Grasso BluAstrum Chiller with Screw Compressors Documents/Grasso... · 9.7.9 Switch cabinet with...

Chiller with Screw CompressorsGrasso BluAstrum

Operating Manual (Translation of the original text)L_621511_6

COPYRIGHTAll Rights reserved.No part of this documentation may be copied or pub-lished by means of printing, photocopying, microfilmor otherwise without prior written consent of

• GEA Refrigeration Germany GmbHherein after referred to as the manufacturer. Thisrestriction also applies to the drawings and diagramscontained in the documentation.

LEGAL NOTICEThese operating instructions are part of the technicaldocumentation for the scope of delivery. They con-tain important instructions for ensuring safe andproper transport, installation, start-up, economicoperation, maintenance and repair of the unit. Theirobservance helps in avoiding dangers, reducingrepair costs and down-times and increasing the relia-bility and durability of the unit.These operating instructions are intended for theusers of the equipment and are specifically intendedfor the operating company and its operating andmaintenance personnel.It is essential that the operating company and itsoperating and maintenance staff read these operat-ing instructions prior to transport, installation, start-up, use, maintenance, repair, disassembly and dis-posal. This obligation to read also applies to person-nel involved in activities in the life phases of themachine.The operating company must supplement theseoperating instructions with instructions regardinghealth and safety at work and environmental protec-tion on the basis of existing national regulations forindustrial safety.In addition to these operating instructions and thebinding accident prevention regulations valid for therespective country and area where the product isused, the recognised technical regulations for safeand professional work must also be observed.These operating instructions are part of the unit. Theentire documentation comprises these operatinginstructions and all additional operating instructionssupplied with the unit. It must be kept readily availa-ble where the unit is installed. The entire documenta-tion must also be forwarded if the unit is installed atanother location and if the unit is sold.

These operating instructions have been written ingood faith. However, GEA Refrigeration GermanyGmbH cannot be held responsible for any errors that

this document may contain or for their consequen-ces.The manufacturer reserves the right to make techni-cal modifications during the course of further devel-opment of the equipment covered by these operatinginstructions.Illustrations and drawings in these operating instruc-tions are simplified representations. As a result of theimprovements and changes, it is possible that theillustrations do not exactly match the unit you areoperating. The technical data and dimensions aresubject to change. No claims can be made on thebasis of them.The manufacturer cannot accept liability for damages

• which occur during the warranty period as aresult of

– improper operating conditions and conditionsof use,

– inadequate maintenance,

– improper operation,

– incorrect installation,

– incorrect or improper connection of the mainelectrical drive,

• or which result from or can be attributed toimproper modifications or failure to observe theinstructions;

• through the use of accessories or spare partswhich were not supplied or recommended by themanufacturer.

Operating Manual | Grasso BluAstrumChiller with Screw Compressors

2 GEA Refrigeration Germany GmbH | L_621511_6 | Generated 01.04.2015

SYMBOLS USED IN THIS MANUALDanger!

Stands for an immediate danger whichleads to heavy physical injuries or tothe death.

Warning!

Stands for a possibly dangerous situa-tion which leads to heavy physicalinjuries or to the death.

Caution!

Stands for a possibly dangerous situa-tion which could lead to light physicalinjuries or to damages to property.

Hint!

Stands for an important tip whoseattention is important for the designa-ted use and function of the device.


GEA Refrigeration Germany GmbH | L_621511_6 | Generated 01.04.2015 3

PREFACEThe figure on the front page shows the chiller withhousing (optional equipment feature).



LAYOUT INFORMATION

Bullet points and numbered list charactersBullet 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 descriptive text:Descriptive text with consecutive numbering:

– Numbered list point 1

– Numbered list point 2

Handling instructionsHandling instructions require you to do something. Several consecutive steps result in a handling sequence thatshould be run in the specified order. The handling sequence can be divided into separate steps.Handling sequence

1. Handling sequence step 1

– step 1,

– step 2,

– step 3.

2. Handling sequence step 2The subsequent handling sequence is the expected result:

® Result of the handling sequence.

Individual handling stepsIndividual handling steps are marked thus:

– Individual work steps





TABLE OF CONTENTS1 BASICS 13

1.1 Importance of the documentation 131.2 Requirements for personnel, obligation to exercise due care 131.3 Legal foundations (Germany) 141.4 Specified Use 151.5 Warning against foreseeable abusive use 151.6 CE mark 16

2 TRADEMARK RIGHTS 172.1 Evaporator with distributed injection 172.2 Evaporator with integrated liquid separation 17

3 MANUFACTURER INFORMATION 184 CUSTOMER SERVICE 19

4.1 Technical customer service department 194.2 Spare parts 194.3 Training courses 194.4 Service contracts 19

5 SAFETY 205.1 General information for safety 205.2 Behaviour in the case of emergency 205.3 Possible residual hazards 20

6 TRANSPORT, STORAGE 226.1 General instructions 226.2 Delivery 226.3 Transport (crane transport) 226.4 Storage 23

7 INSTALLATION 257.1 Basic information for installation 257.2 Information regarding installation in machinery room 257.3 Rigid installation 267.4 Anti-vibration mounting 267.5 Electrical connection 267.6 Sound insulation, weather protection 26

8 TECHNICAL SPECIFICATIONS 279 DESCRIPTION OF DESIGN AND FUNCTION 29

9.1 Chiller with screw compressors - BluGenium series 299.2 Technical specifications 309.3 Location of the product identification (type plate) 319.4 Information and safety labels on the product 32

9.4.1 Labelling of the pressure and temperature sensors, heater 329.4.2 Label of the safety valve 329.4.3 Labels of the screwed connections with DiNova ring 329.4.4 Labels of the pipelines 339.4.5 Marking the direction of rotation of the compressor drive motor 339.4.6 Labeling of the control / control cabinet 349.4.7 Designation of the earth connection 349.4.8 Labelling of parts delivered separately 359.4.9 Labelling the parts of the level indicator supplied separately 36

9.5 Process flow diagram 379.6 Design 37

9.6.1 BluAstrum series - with condenser 389.6.2 BluAstrum series - without condenser 38

9.7 Main components 389.7.1 Compressor 389.7.2 Compressor drive motor 399.7.3 Coupling 399.7.4 Evaporator 399.7.5 Condenser 409.7.6 Oil separator 409.7.7 Oil cooler 419.7.8 Suction filter combination SFC 41



9.7.9 Switch cabinet with control 419.7.10 Safety devices 429.7.11 Monitoring and display of process values 439.7.12 Fittings 44

9.8 Components installed by the client 449.9 General functional description 449.10 Refrigerant circuit 459.11 Oil circuit 45

9.11.1 Oil heater 459.11.2 Oil Cooling 469.11.3 Oil filter 469.11.4 Oil return from the low pressure side 46

9.12 Capacity control of the compressor 469.13 Level control of the evaporator 479.14 Technical specifications 48

9.14.1 Basic terms 489.14.2 Operating media 48

9.14.2.1 Refrigerant 489.14.2.2 Refrigeration machine oils 499.14.2.3 Secondary refrigerant 499.14.2.4 Heating agents 49

9.14.3 Materials used in heat exchangers 5010 OPERATION LIMITS 5111 START-UP 53

11.1 Important information for start-up 5311.2 Basics 5411.3 Connecting the chiller 5411.4 Connecting the pipes 5411.5 Water pipes 5511.6 Electrical connection 5611.7 Paint and insulation 5711.8 Start-up procedure 57

11.8.1 Checking the electrical connection 5711.8.2 Leak test 5711.8.3 Drying, vacuum 5711.8.4 Operating position of valves 5911.8.5 Oil charge 6211.8.6 Pressure compensation with the cooling system 6211.8.7 Checking the fault monitoring 6211.8.8 Adjustment of oil pressure 6311.8.9 Checking the direction of rotation of the drive motor 6311.8.10 Mounting the coupling 6311.8.11 Checking the water circuits 6411.8.12 Charging refrigerant 6411.8.13 Initial startup 6511.8.14 Checking the oil cooler 65

11.9 Start-up after long standstill periods 6511.10 Restarting after approx. 1 year standstill 65

12 OPERATING THE CHILLER 6612.1 Important information for the operator 6612.2 Requirements for switching on 6612.3 Overview of the operating modes 6712.4 Setting of setpoint and limiting values as well as safety devices 6812.5 Operation of the chiller 6812.6 Equipment Protocol 69

12.6.1 Data sheet of operating parameters for refrigerant circuit (template) 7012.6.2 Data sheet oil filling (template) 7212.6.3 Data sheet refrigerant filling (template) 73

12.7 Guide to failures, their causes and remedies 7413 CLEANING, MAINTENANCE, REPAIR 76

13.1 Important information for service personnel 7613.2 Cleaning the heat exchanger 76

13.2.1 Mechanical cleaning 76



13.2.2 Chemical cleaning 7613.3 Maintenance 77

13.3.1 General instructions 7713.3.2 Repair work 7913.3.3 Repair information 7913.3.4 Repairs of pressure vessels subject to approval inspection 7913.3.5 Maintenance work 79

13.3.5.1 Maintenance of the screw compressor 7913.3.5.2 Replacing the oil filter 7913.3.5.3 Maintenance of suction filter combination SFC 8013.3.5.4 Oil draining, oil filling, oil change 8113.3.5.5 Tightening screw fastenings 8213.3.5.6 Checking the function of check valves 8313.3.5.7 Searching for leaks on the refrigerant side / leak test 8313.3.5.8 Venting the refrigerant circuit 8313.3.5.9 Finding and fixing leakages 8313.3.5.10 Charging and topping up with refrigerant 8413.3.5.11 Draining refrigerant circuit 8413.3.5.12 Refrigerant side evacuation 8513.3.5.13 Maintenance of the compressor drive motor 8513.3.5.14 Checking the operating parameters 8513.3.5.15 Checking the earth connection 8613.3.5.16 Maintenance of the switching cabinet 8613.3.5.17 Insulation 8613.3.5.18 Check of the tightening torque on the adjusting elements of the fixing base. 86

