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GEA RedGenium, Operating Instruction

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GEA RedGenium Operating Instruction Download Page 25

2.9

Residual risks

Warning!

 

Despite careful design of the product and the implementation of all safety-
relevant regulations, further risks for persons and the product during the life-
time of the product cannot be fully ruled out.
► The additional safety instructions in the individual chapters of this manual
must therefore be carefully observed!

The residual risks that were ascertained during the risk assessment carried out
for the product according to safety standard EN ISO 14121 - Safety of Machines -
are:

•

External venting of the secondary refrigerant circuit (see EN 378-1)

•

mechanical hazards due to sharp sheet metal edges and projecting parts

•

electrical hazards 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 caused by vibration due to improper installation

•

hazards due to working materials and other materials in case of allergies or
the like.

•

neglect of ergonomic principles

•

combinations of various hazards

•

unexpected starting, unexpected rotation in case of wrong electrical connec-
tions or defects

•

shut down, emergency stop when defects are detected

•

changes to the rotational speed

•

power failure

•

failure of the control circuit or control loop,

•

incorrect assembly

•

fracture during operation

•

operating media or objects getting thrown out

•

loss of stability

•

personnel slipping, tripping or falling

•

danger from mixing of media

Safety

Residual risks

L_151511_2

 

19.12.2019

25

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: ...fety 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 valid for the respective country and area where the product is used the recognised technical regulations for safe and professional work must also be observed These operating instructions are part of...

Page 3: ...stallation 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 accessories or spare parts which were not supplied or rec ommended by the manufacturer L_151511_2 19 12 2019 3 ...

Page 4: ...h 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 dangerous situation Notice Stands for important information that must be observed for the intended use and function of the product Description of the required action for the intended function of the p...

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: ...int 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 order The handling sequence can be divided into individual steps Handling sequence 1 Handling sequence step 1 step 1 step 2 step 3 2 Handling sequence step 2 The subsequent handling sequence is the expe...

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

Page 9: ...f 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 35 Evaporator 35 Condenser 36 Oil cooler 37 desuperheater optional 37 Subcooler optional 39 Control cabinet with control 40 Fittings 41 Pressure limiting safety devices 41 Components installed by the...

Page 10: ...tion 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 7 2 Important information for start up 68 7 3 Basic settings 70 7 4 Basic and further steps 70 7 4 1 Connecting the product 71 Connecting the pipes 71 Water pipes 72 Electrical connection 74 7 4 2 Pa...

Page 11: ...ion 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 circuit 100 10 4 12 Charging refrigerant 101 10 4 13 Draining the refrigerant 101 10 4 14 Maintenance of the compressor drive motor 102 10 4 15 Checking the operating parameters 102 10 4 16 Maintenance ...

Page 12: ...Plans 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 terms 116 L_151511_2 12 19 12 2019 ...

Page 13: ...ort 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 Fig 24 Process flow chart 51 Fig 25 Designation of the lifting points 57 Fig 26 Secondary refrigerant system 73 Fig 27 Vacuum required to remove moisture from refrigerating plants 77 Fig 28 Stop val...

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 industrial safety health protection and environ mental protection In addition to this operating manual and the mandatory accident prevention regu lations applicable for the respective place of insta...

Page 16: ...efrigeration 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 exceptional service for the supplied components 1 3 1 Technical customer service department Do you require support from the technical customer service department Spe cially trained experienced service ...

Page 17: ...s 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 Landline weekdays from 8 to 17 hour 49 30 43 59 27 50 Fax 49 30 43 59 27 58 Email gea refrigeration de spareparts gea com Order spare parts from our G Pos online shop Grasso Parts online shop www g pos...

Page 18: ...as 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 Equipment Directive Compliance with the machinery directive is confirmed by the respective supplied certificate 1 6 Trademark rights The product contains technical solutions for which GEA Refrigeratio...

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 reserves the right to make technical modifications The product described here corresponds to the state of the art at the time this operating manual was published The manufacturer must be consulted in all ca...

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 equipment The connection lines must be installed only when de energised Intended use includes observance of this manual and all supplied operating man uals as well as compliance with the maintenance and s...

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 product documentation and certifications must be observed in order to obtain this state for the for the operating time The general safety regulations and the provisions and guidelines referred to in...

Page 22: ...ty 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 additional safety instructions as defined in Appendix E must be observed for the designated use in potentially explosive atmos pheres installation zones 1 and 2 in accordance with EN 60079 10 The follo...

