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GEA RedGenium manual available for free PDF download: Operating Instruction
GEA RedGenium Operating Instruction (118 pages)
Brand:
GEA
| Category:
Heat Pump
| Size: 9.59 MB
Table of Contents
Table of Contents
9
General Information
15
Information about the Document
15
Customer Services
16
Manufacturer Address
16
Technical Customer Service Department
16
Spare Parts
17
Training Courses
17
CE Mark
18
Declaration of Conformity, Declaration of Incorporation
18
Evaporator with Distributed Injection
18
Evaporator with Integrated Liquid Separation
18
Fig. 1 CE Mark
18
Safety
19
Service Contracts
18
Trademark Rights
18
Intended Use
19
Warning against Foreseeable Abusive Use
20
General Safety Instructions and Dangers
21
Legal Foundations (Germany)
21
Operator Duty of Care
21
Subsequent Changes
21
Personnel Qualification
23
Protective Equipment
24
Residual Risks
25
Emergency Measures / Procedure (First Aid)
26
Description Design
27
Technical Specifications
28
Fig. 2 Mounting Location of the Product Identification (Nameplate)
30
Mounting Location of the Product Identification (Nameplate)
30
Product Designation, Heat Pumps with Reciprocating Compressors
31
Fig. 3 Standard GEA Redgenium Heat Pump
32
Reciprocating Compressor
33
Main Components
32
Fig. 4 Position of the Reciprocating Compressor
33
Compressor Drive Motor
34
Fig. 5 Arrangement of the Compressor Drive Motor
34
Coupling
35
Evaporator
35
Fig. 6 Arrangement of the Coupling
35
Fig. 7 Arrangement of the Evaporator
35
Condenser
36
Fig. 8 Position of the Condenser
36
Oil Cooler
37
Desuperheater (Optional)
37
Fig. 10 Position of the Desuperheater
37
Subcooler (Optional)
39
Fig. 9 Arrangement of the Oil Cooler
37
Fig. 11 Position of the Subcooler
39
Control Cabinet with Control
40
Fig. 12 Position of the Control Cabinet
40
Fittings
41
Pressure Limiting Safety Devices
41
Components Installed by the Client
42
Fig. 13 Safety Labels of the Pressure and Temperature Sensors
43
Fig. 14 Marking the Safety Valves
43
Information and Safety Labels on the Product
43
Labels of the Pressure and Temperature Sensors, Heater
43
Marking the Safety Valves
43
Labels of the Screwed Connections with Cutting Ring
43
Fig. 15 Labelling of the Screwed Connections
44
Labelling of the Pipes
45
Marking of Direction of Rotation of the Compressor Drive Motor
45
Fig. 16 Labelling of the Pipes
45
Fig. 17 Marking of Direction of Rotation of the Compressor Drive Motor
45
Label, Pressurised Product
46
Label for Transport
46
Label of the Change-Over Valve
46
Fig. 18 Label, Pressurised Product
46
Fig. 19 Label for Transport
46
Fig. 20 Label of the Change-Over Valve
46
Labelling of the Control / Control Cabinet
47
Designation of the Earthing Connection
47
Fig. 21 Test Verification for the Control System
47
Fig. 22 Designation of the Earthing Connection
47
Installation and Labelling of Parts Delivered Separately
49
Fig. 23 Labelling of the Parts Delivered Separately
49
Functional Description
49
Fig. 24 Process Flow Chart
51
Process Flow Chart
51
Oil Circuit
52
Oil Heater
52
Oil Cooling
52
Oil Filter
52
Oil Return from the Low Pressure Side
52
Refrigerant Circuit
52
Capacity Control
53
Level Control of the Evaporator
54
Transport and Storage
55
Personnel Qualification for Transport and Storage
55
Safety Instructions for Transport and Storage
55
Storage Conditions
56
Fig. 25 Designation of the Lifting Points
57
Transport (Crane Transport)
57
Disposal of Packaging Material
58
Technical Data
59
Basic Terms
59
Key Data
59
Operating Media
59
Refrigerant
59
Heating Agents
60
Refrigerator Oils
60
Secondary Refrigerant
60
Materials Used in Heat Exchangers
61
Operation Limits
62
Monitoring and Display of Process Values
64
Sound Pressure Level
64
Assembly and Installation
65
Electrical Connection
65
Personnel Qualification and Training
65
Requirements and Information on Installation
65
Safety Instructions
65
Information Regarding Installation in the Machine Room
66
Installation of the Screw Compressor for Insulation against Structure-Borne Sound
