expansion tanks are obligatory, as this hydraulic system is three closed water cir-
cuits. The expansion vessels each provide a required water supply and compensate
for the temperature-related volume changes of the hydraulic system. When dimension-
ing the expansion tanks, the respective system volume (evaporator circuit, condenser
circuit, heating system) must be taken into account.
cavitation on the suction side of the pump. If cavitation is not detected in time, the water
pump and other system components can be damaged
switch: pressure switch of the plant should be used at all times. Some units have an electrical
input that can process the potential-free contact of the water system pressure switch.
The unit control system processes the falling system pressure, stops the unit and the
pump and prevents expensive plant failures.
characteristics curve have to be matched with one another. If no variable speed pumps
are selected, control valves must be used. These are used for the important alignment
of water pumps and hydraulic network with each other. In plants with only one con-

20
sumer, the water flow rate can be adjusted. Hydraulic rebalancing is used in plants with
multiple consumers for regulating different volume flows or compensating different
pressure drops in the pipework. On the condenser side, different pressure losses of the
buffer tank plus the plate heat exchanger must be balanced with the pressure loss of
the recooling plant plus the MV1 valve.
3-way valve MV2 The on-site valve MV2 should be designed as a changeover valve, for example as a
ball valve with a 90° bore. The advantage is a significantly lower pressure drop com-
pared to a spindle valve. Together with switching of unit between heating and cooling,
the MV2 valve must be moved to position B → AB for summer operation or to position
A → AB for winter operation.
3-way valve MV3 The on-site valve MV3 should be designed as a spindle valve. The correct KVS value
is important in order to achieve high control accuracy without oscillation. The valve
must be controlled by the customer. The setpoint of the chilled water inlet must be con-
trolled via the valve. This prevents water that is too cold from flowing into the consum-
ers of the air-conditioning system during or after heating operation and causing a risk
of frost. In hot water mode, the chilled water temperature can fall well below the desired
setpoint in chilled water mode or even below 0 °C.
schematic diagram.
Cooling operation
At the beginning of the seasonal cooling phase, the customer's valve MV2 must be
moved to position B → AB by a customer's control unit. The pump P5 for pumping
water between the chilled water buffer tank and the consumer of the air-conditioning
system, as well as the control valve MV3 for controlling the chilled water setpoint tem-
perature must be controlled by the customer. When the unit is enabled, pumps P1 and
compressors are switched on gradually.

Shortly after compressor start the operating limits must be observed. For this reason,
3-way valve (MV1). The 3-way valve is controlled directly by the unit, depending on the
condensing pressure, via a 0-10 V signal. This method ensures that the minimum cool-
ing water temperature is maintained even at very low outside air temperatures. When
the condensation pressure is too low, connection B of the 3-way valve (MV1) opens.
The temperature of the inlet medium thereby increases in the condenser of the unit and
the condensation pressure rises. The unit works within the range of application. As
soon as the condensing pressure of the unit has reached the required limit value, port
B of the 3-way valve is slowly closed again. When the heat-rejection circuit has
achieved a required high temperature, as a rule the system is regulated only via the
fan control of the heat-rejection system. The power of the heat-rejection system is addi-
tionally controlled by the speed of the fan motor, depending on the cooling water dis-
charge temperatures from the dry cooler. This ensures optimum recooling water
temperatures and constant operating conditions all year round. In order to achieve an
optimal energy efficiency of the unit, the cooling water temperature must be kept as low
as possible within the operating limits.

20
Heating operation
Before the start of the seasonal heating phase, the on-site valve MV2 must be moved
to position A → AB by an on-site control unit. In addition, pump P3 must be started by
the customer to ensure that the water from the geothermal source flows to the chilled
water buffer tank. The pump P4 must be activated by the customer, so that the heating
water is pumped from the plate heat exchanger to consumers. When the unit is
enabled, pumps P1 and P2 are activated by the control of the unit. Depending on the
water temperature, the compressors are switched on gradually. For heating operation,
it is recommended for energy saving reasons to use an outdoor temperature-depen-
dent supply temperature. For this purpose, the unit must be equipped with an optional
outdoor temperature sensor, which must be installed by the customer

