Related Manuals for GEA RedGenium
Summary of Contents for GEA 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 The entire documentation must also be forwarded if the product is installed at another location and if the product is sold. These operating instructions have been written in good faith. However, GEA Refrigeration Germany GmbH cannot be held responsible for any errors that this document may contain or for their consequences.
- Page 3 – improper operating conditions and conditions of use, – inadequate maintenance, – improper operation, – incorrect installation, – 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;...
- Page 4 SYMBOLS USED Danger Stands for an immediate danger leading to severe physical injuries or death. ► Description for avoiding the danger. Warning! Stands for a potentially dangerous situation leading to severe physical inju- ries or death. ► 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.
- 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...
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- Page 7 LAYOUT INFORMATION Bullet points and numbered list characters Bullet points are used to separate logical contents within a section: • Bullet point 1 – Types of bullet point 1. • Bullet point 2 – Types of bullet point 2. Numbered list characters are used to separate enumerations within a descrip- tive text: Descriptive text with consecutive numbering: •...
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Page 9: Table Of Contents
TABLE OF CONTENTS General Information Information about the document Manufacturer address Customer services 1.3.1 Technical customer service department 1.3.2 Spare parts 1.3.3 Training courses 1.3.4 Service contracts Declaration of Conformity, Declaration of Incorporation CE mark Trademark rights 1.6.1 Evaporator with distributed injection 1.6.2 Evaporator with integrated liquid separation Safety... - Page 10 Oil filter Oil return from the low pressure side 3.2.4 Capacity control 3.2.5 Level control of the evaporator Transport and storage Personnel qualification for transport and storage Safety instructions for transport and storage Storage conditions Transport (crane transport) Disposal of packaging material Technical data Key data Basic terms...
- Page 11 Description of the control elements 8.3.1 Requirements for switching on 8.3.2 Compressor regulation 8.3.3 Setting of setpoint and limit values as well as safety devices 8.3.4 Operation of the system Cleaning Special personnel qualification Safety Instructions Clean 9.3.1 Mechanical cleaning 9.3.2 Chemical cleaning of the heat exchanger Maintenance...
- Page 12 12.4 Dismantling, disposal Plans 13.1 Equipment log 13.1.1 Data sheet (sample) 13.1.2 Data sheet of oil filling (template) 13.1.3 Data sheet of refrigerant filling (template) Appendix 14.1 Abbreviations and terms L_151511_2 19.12.2019...
- Page 13 TABLE OF FIGURES Fig. 1 CE mark Fig. 2 Mounting location of the product identification (nameplate) Fig. 3 Standard GEA RedGenium heat pump Fig. 4 Position of the reciprocating compressor Fig. 5 Arrangement of the compressor drive motor Fig. 6 Arrangement of the coupling Fig.
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Page 15: General Information
General Information Information about the document General Information Information about the document This operating manual is part of the technical documentation. It contains advice for operating the product safely, properly and economically. The observance of the operating manual helps in avoiding dangers, reducing repair costs and down- times, and increasing the reliability and durability of the product. -
Page 16: Manufacturer Address
General Information Manufacturer address Manufacturer address GEA Refrigeration Germany GmbH is a company of the GEA Group AG and pro- vides its customers around the world with high-quality components and services for refrigeration and process technology applications. Locations: GEA Refrigeration Germany GmbH Werk Berlin Holzhauser Str. -
Page 17: Spare Parts
1.3.2 Spare parts GEA Refrigeration Germany GmbH has its own practical and rapidly working spare parts department to supply the necessary spare parts worldwide. Neces- sary spare parts are shipped as quickly as possible. In most cases, you will receive your spare parts within 24 hours after placing the order. -
Page 18: Service Contracts
CE mark The CE mark is affixed to the nameplate. The CE mark for products from GEA Refrigeration Germany GmbH is provided 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. -
Page 19: Safety
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. -
Page 20: Warning Against Foreseeable Abusive Use
Safety Warning against foreseeable abusive use ler or the operator, not the manufacturer, is responsible for all injury to personnel and damage to property which results from non-authorised use. The pressure equipment is not designed for dynamic loads. If there is a risk of lightning strikes, the pressure equipment must be earthed. -
Page 21: Operator Duty Of Care
Safety Operator duty of care Operator duty of care The statutory regulations for meeting the obligation to exercise due care must be observed. Meeting the obligation to exercise due care according to the current level of tech- nology requires that everything that is •... - Page 22 Safety Legal foundations (Germany) • DIN EN 378, Part 1 to Part 4 / VO 2009/125/EC Safety-related technical requirements and environmental requirements • Accident Prevention Regulation including implementation regulations (BGR 500, chapter 2.35) on refrigeration plants, heat pumps and cooling equipment (BGV B3) regarding noise •...
