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4 Chilled/warm water generator with plate heat exchanger for the system
separation, dual circuit buffer tank and extensive system hydraulics ...... 19
8 Sequence control gear of chiller/heat pump with dual circuit buffer tank
and extensive system hydraulics ............................................................ 39
Legend .................................................................................................. 83
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 recommen-
dations 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 com-
munication 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.
Area of application
Generation of cold or warm water for comfort air conditioning or for process appli-
cations.
The deployment of a single-circuit buffer tank system is a simple consumer network
condition, which however requires the satisfaction of important prerequisites.
For released units, the medium flows from the buffer tank to the water pump in the
unit. The medium is chilled or warmed up for the required load reduction. 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 reduc-
tion. The bypass line B is closed. If the load reduction 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 reduction. 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 reduction, 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 reduction 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 trans-
ported 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.
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 unneces-
sarily frequent on and off switching of the compressors.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 pres-
sure fall on 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 switch: If units and water pumps are mounted on 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 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.
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 com-
pressors with too short runtimes as well as a considerably worsened energy effi-
ciency of the overall system.
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 tem-
perature is measured and compared with the preset setpoint. Depending on the
extent of the deviation, the individual compressors are switched on in order to chill
the water to the setpoint. 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 per-
form 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 provided 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 regulation. 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
provided 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. Further-
more, the entire unit is thereby put out of commission, even though possibly only
one of several refrigeration circuits was affected.
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. DencoHappel 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 sub-
jected to outside temperatures below 5°C. For the water-based components in the
unit, suitable options are available and provided by the factory.
Consumers
Buffer tank
Unit
Area of application
Generation of cold or warm water for comfort air conditioning or for process appli-
cations.
By using a single-circuit buffer tank system and a plate heat exchanger for system
separation, a simple consumer network is conditioned, where however important
prerequisites must be satisfied.
Plate heat
Unit Buffer tank Consumers
exchanger
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 second-
ary 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 con-
tents, especially because the buffet tank is in the secondary circuit. The minimum sys-
tem 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 separation, 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 reduction. The chilled/warm water now flows to the consumer and is once
again warmed up or cooled down.
The 3-way valve in the position A – AB is fully opened at maximum capacity reduc-
tion. The bypass line B is closed. If the load reduction of the consumer drops, then
the bypass line B is opened. This ensures that, independent of the load reduction, a
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 unneces-
sarily frequent on and off switching of the compressors.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 pres-
sure fall on the highest point of the plant, where the water pumps is often mounted,
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 com-
pressors with too short runtimes as well as a considerably worsened energy effi-
ciency of the overall system.
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 tem-
perature is measured and compared with the preset setpoint. Depending on the
extent of the deviation, 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 compressors are switched off or on depending on the tem-
perature change. The water pumps remain in continuous operation so that the plant
can perform readings of the current water temperature in the system.
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. DencoHappel recommends to use 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.
13
02
03
Chiller/heat pump with dual circuit-buffer tank and
extensive system hydraulics
Area of application
Generation of cold or warm water for comfort air conditioning or for process appli-
cations.
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
For released units, the medium flows from the buffer tank to the water pump in the
unit. The medium is chilled or warmed up for the required load reduction. 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 run-
time of the compressors. A constant water volume flow through the unit is guaran-
teed with the dual circuit buffer tank.
The consumer circuit can be designed in any number of complex forms.
This includes e.g.:
• Employment of speed-regulated pumps
• Employment 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.
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 at-
tached 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.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 pres-
sure fall on 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 switch: If units and water pumps are mounted on 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 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.
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 com-
pressors with too short runtimes as well as a considerably worsened energy effi-
ciency of the overall system.
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 tem-
perature is measured and compared with the preset setpoint. Depending on the
extent of the deviation, 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 compressors are switched off or on depending on the tem-
perature 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 provided 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 regulation. 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
provided 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. Further-
more, the entire unit is thereby put out of commission, even though possibly only
one of several refrigeration circuits was affected.
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. DencoHappel 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 sub-
jected to outside temperatures below 5°C. For the water-based components in the
unit, suitable options are available and provided by the factory.
