GEA RedGenium Bedienungsanleitung

Heat pump

GEA RedGenium, Compressor frame size V-HP 300 - 600

Operating instruction (Translation from the original language)

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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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