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Page 23: Personnel Qualification
Safety Personnel qualification Personnel qualification Qualification All work explained in this manual (assembly, electrical connection, start-up, oper- ation, etc.) may only be carried out by trained technical personnelwho observe the relevant technical regulations. Technical personnel are representatives of the product manufacturer and per- sons who, as a result of their technical training, experience and personal instruc- tion in training measures, have sufficient knowledge of: •... -
Page 24: Protective Equipment
Safety Protective equipment Minimum age The minimum age for the operation of the product and installation is 18 years. All persons involved in the assembly and installation of the product must get them- selves trained at regular intervals or familiarise themselves with the current tech- nical data of the product. -
Page 25: Residual Risks
Safety Residual risks 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 -... -
Page 26: Emergency Measures / Procedure (First Aid)
Safety Emergency measures / procedure (first aid) Notice Danger of media mixture basically exists with damage to evaporators/ condensers (e.g. plate penetration). This can result in the ammonia transferring onto the liquid side of the heat exchanger and thus causing ammonia to withdraw from the secondary refrigerant side. -
Page 27: Description Design
• Low-voltage installation with frequency inverter and control The modular construction of the GEA RedGenium was optimised for a compact design. The arrangement of the components ensures the very small dimensions for large capacities. The GEA RedGenium is equipped with: •... -
Page 28: Technical Specifications
Type of oil: highly refined mineral oils CPI CP-1009-100 Caution! Please contact the manufacturer in case of other types of oil. ► Contact the service or the design department of GEA Refrigeration Germany GmbH. Oil cooling: Standard scope of delivery (air cooled) - Page 29 Description Design Optional equipment Designation Design Spare oil filter: can be supplied Communication: Profibus DP Profinet 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) L_151511_2...
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Page 30: Mounting Location Of The Product Identification (Nameplate)
Fig.2: Mounting location of the product identification (nameplate) 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:... -
Page 31: Product Designation, Heat Pumps With Reciprocating Compressors
Code Description RedGenium Heat pump series Heat pump frame size (output) RedGenium = Heat pump series 9 = Heat pump frame size (output) at 1500 rpm in kW in relation to the heat out- Compressor frame Frame size size V-HP 300... -
Page 32: Main Components
Description Design 3.1.4 Main components The heat pumps of the GEA RedGenium series consist of the following compo- nents: Fig.3: Standard GEA RedGenium heat pump Common base frame for all components Reciprocating compressor Compressor drive motor Coupling Switching cabinet, control, and regulator... -
Page 33: Reciprocating Compressor
3.1.4.1 Reciprocating compressor Fig.4: Position of the reciprocating compressor The GEA RedGenium uses open, single-action, multi-cylinder reciprocating com- pressors for the refrigerant ammonia (R717). The reciprocating compressors are characterised by compact design, high relia- bility, high quality components and ease of maintenance. -
Page 34: Compressor Drive Motor
Standard: The compressor 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). -
Page 35: Coupling
Description Design 3.1.4.3 Coupling Fig.6: Arrangement of the coupling The coupling helps in transmission of torque between compressor and compres- sor drive motor. The elastic design of the coupling brings about 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: Condenser
Description Design In the evaporator heat is absorbed from the secondary refrigerant (which is thereby cooled) by way of evaporation of the refrigerant. Liquid drops are effectively separated in the liquid separator integrated into the evaporator. Design, manufacture and acceptance of the evaporator with integrated liquid sep- arator comply with the requirements of the Pressure Equipment Directive. -
Page 37: Oil Cooler
Fig.9: Arrangement of the oil cooler The GEA RedGenium heat pumps are equipped with an air cooled oil cooler. The oil cooler is used for cooling the oil heated in the compressor in order to ensure sufficient oil viscosity for supplying to the compressor. - Page 38 Description Design Depending on the specific project conditions, incorporating a desuperheater may have partly significant energy advantages and increase the efficiency of the heat pump, since the desuperheater capacity adds to the heating and cooling capacity 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.