Consumer circuit
Buffer tank
Plant circuit
Unit
Area of application
Generation of cold or warm water for comfort air conditioning or for process appli-
cations.
Chilled/warm water generator with plate heat exchanger for the system separation,
dual circuit buffer tank and extensive system hydraulics
Consumers
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 second-
ary 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 pro-
vides the primary side of the unit with chilled/heated water glycol mixture. The
medium is chilled or warmed up for the required load reduction. 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 com-
pressors.
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 at-
tached at the lower connections of the buffer tank.
In order to determine the minimum system content of the unit, in this case only the
volume 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.
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.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 pres-
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 com-
pressors with too short runtimes as well as a considerably worsened energy effi-
ciency of the overall system.
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 tem-
perature is measured and compared with the preset setpoint. Depending on the
extent of the deviation, 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 compressors are switched off or on depending on the tem-
perature 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 provided as an option. Both the water pump in the primary as well as in the sec-
ondary circuit must be operated with the enabling contact. Both pumps must always
be simultaneously in operation.
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. DencoHappel recommends to use 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.
23
04
05
Chiller/heat pump with single-circuit buffer tank and
several different consumers
Area of application
Generation of cold or warm water for comfort air conditioning or for process appli-
cations.
The deployment of a single-circuit buffer tank system is a simple consumer network
condition, which however requires the satisfaction of important prerequisites.
For released units, the medium flows from the buffer tank to the water pump in the
unit. The medium is chilled or warmed up for the required load reduction. The
chilled/warm water now flows through the consumer and is once again warmed up
or cooled down.
In this case, it can be about consumers of the same or unequal power consumption
at identical water temperatures. The required water quantity must be adjusted indi-
vidually 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 reduction, the 3-way valve is
fully opened to the position A – AB. The bypass line B is closed. If the load reduction
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 reduction. 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 reduction, water no longer circulates to the consumer. The water tem-
perature 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 reduction increases again, the unit switches
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 unneces-
sarily frequent on and off switching of the compressors.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 pres-
sure fall on 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.
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 com-
pressors with too short runtimes as well as a considerably worsened energy effi-
ciency of the overall system.
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 tem-
perature is measured and compared with the preset setpoint. Depending on the
extent of the deviation, 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 compressors are switched off or on depending on the tem-
perature 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 provided 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 regulation. 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
provided 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. Further-
more, the entire unit is thereby put out of commission, even though possibly only
one of several refrigeration circuits was affected.
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. DencoHappel 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 sub-
jected to outside temperatures below 5°C. For the water-based components in the
unit, suitable options are available and provided by the factory.
Buffer tank
Geko®
Geko®
Geko®
Geko®
Unit
Geko®
Area of application
Generation of cold or warm water for comfort air conditioning or for process appli-
cations.
The deployment of a single-circuit buffer tank system is a simple consumer network
condition, which however requires the satisfaction of important prerequisites.
For released units, the medium flows from the buffer tank to the water pump in the
unit. The medium is chilled or warmed up for the required load reduction. The
chilled/warm water now 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 con-
nected according to the Tichelmann principle to ensure an almost equal water quan-
tity 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 reduction, the 3-
way valve is fully opened to the position A – AB. The bypass line B is closed. If the
load reduction 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 reduction. 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 reduction, water no longer circulates to the consumer.
The water temperature approaches the unit setpoint and the compressors gradually
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 unneces-
sarily frequent on and off switching of the compressors.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 pres-
sure fall on 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 switch: If units and water pumps are mounted on 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 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.
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 com-
pressors with too short runtimes as well as a considerably worsened energy effi-
ciency of the overall system.
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 tem-
perature is measured and compared with the preset setpoint. Depending on the
extent of the deviation, 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 compressors are switched off or on depending on the tem-
perature 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 provided 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 regulation. 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
provided 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. Further-
more, the entire unit is thereby put out of commission, even though possibly only
one of several refrigeration circuits was affected.
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. DencoHappel 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 sub-
jected to outside temperatures below 5°C. For the water-based components in the
unit, suitable options are available and provided by the factory.