14 DECOMMISSIONING 8714.1 Shutdown in the event of dangerous situations 8714.2 Taking out of service for a period <48 hours 8714.3 Taking out of service for a period <48 hours 8714.4 Measures during shutdowns 88

14.4.1 Monthly measures during shutdown 8814.4.2 Four weeks before restarting 88

14.5 Winter operations 8815 DECOMMISSIONING, DISPOSAL 89





TABLE OF FIGURESfig. 1 CE mark 16fig. 2 Designation of the lifting points 22fig. 3 Attachment to the lifting point 23fig. 4 Transport without casing 23fig. 5 Transport with casing 23fig. 6 Location of the product identification (type plate) 31fig. 7 Safety labels of the pressure and temperature sensors, heater 32fig. 8 Label of the safety valve 32fig. 9 Labels of the screwed connections 32fig. 10 Labels of the pipelines 33fig. 11 Marking the direction of rotation of the compressor drive motor 33fig. 12 Test verification for the control system 34fig. 13 Designation of the earth connection 34fig. 14 Labelling of the parts delivered separately 35fig. 15 Labelling the parts of the level probe supplied separately 36fig. 16 BluAstrum process flow diagram 37fig. 17 Arrangement of the compressor 38fig. 18 Arrangement of the compressor drive motor 39fig. 19 Arrangement of the coupling, 39fig. 20 Arrangement of the evaporator 39fig. 21 Position of the condenser 40fig. 22 Arrangement of the oil separator 40fig. 23 Arrangement of the oil cooler 41fig. 24 Arrangement of the suction filter combination SFC 41fig. 25 Position of the switching cabinet 41fig. 26 Position of the vessel and level indicator on the evaporator type 6HH (black), 5HH (red)

and 4HH (blue) 47fig. 27 Secondary refrigerant system 56fig. 28 Vacuum required to remove moisture from refrigerating plants 58fig. 29 Stop valve open 59fig. 30 Stop valve closed 59fig. 31 Check valve 59fig. 32 Shuttable check valve 59fig. 33 Control valve 60fig. 34 Shuttable check valve 60fig. 35 Solenoid valve 60fig. 36 Change-over valve 60fig. 37 Oil pressure control valve 60fig. 38 Overflow valve, safety valve 61fig. 39 Pressure controlled check valve 61fig. 40 Quick acting valve, spring-loaded 61fig. 41 Charging valve, drain valve 61fig. 42 Service valve 61fig. 43 Oil temperature limiter 62fig. 44 Temperature controlled control valve 62fig. 45 Motor direction of rotation 63





1 BASICS

1.1 Importance of the documentation

This operating manual is part of the technical docu-mentation. It contains advice for operating the chillersafely, properly and economically. The observanceof the operating manual helps in avoiding dangers,reducing repair costs and downtimes, and increasingthe reliability and durability of the chiller.This operating manual is directed at the users of thechiller and is specifically intended for the operatingcompany and its operating and maintenance person-nel. This operating manual must be read prior totransport, installation, commissioning, maintenance,repair, disassembly/disposal. It is imperative tostrictly observe the instructions and informationgiven!All work explained in this operating manual must onlybe carried out by technical personnel.This operating manual must be supplemented withinstructions based on prevailing national regulationsregarding industrial safety, health protection andenvironmental protection.In addition to this operating manual and the manda-tory accident prevention regulations applicable forthe respective place of installation, the acceptedtechnical regulations for safe work according to goodprofessional practices must also be observed.The operating manual is part of the total product.The entire documentation, consisting of this operat-ing manual as well as all supplied additional instruc-tions, must always be kept easily accessible at theplace of installation of the chiller. The complete set ofdocumentation must also accompany the chiller if itis sold.

1.2 Requirements for personnel, obliga-tion to exercise due care

QualificationAll work explained in this manual (assembly, electri-cal connection, commissioning, operation, etc.) mayonly be carried out by trained technical personnelwho observe the relevant technical regulations.Technical personnel are representatives of the unitmanufacturer and persons who, as a result of theirtechnical training, experience and personal instruc-tion in training measures, have sufficient knowledgeof:

– applicable international and national standards,

– applicable occupational safety regulations,

– applicable accident prevention regulations,

– applicable environmental protection regulations,

– the construction and functioning of the unit,

– recognised technical regulations for safe workaccording to good professional practice.

The technical personnel must:

– be able to assess the work assigned to them,recognise and avoid possible dangers,

– be authorised by those responsible for the safetyof the system to carry out the requisite work andactivities.

Caution!

No arbitrary changes may be made tothe control or other componentsbelonging to the unit. Maintenancework may only be done by authorisedservice staff.

Special requirements for the electrical techni-ciansWork on electrical components and modules mayonly be carried out by an electrical technicianaccording to the rules relevant to electrical engineer-ing. Furthermore the operator has to take care thatthe electrical systems, tools and fixtures are oper-ated according to the rules relevant to electrical engi-neering and applicable standards and serviced prop-erly.

– In principle it is prohibited to carry out work onparts under voltage.

– Fuses may only be replaced and not repaired orbypassed.

– Only the fuses specified in the electrical circuitdiagram may be used.

– A two-pole voltage tester must be used to ensurethat the parts are de-energised.

– The power supply as well as the unit casing mustbe sufficiently grounded and tagged with a suita-ble label.

– Deficiencies noticed in the electrical systems/modules/tools and fixtures must be correctedimmediately. If an acute danger exists before


Basics


then, the chiller must not be operated in thedefective condition.

Minimum ageThe minimum age for the operation of the chiller andinstallation is 18 years. All persons involved in theassembly and installation of the chiller and the sys-tem must get themselves trained at regular intervalsand/or familiarise themselves with the current techni-cal data of the unit. The training and instructions is tobe conducted at least once a year, unless someother interval has been agreed upon with the manu-facturer.

Obligation to exercise due careThe statutory regulations for meeting the obligationto exercise due care are to be observed.Meeting the obligation to exercise due care accord-ing to the current level of technology requires thateverything that is

– technically possible (use of accepted technologi-cal rules) and

– economically reasonablebe done to prevent damage in a protectively safemanner.

1.3 Legal foundations (Germany)

The following standards, regulations, ordinances andlaws have to be strictly observed to ensure the safetyand functional reliability of the chiller:

– EC Machinery Directive 2006/42/EC

– EC Pressure Equipment Directive 97/23/CE -AD Instruction Sheets 2000

– Ordinance on Failures (12. BlmSchV) with 1failure VwV

– Federal Emissions Control Act (BImSchG), 4.BimSchV

– Water Resources Management Law (WHG),VawS

– Ordinance on Hazardous Substances (Gef-StoffV)

– Closed Substance Cycle Waste ManagementAct (KrW-AbfG)

– EN 378, Parts 1 to 4 Safety and environmentalrequirements

– Accident-Prevention Rule including implemen-tation regulations (BGR 500, chapter 2.35)Refrigeration plants, heat pumps and coolingequipment (BGV B3) Noise

– EN 12284 Refrigerating systems and heatpumps – Valves – Requirements, testing andmarking

– DIN 2405 Pipes in refrigeration plants, marking

– VDMA Directives, particularly VDMA 24 243and 24 020

– VDI Guidelines

– Instruction Sheets for Handling Ammonia,Instruction Sheet for halogenated hydrocar-bons containing fluorine BGI 648

– Safety Data Sheet for ammonia and other refrig-erants and refrigeration oils

The list of rules and standards has been taken fromStatus Report No. 5 of Deutscher Kälte- und Klima-technischer Verein "Sicherheit und Umweltschutz beiAmmoniak-Kälteanlagen (Safety and environmentalprotection in ammonia refrigeration plants)" and fullyapplies to other refrigerants as well.The following:

– standards,

– safety regulations,

– guidelines and sound engineering practice,listed in these operating instructions must beobserved at least!

Hint!

If the chiller is used in a country otherthan Germany, the rules and regula-tions applicable at the place of instal-lation must be observed and compliedwith!

The mandatory accident prevention regulationsapplicable for the respective country and area wherethe product is used must also be observed.Failure to observe the safety instructions can lead todanger to personnel and the environment as well asdamage to the unit.

Basics Operating Manual | Grasso BluAstrumChiller with Screw Compressors


1.4 Specified Use

Hint!

Observe the chapter "Specified Use"of the installation instructions for thecompressor!

The chiller must only be operated up to a maximumdischarge pressure in accordance with the typeplate.It is imperative that the conditions for using the chillerwith regard to pressure and temperature are main-tained, even if an external condenser is used.Do not change the setting values of the safety pres-sure switch. This would endanger the operatingsafety of the refrigeration plant.If the switch-off value is set higher than 0.9 x maxi-mum operating pressure (see EN378-2) of the highpressure section of the refrigerating system, this mayresult in the bursting of the tank of this section of thesystem.

The operating regime stipulated by the manufacturer,especially for the starting phase of the chiller, mustbe observed.Operating parameters must be monitored and mustremain within the specified limits.

The chiller unit has been designed and manufac-tured for a special application under defined condi-tions of use. Unauthorised structural modificationsare not allowable. We assume no liability for anyresulting damage or injury. In the interest of furtherdevelopment, GEA Refrigeration Germany GmbHreserves the right to technical modifications. Thechiller described here meets the current state of theart at the time of the printing of this operating man-ual.The manufacturer must be consulted in all cases asto the permissibility of the modification if there is anychange of the application or the conditions of use.

The refrigerant circuit must be designed so that aconstant volume flow on the evaporator is alwaysensured. If the volume flow is reduced, this can leadto freezing of the secondary refrigerant and to trig-gering the chiller safety device.

The cooling water flow must be ensured with water-cooled condensers. If the water flow is reduced orobstructed, there is a discharge pressure increasefollowed by the compressor switching off.

Do not make any modifications to the chiller and thecompressor control system.

These may impair the safety and functionality of thechiller. They will also invalidate the guarantee.