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Page 39: Subcooler (Optional)
Description Design 3.1.4.8 Subcooler (optional) Fig.11: Position of the subcooler Depending on the specific project conditions, incorporating a subcooler may have partly significant energy advantages and increase the efficiency of the heat pump, since the subcooler capacity adds to the heating and cooling capacity without requiring additional drive power. -
Page 40: Control Cabinet With Control
“Operation”, “Warning” and “Fault”, EMERGENCY STOP button, coupling elements as well as the casing. The control cabinet with the control is directly mounted on the GEA RedGenium. The following functions are implemented as standard in the control cabinet with the control: •... -
Page 41: Fittings
Description Design The documentation for the control (operating manual, circuit diagram, parameter list, communication guideline) is an integral part of the product documentation. Notice The communication guideline offers detailed information about communica- tion of the controller. ► The communication guideline can be made available before a planned installation. -
Page 42: Components Installed By The Client
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 included in the original safety concept. -
Page 43: Information And Safety Labels On The Product
Description Design 3.1.5 Information and safety labels on the product Danger Danger to life by failure to observe and follow the labels on the product! ► Be sure to observe and follow the safety-relevant labels on the product! 3.1.5.1 Labels of the pressure and temperature sensors, heater (safety labels) Fig.13: Safety labels of the pressure and temperature sensors, heater... -
Page 44: Fig. 15 Labelling Of The Screwed Connections
Description Design Fig.15: Labelling of the screwed connections The informative label for all screwed connections with cutting ring (handling instructions) is attached to the oil separator in a clearly 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: Labelling Of The Pipes
Description Design 3.1.5.4 Labelling of the pipes (information plate) Pipelines in plants must be labelled as follows (DIN 2405): • Refrigerant • Direction of flow • Physical state Fig.16: Labelling of the pipes Arrow head (indication of the direction of flow) Compression stage Information field (label of the refrigerant) 3.1.5.5 Marking of direction of rotation of the compressor drive motor... -
Page 46: Label, Pressurised Product
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:... -
Page 47: Labelling Of The Control / Control Cabinet
Description Design 3.1.5.9 Labelling of the control / control cabinet (information plate) • Label on the rear side of the control unit of the control system (visible after opening the switching cabinet): – Project name – Build number of the product –... - Page 48 Description Design Notice The cross-section of the ground wire must be at least 10 mm². Alternatively, 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.
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Page 49: Installation And Labelling Of Parts Delivered Separately
► Note the hints given in the chapter “Start-up/water piping”. Functional description GEA RedGenium heat pumps are used for hot water provision by heating of the heat carrier as well as cold water or cold brine cooling for air conditioning or for industrial processes. - Page 50 (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 (NH -717) as the refrigerant.