Geko®
Geko®
Buffer tank
Geko®
Geko®
Geko®
Geko®
Unit
Geko®
Area of application
Generation of cold or warm water for comfort air conditioning or for process
applications.
The consumers are primarily equipped with straight-way valves for regulation. The
secondary-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.
The secondary side is equipped with a speed-regulated pump. The unit requires a
constant water flow-rate for trouble-free operation, therefore a system separation is
created 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 pri-
mary 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-
regulated pump, straight-way regulating valves can be used. The secondary pump
can adjust the pump characteristics of a variable plant characteristics curve within the
variable pump characteristics range and can set an optimal operating point.
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 unneces-
sarily frequent on and off switching of the compressors.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 pres-
sure fall on 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 switch: If units and water pumps are mounted on 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 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 rebalancing is used in plants with multiple consumers for regulating differ-
ent volume flows or compensating different pressure drops in the pipework.
Ventilation: Vent valves and air collector 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.
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 com-
pressors with too short runtimes as well as a considerably worsened energy effi-
ciency of the overall system.
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 tem-
perature is measured and compared with the preset setpoint. Depending on the
extent of the deviation, 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 compressors are switched off or on depending on the tem-
perature 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 release: 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 provided as an option. Both the water pump in the primary as well as in the sec-
ondary circuit 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 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 regulation. 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
provided with voltage.
Error messaging: 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. Further-
more, the entire unit is thereby put out of commission, even though possibly only
one of several refrigeration circuits was affected.
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. DencoHappel recommends to use 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 is employed as a system separa-
tion, filling the entire plant with anti-freeze is not required.
Area of application
Generation of cold or warm water for comfort air conditioning or for process appli-
cations.
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 prerequi-
sites must be satisfied.
Sequencer
Unit n
Consumers
Unit 2
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 differ-
ent power ratings. Every unit must have its own pump.
For released units, the medium flows from the buffer tank to the water pump in the
unit. The medium is chilled or warmed up for the required load reduction. 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 run-
time of the compressors. A constant water volume flow through the unit is guaran-
teed with the dual circuit buffer tank.
The consumer circuit can be designed in any number of complex forms.
This includes e.g.:
• Employment of speed-regulated pumps
• Employment 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.
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 at-
tached 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.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 pres-
sure fall on 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 switch: If units and water pumps are mounted on 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 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.
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
operated with this unit. The water inlet and water outlet temperature serves as the
controlled 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 fur-
nished with a Modbus interface. Now only the sequencer is accessed for all addi-
tional 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 pre-
set 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.
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 provided 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 regulation. 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
provided with voltage.
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. DencoHappel 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 sub-
jected to outside temperatures below 5°C. For the water-based components in the
unit, suitable options are available and provided by the factory.
Unit n
Consumers
Buffer tank
Unit 1
43
08
09
Chiller, water-cooled plant, 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
applications.
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 reduction, the medium takes up the waste heat and flows on to the
heat-rejection system where the heat is returned to the ambient air.
Water filter: 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 filters are a prerequisite for the reliable and faultless function of the unit.
Expansion vessel: 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.
Ventilation: Vent valves and air collector 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.
For water-cooled units, it is necessary to remove non-required heat from the cooling
process 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 oper-
ating 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 optimal heat-rejection water temperatures and constant operating condi-
tions 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 oper-
ating limits.
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 provided 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 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.
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
provided with voltage.
Frost protection
In order to protect the heat-rejection circuit from frost, the employment of a water/
glycol mixture is definitely required. DencoHappel recommends to use at least 30%
ethylene glycol.
Unit
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 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 reduction, 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 con-
densation pressure is too low, the 3-way valve conducts the medium once again into
the condenser to increase the condensation pressure. Operation within the permis-
sible condensation pressure is thereby guaranteed throughout the year.
Water filter: 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 filters are a prerequisite for the reliable and faultless function of the unit.
Expansion vessel: 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.
Ventilation: Vent valves and air collector 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.
