GEA RedGenium Operating Instruction Download Page 1

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Heat pump

GEA RedGenium, Compressor frame size V-HP 300 - 600

Operating instruction (Translation from the original language)
L_151511_2

Summary of Contents for RedGenium

Page 1: ...Heat pump GEA RedGenium Compressor frame size V HP 300 600 Operating instruction Translation from the original language L_151511_2...

Page 2: ...ety at work and environmental protection on the basis of existing national regulations for industrial safety In addition to these operating instructions and the binding accident prevention regulations...

Page 3: ...tallation incorrect or improper connection of the main electrical drive or which result from or can be attributed to improper modifications or failure to observe the instructions through the use of ac...

Page 4: ...Description for avoiding the dangerous situation Caution Stands for a potentially dangerous situation which could lead to minor physi cal injuries or damage to property Description for avoiding the d...

Page 5: ...PREFACE The figure on the front page shows the heat pump with subcooler optional project related equipment feature L_151511_2 19 12 2019 5...

Page 6: ...L_151511_2 6 19 12 2019...

Page 7: ...nt 1 Numbered list point 2 Handling instructions Handling instructions prompt you to do something Several steps in sequence time form a handling sequence that should be completed in the prescribed ord...

Page 8: ...L_151511_2 8 19 12 2019...

Page 9: ...the product identification nameplate 30 3 1 3 Product designation heat pumps with reciprocating compressors 31 3 1 4 Main components 32 Reciprocating compressor 33 Compressor drive motor 34 Coupling...

Page 10: ...ion 66 6 4 3 Installation of the Screw Compressor for Insulation against Structure borne Sound 66 6 4 4 Outdoor installation weather protection 66 7 Start up 68 7 1 Special personnel qualification 68...

Page 11: ...on of check valves 98 10 4 8 Searching for leaks on the refrigerant side leak test 98 10 4 9 Venting the refrigerant circuit 99 10 4 10 Refrigerant side evacuation 100 10 4 11 Draining refrigerant cir...

Page 12: ...lans 112 13 1 Equipment log 112 13 1 1 Data sheet sample 113 13 1 2 Data sheet of oil filling template 114 13 1 3 Data sheet of refrigerant filling template 115 14 Appendix 116 14 1 Abbreviations and...

Page 13: ...rt 46 Fig 20 Label of the change over valve 46 Fig 21 Test verification for the control system 47 Fig 22 Designation of the earthing connection 47 Fig 23 Labelling of the parts delivered separately 49...

Page 14: ...L_151511_2 14 19 12 2019...

Page 15: ...work explained in this operating manual must only be carried out by technical personnel This operating manual must be supplemented with instructions based on prevail ing national regulations regarding...

Page 16: ...frigeration Germany GmbH supplies products of high quality and reliabil ity In addition the manufacturer ensures continuous operation of the refrigeration and process technology system and provides ex...

Page 17: ...quickly as possible In most cases you will receive your spare parts within 24 hours after placing the order You can contact us using the following hotlines Wireless out of hours 49 0 172 30 14 579 La...

Page 18: ...s defined in the Pressure Equipment Directive i e pressure equipment is placed on the market with the required equipment parts with safety function This com plete assembly is subject to the Pressure E...

Page 19: ...conditions of use Unauthorised structural modifications are not permitted We assume no liability for any resulting damage In the interest of fur ther development GEA Refrigeration Germany GmbH reserve...

Page 20: ...must be filled only with the refrigerant specified in the contract The pressure equip ment must be installed in the system in such a way that no vibration or pulse is transferred to the pressure equip...

Page 21: ...was developed manufactured and is reliable according to the cur rently valid rules of technology It was checked and has left the factory in a safety related perfect condition The specifications of the...

Page 22: ...y and environmental protection in ammonia refrigeration plants and also fully applies to other refrigerants Danger There is a danger to people and products in potentially explosive atmos pheres The ad...

Page 23: ...s may be made to the control or other components belonging to the product Maintenance work may only be done by authorised service staff Special requirements for the electrical technicians Work on elec...

Page 24: ...n before beginning the work Should an emergency situation arise despite adhering to the safety regulations the product must be shut down immediately and isolated from the electrical mains The mains ca...