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Page 51: Process Flow Chart
Description Functional description 3.2.1 Process flow chart Notice For a detailed list of all items, see object-specific customer parts list and P+I diagram. ► The customer parts list and the P+I diagram are part of the product docu- mentation. Depending on the project conditions, the heat carrier flows through the desuper- heater, condenser and subcooler. -
Page 52: Refrigerant Circuit
Description Functional description 3.2.2 Refrigerant circuit The reciprocating compressor sucks the refrigerant vapours from the evaporator through the suction filter. The heat is removed from the compressed gas, con- densed and chilled in the condenser by emitting the heat absorbed in both the evaporator and compressor. -
Page 53: Capacity Control
Description Functional description Expelling oil from the draining vessel After evaporation, hot gas is led via the solenoid valve (2310.1) into the drain- ing vessel for a short while and this pushes the oil into the crankcase of the reciprocating compressor. The control time parameters for the solenoid valves can be set at the control panel. -
Page 54: Level Control Of The Evaporator
Description 3.2.5 Level control of the evaporator The liquid refrigerant is injected into the evaporator via an electronic expansion valve. Control is effected by calculating the mass flow of refrigerant in relation to the pressure loss across the expansion valve and its characteristics. In addition, the fluid level of ammonia is evaluated in an oblique pipe after the condenser. -
Page 55: Transport And Storage
Transport and storage Personnel qualification for transport and storage Transport and storage Personnel qualification for transport and storage Notice All work explained in these operating instructions must only be carried out by qualified personnel. ► These operating instructions must be read prior to transport, storage and delivery to the installation site. -
Page 56: Storage Conditions
Transport and storage Storage conditions Storage conditions When the product is delivered, check for possible transport damage and report any damage to the manufacturer in writing. The storage area of product must be a safe and sheltered environment secured against access of unauthorized personnel. The product should be placed on a flat, load bearing surface on suitable timber supports. -
Page 57: Transport (Crane Transport)
Transport and storage Transport (crane transport) Transport (crane transport) Transport with a forklift is not intended! The product is a high-quality product which must be handled with extreme care during transport. Protect the equipment from impacts and put it down carefully. When transported by crane, the product must have the same position (frame downwards) as in operation. -
Page 58: Disposal Of Packaging Material
When introduced on the customer side, additional and other regulations can apply that are not within the area of responsibility 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. -
Page 59: Technical Data
Technical data Key data Technical data Key data Products of GEA Refrigeration Germany GmbH are designed and produced for special applications. For technical specifications, see the following documents: • order specification, • parameter list, • general assembly drawing, • P+I diagram, •... -
Page 60: Refrigerator Oils
► The selection criteria and selection tables are summarised in the techni- cal information "GEO Grasso VHP". This technical information forms part of the product documentation. ► GEA Refrigeration Germany GmbH can provide assistance in the selec- tion of a suitable refrigerator oil on request. Recommended oil type: CPI CP-1009-100 Please contact the manufacturer in case of other types of oil. -
Page 61: Materials Used In Heat Exchangers
Technical data Materials used in heat exchangers If brines are used as the heating agent in the condenser, it must also be checked whether the inhibitors remain thermally stable at the desired temperatures. Caution! Note the water quality ► Since the water quality can vary considerably, we recommend that each user consult a corrosion protection specialist for his particular case. -
Page 62: Operation Limits
Technical data Operation limits Operation limits The heat pumps from the GEA RedGenium series can be operated within the specified operation limits according to the respective specifications under diverse work conditions. The operation limits listed below are based on the operational principle of the reciprocating compressor, thermodynamic relationships, the ves- sels and safety devices in use, and the practical operating conditions. - Page 63 Technical data Operation limits In addition to the operating limits stated in the tables, the applicable operating conditions of the compressor must also be considered (e. g. start-up regime, oil pressure, oil quantity, oil type etc.). The oil temperature at the compressor inlet must be at least 18 °C and below 70 °C.
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Page 64: Monitoring And Display Of Process Values
Measuring-surface sound-pressure level strongly depends on the type of the heat pump and especially on the type of the drive motor (manufacturer, type, protection type). ► We can provide you with the values on request. Contact the Design or Sales department at GEA Refrigeration Germany GmbH. L_151511_2 19.12.2019... -
Page 65: Assembly And Installation
Assembly and installation Personnel qualification and training Assembly and installation Personnel qualification and training Personnel working on and with the product must have the respective qualifica- tion. The area of responsibility, competence and the monitoring of the personnel must be regulated precisely by the operator. If personnel do not have the neces- sary knowledge, this must be trained or instructed. -
Page 66: Preparing For Assembly
Assembly and installation Preparing for assembly If greater cushioning is required (installation on a floor ceiling or on the roof), vibration dampers must be provided. In this case, the suitable type of vibration damper must be determined and realised. The pipes for the secondary refrigerant must be decoupled using expansion joints where vibration dampers are used. - Page 67 Assembly and installation Notice The product is not intended for unprotected outdoor 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. L_151511_2 19.12.2019...