For water-cooled units, it is necessary to remove non-required heat from the cooling
process 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
observance of the minimum water temperature also at very low outdoor air tempera-
tures. 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 con-
denser of the unit and the condensation pressure rises. The unit works within the
range of application. As soon as the condensation pressure of the unit has reached
the upper limit value, the connection B of the 3-way valve is once again slowly
closed. 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 operat-
ing 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.
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 provided 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 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.
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
provided with voltage.
In order to protect the heat-rejection circuit from frost, the employment of a water/
glycol mixture is definitely required. DencoHappel recommends to use at least 30%
ethylene glycol.
Unit
Area of application
Heat-rejection
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
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 at-
tached 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.
Water filter: 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 filters are a prerequisite for the reliable and faultless function of the unit.
Frost protection
In order to protect the heat-rejection circuit from frost, the employment of a water-
glycol mixture is definitely required. DencoHappel recommends to use at least 30%
ethylene glycol.
Buffer tank
Unit
Heat-rejection circuit
Producer Consumer
circuit circuit
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
Chilled-water circuit
Auxiliary heating
E heating
Desuperheater circuit
Fresh water inlet
Combi 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 de-
superheater 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 desu-
perheater 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 lim-
its which must be maintained. The medium discharge temperature from the desuper-
heater must not fall below 30 °C. In order to ensure this, a 3-way valve must be used.
Water filter: 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 filters are a prerequisite for the reliable and faultless function 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-
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 sta-
tus contact 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.
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. DencoHappel 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 sub-
jected to outside temperatures below 5°C. For the water-based components in the
unit, suitable options are available and provided by the factory.
Unit
Chilled-water circuit
Auxiliary heating
E heating
Desuperheater circuit
Fresh water outlet
Combi storage tank
Area of application
Heat-rejection circuit with heat recovery for water-cooled units which are used for
generating chilled or warm water for comfort air conditioning or for process appli-
cations.
Heat-rejection system
Unit
Chilled-water circuit
Buffer tank
Plate Heat Exchanger
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 pri-
mary side of a plate heat exchanger. If necessary, the heat is transferred to a second-
ary sided water circuit and stored in a buffer tank.
When the temperature of the water-glycol mixture is too low, the 3-way valve MV1
conducts 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.
Water filter: 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 filters are a prerequisite for the reliable and faultless function of the unit.
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 cor-
responding 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
In order to protect the heat-rejection circuit from frost, the employment of a water/
glycol mixture is definitely required. DencoHappel recommends to use at least 30%
ethylene glycol.
Unit
Plate Heat Exchanger Buffer tank
65
13
14
Cold/warm water generator with variable-speed pump, single-
circuit buffer tank and 2-way valves (VPS A-Control)
Area of application
Generation of cold or hot water for comfort air conditioning or for process applica-
tions. The consumer network is easily formed and the consumers are equipped with
2-way valves.
By the use of a variable-speed pump, the hydraulic system can be planned securely
and in an energy saving way.
DP2
p
DP1 V1
p P
FL T
For released units, the medium flows from the buffer tank to the water pump in the
unit. The medium is chilled or warmed up for the required load reduction. The cold/
hot water now flows over the consumers and is warmed or cooled down once again.
In this case, it can be about consumers of the same or unequal power consumption
at identical water temperatures. The required volume of water must be individually
adjusted for every consumer with control valves, only so can the respective perfor-
mance be ensured at full load. The power control of every consumer takes place by
2-way valves. At partial load, the changing pressure losses is compensated by the
speed-controlled pump.
For fault-free operation of the device, a minimum water-air flow through the heat
exchanger of the device is required. To ensure this, the bypass valve V1 is employed.
Is the minimum water flow over the heat exchanger not achieved, the bypass valve
V1 opens and thereby ensures fault-free operation.
One cycle 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 unneces-
sarily frequent on and off switching of the compressors.
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 en-
abling contact may not be used to control capacity or temperature. The capacity con-
trol of the device and the associated control system of the water temperature may
only take place with the internal control of the device. Otherwise the consequence
is a cycle operation of the compressors with too short runtimes as well as a consid-
erably worsened energy efficiency of the overall system.