The pressure equipment described here must not beused for any purpose other than the purpose speci-fied here. If the pressure equipment is not usedaccording to the regulations, the safe use of theequipment is not guaranteed. The supplier/installeror the operator – and not the manufacturer – isresponsible for all personal injury and damage toproperty resulting from improper use.The pressure equipment is not designed for dynamicloads. If there is a risk of lightning strikes, the pres-sure equipment must be earthed. The supplier/instal-ler must record instructions for regular inspection ofthe pressure equipment in his operating manual anddefine the behaviour of the end user in the event ofdamage. In order to prevent burns or frostbite, thepressure receptacle must not be touched duringoperation. This can be prevented by respectivesafety measures. Respective warning signs must beaffixed. Chillers must be equipped with safety valvesaccording to EN 378. The foundation must providesufficient rigidity.The supplier/installer must carefully install the acces-sories for the pressure equipment. The pressureequipment must not be damaged during installationand must be painted after installation. The pressureequipment must only be filled with the refrigerantspecified in the contract. The pressure equipmentmust be installed in the chiller or the system in sucha way that no vibration or pulse is transferred to thepressure equipment. The contacts must be installedwhen de-energised.

Specified use includes observance of this manualand all supplied operating manuals as well as com-pliance with the maintenance and service intervalsand conditions stipulated therein.Warranty claims and authorisation for operationbecome void if the equipment is not used for itsproper purpose.

1.5 Warning against foreseeable abu-sive use

A chiller is said to have been abused if:

– Unauthorised refrigerants, fuels and secondaryrefrigerants and cooling media are used.

Hint!

Observe the specifications for theproject!


Basics


– Electrical components are wrongly connected,

Hint!

Observe voltage and frequency!

– Mechanical components are wrongly connected,

Hint!

Observe pressure and temperature!

– The supporting, hanging and storage facilitiesare misused,

– Control and regulation units including controlsoftware are tampered with,

– The driving power generated by the motor isused for purposes other than the operation of therespective compressors and pumps.

1.6 CE mark

By affixing the CE mark, the manufacturer confirmsthe conformity of the product with the applicable ECDirectives and compliance with the principle require-ments stipulated within them.

fig.1: CE mark

The CE mark is affixed to the nameplate.The CE mark for products from GEA RefrigerationGermany GmbH is provided as defined in the Pres-sure Equipment Directive, i.e. pressure equipment isplaced on the market with the required equipmentparts with safety function. This complete assembly issubject to the Pressure Equipment Directive.

Basics Operating Manual | Grasso BluAstrumChiller with Screw Compressors


2 TRADEMARK RIGHTS

The chillers contain technical solutions for whichGEA Refrigeration Germany GmbH holds the pat-ents or has applied for them.

2.1 Evaporator with distributed injection

The design of the evaporator with distributed injec-tion, forced circulation, collection and return flow ofrefrigerant and oil is protected by law.Patent DE 10 2010 010 840 B4 "Overrun evaporatorwith forced circulation"

2.2 Evaporator with integrated liquidseparation

A patent has been applied for the position anddesign of the liquid separation integrated in the evap-orator.Patent application 10 2013 010 510 A1


Trademark rights


3 MANUFACTURER INFORMATION

GEA Refrigeration Germany GmbH is a companywithin GEA Refrigeration Technologies, the Refriger-ation Technology Segment of the GEA Group andprovides its customers around the world with high-quality components and services for refrigeration andprocess technology applications.

Locations:

GEA Refrigeration Germany GmbHFactory BerlinHolzhauser Str. 16513509 Berlin, GermanyTel.: +49 30 43592-600Fax: +49 30 43592-777Web: www.gea.comE-Mail: [email protected]

GEA Refrigeration Germany GmbHFactory HalleBerliner Straße 13006258 Schkopau/ OT Döllnitz, GermanyTel.: +49 345 78 236 - 0Fax: +49 345 78 236 - 14Web: www.gea.comE-Mail: [email protected]

Manufacturer Information Operating Manual | Grasso BluAstrumChiller with Screw Compressors


4 CUSTOMER SERVICE

GEA Refrigeration Germany GmbH supplies prod-ucts of high quality and reliability. In addition, themanufacturer ensures continuous operation of therefrigeration and process technology system andprovides exceptional service for the componentssupplied.

4.1 Technical customer service depart-ment

Do you require support from the technical customerservice department? Specially trained, experiencedservice technicians are available on call for you inorder to provide assistance in case of technical prob-lems and to offer support in the framework of ourafter-sales service.24/7 Hotline:the hotlines can reached around the clock on everyday of the week:

• Wireless+49 (0) 172 39 12 050

• Landline, weekdays from 7 to 17 hours+49 (30) 43 59 27 61+49 (30) 43 59 27 62

• Email:[email protected]

outside of Germany, Austria and Switzerland pleasecontact:

• local sales officewww.gearefrigeration.de

technical support for liquid chillers with reciprocatingcompressors in Germany, Austria and Switzerland

• 24/7 Hotline+49 (345) 78236 20

The specialists of our Technical Customer Servicedepartment support you in installations, acceptan-ces, maintenance, operating questions, on-siteinspections and repairs of our products.

4.2 Spare parts

GEA Refrigeration Germany GmbH has its own prac-tical and rapidly working spare parts department tosupply the necessary spare parts worldwide. Neces-sary spare parts are shipped as quickly as possible.

In most cases, you will receive your spare partswithin 24 hours after placing the order.You can contact us using the following hotlines:

• Wireless, out of hours+49 (0) 172 30 14 579

• Landline, weekdays from 8 to 17 hour+49 (30) 43 59 27 50

• Fax+49 (30) 43 59 27 58

• [email protected]

• Order spare parts from our G-Pos. onlineshop(Grasso Parts online shop)[email protected]

4.3 Training courses

Warning!

All work on our systems must only becarried out by technical personnel!Acquire the technical know-howrequired for this in good time!

Comprehensive training courses are held regularlyfor service technicians and mechanics, thus ensuringthe safe and proper use and maintenance of our sys-tems.

• [email protected]

4.4 Service contracts

It is possible to sign a long-term service agreement(service contract). For further information regardingthe content, scope and conditions of the possibleservice options, please contact the Technical Cus-tomer Service department.

• Email:[email protected]


Customer service


5 SAFETY

5.1 General information for safety

The safety aspects to be observed for operating theequipment are shown in the chapter on "Safety".The equipment has been developed and manufac-tured according to the currently applicable state ofthe art and is reliable in operation. It has been testedand left the factory in a technically faultless safe con-dition.In order to maintain this condition for the operationtime, the details of the project documentation andcertificates must be observed and complied with.When operating the equipment, at least the generalsafety regulations and the provisions and guidelinesreferred to in this documentation must be observed.Only compliance with all provisions and guidelineswill enable optimum protection of the personnel aswell as dangers to the environment and the safe andsmooth operation of the equipment.

5.2 Behaviour in the case of emergency

Hint!

Familiarise yourselves with the localevacuation plan before beginning thework.

Should an emergency situation arise despite adher-ing to the safety regulations, the chiller must be shutdown immediately and isolated from the electricalmains.The mains cable must be blocked in such a way it isnot possible to restart the unit accidentally andmarked as such.The operator of the complete system has to takecare that an isolation device, e.g. a mains switch withappropriate contact rating and an integrated indica-tor, is pre-installed in the mains cabling on site.A separate mains cable/feed cable must be laid forthe operation of the chiller.The mains cable/feed cable is to be specially protec-ted and provided with an emergency stop switch.

5.3 Possible residual hazards

Warning!

Despite careful design of the machineand the implementation of all safety-relevant regulations, further risks forpersons and machine during all lifephases of the chiller cannot be fullyruled out. The additional safetyinstructions in the individual chaptersof this manual must therefore be care-fully observed!

The residual risks that were ascertained during therisk assessment carried out for the product accordingto safety standard EN ISO 14121 - Safety ofMachines - are:

– mechanical hazards due to sharp sheet metaledges and projecting parts

– electrical hazards as a result of inadvertentlycoming in contact with terminals and cables

– thermal hazards as a result of inadvertently com-ing in contact with heat exchangers and pipes

– exposure to noise

– hazards caused by vibration due to improperinstallation

– hazards due to working materials and othermaterials in case of allergies or the like.

– neglect of ergonomic principles

– combinations of various hazards

– unexpected starting, unexpected rotation in caseof wrong electrical connections or defects

– shut down, emergency stop when defects aredetected

– changes to the rotational speed

– power failure

– failure of the control circuit or control loop

– incorrect assembly

– fracture during operation

– operating media or objects getting thrown out

– loss of stability

– personnel slipping, tripping or falling

– danger from mixing of media

Safety Operating Manual | Grasso BluAstrumChiller with Screw Compressors


Hint!

In general damage to the evaporator/condenser (e.g. plate fracture) createsthe danger that he media will mix.It may cause ammonia to flow to theliquid side of the heat exchanger.To prevent subsequent damage to thehydraulic system, measures need tobe taken on the building side. Thesemay take the form of:

19.1 Separator heat exchangers in glycolsystems with copper piping.

19.2 NH3-sensors in the pipe systemclose behind the heat exchangers.

Hint!

There no radiation hazards


Safety


6 TRANSPORT, STORAGE

6.1 General instructions

Caution!

Adequate lighting must be ensuredduring loading and unloading as wellas for storage in order to avoid injuriesand damage to property.There is a danger of impacts andstumbling due to protruding parts onthe equipment (e.g. valve caps). Thereis also the danger of being cut onsharp edges and surfaces. There is adanger of crushing parts of the bodyduring the transport work. Personalprotective equipment (work clothing,work books, gloves) must be wornduring all activities on the equipment.

Hint!

These operating instructions must beread prior to transport, storage anddelivery to the installation site. It isimperative to strictly observe theinstructions and information given!All work explained in these operatinginstructions must only be carried outby qualified personnel.

6.2 Delivery

Shipment is made in the type of packing stipulated inthe order. The liquid chiller is generally supplied with-out packing.The chiller has an inert gas filling (dried air, 0.2 baroverpressure) in the refrigerant circuit.The heat exchanger connections are closed.

Warning!

The compressors of the chiller are notcharged with oil, therefore the chillermust not be started before it is prop-erly installed and commissioned.