Page 25: ...rds as a result of inadvertently coming in contact with terminals and cables thermal hazards as a result of inadvertently coming in contact with heat exchangers and pipes exposure to noise hazards cau...

Page 26: ...tory protection equipment independent of the ambient air First aid equipment Emergency shower for eye rinsing The respiratory protection equipment must be suitable for that refrigerant It must consist...

Page 27: ...arator fully welded chiller plate condenser air cooled oil cooler fully welded chiller plate subcooler optional equipment feature fully welded liquid cooled plate heater optional equipment feature exp...

Page 28: ...t of GEA Refrigeration Germany GmbH Oil cooling Standard scope of delivery air cooled Oil heaer scope of delivery Oil filter Single stage filter Spare oil filter Oil pressure filter cartridge delivere...

Page 29: ...finet module Electric motor customer specific design possible on request Subcooler can be supplied Desuperheater can be supplied Flow monitor electronic Vibration isolators can be supplied Approval of...

Page 30: ...Data on the nameplate Designation Description GEA Refrigeration Germany GmbH Contact data of the manufacturer Type Type designation of the product Serial no Serial number of the product Year of manuf...

Page 31: ...rpm in kW in relation to the heat out put Compressor frame size Frame size V HP 300 RedGenium 500 V HP 450 RedGenium 800 V HP 600 RedGenium 1100 Sample labelling Example Description RedGenium 1100 He...

Page 32: ...Common base frame for all components 10 Reciprocating compressor 15 Compressor drive motor 95 Coupling 180 Switching cabinet control and regulator 200 Oil cooler 1000 Water cooled subcooler 2000 Evapo...

Page 33: ...transmitters installed on the compressor are used to monitor the operating values of the compressor With the compressor the indi vidual cylinders can be switched off either by bypass valves or suctio...

Page 34: ...r is directly driven by an air cooled 4 pole electric motor IP23 with an operating voltage of 400 V 50 Hz using a coupling The GEA RedGenium series is equipped as standard with a motor which is rpm re...

Page 35: ...decoupling from otherwise disturbing influences such as axial or radial forces vibrations or offset Speed fluctuations and speed shocks are damped and cushioned while torsional vibrations are reduced...

Page 36: ...ce certificate is a part of the product documentation 3 1 4 5 Condenser Fig 8 Position of the condenser In the condenser the compressed refrigerant vapour is desuperheated and lique fied by dissipatin...

Page 37: ...er is used for cooling the oil heated in the compressor in order to ensure sufficient oil viscosity for supplying to the compressor The documentation of the oil cooler acceptance certificate is part o...

Page 38: ...ithout requiring additional drive power Before condensing the refrigerant is heated in the desuperheater by a certain temperature difference depending on the level of the heat carrier inlet and outlet...

Page 39: ...to the heating and cooling capacity without requiring additional drive power After condensing the refrigerant is supercooled in the subcooler by a certain tem perature difference depending on the leve...

Page 40: ...perating mode and status signals Automatic start up and shutdown of the heat pump as well as capacity regula tion depending on the water brine outlet temperature However control is possible only by on...

Page 41: ...reduc tion and direction of the flow of liquid as well as the medium itself The safety fittings are used to limit the pressure in systems which are under pres sure Each fitting is designed for the sp...

Page 42: ...nctioning of the safety devices for pressure limiting They are specified in the respective opera tional safety regulations 3 1 4 12 Components installed by the client Warning GEA Refrigeration Germany...

Page 43: ...tube it must be ensured that the pipes into which the sensors are mounted are not pressurised The pressure free state can be achieved by closing the shut off valves before the sensor to be replaced Be...

Page 44: ...early visible manner Importance of the labels If leakage occurs at a screwed connection escaping gases or liquids the screwed connection must be tightened Counter hold the screw socket using a spanner...

Page 45: ...ression stage 3 Information field label of the refrigerant 3 1 5 5 Marking of direction of rotation of the compressor drive motor information plate Fig 17 Marking of direction of rotation of the compr...

Page 46: ...ransport Importance of the labels Adherence to all guidelines and information on the transport instruction The transport instruction for the respective product can be called up as separate document at...

Page 47: ...the control system Fig 21 Test verification for the control system 3 1 5 10 Designation of the earthing connection Safety labels Fig 22 Designation of the earthing connection Importance of the labels...

