GEA RedGenium User manual

Heat pump
GEA RedGenium, Compressor frame size V-HP 300 - 600
Operating instruction (Translation from the original language)
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COPYRIGHT
All Rights reserved.
No part of this documentation may be copied or published by means of printing,
photocopying, microfilm or otherwise without prior written consent of
•GEA Refrigeration Germany GmbH
herein after referred to as the manufacturer. This restriction also applies to the
drawings and diagrams contained in the documentation.
LEGAL NOTICE
These operating instructions are part of the technical documentation for the
scope of delivery. They contain important instructions for ensuring safe and
proper transport, installation, start-up, economic operation, maintenance and
repair of the product. Their observance helps in avoiding dangers, reducing repair
costs and down-times and increasing the reliability and durability of the product.
These operating instructions are intended for the users of the product and are
specifically intended for the operating company and its operating and mainte-
nance personnel.
It is essential that the operating company and its operating and maintenance staff
read these operating instructions prior to transport, installation, start-up, use,
maintenance, repair, disassembly and disposal. This obligation to read also
applies to personnel involved in activities during the lifetime of the product.
The operating company must supplement these operating instructions with
instructions regarding health and safety 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 the product. The entire documentation
comprises these operating instructions and all additional operating instructions
supplied with the unit. It must be kept readily available where the product is
installed. 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.
The manufacturer reserves the right to make technical modifications during the
course of further development of the product covered by these operating instruc-
tions.
Illustrations and drawings in these operating instructions are simplified represen-
tations. As a result of the improvements and changes, it is possible that the fig-
ures do not exactly match the product you are operating. The technical data and
dimensions are subject to change. No claims can be made on the basis of them.
The manufacturer cannot accept liability for damages
•which occur during the warranty period as a result of
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–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;
•through the use of accessories or spare parts which were not supplied or rec-
ommended by the manufacturer.
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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.
► 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 product.
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PREFACE
The figure on the front page shows the heat pump with subcooler (optional
project-related equipment feature).
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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:
•Numbered list point 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 expected result:
®Result of the handling sequence.
Individual handling steps
Individual handling steps are marked thus:
–Individual work steps
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TABLE OF CONTENTS
1 General Information 15
1.1 Information about the document 15
1.2 Manufacturer address 16
1.3 Customer services 16
1.3.1 Technical customer service department 16
1.3.2 Spare parts 17
1.3.3 Training courses 17
1.3.4 Service contracts 18
1.4 Declaration of Conformity, Declaration of Incorporation 18
1.5 CE mark 18
1.6 Trademark rights 18
1.6.1 Evaporator with distributed injection 18
1.6.2 Evaporator with integrated liquid separation 18
2 Safety 19
2.1 Intended use 19
2.2 Warning against foreseeable abusive use 20
2.3 Operator duty of care 21
2.4 Subsequent changes 21
2.5 General safety instructions and dangers 21
2.6 Legal foundations (Germany) 21
2.7 Personnel qualification 23
2.8 Protective equipment 24
2.9 Residual risks 25
2.10 Emergency measures / procedure (first aid) 26
3 Description 27
3.1 Design 27
3.1.1 Technical specifications 28
3.1.2 Mounting location of 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 client 42
3.1.5 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
Labelling of the pipes 45
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
Labelling of the control / control cabinet 47
Designation of the earthing connection 47
Installation and labelling of parts delivered separately 49
3.2 Functional description 49
3.2.1 Process flow chart 51
3.2.2 Refrigerant circuit 52
3.2.3 Oil circuit 52
Oil heater 52
Oil cooling 52
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Oil filter 52
Oil return from the low pressure side 52
3.2.4 Capacity control 53
3.2.5 Level control of the evaporator 54
4 Transport and storage 55