Page 23: ...es 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 electrical components and modules may only be carried out by a trained electricianin accordance with the electrical engineering regulations Fur thermore the operator has to take care that the electrical ...

Page 24: ...an 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 cable must be blocked in such a way that it is not possible to restart the unit accidentally and marked as such The operator of the complete system has to take care that an isolation device e g a mains...

Page 25: ...ards 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 caused by vibration due to improper installation hazards due to working materials and other materials in case of allergies or the like neglect of ergonomic principles combinations of various hazards une...

Page 26: ...atory 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 of at least two independent respiratory protective apparatuses First aid equipment medicine and special chemical preparations as well as pro tective coverings etc must be available and stored outsid...

Page 27: ...parator 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 expansion device with electronic fuel injection valve a freely programmable control All operating and fault signals as well as the process variables can be read from a display Touch Panel The control is...

Page 28: ...nt 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 delivered separately included Oil level switch none Pressure sensors on sensor block compressor Safety pressure switch electronic Overflow valve scope of delivery Safety valve HP LP Double safety valve with ...

Page 29: ...ofinet 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 pressure equipment CE PED module H1 complete heat pump Description Design L_151511_2 19 12 2019 29 ...

Page 30: ...e 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 manufacture Year of manufacture of the product Weight without filling Weight without filling of the product Refrigerant Information on the refrigerant used Max operating pressure Max permissible operating...

Page 31: ...0 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 Heat pump with reciprocating compressor evaporator with integrated separa tor RedGenium Heat pump frame size 1100 with V HP 600 compressor Evaporator and condenser designed as fully welded plate heat e...

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 Evaporator with integrated liquid separator 2100 Water cooled condenser 2900 Water cooled desuperheater Description Design L_151511_2 32 19 12 2019 ...

Page 33: ...e 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 suction valve relief devices The compressors have the following equipment features Start up load relief Capacity control by cylinders switch off Monitoring oil difference pressure Oil heater Monitoring dis...

Page 34: ...or 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 regulated via a frequency converter 500 to 1500 rpm Optional Motor version with protection class IP55 The documentation for the electric motor operating manual is an integral part of the product docume...

Page 35: ...t 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 The documentation of the coupling operating manual is a part of the prod uct documentation 3 1 4 4 Evaporator Fig 7 Arrangement of the evaporator Description Design L_151511_2 19 12 2019 35 ...

Page 36: ...nce 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 dissipating the energy absorbed in the evaporator and compressor to the heat carrier heating Design manufacture and acceptance of the condenser comply with the require ments of the Pressure Equipment Directive...

Page 37: ...ler 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 of the product documentation 3 1 4 7 desuperheater optional Fig 10 Position of the desuperheater Description Design L_151511_2 19 12 2019 37 ...

Page 38: ...without 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 temperatures and its heat is transferred to the heat carrier The documentation of the desuperheater operating instructions accept ance certificate is an integral part of the product documentation De...

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 level of the heat carrier inlet and outlet temperatures and its heat is transferred to the heat carrier The documentation of the subcooler operating manual acceptance certifi cate is part of the product ...

Page 40: ...operating 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 one variable Monitoring of all operating parameters Compressor capacity limitation in case the measured discharge pressure suction pressure heat carrier outlet temperature or secondary refrigerant outl...

Page 41: ...e 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 specific application The fittings can be operated manually or by motor e g by gear motors or pneumatic or hydraulic cylinders In reset fittings the flow of fluid in the pipe causes automatic closing of...

Page 42: ...unctioning 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 GmbH does not assume any liability for arising damages or for the violation of the safety regulations resulting from the use of unsuitable materials or a modification to the product that is not incl...

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 Before replacing oil heater it must be ensured that the compressor into which the oil heater is screwed in is not pressurised 3 1 5 2 Marking the safety valves safety labels Fig 14 Marking the safety v...

Page 44: ...learly 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 Tighten the union nut by about 1 4 to 1 3 of a turn beyond the point where the increase in force is felt The leakage is remedied Description Design L_151511_2 44 19 12 2019 ...

Page 45: ...pression 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 compressor drive motor The direction of the arrow indicates the direction of rotation of the compressor drive motor The compressor s direction of rotation is cast into the compressor coupling side Descrip...

Page 46: ...transport 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 GEA Refrigeration Germany GmbH 3 1 5 8 Label of the change over valve Handling instructions Fig 20 Label of the change over valve Importance of the labels Representation showing which valve setting ...

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 Ensure that the product is properly grounded before start up Connect the earth ing connection The necessary mounting hardware and cables are not included in the scope of delivery See general assembly...