6.3 Transport (crane transport)

Warning!

The BluAstrum is not intended fortransport with a fork lift truck!

BluAstrum is a high-quality product which must behandled with extreme care during transport. Protectthe equipment from impacts and put it down care-fully.When transported by crane, the BluAstrum musthave the same position (frame downwards) as inoperation. Do not use any other lifting points thanthose specially provided for this purpose. The liftingpoints are marked!

fig.2: Designation of the lifting points

Transport, Storage Operating Manual | Grasso BluAstrumChiller with Screw Compressors


fig.3: Attachment to the lifting point

Caution!

It is prohibited to strap the BluAstrumto any fittings or pipes or to the eye-bolts/lugs on the compressor, electricmotor, container or switching cabinet.

Take special care not to attach the ropes near tosmall nominal diameter pipes or insulation and todamage them. Use spacers if necessary.The lifting points are not arranged in one plane. Theropes must be longer than 3 m. The height differen-ces between individual lifting points must be com-pensated by suitable extensions.Make suitable arrangements (timber or underlaymade of insulation material) to avoid damage to thesurface.Shackles must be used.

fig.4: Transport without casing

fig.5: Transport with casing

Danger!

Make certain there is no one under thesuspended load during transport withthe crane!

Position the BluAstrum on the transport vehicle insuch a way that it is prevented from sliding, tilting orfalling down. Load securing is preferably carried outby lashing to the specified points. The pipes andequipment parts of the chiller must not be steppedon. Components must be secured against vibrations.The competent staff member or the company isresponsible for ensuring transport safety.

Warning!

The BluAstrum must be adequatelyprotected from external influencesduring transport.

Transport packaging (optional): FoilThe foil must only be removed before erecting theBluAstrum at the intended installation location in themachine room. Up until this point in time, the foilserves to protect the BluAstrum against externalinfluences.

6.4 Storage

When the chillers are delivered, check for possibletransport damage and report any damage to themanufacturer in writing.The storage area of chillers shall be roofed, plainand paved and secured against access of unauthor-ised persons. The chiller is to be protected againstknocks and impacts.


Transport, Storage


Warning!

Chiller units must be adequately pro-tected from external influences(humidity, frost, extreme heat) duringstorage. This usually concerns lengthystanding times outdoors before instal-lation and start-up of the refrigerationplant. GEA Refrigeration GermanyGmbH recommends the use of plasticsheeting to cover the whole product.For BluAstrum, version without cas-ing: The venting slits of the electricmotors must always be covered!

Storage temperature: 5°C ... 40°CThe composition of the paint on the chiller isdesigned for installation in the machine room (indoorinstallation). Contact with water (including waterspray) must be avoided.

Hint!

At the time of delivery, the chiller is fil-led with protective gas. Check the pro-tective gas filling once a week andrecharge to the specified overpressureof 0.2 bar if required. Dry air (dewpoint below -40°C) is to be used forthis purpose.

The transport packing (foil), that needs to be openedfor turning the compressor shaft and for checking theprotective gas filling, must be closed again after car-rying out the activities in order to ensure protectionagainst external influences. The packing (foil) mustbe replaced as needed and for lengthy storagetimes.

Warning!

Regular ventilation of the chiller pack-aging must be ensured in order to pre-vent condensation on the surfaces ofthe machine.

Long-term storageWith a standstill of the compressor for more than 16weeks prior to start-up, there is a danger that theshaft seal may stick on the shaft and therefore bedamaged on start-up. Because of this, removal andcleaning of the shaft seal is mandatory in order toensure that it functions correctly:

1. Use two pressure screws to remove the cover ofthe shaft seal, including the stationary gasketinserted in it.

2. Removal of the seal package arranged on theshaft with the corresponding rotating ring byhand, or if it is tightly seated, by pulling it outusing a device. If loosely seated, the seal pack-age might stick to the rotating ring and is alreadypulled out when the cover is removed.

3. Clean the shaft seat with a lint-free cloth. Greaseit lightly and push the sealing package back ontothe shaft again.

4. After pushing onto the shaft, the seal packagemust be manually compressed against the springpressure which acts on it. At the same time, itmust be checked that the gasket springs outagain.

5. Then re-fit the cover of the shaft seal.

Warning!

Danger of cuts and crushing injuries.

Transport, Storage Operating Manual | Grasso BluAstrumChiller with Screw Compressors


7 INSTALLATION

7.1 Basic information for installation

Caution!

During installation make sure thatleaking operating materials do notreach the soil, groundwater or surfacewater (Federal Water Act WHG). Followthe legal regulations at the site ofinstallation (e.g. for Germany: FederalWater Act WHG).

All foundation calculations, the selection of materialsand the soil analysis are the owner’s responsibility.Prior to installation, a plan must be created forproper and professional installation. Electrical con-nections and connections for operating media mustbe made. In addition to the installation surface of theBluAstrum, it must be ensured that sufficient space isavailable during maintenance work on the pipes aswell as for operation.Install the BluAstrum on a level surface. The differ-ence from the horizontal must not be more than 0.3%. Provide enough space for maintenance work.

Hint!

Do not cover the ventilation openingon the casing (if available)!

Due to its own weight, the BluAstrum standssecurely on the installation surface. Rubber ribbedplates between the contact surface and frame or themachine base frame of the BluAstrum are intendedfor damping. In the version without casing, levelmount elements are intended for damping (optionalscope of supply).If more damping is required (installation on a floorslab or on the roof), vibration dampers must be provi-ded. In this case, the suitable type of vibrationdamper must be determined and realised. The pipesfor the cooling agent must be decoupled usingexpansion joints where vibration dampers are used.The welded seams must be inspected in accordancewith the Pressure Equipment Directive after weldingwork by the customer or operator on pipe line con-nections and flanges.

7.2 Information regarding installation inmachinery room

The chiller has to be installed in the closed machineroom and on a level surface. Provide enough spacefor maintenance work.Unless other order-related limitations have to betaken into account, the allowable ambient tempera-ture in operation is +5 to +40℃.

Hint!

The relevant regulations must beobserved when designing the machineroom and the safety equipment. Forfurther information on machine roomsituation, please consult our brochure"Machine room situation and fillingvolumes for NH3 refrigeration installa-tions according to accident preventionregulations"

Special features for installation with casing(option).The housing functions as a design cover to reducenoise.The housing is not a machine room as defined inDIN EN 378-3, but merely serves to reduce noiseand as protection against contact.The ventilation of the motor is carried out both on theintake and outlet glands in the side walls and via theroof of the housing.

Hint!

The intake and outlet glands may notbe moved!Minimum freeboard over the upperedge of the housing roof: 30 mm

Access to the components of the chiller during main-tenance work shall be provided through the com-pletely removable side walls.

Hint!

The side walls of the housing may onlybe removed when the machine is shutdown!Measurement for removal side wall:1m


Installation


7.3 Rigid installation

The frame of the chiller is placed on foundation boltson a prepared foundation. The frame must be level-led with suitable shims such that the coarse align-ment (radial and angular misalignment ≤ 0.25 mm) atthe coupling is attained again. Then tighten the foun-dation bolts.

7.4 Anti-vibration mounting

The frame of the screw compressor unit shall bealigned with the levelling bolts until the coarse align-ment (radial and angular misalignment ≤ 0,25 mm) atthe coupling is attained again.Before tighting the foundation bolts of isolatorscheck, that the isolators are free over the spring (pre-dominantly made of rubber) and not lie on the foun-dation.

7.5 Electrical connection

Danger!

Contact with live components is pro-hibited.Produce the earth connection accord-ing to the designation in the generalassembly drawing. See chapter "Des-ignation of the earth connection".

Before starting work, make sure that all parts to beconnected are de-energised, e.g. by removing themain fuse in all phases or installing a jumper wire.The insulation resistance of the electrical tools andfixtures and wiring is to be checked. The connectionmay only be undertaken if this value lies in the allow-able range.All electrical connections must be established and allelectrical consumers/sensors must be connectedaccording to the circuit diagram.

7.6 Sound insulation, weather protec-tion

If the chiller is intended for outside installation, itmust be equipped with a suitable casing for soundand weather protection by the customer. Theweather protection must provide sufficient protectionfor the machine with regard to the climatic conditionsat the installation location.

Hint!

The chiller is not intended for unpro-tected outside installation. Protectionagainst outside influences, especiallydirt, dust and moisture (wetness) isessential.

GEA Refrigeration Germany GmbH will not acceptliability for damage due to incorrect outdoor installa-tion.

Installation Operating Manual | Grasso BluAstrumChiller with Screw Compressors


8 TECHNICAL SPECIFICATIONS

Hint!

The BluAstrum is manufactured and delivered according to technical specifications. On thebasis of the standard equipment, optional equipment variants can be considered.

Standard equipment

Operating pressure: max. 28 bar

Intended environment: closed machine rooms

Ambient temperatures: +5°C to +40°C(+5°C to +32°C with housing)

High above sea level: ≤ 1000m above sea level

Secondary refrigerant outlet tem-perature1:

-15°C/ 6°C/ 15°C

Electric motor: scope of delivery

Refrigerant: R717

Type of oil: highly refined mineral oils, e.g. CPI1009-68 or approved Polyalphaolefinoil (PAO) like Klüber Summit R100 or Klüber Summit R200

Caution!

Please contact the manufacturer in case of other types ofoil.