4.1 Personnel qualification for transport and storage 55
4.2 Safety instructions for transport and storage 55
4.3 Storage conditions 56
4.4 Transport (crane transport) 57
4.5 Disposal of packaging material 58
5 Technical data 59
5.1 Key data 59
5.2 Basic terms 59
5.3 Operating media 59
5.3.1 Refrigerant 59
5.3.2 Refrigerator oils 60
5.3.3 Secondary refrigerant 60
5.3.4 Heating agents 60
5.4 Materials used in heat exchangers 61
5.5 Operation limits 62
5.6 Monitoring and display of process values 64
5.7 Sound pressure level 64
6 Assembly and installation 65
6.1 Personnel qualification and training 65
6.2 Safety Instructions 65
6.2.1 Electrical connection 65
6.3 Requirements and information on installation 65
6.4 Preparing for assembly 66
6.4.1 Information regarding installation in the machine room 66
6.4.2 Rigid installation 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 Paint and insulation 75
7.5 First start - Start-up procedure 75
7.5.1 Checking the electrical connection 75
7.5.2 Leak test 75
7.5.3 Drying, vacuum 76
7.5.4 Operating position of valves 78
7.5.5 Oil filling 81
7.5.6 Checking the fault monitoring 82
7.5.7 Setting the oil differential pressure 82
7.5.8 Checking the direction of rotation of the drive motor 83
7.5.9 Mounting the coupling 84
7.5.10 Checking the water circuits 84
7.5.11 First refrigerant fill 85
7.5.12 Initial start-up 86
7.6 Handing over to the operator 86
7.7 Restarting 86
7.7.1 Start-up after long standstill periods 86
7.7.2 Restart after about 1 year shut-down 86
8 Operation and control 88
8.1 Personnel qualification - Important information for the operator 88
8.2 Safety Instructions 88
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8.3 Description of the control elements 88
8.3.1 Requirements for switching on 88
8.3.2 Compressor regulation 89
8.3.3 Setting of setpoint and limit values as well as safety devices 89
8.3.4 Operation of the system 90
9 Cleaning 91
9.1 Special personnel qualification 91
9.2 Safety Instructions 91
9.3 Clean 91
9.3.1 Mechanical cleaning 91
9.3.2 Chemical cleaning of the heat exchanger 91
10 Maintenance 92
10.1 Personnel qualification - Important information for service personnel 92
10.2 Safety Instructions 92
10.3 Preparation for maintenance 93
10.3.1 General instructions 93
10.3.2 Maintenance intervals 94
10.4 Maintenance work 95
10.4.1 Opening the compressor 95
10.4.2 Replacing the oil filter 95
10.4.3 Dismantling the compressor suction filter 95
10.4.4 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
10.4.5 Tightening screw fastenings 98
10.4.6 Coupling maintenance 98
10.4.7 Checking the function 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 of the switching cabinet 103
10.4.17 Checking the earthing connections 103
10.4.18 Insulation 103
10.4.19 Checking the tightening torques at the adjusting elements. 103
11 Alarms 104
11.1 Special personnel qualification 104
11.2 Safety Instructions 104
11.3 Special dangers 104
11.3.1 Shut-down in the event of dangerous situations 104
11.4 Instructions regarding malfunctions, their causes and remedies 105
11.5 Repairs 107
11.5.1 Repair information 107
11.5.2 Repairs of pressure vessels subject to approval inspection 107
12 Decommissioning 108
12.1 Special personnel qualification 108
12.2 Safety Instructions 108
12.3 Temporary decommissioning 108
12.3.1 Shut-down for a period of <48 hours 108
12.3.2 Shut-down for a period of >48 hours 109
12.3.3 Measures during downtimes 109
12.3.4 Monthly measures during downtime 109
12.3.5 Four weeks before restarting 110
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12.4 Dismantling, disposal 111
13 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
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TABLE OF FIGURES
Fig. 1 CE mark 18
Fig. 2 Mounting location of the product identification (nameplate) 30
Fig. 3 Standard GEA RedGenium heat pump 32
Fig. 4 Position of the reciprocating compressor 33
Fig. 5 Arrangement of the compressor drive motor 34
Fig. 6 Arrangement of the coupling 35
Fig. 7 Arrangement of the evaporator 35
Fig. 8 Position of the condenser 36
Fig. 9 Arrangement of the oil cooler 37
Fig. 10 Position of the desuperheater 37
Fig. 11 Position of the subcooler 39
Fig. 12 Position of the control cabinet 40
Fig. 13 Safety labels of the pressure and temperature sensors,
heater 43
Fig. 14 Marking the safety valves 43
Fig. 15 Labelling of the screwed connections 44
Fig. 16 Labelling of the pipes 45
Fig. 17 Marking of direction of rotation of the compressor drive motor 45
Fig. 18 Label, Pressurised product 46
Fig. 19 Label for transport 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 valve open 78
Fig. 29 Stop valve closed 78
Fig. 30 Check valve 78
Fig. 31 Shuttable check valve 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
Fig. 45 Motor direction of rotation (schematic representation) 83
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1 General Information
1.1 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.
