Witt HRP Series User manual

Content
1. INTRODUCTION..................................................................................................................................1
1.1 INTENDED USE.............................................................................................................................1
1.2 SAFETY REQUIREMENTS ...........................................................................................................1
1.3 SAFETY ADVICE...........................................................................................................................1
1.4 DISCLAIMER .................................................................................................................................2
2. TERMS OF WARRANTY.....................................................................................................................3
3. TECHNICAL INFORMATION ..............................................................................................................4
3.1 DESCRIPTION OF TYPES............................................................................................................4
3.2 SCOPE OF DELIVERY..................................................................................................................4
3.3 ORDER INFORMATION ................................................................................................................4
3.4 CODES / CERTIFICATES / APPROVALS.....................................................................................4
4. TECHNICAL DATA..............................................................................................................................5
4.1 GENERAL INFORMATION............................................................................................................5
4.2 ELECTRICAL DATA.......................................................................................................................5
4.3 MATERIALS ...................................................................................................................................8
4.4 PRESSURE RANGE......................................................................................................................8
4.5 DIMENSIONS.............................................................................................................................. 11
4.6 SECTIONAL VIEWS ................................................................................................................... 12
4.7 DESCRIPTION OF OPERATION ............................................................................................... 28
4.8 PERFORMANCE CHARACTERISTIC TABLE ........................................................................... 29
5. APPLICATIONS................................................................................................................................ 31
5.1 GENERAL ................................................................................................................................... 31
5.2 DETERMINATION OF THE DELIVERY HEAD .......................................................................... 32
5.3 DETERMINATION OF THE REQUIRED FLOW......................................................................... 32
5.4 ADAPTATION TO PLANT REQUIREMENTS............................................................................. 33
5.5 USE OF FREQUENCY CONVERTERS ..................................................................................... 34
6. INSTALLATION INSTRUCTIONS.................................................................................................... 35
6.1 PUMP ARRANGEMENT............................................................................................................. 35
6.2 PUMP CONNECTION................................................................................................................. 35
6.3 DOWNLEG DESIGN ................................................................................................................... 37
6.4 PUMP DISCHARGE LINE .......................................................................................................... 38
6.5 PROTECTION OF THE PUMP ................................................................................................... 39
6.6 ELECTRICAL INFORMATION.................................................................................................... 44
7. TRANSPORT AND STORAGE ........................................................................................................ 49
8. INSTALLATION AND APPLICATION.............................................................................................. 50
8.1 PREPARING THE PUMP FOR INSTALLATION ........................................................................ 50
8.2 MOUNTING INSTRUCTIONS..................................................................................................... 50

8.3 PRIOR TO COMMISSIONING.................................................................................................... 53
8.4 COMMISSIONING PROCEDURE .............................................................................................. 53
8.5 DURING NORMAL OPERATION ............................................................................................... 53
8.6 PUMP STANDSTILL (STAND-BY) ............................................................................................. 54
9. SERVICE AND MAINTENANCE ...................................................................................................... 55
9.1 REMOVING A PUMP .................................................................................................................. 55
9.2 SHIPPING OF THE PUMP ......................................................................................................... 55
9.3 GENERAL ADVICE..................................................................................................................... 55
9.4 REPARING A PUMP................................................................................................................... 56
9.5 WARNINGS................................................................................................................................. 56
10. TROUBLE SHOOTING ................................................................................................................ 58
TH. WITT Kältemaschinenfabrik GmbH
Lukasstrasse 32, D-52070 Aachen
Tel. [phone]
https://www.th-witt.com, [e-mail]
Status of documentation: October 2018
1
1. INTRODUCTION
Please read the entire manual careful before selecting, installing, commissioning and
servicing the pump.
1.1 INTENDED USE
The WITT hermetic refrigerant pump type is designed to deliver exclusively refrigerant liquid
at its boiling point.
The pump is labelled with model and design limitation for pressure and temperature.
The HRP refrigerant pump is designed with safety features, which ensures security from the
escape of ammonia; in the event the stator can leaking the pump body and the complete motor
housing is designed to 25 bar pressure to contain high pressure refrigerant will not escape
from the pump or through the electric cable connections.
Performance data of the pump are to be found in chapter 4 Technical data.
1.2 SAFETY REQUIREMENTS
All of the following specified work must be carried out by knowledgeable personnel
experienced in installation and service of refrigeration systems. All personnel must
be familiar with the national legal requirements and safety regulations. All safety
regulations and codes of practice concerning the use of refrigerants must be adhered
to, with special attention paid to protection clothing and wearing of safety glasses.
Service and maintenance should only be carried out when the pump is stopped and
the power supply disconnected.
Under no circumstances are the indicated temperature- and pressure limitations to
be exceeded.
Important! The content of this manual must be adhered to. Deviation from the
specified conditions will make any claim for liability or warrenty void.
1.3 SAFETY ADVICE
The pump is designed for use in industrial refrigeration systems of primary refrigerant.
Refrigerant is used to cool motor and bearings. Any gas that forms in the pump is discharged
to the pressure side. The electrical power consumption of the pump is low in relation to the
refrigeration capacity, due to the effect of the latent heat of the liquid being utilised.
It is very important that everybody responsible for the safe operation and
maintenance of the plant reads this manual.
I you have any problems please do not hesitate to call our service department, our staff will be
glad to assist you.