Page 48: ...ively two separately installed and separately connected ground wire must be used ensuring the minimum cross section in the sum The grounding must be carried out according to current regulations and is...

Page 49: ...the parts delivered separately are installed in the pip ing circuit 1 Remove the parts from the packaging 2 Install the components according to the figure Notice The delivery includes additional parts...

Page 50: ...ndenser and in the oil desuperheater and subcooler optional Based on the GEA Grasso reciprocating compressor series the portfolio of GEA RedGenium heat pumps covers a heating capacity range of approx...

Page 51: ...heat carrier flows through the desuper heater condenser and subcooler Fig 24 Process flow chart 10 Reciprocating compressor 15 Compressor drive motor 45 Suction filter 60 Check valve pressure side 26...

Page 52: ...ating is not regulated The maximum oil temperature is restricted 3 2 3 2 Oil cooling Before it is returned to the compressor for use the oil heated up in the compres sor has to be cooled down to a tem...

Page 53: ...acity control A capacity setting is also achieved through speed control using a frequency inverter in the speed range of 500 to 1500 rpm The capacity setting in the reciprocating compressors is achiev...

Page 54: ...the maximum level sensor indi cates a level that is too high the expansion valve opens further Notice The following points must be checked before commissioning to ensure cor rect functioning of the in...

Page 55: ...on There is a danger of impacts and tripping against protruding parts on the product e g valve caps There is also a danger of cut wounds on sharp edges and surfaces A danger of crushing body parts exi...

Page 56: ...ith protective gas that will prevent a change of the properties of an operating media e g refrigerator oil Check the protective gas filling once a week and recharge to the speci fied overpressure of 0...

Page 57: ...al care not to attach the ropes to small nominal diameter pipes or insu lation and not to cause damage to them Use spacers if necessary Make suitable arrangements timber or insulating material to avoi...

Page 58: ...ponsibility of GEA Refrigeration Ger many GmbH In the event of damages caused by deviations from the described transport instructions and the use of impermissible slinging equipment GEA Refriger ation...

Page 59: ...used as the heat carrier the terms warm water or cooling water are also used Performance test Factory acceptance test FAT test run of the heat pump under defined conditions depending on the sec ondary...

Page 60: ...ended oil type CPI CP 1009 100 Please contact the manufacturer in case of other types of oil 5 3 3 Secondary refrigerant Water non corrosive maximum 150 ppm Cl other approved fluids Ethylene glycol ba...

Page 61: ...r and the outlet temperature on the liquid side are significant for this temperature and pressure Example Parameter Value Heating agent water Inlet temperature 50 C Outlet temperature 70 C Reciprocati...

Page 62: ...15 max 40 Ambient humidity max 95 Notes 1 When considering a specific application all the conditions specified in the table must be taken into account and adhered to 2 If the specified limits are exce...

Page 63: ...mperature at the compressor inlet must be at least 18 C and below 70 C 5 The specified data refer to the operating conditions of a heat pump During downtime or start up the limiting values may be exce...

Page 64: ...t carrier outlet temperature of subcooler Intermediate temperature from the heat carrier circuit after subcooler exit in C Operating hours Running hours Auto start delay Remaining time for auto start...

Page 65: ...range All electrical connections must be established and all electrical consumers sensors must be connected according to the circuit diagram 6 3 Requirements and information on installation Caution D...

Page 66: ...must be levelled with suitable shims such that the coarse alignment radial and angular misalignment 0 25 mm at the coupling is attained again Then tighten the foundation bolts 6 4 3 Installation of t...

Page 67: ...door installation Protection against external influences especially dirt dust and moisture wetness is essential The manufacturer will not accept liability for damage due to incorrect outdoor installat...

Page 68: ...f the product recognised technical regulations for safe work according to good professional practice The technical personnel must be familiar with all legal regulations in Section 2 6 Page 21 and be a...

Page 69: ...tact with parts of the system which are at a very high or very low tempera ture Personal protective equipment must be worn Suitable tools or special tools must be used The direction of rotation of the...

Page 70: ...ir in structions See chapter Customer Service 7 3 Basic settings Notice The Customer Service department of GEA Refrigeration Germany GmbH offers comprehensive support for the start up of the product F...