This operating manual is directed at the users of the product and is specifically
intended for the operating company and its operating and maintenance person-
nel. This operating manual must be read prior to transport, installation, start-up,
maintenance, repair, disassembly/disposal. It is imperative to strictly observe the
instructions and information given!
All 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 installation, the accepted technical
regulations for safe work according to good professional practices must also be
observed.
The operating manual is part of the total product. The entire documentation, con-
sisting of this operating manual as well as all supplied additional instructions,
must always be kept easily accessible at the place of installation of the product.
The complete set of documentation must also accompany the product if it is sold.
General Information
Information about the document
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1.2 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. 165
13509 Berlin, Germany
Tel.: [phone]
Fax: [phone]
Web:www.gea.com
E-Mail: [email protected]
GEA Refrigeration Germany GmbH
Werk Halle
Berliner Straße 130
06258 Schkopau/ OT Döllnitz, Germany
Tel.: [phone] - 0
Fax: [phone] - 14
Web:www.gea.com
E-Mail: [email protected]
1.3 Customer services
GEA Refrigeration 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 technicians are available on call for you in
order to provide assistance in case of technical problems and to offer support in
the framework of our after-sales service.
24/7 Hotline:
the hotlines can reached around the clock on every day of the week:
•Wireless
[phone]
•Landline, weekdays from 7 to 17 hours
[phone]
[phone]
•Email:
General Information
Manufacturer address
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[email protected]
outside of Germany, Austria and Switzerland please contact:
•local sales office
www.gea.com
technical support for liquid chillers with reciprocating compressors in Germany,
Austria and Switzerland
•24/7 Hotline
[phone]
The specialists of our Technical Customer Service department support you in
installations, acceptances, maintenance, operating questions, on-site inspections
and repairs of our products.
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.
You can contact us using the following hotlines:
•Wireless, out of hours
[phone]
•Landline, weekdays from 8 to 17 hour
[phone]
•Fax
[phone]
•Email
[email protected]
•Order spare parts from our G-Pos. online shop
(Grasso Parts online shop)
www.g-pos.gearefrigeration.com
1.3.3 Training courses
Notice
All work on our systems must only be carried out by technical personnel!
► Acquire the technical know-how required for this in good time!
Comprehensive training courses are held regularly for service technicians and
mechanics, thus ensuring the safe and proper use and maintenance of our sys-
tems.
•Email
[email protected]
General Information
Customer services
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1.3.4 Service contracts
There is the possibility of concluding a long-term agreement for services (service
contract). For more information about the content, scope and conditions of possi-
ble services, please contact Technical Support.
•Email:
[email protected]
1.4 Declaration of Conformity, Declaration of Incorporation
Notice
One of the following documents, depending on the product, is part of the
product documentation for the respective project:
► Declaration of incorporation
► Declaration of conformity
1.5 CE mark
By affixing the CE mark, the manufacturer confirms the conformity of the product
with the applicable EC Directives and compliance with the principle requirements
stipulated within them.