2
Avoid any tripping obstacle at ground levels, e.g. cable. If you cannot avoid such obstacles
they should be marked with two-coloured warning tape (warning sign).
Retighten all screw connections after maintenance and repair work!
If you have to disassemble any safety devices for maintenance and repair make sure that upon
completion of said work the re-assembly and proper functioning is checked!
When operating at low temperatures (< 0°C) freeze bites can occur when the surface is
touched. Therefore always wear appropriate protection clothing.
1.4 DISCLAIMER
Even when using the pump for the intended purpose it cannot be entirely excluded that a dan-
ger remains for the life of the user. Translations are carried out to the best of our knowledge.
We are unable to accept any liability for translation errors.
We reserve the right to change descriptions, graphs or other statements.
3
2. TERMS OF WARRANTY
In order to avoid accidents and ensure optimum performance, no modifications or conversions
may be carried out to the refrigerant pump without the explicit written approval by TH. WITT
KÄLTEMASCHINENFABRIK GMBH.
These instructions are based on internationally standardised SI units of measurements.
All data and information on the operation and maintenance of the refrigerant pump is provided
based on our extensive experience and to the best of our technical knowledge.
Our liability or warranty is excluded, if:
·information and instructions in the operating manual are ignored,
·the refrigerant pump including accessories is operated incorrectly or is installed contrary to
these installation instructions
·the refrigerant pump is used for applications other than that for which it was intended,
·safety devices are not used or disconnected
·there have been modifications made without written approval
·the safety regulations are not adhered to
·the refrigerant pump including its filters and required safety devices has not been main-
tained or repaired correctly with respect to frequency or competence this includes the use
of approved spare parts.
Opening the pump within the warranty period will void all implied or explicit
guarantees!
Always return the pump to the supplier for repair or order an exchange pump.
When exchanging any parts respective spare parts only genuine spare parts are to be used.
Statements in this manual shall also apply to any service fluids.