Page 48: ...tively 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 the operator s responsibility Description Design L_151511_2 48 19 12 2019 ...

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 for the heat carrier or cooling medium circuit These parts must then be used accordingly Note the hints given in the chapter Start up water piping 3 2 Functional description GEA RedGenium heat pumps...

Page 50: ...ondenser 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 350 to approx 1100 kW with regard to the cold water range The heat pumps are specially designed for operation with ammonia NH3 R 717 as the refrigerant Notice Consultation with regard to corrosion pr...

Page 51: ...e 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 260 Stop valve 280 Stop valve 290 Motor valve suction side 1000 Subcooler 2000 Evaporator with integrated separator 2100 Condenser 2245 Injector 2860 Expansion valve 2900 Desuperheater Description Func...

Page 52: ...eating 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 temperature at which it has sufficient viscosity 3 2 3 3 Oil filter After cooling the oil passes into the oil filter which holds back solid particles from the full oil flow Due to its large surface the ...

Page 53: ...pacity 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 achieved by raising and lowering the suction valves on the refrigerant compressor using the control oil pressure Notice For details of the control process see documentation of the control The documentation...

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 injection control Checking the settings have compressor frame size and type of expan sion valve been properly selected are pressure transmitters correctly scaled Checking the fill level indicators are ...

Page 55: ...ion 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 exists during transport work All activities must be performed with maximum care Personal protective equipment work clothing work boots gloves must be worn during all activ ities on the product Adequate ...

Page 56: ...with 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 3 0 5 bar if required Dry nitrogen with a residual moisture of 30 ppm is used for this purpose Turn the shaft of the compressor at least once every four weeks approx 10 rev olutions The transport pa...

Page 57: ...ial 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 avoid damage to the surface Danger Danger to life when standing beneath a suspended load Make sure there are no persons under the suspended load during crane transport Position the product on the transpo...

Page 58: ...sponsibility 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 Germany GmbH shall not be liable The transport instructions can be accessed as a separate document at GEA Refrigeration Germany GmbH 4 5 Disposal of packaging material The generation of waste should...

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 refrigerant or heating agent ambient tempera ture at the plant s test bench The maximum heat carrier outlet temperature is limi ted however to 47 C allowing a performance test for the GEA RedAstrum ...

Page 60: ...mended 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 based Propylene glycol based Temper NH3 solution Alcohols e g Ethanol Notice Compatibility with the materials used must be ensured for all secondary refrigerants Recommendation Consult with GEA Refrige...

Page 61: ...er 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 Reciprocating compressor TPressure side up to 150 C Inlet temperature of refrigerant gas in the condenser up to 150 C Operating pressure to be maintained on the water side 500 kPa 1500kPa a 5 4 Materials used i...

Page 62: ...n 15 max 40 Ambient humidity ƒ 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 exceeded for a specific application GEA Refrigera tion Germany GmbH must be consulted 3 The given pressure ratio and pressure difference ensure reliable compressor operation Furthermore allowance must...

Page 63: ...emperature 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 exceeded or fallen short of for a short never long term period of time 6 The operating parameters of the order confirmation apply for an agreed field test Technical data Operation limits L_151511_2 19 12...

Page 64: ...at 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 delay in sec GEA VTrac Continuous monitoring of the compressor and motor bearings by means of two sensors in m s for early detection of sudden bearing damage no normal long term wear Oil return tempe...

Page 65: ...e 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 During installation make sure that leaking operating materials do not reach the soil groundwater or surface water Follow the legal regulations applicable at the site of installation e g for Germany Wa...

Page 66: ...e 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 the Screw Compressor for Insulation against Structure borne Sound For installation on intermediate ceilings matched vibration decoupling must be carried out on the ceiling construction The vibration i...

Page 67: ...tdoor 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 installation Assembly and installation L_151511_2 19 12 2019 67 ...

Page 68: ...of 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 able to act according to them in a conscious manner be able to assess the work assigned to them be able to recognise dangers and avoid them be authorised by those responsible for the safety of the sys...

Page 69: ...ntact 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 drive motor must be checked Before start up i e before you connect the voltage supply check that the coupling between the drive motor and compressor is disconnected Other wise the coupling intermedi...

Page 70: ...eir 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 For contact details see chapter Technical customer service The products are tested and accepted at the factory By the time these products are delivered to the customer the following work will have bee...