still (no unit enabling). To do this, the release must first be withdrawn
Pump release: The release of the pumps P1 and P2 provided by the customer must be made via the
pump release contacts of the unit. In case the unit is not standardly supplied with pump
ON/OFF contacts, then these can be provided as an option.
internal regulation.
For the water pumps to be installed by the customer, no power supply is available from
the unit. The on-site pumps must therefore be provided with voltage.
In addition, pump P3 must be controlled in heating mode with compressor operation so
that the energy from the geothermal source is available to the chilled water buffer tank.
The operation signaling contacts of the compressors must be ordered as optional
accessories and connected to the on-site control system. If at least one compressor is
running and the customer's control system requests heating operation, pump P3 must
be started.
Pump P4 must be activated by the customer in heating mode.
Pump P5 must be activated by the customer in cooling mode.

20
To protect the evaporator circuit and the condenser circuit from frost, it is absolutely
necessary to use a water-glycol mixture. FläktGroup recommends to use at least 30%
ethylene glycol.
Water without glycol is used for the consumer circuit of the heating system (circuit of
pump P4).


Heat-rejection unit
for cooling operation

Chilled water-
Buffer storage
Unit
P3
Hot Water- Warm water Chilled water
Buffer tank Producer Consum-
Water-glycol Water-glycol mixture circuit er
mixture
circuit
P5 3
Heating Climate system

Water Water glycol
Geothermal source for

heating operation
103
20
_i
Legend
3-way motor valve
Bypass valve / 2-way motor valve
Shut-off valve
Cap valve
Ball valve
Regulating valve
Safety valve (spring-loaded)
Strainer
Non-return damper
Pipeline compensator
Expansion tank
Circulating pump
Circulation pump speed controlled
FL Paddle-type flow switch
TS Temperature sensor sequential control
T Thermometer
P Pressure gauge
P Pressure switch
p Differential pressure sensor
DT Measurement of temperature difference

Pipe connection
Electric line

PR-2014-0112-GB_Hydraulik_PU_R3-2020-02_150dpi © Copyright 2020 FläktGroup
WWW.FLAKTGROUP.COM HYDRAULIC MANUAL
FläktGroup is the European market leader for smart and energy efficient Indoor Air
and Critical Air solutions to support every application area. We offer our customers
innovative technologies, high quality and outstanding performance supported by more
than a century of accumulated industry experience. The widest product range in the
market, and strong market presence in 65 countries worldwide, guarantee that we
are always by your side, ready to deliver Excellence in Solutions.
PRODUCT FUNCTIONS BY FLÄKTGROUP

Air Treatment | Air Movement | Air Diffusion | Air Distribution | Air Filtration
Air Management | Air Conditioning & Heating | Controls | Service
» Learn more on www.flaktgroup.com

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Hydraulic Manual

CHILLERS AND HEAT PUMPS

2 PR-2014-0112-GB_Hydraulik_PU_R3-2020-02 • Subject to change

From practical experience, for your practical needs

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 3

unit Buffer tank Consumers

Functional principle of the hydraulics

4 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Important hydraulic components

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 5

Control and regulation

6 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Every unit is subject to relevant operating limits.

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 7

8 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Primary side Secondary side

Functional principle of the hydraulics

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 9

Important hydraulic components

10 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Control and regulation

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 11

Additional notices for planning

Every unit is subject to relevant operating limits.

12 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Primary side Secondary side

Plant circuit Consumer circuit

Functional principle of the hydraulics

14 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 15

Control and regulation

16 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Additional notices for planning

Every unit is subject to relevant operating limits.

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 17

18 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

unit Plate heat Buffer tank

Primary side Secondary side Plant circuit Consumer circuit

Functional principle of the hydraulics

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 19

Important hydraulic components

20 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Control and regulation

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 21

Additional notices for planning

Every unit is subject to relevant operating limits.

22 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Primary side Secondary side Plant circuit Consumer circuit

Geko® Geko® Geko® Geko® Geko® Geko® Geko®

unit Buffer tank

Functional principle of the hydraulics

Important hydraulic components

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 25

Control and regulation

26 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Additional notices for planning

Every unit is subject to relevant operating limits.

PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change 27

28 PR-2014-0112-GB_Hydraulics_PU_R3-2020-02 - Subject to change

Geko® Geko® Geko® Geko® Geko® Geko® Geko®

unit Buffer tank