Page 71: ...ecting the pipes The protective gas filling of the heat pump must be purged by opening the vent valves on the suction side before the connection of the pipes Caution Take special care with heat pumps...

Page 72: ...flushed before connecting This is carried out to remove soil ing foreign particles and welding residue from the system Secondary refrigerant system After the heat pump has been aligned its secondary...

Page 73: ...the pipe diameter must be allowed for The cabling of the temperature sensor and flow monitor must be carried out with an additional cable length of 6 m measured from the outlet point of the chiller F...

Page 74: ...sections must be according to DIN VDE 100 Part 520 Before starting work make sure that all parts to be connected are de energised e g by removing the main fuse in all phases or installing a jumper wir...

Page 75: ...nation in the general assembly drawing See chapter Designation of the earth connection Check that all electrical work has been carried out in accordance with the stand ards e g protective earth insula...

Page 76: ...used as the means to indicate leakages A solution of 50 parts water and 1 part detergent can be used as the foaming agent Leakage is detected by formation of foam A leak detection spray can be used i...

Page 77: ...After the vacuum pressure the temperatures in the machine house and the outdoor temperature in shade must be entered in the log After the vacuum test the pressure compensation must be carried out wit...

Page 78: ...n Enable smooth operation of the product The valves must be in the operating position prior to the start up of the product Fig 28 Stop valve open Stop valve open during normal operation Fig 29 Stop va...

Page 79: ...r valve Change over valve 3 way valve opened from below in arrow direction Fig 36 Oil pressure regulating valve Operating position shut p x x x bar control pressure to be set vis vis reference pressur...

Page 80: ...ck acting valve spring loa ded manually operated if necessary Fig 40 Charging valve drain valve connections with cap Fig 41 Service valve Connection Rp For pressure gauge and pressure transmit ter Fig...

Page 81: ...witch the valves to the operating position Open the stop valve 90 until the oil level has reached the top third of the sight glass assembly in the compressor crankcase When charging with oil for the f...

Page 82: ...il differential pressure The correct oil pressure must be set in the Parameters menu of the control before the compressor drive motor and thus the heat pump may be started Setting value see parameter...

Page 83: ...ing hub motor side is seated tightly It is not required to increase the speed for checking the direction of rotation Notice Before commissioning of the compressor drive motor be sure to check the manu...

Page 84: ...he compressor must be checked Danger Start up must not be carried out unless the coupling protection is fitted Solid mounting of the coupling protection must be checked 7 5 10 Checking the water circu...

Page 85: ...d the refrigerant circuit can be charged with refrigerant through the refrigerant draw in valve s The refrigerant draw in valve is shown on the supplied P I diagram of the product see order dependent...

Page 86: ...ype of packing stipulated in the order The product is generally supplied without packaging The product has a protective gas filling in the refrigerant circuit The media connections are closed Warning...

Page 87: ...nual stop valve of the refrigerant injection 7 Remove all non condensible gases by venting To this end check the con densing pressure and temperature see parameter list 8 Check the oil collection sump...

Page 88: ...devices at regular intervals All covers and hoods must be mounted as intended The installation location of the product must always be sufficiently ventilated Design modifications to the product are n...

Page 89: ...switched on according to the operating manual of the control 8 3 2 Compressor regulation Possibilities of the compressor regulation Manual regulation Automatic regulation Remote regulation via contac...

Page 90: ...user and the product The control system performs the following functions as standard Display of all important physical and technical parameters e g pressure tem perature motor current capacity number...

Page 91: ...emoved for manual mechanical cleaning To do so follow the instructions listed in the corresponding component documentation After completion of the cleaning work correctly mount the com ponent and chec...

Page 92: ...The product must be serviced by appropriately trained operating staff only For all maintenance work the maintenance instructions must be complied with The maintenance manual is part of the product do...

Page 93: ...he repair always ensure that there is complete pressure com pensation between the relevant pressurised spaces and the surrounding air During cleaning repair or maintenance work the product or its comp...

Page 94: ...tion given in the manufacturer s technical documentation for individual components The documentation for the main components is a part of the product doc umentation The service and maintenance work an...