Oil cooling: liquid cooled (internal piping)refrigerant cooled (condenser design type (R) only)

Oil heating: scope of delivery

Oil filter: single stage filter

Spare oil filter: without

Oil level switch: without

Pressure sensors: directly in the pipe

Separate pressure switch: without

Overflow valve: scope of delivery

1 Temperature difference secondary refrigerant maximum 10K/ standard 5K


Technical specifications


Standard equipment

Safety valve HP / LP: double safety valve with change-over valve

Flow monitor: mechanical

Controller: GSC TP

Power panel and frequency con-verter: scope of delivery, cable entry from below

Colour: RAL 5014 (dove grey)

Housing: without

Vibration isolators: without

Approval pressure equipment: CE-PED, Module H (piping)

Documentation: 2x hard copy + 1 CD ROM

Optional equipment

Spare oil filter: can be delivered

Housing: can be delivered, colour: RAL 7035 (pebble grey)

Communication: Profibus DPModbus RTUModbus TCP

Electric motor: customer specific design possible on request

Flow monitor: electronic

Vibration isolators: can be delivered

Approval pressure equipment: CE-PED, Module H1 (complete chiller)

Technical specifications Operating Manual | Grasso BluAstrumChiller with Screw Compressors


9 DESCRIPTION OF DESIGN AND FUNCTION

9.1 Chiller with screw compressors - BluGenium series

BluAstrum Chiller series

9 Nominal chiller capacity (kW) related to cold water operation 12°C/ 6°C

Y Condenser version

BluAstrum = Chiller series

9 Nominal chiller capacity 4500 min-1 kW related to cold water operation 12°C / 6°C

Compressor type Nominal capacity in kW

G 500

H 800

L 900

M 1000

N 1500

R 1800

(Yy) = Condenser version


Description of Design and Function


(W)Water/liquid-cooled plate heat exchanger (fully welded),Chiller for indoor installation

(Wx)Water/liquid-cooled plate heat exchanger (fully welded),Chiller for outdoor installation

(R)Evaporation or air cooled condensers (not in the scope of delivery for GEARefrigeration Germany),Chiller for indoor installation

(Rx)Evaporation or air cooled condensers (not in the scope of delivery for GEARefrigeration Germany),Chiller for outdoor installation

Naming example

BluAstrum 1000 (W) Chiller with screw compressor, flooded evaporation with integrated separator(BluAstum)Nominal capacity of the chiller 1000 kW (1000)Evaporator and condenser designed as fully welded plate heat exchanger,Chiller for indoor installation (W)

9.2 Technical specifications

BluAstrum chillers are designed and manufactured for special fields of application. For technical specifications,see the following:

– order specification,

– list of parameters,

– general assembly drawing,

– P+I diagram.

Description of Design and Function Operating Manual | Grasso BluAstrumChiller with Screw Compressors


9.3 Location of the product identification (type plate)

The type plate contains the most important technical data of the product. This data and the contractual agree-ments define the limits of designated use.As standard, the type plate is fixed to the switching cabinet (deviations of the location are possible).

fig.6: Location of the product identification (type plate)

Data on the type plate:

– Manufacturer

– Type

– Serial number

– Weight without filling

– Refrigerant

– Refrigerant filling quantity

– High pressure side

– Low pressure side

– Allowable pressureThe standard languages are English and German




9.4 Information and safety labels on theproduct

Danger!

The safety-related labels on the pack-age/chiller must be followed!

9.4.1 Labelling of the pressure andtemperature sensors, heater

(safety labels)

fig.7: Safety labels of the pressure and temperature sensors,heater

Importance of the labels:Before replacing pressure and temperature sensorswithout dip tube, it must be ensured that the pipesinto which the sensors are mounted are not pressur-ised. The pressure-free state can be achieved byclosing the shut-off valves before the sensor to bereplaced.Before replacing oil heater it must be ensured thatthe oil separator into which the oil heater is screwedin is not pressurised.

Hint!

Not applicable to oil heaters of theHLP type series.

9.4.2 Label of the safety valve

(safety labels)

fig.8: Label of the safety valve

Importance of the labelsThe safety valve must be connected to a blow-offline.

9.4.3 Labels of the screwed connec-tions with DiNova ring

(handling instructions)

fig.9: Labels of the screwed connections

The informative label for all screwed connectionswith DiNova ring (handling instructions) is attachedto the electric motor in a clearly visible manner.Importance of the labels:If any leakage occurs at a screwed connection(escaping gases or vapours), the screwed connec-tion must be tightened:

Counter-hold the screwed pipe connection usinga wrench. Tighten the pipe nut about 1/4 to 1/3rotation beyond the point where the increase inthe force if felt.

® The leakage is remedied.



9.4.4 Labels of the pipelines

(information plate)Pipelines in refrigeration plants must be labelled asfollows (DIN 2405):

– Refrigerant

– Direction of flow

– State of phase

fig.10: Labels of the pipelines

1 Arrow head (indication of the direction of flow)

2 Horizontal stripe (indication of the state ofphase), green = liquid // blue = gaseous cold //red = gaseous hot

3 Information field (label of the refrigerant)

9.4.5 Marking the direction of rotationof the compressor drive motor

(information plate)

fig.11: Marking the direction of rotation of the compressor drivemotor

The direction of arrow indicates the direction of rota-tion of the compressor drive motor




9.4.6 Labeling of the control / controlcabinet

(information plate)

• Label on the rear side of the control unit of thecontrol system (visible after opening the switch-ing cabinet):

– Project name

– Make number of the package/chiller

– MPI address

• Label on the inside of the switching cabinet:

– Test verification for the control system

fig.12: Test verification for the control system

9.4.7 Designation of the earth connec-tion

Safety labels

fig.13: Designation of the earth connection

Importance of the labelsEnsure that the product is properly grounded beforestart-up. Connect the earth connection. The neces-sary mounting hardware and cables are not includedin scope of supply.See general assembly drawing for the position of theearth connections.

Hint!

The cross-section of the ground wiremust be at least 10 mm². Alternatively,two separately installed and separatelyconnected ground wire must be used,ensuring the minimum cross-sectionin the sum.



9.4.8 Labelling of parts delivered separately

(handling instructions)Mounting of the designation: on the evaporator

fig.14: Labelling of the parts delivered separately

2040 Resistance thermometer - secondary refrigerant outlet temperature

2045 Resistance thermometer - secondary refrigerant inlet temperature (optional)

2050 Flow switch

Importance of the labelsBefore start-up ensure that the parts delivered separately are installed in the piping circuit:

1. Remove the parts from the packaging.

2. Install the components according to the figure.

Hint!

Note the hints given in the chapter "Start-up/water piping".




9.4.9 Labelling the parts of the level indicator supplied separately

(handling instructions)

Hint!

For BluAstrum (R) only.

fig.15: Labelling the parts of the level probe supplied separately

2000 Evaporator

2810/ 2815 Stop valve - low pressure float switch

2850 Level indicator - separator

2875 Stop valve - service

A Vessel

Importance of the labelsBefore start-up, it must be ensured that the part of the level indicator supplied separately (2850) in installed inthe vessel (A).

Hint!

In doing so, follow the instructions given in the manufacturer's documentation for the levelindicator in order to ensure proper installation.The documentation for the level indicator is part of the product documentation.



9.5 Process flow diagram

Hint!

For a detailed list of all items, see object-specific customer parts list and P+I diagram.

fig.16: BluAstrum process flow diagram

10 Screw compressors

20 Oil separator

30 Water-cooled oil cooler

35 Oil filter

45 Suction filter SFC

55 Check valve - suction side

60 Shuttable check valve - pressure side

2000 Evaporator

2100 Condenser

2200 Liquid separator

2245 Injector

2860 Expansion valve

9.6 Design

The BluAstrum chillers work with flooded evapora-tor systems on the basis of gravity recirculation andcan be fitted with a variety of condenser types.The chillers have a modular design and comprise thefollowing main modules:

• Screw compressor package

• Heat exchanger subassembly with integrated liq-uid separator and de-oiling system

• Low-voltage installation with frequency converterand control device

The modular BluAstrum structure is optimised for ahighly compact design. The oil separator and theintegrated fluid separator are installed horizontally.The placement of the components guarantees thevery low quantities for high cooling capacity.




Only fully welded, flat plate evaporators with integra-ted separator are used as evaporators.On the condenser side, the following versions areused:

• Fully welded plate condenser

• Vapour condenser (version (R) of the condenser)

• air cooled condenser (version (R) of the con-denser)

The BluAstrum chillers are supplied, as a standard,ready for connection, fully piped and wired.The BluAstrum (R) chillers are supplied in such acomplete state that on site only the air cooled con-denser or the evaporative condenser has to be inte-grated. The air-cooled condenser or the vapour con-denser need to be available on the building side.The heat exchangers are designed according to theparameters of a project, taking into account a maxi-mum energy efficiency on the evaporator and thecondenser side.

The standard version of the chillers is equipped witha freely programmable control.All operating and fault signals as well as the processvariables can be read from a display (Touch Panel).The control is operated via a Touch Panel.The chillers are supplied without refrigerant. Theyare filled with dry air (approx. 0,2 bar ... 0,5 bar over-pressure).When commissioning a start-up or a factory accept-ance test (FAT) the refrigerating machine oil is inclu-ded in the scope of delivery.

9.6.1 BluAstrum series - with con-denser

The BluAstrum chillers are supplied, as a standard,ready for connection, fully piped and wired.An electronic injection valve is used as expansiondevice.The chiller is equipped with a water-cooled oil cooler.The chiller is supplied with the water-cooled con-denser.

9.6.2 BluAstrum series - without con-denser

A BluAstrum (R) chiller does not include a con-denser in its delivery. the connection to an air-cooledcondenser or a vapour condenser is carried out on

the building side. The modules are connected onsite.The chiller is equipped with a refrigerant-cooled oilcooler.For the safe functioning of the oil cooler, the chiller isequipped with a high-pressure collector.

9.7 Main components

9.7.1 Compressor

fig.17: Arrangement of the compressor

The screw compressor is characterized by a com-pact design, a high reliability, high quality compo-nents and the ease of maintenance.Screw compressors are dual rotor positive displace-ment machines that run according to the principleand are operate by oil injection.The screw compressor is operated with ammonia(NH3, R 717) as the refrigerant. CPI1009-68 is rec-ommended as the refrigerating machine oil.Various series and sizes of screw compressors areavailable for different fields of application.The screw compressor is driven directly by the com-pressor drive motor via a coupling.

Hint!

The documentation of the screw com-pressor (installation instructions, partlists, drawings) is a part of the productdocumentation.