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Page 68: Start-Up
Start-up Special personnel qualification Start-up Special personnel qualification Warning! The start-up of the product must be only be carried out by technical person- nel who are familiar with the contents of the operating manual for the prod- uct. ► The safety regulations for refrigeration plants must always be observed to prevent damage to the product and injury to the operating staff. - Page 69 Start-up Important information for start-up • Check of the external condition of the product (check of insulation, transport damage, protective gas filling,...). • Check that all electrical work has been carried out in accordance with the standards (e.g. protective earth, insulation, shielding, covers). If necessary, an earthing connection must be provided.
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Page 70: Basic Settings
► See chapter "Customer Service". 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... -
Page 71: Connecting The Product
Start-up Basic and further steps The activities described in this chapter "Start-up" must be carried out in the pre- scribed sequence. The product is operated via the control panel (Touch Panel) of the control. After the setpoints have been entered, both automatic and manual operation are possible. -
Page 72: Water Pipes
Start-up Basic and further steps – Heating agents • For heat pumps with TÜV approval: shut off safety valve on the blow-off line Caution! The heat pump requires a constant flow of secondary refrigerant and heat- ing agent for smooth functioning. ►... -
Page 73: Fig. 26 Secondary Refrigerant System
Start-up Basic and further steps The flow switch can only be installed in a horizontal pipe, or a vertical pipe with a flow running in an upward direction. The flow switch must be installed in a distance of 5 to 10 times of pipe diameter behind the previously flowed curve or valve. -
Page 74: Electrical Connection
Start-up Basic and further steps • Water treatment Industrial water usually contains dissolved or solid matter that causes corro- sion or dirt layers to develop or encourages the growth of algae. The water for the condenser and evaporator circuits should be treated chemically to mini- mise such undesirable effects. -
Page 75: Paint And Insulation
Start-up First start - Start-up procedure 7.4.2 Paint and insulation Damage to the paint and insulation during transport and installation must be care- fully repaired. Painting Coating system S 2.15 acc. to EN ISO 12944-5 for environmental conditions C2 acc. to EN ISO 12944-2. Designed for room temperatures of 5 °C up to 40 °C. -
Page 76: Drying, Vacuum
► To prevent damage to the valve insert, vent the low pressure side after pressure-testing the system, or the valve must be fully open during the pres- sure test and during venting. ► If the control (GEA Omni™) is operational, the valve can also be opened via the service menu. 7.5.3... -
Page 77: Fig. 27 Vacuum Required To Remove Moisture From Refrigerating
Start-up First start - Start-up procedure Fig.27: Vacuum required to remove moisture from refrigerating plants Room or Wall temperature in °C Vacuum in mbar Vacuum required to remove moisture from refrigerating plants Measured values have to be checked and recorded hourly after reaching the required vacuum. -
Page 78: Operating Position Of Valves
Start-up First start - Start-up procedure 7.5.4 Operating position of valves For the positions of the manually controllable fittings for the operation of the prod- uct, see P&I diagram. The layout and symbols used in the P+I diagram comply with the specifications of EN 1861, July 1998 Issue. -
Page 79: Fig. 32 Control Valve
Control valve Shuttable check valve with integrated control function open during normal operation Fig.33: Shuttable check valve with integrated control function Controlled by (e.g. GEA Omni™) Fig.34: Solenoid valve Change-over valve (3-way valve), opened from below in arrow direction Fig.35:... -
Page 80: Fig. 37 Overflow Valve, Safety Valve
Start-up First start - Start-up procedure Overflow valve, safety valve Fig.37: Overflow valve, safety valve controlled self-sufficient Fig.38: Pressure controlled check valve manually operated if necessary Fig.39: Quick acting valve, spring-loa- • ½” connections • with cap Fig.40: Charging valve, drain valve •... -
Page 81: Oil Filling
7.5.5 Oil filling Caution! Check the oil grade to be filled! ► See contract/project or recommendation of GEA Refrigeration Germany GmbH. Only charge with fresh, unused oil. The vacuum present in the product before pressure compensation may be uti- lised for charging the package with oil. A separate oil charging pump is required after the pressure compensation and for refilling with oil. -