4
3. TECHNICAL INFORMATION
3.1 DESCRIPTION OF TYPES
Five hermetic pump types are available: HRP3232, HRP5040, HRP 5050, HRP8050 and
HRP10080.
"HRP" means "Hermetic Radial Pump" The numbers give the inlet and outlet pipe connection
size in DN; the first two/three digits give the size of the suction connection while the last two
digits give the size of the discharge connection.
3.2 SCOPE OF DELIVERY
·All HRP pumps, model GF, are complete with canned motor, conical strainer and coun-
ter flanges
·for HRP 3232 an additional oil drain valve type EA 10 GÜ/GB (PN 40) is included
Optional Equipment
·2 x EA: with stop valves on suction side and discharge side; discharge side with vent
valve (pressure gauge connection) and socket for flow switch /differential pressure
switch
·EA + ERA: with suction valve and discharge valve/nonreturn valve, incl. vent valve
(pressure gauge connection) and socket for flow switch /differential pressure switch
·PTC motor control INT 69 V
·oil drain valve type EA 10 GÜ/GB (PN 40)
3.3 ORDER INFORMATION
Please specify the following data when ordering a pump:
·refrigerant
·type HRP 3232, HRP 5040, HRP 505, HRP 8050 or HRP 10080
·Model, e.g. GF ,2 x EA or EA +ERA
·Voltage and frequency.
·(Special requirements if applicable, e.g. PN 65 for HRP 3232)
If you are unsure about the selection, please provide the following additional information:
·evaporating temperature ....°C
·volume flow .... m3/h or capacity and re-circulation rate
·required pressure head …. m
3.4 CODES / CERTIFICATES / APPROVALS
The following certifications are available and can be downloaded from our website www.th-
witt.com:
declaration of incorporation of a partly completed machinery according to EG machinery di-
rective, conformity declaration according to EU- low voltage directive.
5
4. TECHNICAL DATA
4.1 GENERAL INFORMATION
4.2 ELECTRICAL DATA
50 Hz 3 x 400 V
DESCRIPTION
Unit
HRP
HRP
HRP
HRP
HRP
3232
5040
5050
8050
10080
Speed
n
[min-1]
2900
2900
2900
2900
2900
max. power consumption
with NH3
Imax
[A]
1,5
4,7
5,5
7,0
13,0
with CO2
Imax
[A]
2,1
-
7,0
10,0
16,0
With HFC, HFO, e.g.
R134a
Imax
[A]
2,2
5,2
8,5
16,0**
20,0
Motor power factor
with
NH3
Cos
j
[-]
0,61
0,63
0,68
0,80
0,79
with
CO2
Cos
j
[-]
0,83
-
0,80
0,88
0,85
With HFC, HFO, e.g.
R134a
Cos
j
[-]
0,84
0,63
0,85
0,85**
0,89
Effective motor power
N
[kW]
N
wirk
= √ 3 x (U x I
wirk
x cos j)
(values at operating point –see selection tool)
DESCRIPTION
Unit
HRP
3232
HRP
5040
HRP
5050
HRP
8050**
HRP
10080
Volume refrigerant
side
ltr.
1,1
2,8
5
5,5
6,35
Volume transformer
oil
ltr.
0,75
1
1,5
1,5
1,6
Weight pump with
kg
43
55
83
83/110**
117
counterflanges
Sound pressure level
dB(A)
< 70
< 70
< 70
< 70
< 70
Class of terminal box
insulation
IP
54
54
54
54
54
Box cable sockets
prepared to
PG
1 x M16;
1 x M20
1 x M16
1 x M20
1 x M16
1 x M20;
1 x M16
1xM20/M25
**
1 x M16
1 x M25

6
60 Hz 3 x 460 V
DESCRIPTION
Unit
HRP
HRP
HRP
HRP
HRP
3232
5040
5050
8050
10080
Speed
n
[min-1]
3500
3500
3500
3500
3500
max. power consumption
with NH3
Imax
[A]
2,0
6,2
7,3
10,0
16,0
with CO2
Imax
[A]
2,6
-
9,5
16,0
24,0
With HFC, HFO, e.g.
R134a
Imax
[A]
2,9
6,9
11,5
23,5**
28,0
Motor power factor
with NH
3
Cos
j
[-]
0,88
0,86
0,87
0,90
0,90
with CO
2
Cos
j
[-]
0,92
-
0,90
0,90
0,93
With HFC, HFO, e.g.
R134a
Cos
j
[-]
0,93
0,86
0,91
0,85**
0,93
Effective motor power
N
[kW]
N
wirk
= √ 3 x (U x I
wirk
x cos j)
(values at operating point –see selection tool)
* Measure the maximum current during commissioning and set the overload protection to this
value, do not exceed Imax for the relevant refrigerant.
** Model HRP8050 requires for HFCs and HFO, e.g. R134a a special motor with the dimensions and data from
HRP10080
7
FURTHER 60 HZ MOTORS
60 Hz 3 x 380 V
DESCRIPTION
Unit
HRP
HRP
HRP
HRP
HRP
3232
5040
5050
8050
10080
Speed
n
[min-1]
3500
3500
3500
3500
3500
max. power consumption
with NH3
Imax
[A]
2,5
7,5
8,5
12
20
with CO2
Imax
[A]
3,3
-
12
18,5
30
With HFC, HFO, e.g.
R134a
Imax
[A]
3,5
8,5
13,5
24,5**
33
Motor power factor
with NH3
Cos j
[-]
0,88
0,86
0,87
0,90
0,90
with CO2
Cos j
[-]
0,92
-
0,90
0,90
0,93
With HFC, HFO, e.g.
R134a
Cos
j
[-]
0,93
0,86
0,91
0,85**
0,93
Effective motor power
N
[kW]
N
wirk
= √ 3 x (U x I
wirk
x cos j)
(values at operating point –see selection tool)
60 Hz 3 x 575 V
DESCRIPTION
Unit
HRP
HRP
HRP
HRP
HRP
3232
5040
5050
8050
10080
Speed
n
[min-1]
3500
3500
3500
3500
-
max. power consumption
with NH3
Imax
[A]
1,7
4,7
5,5
8
-
with CO2
Imax
[A]
2,2
-
8
12
-
With HFC, HFO, e.g.
R134a
Imax
[A]
2,3
5,5
9
-
-
Motor power factor
with NH3
Cos j
[-]
0,88
0,86
0,87
0,90
-
with CO2
Cos j
[-]
0,92
-
0,90
0,90
-
With HFC, HFO, e.g.
R134a
Cos
j
[-]
0,93
0,86
0,91
-
-
Effective motor power
N
[kW]
N
wirk
= √ 3 x (U x I
wirk
x cos j)
(values at operating point –see selection tool)