Page 71: ...necting 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 that have been subjected to a factory acceptance test FAT There are always small residual amounts of NH3 in this heat pump Heat pumps posing a corresponding hazard are identified with a yellow sign i...

Page 72: ...e 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 refrigerant side can be connected up The piping system for the secondary refrigerant connections must be installed on site by the plant engineer Please refer to the drawing in the supply documentatio...

Page 73: ...s 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 Fig 26 Secondary refrigerant system 2000 Evaporator liquid separator 2040 Resistance thermometer secondary refrigerant outlet temperature 2045 Resistance thermometer secondary refrigerant inlet temper...

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 wire The insu lation resistance of the electrical tools and fixtures and wiring is to be checked The connection may only be undertaken if this value lies in the permissible range Connections and almost ...

Page 75: ...gnation 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 insulation shielding covers 7 5 2 Leak test Warning Danger of ammonia For systems with FAT you must refer to chapter Measures during shut downs See nameplate for permissible operating pressure The necessar...

Page 76: ...e 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 in problem areas Carrying out the test 1 Wet all connecting joints welded seams flange connections screw fasten ings etc with foaming agent 2 Remedy any leakages detectable from the noticeable formati...

Page 77: ...m 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 with NH3 The existing vacuum can be used to draw in the oil if not already filled Warning If present block when evacuating the oil pump See also Section Evacuation on refrigerant side in Chapter Mainte ...

Page 78: ...on 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 valve closed Stop valve closed during normal operation Fig 30 Check valve Check valve during normal operation Fig 31 Shuttable check valve Shuttable check valve open during normal operation Start up Fi...

Page 79: ... valve Change over valve 3 way valve opened from below in arrow direction Fig 36 Oil pressure regulating valve Operating position shut Δp x x x bar control pressure to be set vis à vis reference pressure see P I diagram Caution The oil pressure being set too high or too low may result in serious com pressor damage or even total breakdown of the compressor after even a short period of operation See...

Page 80: ...ick 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 42 Thermostatic 3 way valve controlled autonomously using control element Start up First start Start up procedure L_151511_2 80 19 12 2019 ...

Page 81: ...switch 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 first time oil must also be charged via the oil prelu brification valve on the reciprocating compressor The installation and maintenance instruction for the reciprocating compressor which is part of t...

Page 82: ...oil 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 list Warning Maintaining the correct oil differential pressure The oil differential pressure being set too high or too low may result in serious compressor damage or even total breakdown of the compr...

Page 83: ...ling 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 manufacturer information e g for lubrication of the motor The manufacturer information is part of the product documentation If the direction of rotation of the motor is wrong it should be corrected while...

Page 84: ...the 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 circuits Check that the cooling and cold water pumps are running and the shut off fittings in the circuit are in their operating positions If a cooling water or heat carrier controller is installed this m...

Page 85: ...ed 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 docu mentation Notice Comply with occupational safety and health regulations Wear safety glasses and protective gloves Filling procedure for refrigerant 1 Required equipment NH3 filling cylinder scal...

Page 86: ...type 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 The compressors of the product are not filled with oil therefore the product cannot be started immediately after delivery It may only be started after proper assembly installation and commis sioning ...

Page 87: ...anual 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 and empty if necessary 9 Switch on the compressor and observe the operating instructions of the elec trical switchgear Make a compressor package chiller function checkout for testing the sensor and ...

Page 88: ...y 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 not permissible Immediately report any changes to the product to the responsible person The danger areas must always be kept clear Do not position any objects in the danger area Check the proper funct...

Page 89: ...e 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 contacts Remote regulation via a network connection Notice Regulation parameters with a description of their function are represented in the operating manual of GEA Omni The operating manual of GEA Omni is...

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 of running hours operating mode and status signals automatic start up and shut down of the product and capacity control depend ent on the relevant parameter for the application e g suction pressure o...

Page 91: ...removed 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 check it for leakages 9 3 2 Chemical cleaning of the heat exchanger Chemical cleaning has to be carried out only if the heat transfer is significantly deteriorated The cleaning agents used must be suitab...

Page 92: ...a 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 documentation During the guarantee period the maintenance work performed requires docu mented evidence This documented evidence is also a requirement for any warranty claims put to GEA Refrigeration Ge...

Page 93: ...the 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 components must be protected against the entry of moisture in order to prevent impairment of the function of the components The chief principle must be to keep air and moisture entering the product to an...

Page 94: ...ction 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 and maintenance intervals are direct ly matched to the components used The manufacturers instructions are binding and must be observed by the customer to safeguard the guarantee provided by GEA Refrige...