9.7.2 Compressor drive motor

fig.18: Arrangement of the compressor drive motor

Standard: The compressor is driven by an air-cooled 2-pole electric motor IP23 with an operatingvoltage of 400 V; 50 Hz using a coupling.The speed of the electric motor is controlled using afrequency converter (1000 min-1 ... 4500 min-1) andis designed as a flange mounted motor with base,IMB35 configuration.Optional: Other protection types and operating vol-tages on request.

Hint!

The documentation of the electricmotor (operating manual) is a part ofthe product documentation.

9.7.3 Coupling

fig.19: Arrangement of the coupling,

The coupling helps in transmission of torquebetween compressor and compressor drive motor.The non-clutch design of the coupling brings aboutthe neutralisation of the otherwise disturbing influen-ces such as axial or radial forces, vibrations or offset.Speed fluctuations and speed shocks are dampedand cushioned, torsional vibrations are reduced.

Hint!

The documentation of the coupling(operating manual) is a part of theproduct documentation.

9.7.4 Evaporator

fig.20: Arrangement of the evaporator

In the evaporator heat is absorbed from the secon-dary refrigerant (which is thereby cooled) by way ofevaporation of the refrigerant. The evaporator worksby the principle of overflowed evaporation.Liquid drops are effectively separated in the liquidseparator integrated into the evaporator.In the case of external condensing systems (RemoteVP and Remote LP), a maximum level indicator isinstalled in the liquid separator to provide additionalprotection against overfilling. The suction pressureand secondary refrigerant outlet temperature aremonitored to provide reliable protection againstfreezing.Design, manufacture and acceptance of the evapo-rator with integrated liquid separator comply with therequirements of the Pressure Equipment Directive.




Hint!

The documentation of the evaporator(operating and maintenance instruc-tions, acceptance certificate) is a partof the product documentation.

9.7.5 Condenser

fig.21: Position of the condenser

In the condenser the compressed refrigerant vapouris desuperheated and liquefied by dissipating theenergy absorbed in the evaporator and compressorto the cooling medium (heating).Design, manufacture and acceptance of the con-denser comply with the requirements of the PressureEquipment Directive.

1. Condenser designed as a plate heat exchanger(included in the scope of delivery)

Hint!

The documentation of the condenser(operating and maintenance instruc-tions, acceptance certificate) is a partof the product documentation.

2. Condenser design type (R):Client-provided air-cooled condenser (not a partof scope of delivery)Client-provided evaporative condenser (not apart of scope of delivery)

Hint!

Ensure a separate condenser is instal-led for each BluAstrum in case of anoperation with external condenser(version BluAstrum (R))! It is not per-mitted to operate multiple BluAstrumwith only one common condenser.

9.7.6 Oil separator

fig.22: Arrangement of the oil separator

The design of the oil separator is standardised and itis characterised by less oil carry-over.The oil separator is installed horizontally.

Hint!

The documentation of the oil separator(operating and maintenance instruc-tion, acceptance certificate) is a part ofthe product documentation.



9.7.7 Oil cooler

fig.23: Arrangement of the oil cooler

The oil cooler is used for cooling the oil heated in thecompressor in order to ensure sufficient oil viscosityfor supplying to the compressor. The oil temperatureis unregulated.The minimum possible oil inlet temperature issecured by a 3-way valve in the oil circuit.The oil cooler is complete piped on water side.

Hint!

The documentation of the oil cooler(operating manual, acceptance certifi-cate) is a part of the product documen-tation.

9.7.8 Suction filter combination SFC

fig.24: Arrangement of the suction filter combination SFC

The suction filter combination SFC contributes sub-stantially to the high working reliability of the compo-nents and the overall product.

The suction filter combination SFC prevents dirt par-ticles entrained in the intake stream from enteringthe screw compressor unit. The flow through the suc-tion filter element is from the inside to the outside. Itis designed so that monitoring is not required. The fil-ter element can be cleaned.

Hint!

The documentation of the suction filtercombination SFC (operating manual,acceptance certificate) is a part of theproduct documentation.

9.7.9 Switch cabinet with control

fig.25: Position of the switching cabinet

The switching cabinet with control device consists ofthe control with operating and display unit, indicatorlights for ”Running”, ”Warning” and ”Fault”, emer-gency stop button, coupling elements as well as thecasing.The switching cabinet with the control is directlymounted on the BluAstrum.

The control performs the following functions asstandard:

– Display of all important physical and technicalparameters, e.g. pressure, temperature, motorcurrent, capacity, number of run hours, operationmode and status signals

– Automatic start-up and shutdown of the BluAs-trum as well as capacity control depending onthe water (brine) outlet temperature

– Monitoring of all operating parameters




– Compressor capacity limitation, in case themeasured discharge pressure, suction pressure,cooling agent outlet temperature or motor currentindicate overload

– Fault memory with date and time

– Wire failure detection for all analogue input sig-nals

– Password protection for preventing unauthorisedaccess to important parameters

– Non-volatile saving of program

– Possibility of communication with master control-ler via MPI(optionally via Profibus-DP, Modbus RTU orModbus TCP)

– Remote access (optional via Ethernet)

Hint!

The communication guideline offersdetailed information about communi-cation of the GSC TP. The communica-tion guideline can be made availablebefore a planned installation.

9.7.10 Safety devices

The chiller is equipped with a comprehensive soft-ware safety chain preventing too high pressures,temperatures and the hazard of freezing.A suction as well as discharge pressure control anda rated current limitation control cause the Vi controlslide to move towards the minimum position when-ever the adjustable limit values are exceeded.Due to the applicable laws and regulations, variouscertifying bodies require a vast range of auxiliaryequipment with independent safety devices.Following safety equipment is included if the chiller isdelivered with CE label according to EN 378.

– Overflow valve (on the compressor) from dis-charge to suction side

– Double safety valve with pressure relief connec-tion

Hint!

The contractors must guarantee thatthe pressure relief connection is safelyoperated to the outside.

– Safety pressure limiter (2 independent switchingpositions with manual internal and external reset)

– Pressure relief device for each vessel, whichmight be contain liquid refrigerant (true for allvessels with a diameter > 152 mm and a volume> 100 litres). This is not valid for oil separatorsand oil filters.

The scope of delivery for the chiller does not includethe following safety devices in relation to escapingammonia:

– Protective equipment (health and industrialsafety)

– Gas warning device

In case of delivery according to EN 378 with CElabel, all parts of the documentation mentioned in theregulation are also delivered in the national languageof the place where the chiller is installed.All other approvals have to be agreed upon sepa-rately.



9.7.11 Monitoring and display of process values

The following operating parameters are continuously monitored and displayed by the control:

Name Remark

Suction pressure Suction pressure in bar (a) and the corresponding evaporation temperature in°C

Discharge pressure Discharge pressure in bar (a) and the corresponding condensation temperaturein °C

Oil pressure Oil pressure in bar(a)

Oil diff. pressure Oil differential pressure in bar

Oil filter pressure 1 Oil filter pressure in bar (a)

Oil filter differential pressure1 Oil filter differential pressure in bar

Suction temperature Suction temperature in °C

Discharge temperature Discharge temperature in °C

Oil temperature Oil temperature in °C

External temperature Secondary refrigerant outlet temperature in °C

Secondary refrigerant inlettemp. 1

Secondary refrigerant inlet temperature in °C

PS position 1 Position of the control slide in %

Motor current Motor current in A

Motor speed Motor speed in rpm

Heating agent inlet tempera-ture 1

Cooling medium inlet temperature into the condenser in °C

Heating agent outlet temper-ature 1

Cooling medium outlet temperature from the condenser in °C

Run hours Running hours

Slide to minimum Slide to minimum time in sec, remaining time for slide for reaching the minimumposition

Auto start delay Remaining time for auto start delay in sec.




Name Remark

Auto stop delay Remaining time (auto) for auto stop delay in sec.

Start to start Start to start, remaining time between two starts of the compressor in sec.

Stop to start Stop to start timer, remaining time in sec.

External temperature 1 External temperature in °C

1 optional

9.7.12 Fittings

The term fitting generally designates a control ele-ment of the machine. Among other things, the termfitting is also used for valves if these are used for thecontrol and regulation of fluid flows in the piping.Furthermore, all kinds of installations in piping, suchas sight glasses, measurement apertures, filters andsimilar are also designated as fittings. Therefore, fit-tings also include all kinds of valves, such as:

– Stop valves

– Check valves

– Safety valves

– Throttle valvesEach fitting has its own field of use, according to thepressure or temperature in the pipe, the size of thepipe, the sealing requirements for the fitting, thereduction and direction of the flow of liquid as well asthe medium itself.The safety fittings are used to limit the pressure insystems which are under pressure.Each fitting is designed for the specific application.The fittings can be operated manually or by motor,bygear motors, or pneumatic or hydraulic cylinders, forexample. In reset fittings, the flow of fluid in the pipecauses automatic closing of the valve.Depending on the model, different closing elements(e.g.valve discs, flaps, pushers) close the pipe con-nected to the fitting.

Hint!

The documentation of the fittings(acceptance certificates) forms part ofthe product documentation.

9.8 Components installed by the client

Warning!

The components and parts the cus-tomer installs in particular the secon-dary refrigerant and cooling mediumcircuits as well as the oil circuit needto made from materials suitable for thefluids flowing through them. Further-more, in the event of modifications tothe product by the customer, theeffects on the safety devices are to bechecked.GEA Refrigeration Germany GmbHdoes not assume any liability for dam-age arising and the violation of thesafety regulations which result fromthe use of unsuitable materials orthrough modification to the productwhich is not considered in the originalsafety concept.

9.9 General functional description

BluAstrum chillers are used for the cold water or coldbrine cooling for climate control or for industrial pro-cesses.The chillers are assembled and inspected at themanufacturer's factory and are intended for insideinstallation in machine rooms. The BluAstrum isoptionally equipped with a casing for noise reductionand as protection against physical contact.The BluAstrum chillers are automatic refrigerationsystems with screw compressors and flooded plateevaporators to cool the cooling agent. Water andbrines can be used as cooling agents.Equipped with the Grasso screw compressor series,the BluAstrum chillers cover the refrigeration rangeof 600 to 1800 kW for cold water.



The chillers are especially designed for operationwith ammonia (NH3, R 717) as the refrigerant.