Page 82: Checking The Fault Monitoring
Start-up First start - Start-up procedure 7.5.6 Checking the fault monitoring Disconnect the incoming feeder of the compressor driving motor from the mains supply for checking the safety devices (e.g. remove LV/HBC fuse links). Apply voltage to the control. Check limit values. Limit value = see parameter list Set the motor current limitation acc. -
Page 83: Checking The Direction Of Rotation Of The Drive Motor
Start-up First start - Start-up procedure 7.5.8 Checking the direction of rotation of the drive motor Warning! Avoid damaging the motor and compressor when checking the direction of rotation of the drive motor! ► The coupling may not yet connect the motor and compressor when checking the direction of rotation of the drive motor. -
Page 84: Mounting The Coupling
Start-up First start - Start-up procedure 7.5.9 Mounting the coupling The electric switchgear is secured to prevent it from being switched on acci- dentally. Mount the coupling while observing the instructions of the separate documen- tation. The values for radial and angular deviations given in the coupling documenta- tion must be observed in all cases. -
Page 85: First Refrigerant Fill
Start-up First start - Start-up procedure 7.5.11 First refrigerant fill Warning! Exposure to leakage of refrigerant is possible. ► Whenever work is carried out on the parts of the refrigeration circuit car- rying refrigerant or oil, extreme caution is required. Notice In order to charge the refrigerant, the compressor must be ready for opera- tion. -
Page 86: Initial Start-Up
Start-up Handing over to the operator Close refrigerant draw-in valve and stop valve hose, separate the hose from the product and lift up the hose to make liquid refrigerant flow back into the cylinder, then close cylinder valve. Prior to disconnecting the filling hose from the cylinder, and respecting all rel- evant safety rules, carefully drain the gas contents of the hose into the water tank. - Page 87 Start-up If available: open stop valves (or (or shuttable check valves) in the suction line of the economiser (not included as standard for heat pump applications). If present: open the refrigerant supply to the thermosyphon - oil cooler (not included as standard for heat pump applications). If available: open manual stop valve of the refrigerant injection.
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Page 88: Operation And Control
The product must be only be operated by trained and qualified personnel who are familiar with the contents of the operating manual for GEA products. The safety regulations for GEA products must always be correctly complied with in order to prevent injury of the operating personnel and damage to the product. -
Page 89: Compressor Regulation
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 part of the documentation for the control. 8.3.3 Setting of setpoint and limit values as well as safety devices... -
Page 90: Operation Of The System
Operation of the system Caution! Familiarise yourself with the control system documentation. ► Contact the technical customer service department of GEA Refrigeration Germany GmbH if you need assistance. The product is operated via the controller. (Standard: GEA Omni™) The control is mounted directly on the product as standard, but alternatively may also be set up in a control centre. -
Page 91: Cleaning
Cleaning Special personnel qualification Cleaning Special personnel qualification The personnel who clean the product components must have the respective qual- ification for this work. See also Section 6.1, Page 65 for this purpose. Safety Instructions Notice Avoid turning off the system unintentionally. ►... -
Page 92: Maintenance
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 Germany GmbH. The responsible certified specialist company must be informed if any repairs are required. -
Page 93: Preparation For Maintenance
Maintenance Preparation for maintenance 10.3 Preparation for maintenance 10.3.1 General instructions Danger Contact with live components is prohibited. ► Produce the earth connection according to the designation in the general assembly drawing. See chapter "Designation of the earth connection". ► Maintenance work on the running product is not permissible. Work involving intervention in the refrigerant circuit must only be carried out by qualified engineers in accordance with the guarantee conditions. -
Page 94: Maintenance Intervals