66
Outdoor Installation, Weather Protection
66
Start-Up
68
Preparing for Assembly
66
Rigid Installation
66
Important Information for Start-Up
68
Special Personnel Qualification
68
Basic and Further Steps
70
Basic Settings
70
Connecting the Product
71
Connecting the Pipes
71
Water Pipes
72
Fig. 26 Secondary Refrigerant System
73
Electrical Connection
74
Checking the Electrical Connection
75
First Start - Start-Up Procedure
75
Leak Test
75
Paint and Insulation
75
Drying, Vacuum
76
Fig. 27 Vacuum Required to Remove Moisture from Refrigerating
77
Fig. 28 Stop Valve Open
78
Fig. 29 Stop Valve Closed
78
Fig. 30 Check Valve
78
Fig. 31 Shuttable Check Valve
78
Operating Position of Valves
78
Fig. 32 Control Valve
79
Fig. 33 Shuttable Check Valve
79
Fig. 34 Solenoid Valve
79
Fig. 35 Change-Over Valve
79
Fig. 36 Oil Pressure Regulating Valve
79
Fig. 37 Overflow Valve, Safety Valve
80
Fig. 38 Pressure Controlled Check Valve
80
Fig. 39 Quick Acting Valve, Spring-Loaded
80
Fig. 40 Charging Valve, Drain Valve
80
Fig. 41 Service Valve
80
Fig. 42 Thermostatic 3-Way Valve
80
Fig. 43 Temperature Controlled Control Valve
81
Fig. 44 Electronic Expansion Valve
81
Oil Filling
81
Checking the Fault Monitoring
82
Setting the Oil Differential Pressure
82
Checking the Direction of Rotation of the Drive Motor
83
Fig. 45 Motor Direction of Rotation (Schematic Representation)
83
Checking the Water Circuits
84
Mounting the Coupling
84
First Refrigerant Fill
85
Handing over to the Operator
86
Initial Start-Up
86
Restart after about 1 Year Shut-Down
86
Operation and Control
88
Restarting
86
Start-Up after Long Standstill Periods
86
Description of the Control Elements
88
Personnel Qualification - Important Information for the Operator
88
Requirements for Switching on
88
Safety Instructions
88
Compressor Regulation
89
Setting of Setpoint and Limit Values as Well as Safety Devices
89
Operation of the System
90
Cleaning
91
Chemical Cleaning of the Heat Exchanger
91
Clean
91
Mechanical Cleaning
91
Safety Instructions
91
Special Personnel Qualification
91
Maintenance
92
Personnel Qualification - Important Information for Service Personnel
92
Safety Instructions
92
General Instructions
93
Preparation for Maintenance
93
Maintenance Intervals
94
Dismantling the Compressor Suction Filter
95
Maintenance Work
95
Opening the Compressor
95
Replacing the Oil Filter
95
Oil Draining, Oil Filling, Oil Change
96
Importance of Oil Change
96
Oil Change, Maintenance Work
96
Changing the Oil, Implementation
96
Used Oil
97
Draining the Oil
97
Checking the Oil Level
97
Filling with Oil, Topping up with Oil
97
Checking the Function of Check Valves
98
Coupling Maintenance
98
Searching for Leaks on the Refrigerant Side / Leak Test
98
Tightening Screw Fastenings
98
Venting the Refrigerant Circuit
99
Draining Refrigerant Circuit
100
Refrigerant Side Evacuation
100
Charging Refrigerant
101
Draining the Refrigerant
101
Checking the Operating Parameters
102
Maintenance of the Compressor Drive Motor
102
Checking the Earthing Connections
103
Checking the Tightening Torques at the Adjusting Elements
103
Insulation
103
Maintenance of the Switching Cabinet
103
Alarms
104
Safety Instructions
104
Shut-Down in the Event of Dangerous Situations
104
Special Dangers
104
Special Personnel Qualification
104
Instructions Regarding Malfunctions, Their Causes and Remedies
105
Repair Information
107
Repairs
107
Repairs of Pressure Vessels Subject to Approval Inspection
107
Decommissioning
108
Safety Instructions
108
Shut-Down for a Period of <48 Hours
108
Special Personnel Qualification
108
Temporary Decommissioning
108
Measures During Downtimes
109
Monthly Measures During Downtime
109
Shut-Down for a Period of >48 Hours
109
Four Weeks before Restarting
110
Dismantling, Disposal
111
Equipment Log
112
Plans
112
Data Sheet (Sample)
113
Data Sheet of Oil Filling (Template)
114
Data Sheet of Refrigerant Filling (Template)
115
Abbreviations and Terms
116
Appendix
116
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