Hint!

Recommendation: Consultation withGEA Refrigeration Germany GmbHwith regard to corrosion protection forspecific individual cases.

9.10 Refrigerant circuit

The screw compressor draws refrigerant gas fromthe liquid separator and compresses it to condensa-tion pressure.The refrigerant liquefies as it is cooled and is expan-ded in the combined evaporator/liquid separator.Here, the refrigerant vapour and liquid are separa-ted.The liquid is led through the evaporator by gravitycirculation (thermosiphon principle). As a result ofthe liquid refrigerant absorbing heat (flooded evapo-ration), the refrigerant evaporates and the coolingagent is cooled down.During the operation of the screw compressor, oil isinjected into the working chamber and then separa-ted again from the refrigerant in the pressure side oilseparator.The oil that was heated in the compressor is cooledto inlet temperature in an oil cooler prior to injectionin the compressor.Despite the effective oil separation system, oil pene-trates to the low pressure side of the chiller.A special automatic and maintenance-free oil return-ing system developed by GEA Refrigeration Ger-many GmbH returns the oil from the liquid separatorback to the screw compressor.This is a basic precondition for fault-free operation ofthe evaporator system.

9.11 Oil circuit

The screw compressors operate oil-flooded. Duringthe compression process, refrigerating machine oil iscontinuously supplied to the compressor for lubrica-tion, sealing, noise reduction, and absorption of partof the compression heat. After the compression proc-ess, the oil is separated from the refrigerant as far aspossible again in the oil separator. In the next stage,the remaining oil content in the refrigerant is fed backfrom the liquid separator/evaporator.

9.11.1 Oil heater

The oil heater on the oil separator is to be startedwhen the package is shut down in order to ensure aminimum oil temperature and sufficient oil viscosityrequired for restarting the package. The oil heating isnot regulated. The maximum temperature of theheating rod is restricted.




9.11.2 Oil Cooling

Before it is returned to the compressor for use, theoil heated up in the compressor has to be cooleddown to a temperature at which it has sufficient vis-cosity.The liquid-cooled oil cooler is also supplied with thecooling medium. To do this, the oil cooler is alreadypiped on the liquid side. The use of liquids deviatingfrom the cooling medium for the oil cooling can onlybe permitted on request.

9.11.3 Oil filter

After cooling, the oil enters the oil filter which retainssolid particles from the entire oil flow.Due to its large surface, the star-folded glass fibreelement has a high absorbing capacity and thus along operating lifetime. The filter has a relative filterfineness of 25 µm.

9.11.4 Oil return from the low pressureside

In spite of a very good oil separation in the oil sepa-rators, oil will always reach other parts of the plant.For returning the oil from the liquid separator, thechiller is equipped with a special automatic oil returnsystem. The automatic oil return system works with adraining vessel and two solenoid valves as standard.

1. Filling the draining tank (2300)A refrigerant/oil mixture is drained from anappropriate point between the liquid separatorand the evaporator and led to the draining tank.To this end, a solenoid valve (2305) is opened.

2. Evaporation of refrigerantThe solenoid valve (2305) is closing. Perhapsexisting liquid refrigerant can evaporate in thedraining vessel by taking up the surroundingheat. The evaporation time is restricted by thecontrol.

3. Expelling oil from the draining vesselAfter the evaporation period, hot gas is led viathe solenoid valve (2310) into the draining vesselfor a short while and this pushes the oil into thesuction nozzle of the chiller.The oil draining cycle is actuated by the control.The control time parameters for the solenoidvalves can be set at the control panel.

In the case of high-pressure applications, both sole-noid valves can be replaced by a joint motor valve.

9.12 Capacity control of the compressor

The capacity control of the compressor is carried outeasily and efficiently by means of a frequency inver-ter (speed 1000 - 4500 rpm).Corresponding to this speed band and independentof the operating conditions, the compressor can beinfinitely regulated in the performance range ofapprox. 25 - 100 % and according to the require-ments of the control.Due to the speed adjustment with frequency inverter,the rotor pair of the compressor is fully charged evenduring part-load operation. The compressor does nothave a control slide, only a Vi slide.Depending on the back pressure (evaporating tem-perature), the outlet opening on the compressor isoptimally adapted to the respective operating condi-tions using this Vi slide.

Hint!

For details of the control process, seedocumentation of the control.



9.13 Level control of the evaporator

Hint!

This type of level control is applicable air cooled condensers and evaporation condensers.

Caution!

The level indicators in the vessel are supplied loose and must be installed in-situ prior tostart-up.In doing so, follow the instructions given in the manufacturer's documentation for the levelindicator in order to ensure proper installation.The documentation for the level indicator is part of the product documentation.

The liquid refrigerant is injected into the evaporator via an electronic expansion valve. The level in the evaporatoris evaluated to control the expansion valve. A vessel with a level indicator is installed on the evaporator for thispurpose.The level is determined with the help of the weight of a rod (measuring body) suspended freely in the liquidrefrigerant. The weight of the rod is measured with the help of a spring balance. It is reduced by the uplift (buoy-ancy). The uplift is a function of the immersion depth of the rod and thus, the level of the liquid present in theevaporator.If the measuring body hangs in the gas space, it is then not immersed in the liquid. Thus, the uplift is equal tozero and the force measured is equal to the weight of the rod including the chain. The measured value is 4 mAand this is then defined as the 0% level.If the upper edge of the measuring body meets the liquid surface or if the upper edge of the measuring body ismore or less covered by liquid, the spring balance measures the weight minus the maximum uplift. The meas-ured value is then 20 mA and the level height is defined as 100%.In other words, with the construction selected, with a measured value of 0% the tank may be up to 33% full (seeFigure)!

fig.26: Position of the vessel and level indicator on the evaporator type 6HH (black), 5HH (red) and 4HH (blue)

1 Chain length

2 Measuring range




Measured value sensor in the vessel

Rod length (= measuringrange) 750 mm

Chain length 100 mm

Setting values for the level indicator

Evaporator tank 6HH 5HH 4HH

Setpoint for the middle of the tank 31 % 24% 20%

Value of the end of the measuring range until the setpoint is atthe middle of the tank 235 mm 180 mm 150 mm

Setpoint 20 mm above the middle of the tank 29% 21 % 17%

Value of the end of the measuring range until the setpoint is20 mm below the middle of the tank 215 mm 160 mm 130 mm

Alarm shutdown, max. level 30 mm above the middle of thetank 35 % 28% 24%

XP = 20 %

TN 0 40 s

9.14 Technical specifications

9.14.1 Basic terms

Refrigerant Materials circulating in a plant (liq-uid or gas), which by means oftheir change of state of the pack-age withdraw heat from anothermedium (cooling or heating agent)or can dissipate heat to thismedium.

Cooling agent Fluids that can absorb the heat ofa system and dissipate it to arefrigerant (reversible process)and are used for the cooling of asystem (industrial process)

Heatingagents

Media (liquid or gas) that, fore-xample, transport and dissipatethe absorbed heat. If water is usedas the heat carrier, the termswarm water or cooling water arealso used.

Performancetest

Factory acceptance test (FAT),test run of the chiller under operat-ing conditions (refrigerant NH3) atthe plant's production facility.

9.14.2 Operating media

9.14.2.1 Refrigerant

The chiller is exclusively operated using ammonia asthe refrigerant. All components of the chiller aredesigned for the use of ammonia as the refrigerant.



Hint!

The safety data sheet for the refriger-ant used must be observed. The safetydata sheet is part of the product docu-mentation.

9.14.2.2 Refrigeration machine oils

Caution!

In order to ensure an adequate load-bearing capacity of the sleeve bear-ings and to ensure the service life ofthe roller bearings, a minimum viscos-ity of 7cSt upstream of the compressoris required. A suitable oil must becarefully selected in consideration ofthe operating conditions.The selection criteria and selectiontables are summarised in the technicalinformation "Lubricant oils for screwcompressors". This technical informa-tion is part of the product documenta-tion.GEA Refrigeration Germany GmbH canprovide assistance in the selection ofa suitable refrigeration machine oil onrequest.

Recommended oil type:CPI1009-68, Klüber SummitR100 and Klüber Summit R200Please contact the manufacturer in case of othertypes of oil.

9.14.2.3 Secondary refrigerant

• Water, non corrosive, maximum 200 ppm Cl

• Approved brines:

– Ethylene glycol based

– Propylene glycol based

– Tempering

– NH3 solution

Hint!

Prior to their use, compatibility withthe materials used must be ensuredfor other secondary refrigerants.

9.14.2.4 Heating agents

• Water, non corrosive, maximum 100 ppm Cl

• Approved brines:

– Ethylene glycol based

– Propylene glycol based

– Tempering

Hint!

Prior to their use, compatibility withthe materials used must be ensuredfor other cooling media.

If brines are used as the heating agent in the con-denser, it must also be checked whether the inhibi-tors remain thermally stable at the desired tempera-tures.

Hint!

Since the water quality can vary veryconsiderably, we recommend thateach user consults a corrosion protec-tion specialist for his particular case.

Warning!

Prevent the boiling of the heatingagent in the condenser! The operatingpressure of the heating agent mustalways be above the respective boilingpressure of the heating agent whichcorresponds to the medium tempera-ture. The inlet temperature on theammonia side of the condenser is sig-nificant for this temperature and pres-sure.




Example

Heating agent water:

Inlet tempera-ture 30°COutlet tempera-ture 35°C

Screw compressor: Tc = 37°C

Inlet temperature of refrigerantgas in the condenser: 95°C

Operating pressure to be com-plied with on the water side: 1.0 bar abs.

9.14.3 Materials used in heat exchang-ers

In order to assess the corrosion behaviour of thecomponents that are in contact with the coolingagent or with the heating agent, the plate materialused for the heat exchanger plates is instrumental(standard plate material is AISI 316). Their type isdesignated in the “Technical Specifications” for therespective order.