We advise you to sign a long-term service agreement with a qualified company authorised by GEA Refrigeration Germany GmbH to carry out the necessary service and maintenance work. Our service department is available for this or can help you to find a suitable partner. -
Page 95: Maintenance Work
Maintenance Maintenance work 10.4 Maintenance work 10.4.1 Opening the compressor Notice Carry out the work on the compressor in accordance with the compressor maintenance manual. ► The Installation and Maintenance Manual is part of the product documen- tation. If the compressor has to be opened to clean the crankcase or replace compo- nents, the pressure must be relieved first. -
Page 96: Oil Draining, Oil Filling, Oil Change
Maintenance Maintenance work 10.4.4 Oil draining, oil filling, oil change 10.4.4.1 Importance of oil change Aged oil demonstrates a loss of lubricity. Because of this, all rotating components of the compressor are endangered. The oil filter elements become prematurely clogged and must be cleaned and replaced at shorter intervals. The oil in the product requires changing •... -
Page 97: Used Oil
Maintenance Maintenance work The chiller must be run for at least half an hour to reach its operating temper- ature before the oil can be changed. First shut down the chiller as described in the operating instructions. Close the stop valves of the compressor side and the compressor pressure side and evacuate the compressor. -
Page 98: Tightening Screw Fastenings
Maintenance Maintenance work Notice Oil removed from the compressor must not be re-used. Use only fresh oil from closed tanks! You must rule out mixing different types of oil. ► For permissible types of oil, please refer to the technical specifications. 10.4.5 Tightening screw fastenings Screw connections of components may become loose by vibration and move-... -
Page 99: Venting The Refrigerant Circuit
Maintenance Maintenance work Lower refrigerant levels in the containers are due to loss of refrigerant as a result of leaks. For this reason, all pipes, connections and valve glands should be checked regularly, especially in the initial period after assembly or commission- ing. -
Page 100: Refrigerant Side Evacuation
Maintenance Maintenance work A sure sign of air or other inert gases is that the temperature gap between con- densing temperature (from condensing pressure) and heating agent outlet is wid- ening. Contamination of the circuit with air or other gases is caused by careless- ness during evacuation, filling oil or contaminated refrigerant If this gas obstructs further operation: •... -
Page 101: Charging Refrigerant
Maintenance Maintenance work 10.4.12 Charging refrigerant See Section 7.5.11, Page 85 10.4.13 Draining the refrigerant Caution! Refrigerant may escape. ► Protective clothing must be worn (eye protection and protective gloves). The refrigerant must be drained: • if the plant is overfilled, •... -
Page 102: Maintenance Of The Compressor Drive Motor
► The control of the operating parameters is carried out via a Touch Panel. The project-related setting values and limits are given in the parameter list. ► Inform the GEA Refrigeration Germany GmbH technical customer serv- ice if the parameters are outside of the permissible limits. -
Page 103: Maintenance Of The Switching Cabinet
Maintenance 10.4.16 Maintenance of the switching cabinet Warning! Contact with live components is prohibited. ► Disconnect the switching cabinet from electricity before starting mainte- nance! Terminal screws must be checked for tightness and if necessary tightened at reg- ular intervals (every 5000 operating hours or at least once per year). Check the contactor contacts for burnup. -
Page 104: Alarms
Alarms Special personnel qualification Alarms 11.1 Special personnel qualification The personnel for troubleshooting / repair must have the respective qualification for this work. See also Section 6.1, Page 65 for this purpose. 11.2 Safety Instructions Observe the following safety instructions for eliminating faults: •... -
Page 105: Instructions Regarding Malfunctions, Their Causes And Remedies
11.4 Instructions regarding malfunctions, their causes and remedies The products manufactured by GEA Refrigeration Germany GmbH are highly advanced, automatic and extremely efficient systems. Faults can occur neverthe- less and impede continuous working of the system or cause a failure of a part or of the entire system. - Page 106 Alarms Instructions regarding malfunctions, their causes and remedies Fault table Fault Cause Remedy Malfunction of compressor suction valve, Repair. pressure valve or overflow safety valve. (see installation and maintenance instruc- tions for compressor). Compressor output controller does not Repair. work. (see installation and maintenance instruc- tions for compressor).