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 evacuation Comply with the occupational safety regulations 10 4 2 Replacing the oil filter Change the oil in accordance with the compressor maintenance manual 10 4 3 Dismantling the compressor suction fi...

Page 96: ...filters 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 instructions The assessment of the condition of the refrigerator oil by means of a general vis ual inspection contamination or laboratory analysis must be carried out after 5000 operating hours or at th...

Page 97: ...ts 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 no longer suitable for use in products It has to be stored or transported in appropriately labelled containers in accordance with the legal provisions The operator is responsible for its proper disp...

Page 98: ...e 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 valve to be effective it is important to perform function checks at regular intervals A control takes place by checking the noise behaviour of the valves during opera tion An error function on the su...

Page 99: ...Never 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 the refrigerant circuit which corresponds to the specified operating pressure When system parts are individually tested the maximum operating pressure indicated on the respective system part for the c...

Page 100: ...nt 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 intervention in the refrigerant circuit and elimination of leaks before start up restarting Evacuate the product using a vacuum pump The compressor must not be used for evacuation During evacuation al...

Page 101: ...xed 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 spilling any refrigerant The refrigerant is weighed with a scale remembering that the cylinder should only be filled to 80 of the capacity If this percentage is not reached and there is still refrig...

Page 102: ...hecked 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 manufacturer Oil temperature X See parameter list The viscosity must not be less than 10cSt Oil pressure X The oil difference pressure to the discharge pressure must not be lower than 1 7 bar In the event...

Page 103: ...mponents 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 on the insulation are included in the P I diagram Caution No screw connections must be used under the insulation if pipes are insula ted It must be possible to remove the insulation and the pipes mu...

Page 104: ...Make 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 means of automatic monitoring of the individual operating parameters the control detects hazardous situations in good time and automatically switches off the product The cause of the fault is then displa...

Page 105: ...fluences 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 increase is prevented by high motor current or high discharge pressure Check the settings in the control menu see control operating instructions Suction pressure too low output drops Slow loss of ref...

Page 106: ...or 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 Incorrect setting or defective lubricating oil pressure regulator Adjust or repair see installation and maintenance instruc tions for compressor Refrigerant in the oil Defective compressor crankcase oil heat...

Page 107: ...causing 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 use a pipe with NBK surface quality annealed and descaled mechanically or chemically descaled after annealing When carrying out repairs to piping systems care should be taken to maintain the origina...

Page 108: ...ioning 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 as Plant not in operation must be ob served If the product is shut down for a period of 48 hours the following activities must be performed 1 Switch off the compressor in accordance with the operati...

Page 109: ...cal 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 or lockable check valves 5 Shut off secondary refrigerant heating agent or cooling water supply 6 Block the manual stop valve of the refrigerant injection if present 7 Ensure that the vent slits of t...

Page 110: ...e 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 for the electric motor Run the oil pump if present for about 5 minutes Check the system for leak tightness Decommissioning Temporary decommissioning L_151511_2 110 19 12 2019 ...

Page 111: ...prevented 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 ties e g toxicity inflammability must be taken into account see also the safety data sheet for the refrigerant Personal protective equipment accord ing to EN 378 3 must be worn National regulations e...

Page 112: ...ed 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 type of the filled or recovered oil including quantitative balance Changes to and replacement of components Regular and routine inspections with results and dates Longer shut down periods Identificatio...

Page 113: ...tsuc 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 carrier intermediate temperatures C t K1 secondary refrigerant inlet temperature C tK2 secondary refrigerant outlet temperature C Oil level in compressor 6 Refrigerant level in the sight glass 7 Remarks...

Page 114: ...er 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 example quantity balance result of oil analysis Service technician Plans Equipment log L_151511_2 114 19 12 2019 ...

Page 115: ...at 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 intake kg Remarks for example quantitative balance Service technician Plans L_151511_2 19 12 2019 115 ...

Page 116: ... Standard by the Deutsches Institut für 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 measurement unit hour H2O2 Hydrogen peroxide chemical molecular formula HP High pressure Hz Frequency measurement unit Hertz IP Protection type for electric operating material ISO International standard ...

Page 117: ... t0h Suction temperature compressor inlet tc Condensing temperature te Discharge temperature compressor outlet toil oil inlet temperature into the compressor TÜV German technical monitoring association V Electric voltage measurement unit Volt VDI Verein Deutscher Ingenieure Association of German Engineers VDMA Verband Deutscher Maschinen und Anlagenbau e V Association of German Mechanical and Plan...

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