8
4.3 MATERIALS
Pump housing: EN-GJS-400-18-LT
Stator: steel / copper
Rotor: steel/aluminium
Bearings: PTFE
Shaft: C 35+C
Motor can: 1.4301
Impellers: GX22CrNi17M
Main bolts: 8.8
Counter flanges: P355NL1 or C22.8
Bolts for counter flanges: 8.8
Gaskets soft gasket asbestos free
Transformer oil Fuchs Renolin Eltec
Painting system: W 9.1 + W 9.2
W 9.1 + W 9.2 = 2 k epoxy finish according to DIN ISO 12944/5, RAL 7001
4.4 PRESSURE RANGE
25 bar
models
40 bar
models
65 bar
models
Design pressure
(inside pump housing, motor can and sta-
tor housing)
25
40
65
Test pressure (with oil) [bar]
60
6
0
98
Allowable pressure range
[bar]
25 (+50 / -10°C)
18,75 (-10 / -60°C)
40 (+50 / -10°C)
30 (-10 / -60°C)
65 (+50 / -10°C)
48,75 (-10 / -60°C)
For pressure testing with oil FUCHS Reniso
Synth 68 is used.
9
The following table gives an overview of available standard and special pump types. Futher
pump types are under development.
Nenndruck und verfügbare Pumpen / Design pressure and available pumps
Frequency
Design
Press.
Refrigerant
pump type
[Hz]
[bar]
50 / 60
25
NH
3
, CO
2
,
R22
HRP3232
HRP5040
HRP5050
HRP8050
HRP10080
50 / 60
25
40
Other HFC,
HFO
Standard
Standard
Standard
Standard
Standard
NH
3
, CO
2
,
R22
Special
40
Other HFC,
HFO
Not
available
Standard
Special
65
All refrigerants
Not
available
Not
available
Not
available
90
Only CO2
Not
available
Standard

10 4.5 DIMENSIONS Fig. 1 HRP 3232
11
HRP
5040
5050
8050
10080
L
540
520
555
725
B
260
310
310
355
H
283
349
351
362
a1
150
180
180
180
a2
228
234
255
302
a3
196
170
170
290
b1
105
133
133
133
b2
154
174
174
222
c
53
53
66
70
d1
60,3
60,3
88,9
114,3
d2
48,3
60,3
60,3
88,9
l1
155
155
178
212
m1
115
145
145
145
m2
168
204
206
217
m3
130
190
190
190
HRP
5040
5050
8050
10080
f1
249
249
340
467
f2
241
249
243
---
f3
270
284
284
473
h1
115
115
155
176
h2
105
115
115
179
Fig. 2 HRP 5040/5050/8050/10080