Fig.1: 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.
Compliance with the machinery directive is confirmed by the respective supplied
certificate.
1.6 Trademark rights
The product contains technical solutions for which GEA Refrigeration Germany
GmbH holds the patents or has applied for them.
1.6.1 Evaporator with distributed injection
The design of the evaporator with distributed injection, forced circulation, collec-
tion and return flow of refrigerant and oil is protected by law.
Patent DE 10 2010 010 840 B4 "Overrun evaporator with forced circulation"
1.6.2 Evaporator with integrated liquid separation
A patent has been applied for the position and design of the liquid separation
integrated in the evaporator.
Patent application 10 2013 010 510 A1
General Information
Declaration of Conformity, Declaration of Incorporation
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2 Safety
2.1 Intended use
Notice
Observe the chapter "Intended use" in the installation and maintenance
manual for the compressor!
► The installation and maintenance manual for the compressor is part of
the product documentation.
A product must only be operated up to a maximum discharge pressure in accord-
ance with the nameplate.
It is imperative that you comply with the applicable conditions of use with respect
to pressure and temperature for the product. (Compliance with the operating con-
ditions even if, for example, an external condenser is used for liquid chillers.)
Do not change the setting values of the safety pressure switch. This would
endanger the operating safety of the system.
If the switch-off value is set higher than the maximum operating pressure (see
EN378-2) of the high pressure section of the system, this will lead to bursting of
the tank of this section of the system.
The operating regime stipulated by the manufacturer, especially for the starting
phase of the system, must be observed.
Operating parameters must be monitored and must remain within the specified
limits.
The product has been designed and manufactured for a specific application
under defined 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 cases as to the permissibility of modifi-
cation in the event of any change application or conditions of use.
The secondary refrigerant circuit must be designed so that a constant swept vol-
ume on the evaporator is always ensured. If the swept volume is reduced, this
can lead to freezing of the secondary refrigerant and to triggering the system
safety device.
Flow of media must be to ensured. If the water flow is reduced or prevented, an
end pressure increase with a subsequent switch-off of the compressor will occur.
Do not make any modifications to the product and the compressor control.
These may impair the safety and functionality of the product. They will also inva-
lidate the guarantee.
The pressure equipment described here must not be used for any purpose other
than the purpose specified here. If the pressure equipment is not used according
to the regulations, safe use of the product is not guaranteed. The supplier/instal-
Safety
Intended use
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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. The supplier/installer
must include instructions for regular inspection of the pressure equipment in his
operating instructions and must specify the procedure to be followed by the end
user in the event of damage. In order to prevent burns or frostbite, the pressure
equipment must not be touched during operation. This can be prevented by
appropriate safety measures. The appropriate warning signs must be affixed.
Refrigerating systems/heat pumps must be equipped with safety valves accord-
ing to EN 378. The supporting surface must provide sufficient rigidity.
The supplier/installer must exercise due care when installing the accessories for
the pressure equipment. The pressure equipment must not be damaged during
installation and must be painted after installation. The pressure equipment 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 service intervals and condi-
tions stipulated therein.
Improper use of the equipment shall void any warranty entitlement and approval
for operation.
2.2 Warning against foreseeable abusive use
A product is said to have been abused if:
• Notice
Unauthorised refrigerants, fuels as well as secondary refrigerants and cool-
ing media are used.
► Observe the specifications for the project!
• Notice
electrical components are wrongly connected.
► Observe voltage and frequency!
• Notice
mechanical components are wrongly connected.
► Observe pressure and temperature!
•The supporting, hanging and storage facilities are misused,
•Control and regulation units including control software are tampered with,
•The driving power generated by the motor is used for purposes other than the
operation of the respective compressors and pumps.
Safety
Warning against foreseeable abusive use
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