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. DencoHappel 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 sub-
jected to outside temperatures below 5°C. For the water-based components in the
unit, suitable options are available and provided by the factory.
V1
Buffer tank
P
P
P
P
T
FL
DP1
p
Unit
DP2
p
Area of application
Generation of cold or hot water for comfort air conditioning or for process applica-
tions. The consumer network can be made arbitrarily complex. Both on the primarily
as well as also on the secondary side, speed-controlled pumps are employed.
With the use of variable speed pumps, primarily and secondary circuits can be
planned securely and in an energy saving manner.
Consumers
T T T
T T T P P P
P P P
P2-P4
AB
B
A
T2
DT P
P1
FL T
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 posi-
tion 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.
For released units, the medium flows from the buffer tank to the water pump in the
unit. On required load acceptance, the medium is refrigerated or warmed and there-
fore available to the secondary network with the pumps P2 to P4. If there is only a
small or no cooling/heating requirement and the volume of water was thereby
reduced over the secondary side consumers, the water is with a bypass line between
supply line and return flow distributer once again supplied to the primary circuit. A
minimum volume of water is thereby ensured with the unit.
The consumer circuit can be designed in any number of complex forms. Among these
are e.g.
• Employment of speed-regulated pumps
• Employment of 2-way or 3-way valves
• Consumer circuits in different temperature ranges.
• Consumer circuits with various power capacities and water/volume flows
The volume of water of the primarily circuit must always be greater than the volume
of water of the secondary circuit over the consumers.
One cycle 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 unneces-
sarily frequent on and off switching of the compressors.
Water filter: 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 filters 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 electri-
cally 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 installa-
tions) 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 con-
nected hydraulic 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 vessel 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 on 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 switch: If units and water pumps are mounted on 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 with an electrical input that can process the floating contact of the water
pressure switch of the plant. A falling system pressure is processed in the control sys-
tem of the device, then at of this malfunction stops both the unit as well as also the
pump and prevents cost intensive plant breakdowns.
Ventilation: Vent valves and air collector 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.
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.
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.
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. DencoHappel recommends to use at least 30% ethylene glycol.
P2-P4
T
P
T
T1
T
P
AB A
B
Consumers
T2
P
T
P
T
P
T
Buffer tank
P
P
P1
P
P
P
T
T
FL
DT
Unit
Area of application
Generation of cold or hot water for comfort air conditioning or for process applica-
tions. The consumer network is easily formed 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.
A
A
B
B
AB
AB
AB
AB
AB
AB
AB
DT P
FL T
For released units, the medium flows from the buffer tank to the water pump in the
unit. The medium is chilled or warmed up for the required load reduction. The cold/
hot water now flows over the consumers and is warmed or cooled down once again.
In this case, it can be about consumers of the same or unequal power consumption
at identical water temperatures. The required volume of water must be individually
adjusted for every consumer with control valves, only so can the respective perfor-
mance be ensured at full load. The power control of every consumer takes place by
3-way valves.
One cycle 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 unneces-
sarily frequent on and off switching of the compressors.
Water filter: 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 filters 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 electri-
cally 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
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 en-
abling contact may not be used to control capacity or temperature. The capacity con-
trol of the device and the associated control system of the water temperature may
only take place with the internal control of the device. Otherwise the consequence
is a cycle operation of the compressors with too short runtimes as well as a consid-
erably worsened energy efficiency of the overall system.
Pump release: After completed release, the unit the speed-controlled pump P1 switches with a
specified start rotational speed, examines the air 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 compressors are switched on in order to chill or heat the water to the
setpoint.
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. DencoHappel 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 sub-
jected to outside temperatures below 5°C. For the water-based components in the
unit, suitable options are available and provided by the factory.
A AB
Buffer tank
B
A AB
A AB
P
P
A AB
P
P
B
T
A AB
T
FL
B
DT
A AB
Unit
A AB
Shut-off valve
Cap valve
Ball valve
Regulating valve
Strainer
Non-return damper
Pipeline compensator
Expansion tank
Circulating pump
TS
Temperature sensor sequential control
T Thermometer
P Pressure gauge
P Pressure switch
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