12
4.6 SECTIONAL VIEWS
Fig. 3 a HRP 3232
13
Fig. 3b HRP5040/HRP 5050/HRP 8050/HRP 10080

14
Parts list HRP 3232 and HRP 5040
HRP 3232
HRP 5040
part
Dimension Code - No. Weight Dimension Code - No. Weight
No.
[g] [g]
suction casing
01
DN 32
2162.000336
5960
DN 50
2162.000018
5380
suction intermediate piece
2
Ø150
2162.000309
1080
Ø150
2162.000026
1087
guide vane-intermediate piece 1
3
---
---
Ø150
2162.000030
1775
discharge intermediate piece
3
Ø150
2162.000311
1240
---
---
return intermediate piece
4
---
---
Ø150
2162.000036
2037
guide vane-intermediate piece 2
5
---
---
Ø150
2162.000031
1862
discharge casing
6
DN32
2162.000307
4020
DN40
2162.000022
2540
bearing casing
7
---
---
Ø150
A7
2080
stator casing
8
Ø150
A8
6660
Ø150
A8
8260
motor cover
9
Ø150
2162.000303
2720
Ø150
2162.000010
2980
can complete (parts 11-13)
10
Ø80
A10
1660
Ø80
A10
1740
bearing cover
14
Ø79
A10
541
Ø79
A10
497
socket head cap screw
21
M6 x 25
A10
7
M6 x 25
A10
7
socket head cap screw
22
M8 x 185
5112.BH61F4
74
M8 x 275
5112.BH61HM
109
hexagon head cap screw
24a
M16 x 55
5111.AHA1BI
107
M12 x 55
5111.AH81BI
60
hexagon nut
24b
M16
5151.AHA100
30
M12
5151.AH8100
15
hexagon head cap screw
25a
---
---
M12 x 55
5111.AH81BI
60
hexagon nut
25b
---
---
M12
5151.AH8100
15
torx screw for conn. box
26
4x30 TX20
5143.CLGAAT
3
4x30 TX20
5143.CLGAAT
3
earthing screw
27
M4 x 10
5112.AO31A9
1
M4 x 10
5112.AO31A9
1
long socket head cap screw
28
M16x280
5112.BHA2HR
454
M16x450
5112.BHA3MH
730
set screw
29
---
---
M6 x 10
A7
1
Gasket suction flange
31
51/65x1
5631.254I10
3
55/77x1
5632.1BIC4I
4
Gasket discharge flange
32
51/65x2
5631.254K10
5
40/60 x2
5632.1B3BNK
6
gasket casing + intermediate
pieces
33
138/149x0,3
E30 2
138/149x0,3
E30 2
Gasket can end
34
50/58x0,3
E30
1
50/58x0,3
E30
1
gasket motor cover
35
24/54x0,5
E30
1
30/40x0,5
E30
1
O-ring EA10 GÜ/GB
37
11x2,5
5642.ABAV01
1
---
---
---
metall gasket for 1/4" screw plug
38
14/20x1,5
E30
3
14/20x1,5
E30
3
set screw protection
39
---
---
Ø 5x5
A7
1
bearing sleeve
41
40/50x20
E41
110
40/50x20
E41
110
bearing bush
42
26/52x23
E41
132
26/52x23
E41
132
bearing strip
43
20/119x1
E42
5
20/119x1
E42
5
retaining disc
44
38,5/52x1
E42
2
38,5/52x1
E42
2
bearing disc
45
35/50x5
2162.000082
38
35/50x5
A7
38
key
46
5 x 7,5
5712.AGF001
4
5 x 7,5
5712.AGF001
4
radial impeller 1
47
Ø 111
2162.000313
175
Ø 111
2162.000040
300
radial impeller 2
48
---
---
Ø 111
2162.000041
273
circlip ring
49
---
---
Ø 18
5541.AAH120
1
temperature switch
50
---
---
70 °C
2162.000071
25
PTC resistor
50
90 °C
A8
25
90 °C
A8
25
transformer oil
51
1 Ltr
9832.100001
1425
1,0 Ltr
9832.100001
1425
stator
52
Ø 139
A8
4980
Ø 139
A8
9340
cable insulating plastic tube
54
A8
1
A8
1
cable protective tube
55
A8
1
A8
1
supporting sleeve
56
Ø 80 x 45
2162.000053
154
Ø 80 x 45
2162.000053
154
Supporting sleeve safety
57
2162.000085
6
2162.000085
6
screw plug 1/4"
58
5116.OG6210
13
5116.OG6210
13
cable inlet nipple
59
A8
27
A8
27
shaft
61
A60
---------
A60
------
rotor
62
Ø 80
A60
3970
Ø 80
A60
3720
balancing disc
64
A60
260
A60
260
connecting box, compl.
71
98/64/38
2162.000075
243
98/64/38
2162.000075
243
15
backup fuse for PTC resistor
71a
2591.000101
1
2591.000101
1
sensor wire
77a
---
---
A7
1
sensor wire insulation
77b
---
---
A7
1
sensor connecting cover
78
---
---
A7
15
sensor inlet nipple
79
---
---
A7
27
counterflange suction side
83
DN32
E21
1720
DN50
E21
1194
counterflange discharge side
84
DN32
E22
1720
DN40
E22
713
threaded bar
86a
M12x180
5122.BFAJEZ
127
M12x180
5122.BFAJEZ
127
hexagon nut
86b
M12
5151.AH8100
15
M12
5151.AH8100
15
limpet washer
86c
Ø30/13x3
5161.K11100
12
Ø30/13x3
5161.K11100
12
suction strainer
91
Ø50x125
2196.000002
13
Ø50x125
2196.000002
13
bearing filter
92
---
---
Ø57x57
2162.000084
54
ejector
93
---
---
A7
80