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Page 107: Repairs
Alarms Repairs 11.5 Repairs Repair work may only be carried out by qualified persons or persons with suitable training with the manufacturer's consent and must strictly comply with the rules set out in the maintenance manual for the components concerned. The following maintenance notes must be observed: Only use original manufacturer replacement or spare parts for repairs and to replace parts subject to wear and tear. -
Page 108: Decommissioning
Decommissioning Special personnel qualification Decommissioning 12.1 Special personnel qualification The personnel for decommissioning must have the respective qualification for this work. See also Section 6.1, Page 65 for this purpose. 12.2 Safety Instructions The following safety instructions must be observed during decommissioning: •... -
Page 109: Shut-Down For A Period Of >48 Hours
Decommissioning Temporary decommissioning Notice Short-term shut-down ► If the product is shut down temporarily, the valves do not need to be op- erated; they remain in their operating positions. If there is a possibility of the temperature in the evaporator rising above the cooling water temperature, the cooling water supply must be interrupted or the stop valve on the com- pressor suction side must be closed. -
Page 110: Four Weeks Before Restarting
Decommissioning Temporary decommissioning 12.3.5 Four weeks before restarting • Check the moisture content and ageing condition of the refrigerating machine oil. Analyse the oil for this purpose. Compare the results of the analysis with the values for fresh oil. We recommend an oil change after 1 year at the lat- est. -
Page 111: Dismantling, Disposal
Decommissioning Dismantling, disposal 12.4 Dismantling, disposal Preparatory measures Notice Components removed must be disposed of correctly and according to legal requirements. ► Components may be under excess pressure and must be depressurised before opening. ► During decommissioning and disposal, it must be ensured that the vari- ous materials are separated and passed on to the recycling system for fur- ther processing. -
Page 112: Plans
3 kg of refrigerant are required to keep an equipment log under EN378 Part 2. ► The technical customer service at GEA Refrigeration Germany GmbH of- fers support in maintaining the equipment log. ► The equipment log needs to be stored for at least five years after manu- facture and presented to the relevant authorities upon request. -
Page 113: Data Sheet (Sample)
Plans Equipment log 13.1.1 Data sheet (sample) Operating parameters of refrigerant circuit User Refrigerant Type of oil Heat pump - Type / Manufacturer Construction no. / year of manufacture Compressor - Type / Manufacturer Construction no. / year of manufacture Date / Time Operating hours Power steps... -
Page 114: Data Sheet Of Oil Filling (Template)
Plans Equipment log 13.1.2 Data sheet of oil filling (template) Oil charging User Refrigerant Type of oil Heat pump - Type / Manufacturer Construction no. / year of manufacture Compressor - Type / Manufacturer Construction no. / year of manufacture Date Operating Filled... -
Page 115: Data Sheet Of Refrigerant Filling (Template)
Plans 13.1.3 Data sheet of refrigerant filling (template) Refrigerant filling User Refrigerant Type of oil Heat pump - Type Manufacturer Construction no. / year of manufacture Compressor - Type / Manufacturer Construction no. / year of manufacture Date Operating Removed Refrigerant Remarks Service... -
Page 116: Appendix
Appendix Abbreviations and terms Appendix 14.1 Abbreviations and terms Abbreviation Remark Figures in percent ° Symbol for the divider of a scale [degrees] All degrees stand for the angle [angular degree] unless explicitly specified otherwise. °F Temperature measurement unit [degrees Fahrenheit] °C Temperature measurement unit [degrees Celsius] Δp... - Page 117 Appendix Abbreviation Remark Low pressure Energy measurement unit [Newton metre] Details for the torque: 1 Nm = 0.737 lbft Pound-Force (lb) + Feet (ft) Maximum permitted pressure Suction pressure Item Position Piping and instrumentation flow diagram Suction temperature (compressor inlet) Condensing temperature Discharge temperature (compressor outlet) oil inlet temperature into the compressor...