Page 95: ...valve and use an extraction device to remove remaining refrigerant The compressor may now be opened After opening the compressor and prior to a restart remove any air that may have entered during evac...

Page 96: ...ilters If the degree of ageing cannot be assessed reliably by laboratory analysis and the results of visual examination it is advisable to change the oil at the following intervals see maintenance ins...

Page 97: ...s for leakages The oil charge oil and start up of the chiller must be accomplished in accordance with the operating instructions 10 4 4 4 Used oil Refrigeration machine oil drained from the circuit is...

Page 98: ...with the steel disc coupling documentation 6 Re grease the coupling if provided for in the maintenance instructions for the coupling 10 4 7 Checking the function of check valves In order for a check...

Page 99: ...ever use oxygen to build up the pressure For the leak test for determining the leakage on the refrigerant side e g with escaping inert gas or refrigerant filling a test pressure must be generated in t...

Page 100: ...t side evacuation Note Shut off the oil pump if present during evacuation The purpose of evacuating the system is to remove air and moisture from the refrigerant circuit Evacuation is required after i...

Page 101: ...ed firmly to the closed refrigerant cylinder The drain valve is opened slowly The valve on the refrigerant cylinder is then also opened slowly Due to the hazards involved you should take care to avoid...

Page 102: ...ecked Every 24 to 72 h Weekly Monthly Remark Discharge temperature X Maximum discharge temperature 150 C in individual cases e g heat pump applications this may be exceeded in agreement with the manuf...

Page 103: ...ponents tanks and pipes for damage Damaged insulation must be replaced The insulation thickness should be selec ted in accordance with the temperature and humidity at the point of installation Details...

Page 104: ...ake sure that all parts can be mounted without being damaged 11 3 Special dangers 11 3 1 Shut down in the event of dangerous situations The safety equipment of the product complies with EN 378 By mean...

Page 105: ...luences Check and repair the capacity control device for the compressor Product output does not increase although the refrigerant temperature is way above the set point Product status is LIMIT Output...

Page 106: ...r crankcase too low Add oil and or check oil return system Oil filter on suction and or pressure side is clogged Clean or replace see installation and maintenance instruc tions for compressor Incorrec...

Page 107: ...ausing only a minimum amount of dirt to collect in the system Pipes bent on a pipe bending machine only using refrigerator oil If repairing the piping system from your own stocks we recommend that you...

Page 108: ...oning Always allow the system to cool down before decommissioning 12 3 Temporary decommissioning 12 3 1 Shut down for a period of 48 hours Notice Labelling obligation The obligation to label the plant...

Page 109: ...al switchgear 2 Switch off all ancillary drives 3 Switch off the main switch of the three phase electric system Removing the main fuse 4 Close the stop valve on the suction side and the pressure side...

Page 110: ...analysis with the values for fresh oil We recommend an oil change after 1 year at the lat est See maintenance instructions Check the insulation resistance of the drive motors see the operating manual...

Page 111: ...revented Disposal and decommissioning work must only be carried out by personnel which is qualified according to EN 13313 In case of contact with refrigerant or operating media their hazardous proper...

Page 112: ...d or recovered refrigerant including quantitative balance If recovered refrigerant is used then the analytical findings and the source of the recovered refrigerant need to be specified Quantity and ty...

Page 113: ...suc t0 overheating 5 K Poil oil difference pressure bar toil oil temperature C Imot compressor motor current A tW1 heat carrier inlet temperature C tW2 heat carrier outlet temperature C tW3 4 heat car...

Page 114: ...r Construction no year of manufacture Compressor Type Manufacturer Construction no year of manufacture Date Operating hours Filled recovered oil quantity in l Absorbed oil quantity in l Remarks for ex...

Page 115: ...t pump Type Manufacturer Construction no year of manufacture Compressor Type Manufacturer Construction no year of manufacture Date Operating hours Removed refrigerant quantity kg Refrigerant quantity...

Page 116: ...tandard by the Deutsches Institut f r Normung e V DIN dm3 Volume measurement unit cubic decimetre DN DN nominal diameter EC European Community EN European Standard EX Explosion protection h Time measu...

Page 117: ...t0h Suction temperature compressor inlet tc Condensing temperature te Discharge temperature compressor outlet toil oil inlet temperature into the compressor T V German technical monitoring association...

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