10 OPERATION LIMITS

The Grasso BluAstrum chillers (flooded evaporation) can be operated under the most varied operation condi-tions within the given limits of application according to the requirements involved. The limits of application listedbelow are based on the operational principle of the Screw Compressor, thermodynamic relations, used vesselsand safety devices and practical operating conditions. The appropriate Compressor model design should beselected for the particular operating conditions.

Refrigerant NH3

Speed n min-1 min 1000

max 4500

Suction pressure p0 bar (a) minmax

1.97.3

Outlet temperature of water as sec-ondary refrigerant

tWA °C minmax

+ 2.5+ 15

Outlet temperature with frost-resist-ant secondary refrigerants

tWA °C minmax

- 15+ 15

Discharge pressure p bar (a) minmax

7.319.3

Condenser inlet temperature ofcooling medium

tKwe °C minmax

1240

Condensing temperature t °C minmax

1554

Discharge temperature at compres-sor outlet

t1 °C minmax

50100

Pressure ratio (p/p0) π - min > 1.5

Pressure difference (p-p0) 1 Δp bar min 3 2

Notes

1. When considering a specific application, all theconditions specified in the table must be takeninto account and adhered to.

2. If the specified limits are exceeded for a specificapplication, the manufacturer must be consulted.

3. In addition to the operation limits given in thetables, consider the operating conditions whichmust be observed for the compressor (e.g. start-

up regime, oil pressure, oil quantity, type of oiletc.).

4. The oil temperature at the compressor inlet mustbe least 18°C.

5. The specified data refer to the operating condi-tions of a cooling or air-conditioning system.During downtime or start-up, the limiting valuesmay be exceeded or fallen short of for a short(never //long-term) period of time.


Operation limits


1 The given pressure difference ensures reliablecompressor operation. Furthermore, allowance mustbe made for the pressure difference necessary forthe control valves fitted in the refrigerating plant.2 To comply with the minimum pressure difference,we recommend customer to provide a water-side 3-way valve.

Operation limits Operating Manual | Grasso BluAstrumChiller with Screw Compressors


11 START-UP

11.1 Important information for start-up

Warning!

Contact with live components is pro-hibited.

Hint!

The customer service department pro-vides comprehensive support for thestart-up of the chiller. For contactdetails, please refer to the chapterentitled "Technical customer service".

Warning!

Start-up of the chiller must be only becarried out by trained and qualifiedpersonnel who are familiar with thecontents of the operating manual.The safety regulations for the refriger-ation plant must always be observedin order to prevent damage to the com-pressor unit and injury to operatingpersonnel.

The chillers are tested and accepted at theworks. By the time these chillers are delivered tothe customer, the following work will have beencarried out:

• Complete installation of the cooling system andin particular:

– Cleaning and drying of the refrigerant and oilcircuit,

– Leak test with air,

– Evacuation of the refrigerant circuit and fillingwith protective gas to a pressure of 0.3 to 0.5bar (above atmospheric pressure),

• Electrical wiring and testing,

• Factory setting of the setting values on the con-trol cabinet,

• Factory setting of the safety and monitoring devi-ces,

• Works trial runs (at the request of the customer).The following points must be observed beforecommencing with the start-up:

• Check of the external condition of the chiller(check of insulation, transport damage, protec-tive gas filling, etc, ... ).

• Check that all electrical work has been carriedout in accordance with the standards (e.g.protec-tive earth, insulation, shielding, covers). If neces-sary, an earth connection must be provided.

• The area around the machine in which the start-up is carried out must be marked and securedagainst the access of unauthorised persons. Suf-ficient lighting of the working area must beensured to prevent personal injury and materialdamage.

• Operating and functional capability of themachine room equipment (air extraction andventilation).

• Personal protection gear (work clothing, workboots, gloves) must be worn during all work onthe chiller. There is a danger of impact and stum-blingfrom protruding parts on the chiller (e.g.valve caps). There is also a danger of cutwounds on sharp edges and rough surfaces. Allactivities must therefore be carried out with par-ticular attention.

• Suitable hearing protection must be worn inorder to protect against damage to hearing ordeafness.

• Thermal hazards resulting in injuries due toburns or freezing may occur on contact withparts of the system which are at a very high orvery low temperature. Personal protective equip-ment must be worn.

• Suitable tools or special tools must be used.

• The direction of rotation of the drive motor mustbe checked.

– before start-up, i.e. before you connect thevoltage supply to the chiller switching cabi-net, check that the coupling between thedrive motor and compressor is disconnected.Otherwise, the coupling intermediate piecemust be disassembled in accordance withthe assembly instructions.

– It is essential to ensure that the compressordrive motor cannot be started inadvertently.


Start-up


– Check that the required direction of rotationcomplies with the direction of the arrow onthe compressor or the details in the com-pressor documentation.

– In "MANUAL" operating mode, the compres-sor drive motor is started in a star-delta con-nection and is then switched off.

– Change the direction of rotation of the motorif this is not correct!

– The electrical switchgear must then besecured again to prevent it from beingswitched on inadvertently. Mount the cou-pling while following the instructions of theseparate documentation.

Danger!

Solid mounting of the coupling protec-tion must be checked. Start-up mustnot be carried out with the couplingprotection mounted.

• Pipes and pipe sections must be secured toensure sufficient mechanical strength. The pipesand equipment parts of the chiller must not bestepped on.

• Operating media (nitrogen, oil, refrigerant) canescape. Preventive measures must be taken tocollect and dispose of them in an environmen-tally responsible manner (e.g.using an oil pan).Personal breathing protection must be keptready in the event of a refrigerant leak. Thesafety data sheets of the oil and refrigerant usedmust be read prior to commencing start-up work.Familiarise yourself with the evacuation plan ofthe installation location.

• Check the protective gas filling (a positive pres-sure ≥ 0.2 bar must be present)

Hint!

If defects are found, notify Service andproceed according to their instruc-tions.

11.2 Basics

The compressor must only be switched on when thechiller has been correctly connected and chargedwith operating materials.The activities described in this chapter "Start-up"must be carried out in the prescribed sequence.

The chiller is operated via the control panel (TouchPanel) of the control.After the setpoints have been entered, both auto-matic and manual operation are possible.The software of the controller and operation via theterminal are described separately in the operatingmanual for the control system.

11.3 Connecting the chiller

Caution!

All mechanical connections must bemade according to the P+I diagramwhich is valid for the project. The P+Idiagram is part of the product docu-mentation.

Caution!

All electrical connections must bemade according to the circuit diagramwhich is valid for the project. The cir-cuit diagram is part of the productdocumentation.

Check that components which have been removedfor transport, separately supplied components andcomponents provided by the client are firmlyattached.Check that all screws are tight.

11.4 Connecting the pipes

The protective gas filling of the chiller must bepurged by opening the vent valves on the suctionside before the connection of the pipes.All pipe connections must be made in such mannerthat the transmission of thermal expansion and vibra-tion to the chiller is limited as far as possible.Bellows-type expansion joints made of steel, or flexi-ble metal hoses can be used for refrigerant and oillines, bellows-type expansion joints made from rub-ber can be used for water connections.All pipe connections must be provided with anchorpoints immediately next to the chiller.

• Connection of:

– Secondary refrigerant

– Heating agents

Start-up Operating Manual | Grasso BluAstrumChiller with Screw Compressors


• If chillers are subject to acceptance by TÜV (theTechnical Surveyance Board), then also: con-nect safety valve to the blow-off line

Caution!

The chiller requires a constant flow ofsecondary refrigerant and heatingagent for smooth functioning.

Hint!

In principle, all the connections mustbe made in accordance with the P+Idiagram applying to the respectiveproject. Attach the pipes to the chillerin such a way that it does not imposeany additional static or dynamic loads.All the pipes and systems to be con-nected must be checked for leakswhen the work is complete.

11.5 Water pipes

The chiller is mounted on vibration isolators whichmeans that the connections of the water piping mustbe flexible.Charging and draining must be possible.

Hint!

Check the water quality.

The pipes must be flushed before connecting. This iscarried out to remove soiling, foreign particles andwelding residue from the system.

• Secondary refrigerant systemAfter the chiller has been aligned, its secondaryrefrigerant side can be connected up. The pipingsystem for the secondary refrigerant connectionsmust be installed on site by the plant engineer.Please refer to the drawing in the supply docu-mentation for the dimensions and position of thewater connections to the evaporator.The evaporator must be connected to a closedsecondary refrigerant circuit on the pressure sideof the pump.Arrange a dirt collector immediately upstream ofthe evaporator (recommended mesh size 0.9mm).The volume flow of secondary refrigerant shouldbe kept at a constant level.

Temperature sensor item 2040 for measurementof the outlet temperature and optional item 2045for measurement of the inlet temperature of thesecondary refrigerant are delivered loose with aseparate welded sleeve and are, like the flowmonitor item 2050, to be installed into the pipe-line system by the installer.The flow switch can only be installed in a hori-zontal pipe, or a vertical pipe with a flow runningin an upward direction. The flow monitor must beinstalled in a distance of 5 to 10 times of pipediameter behind the previously flowed curve orvalve. The outlet run must equal 3 to 5 times thepipe diameter.If an electronic flow sensor is installed in a hori-zontal pipe, this must be carried out laterally. Inthe case of installation from above, the pipe tobe monitored must be completely filled. In thecase of installation from below, contaminantdeposits will falsify the measurement.Between the secondary refrigerant - outlet tem-perature from the evaporator / chiller and thetemperature controller item 2040 there should beat least 2 m of pipeline and two 90° changes ofdirection installed via pipe elbows or fittings. Ifthe temperature sensor item 2040 is installedimmediately downstream of the flow monitor item2050, then a clearance of 5 to 10 times the pipediameter must be allowed for.The cabling of the temperature sensor and flowswitch must be carried out with an additionalcable length of 6 m measured from the liquidcooler outlet.


Start-up


fig.27: Secondary refrigerant system

2000 Evaporator/liquid separator

2040 Resistance thermometer - secondary refrigerantoutlet temperature

2045 Resistance thermometer - secondary refrigerantinlet temperature

2050 Flow switch

• Heating agent systemThe size and position of the water connectionsfor the condenser are indicated in the drawingcontained in the order documentation.Install the condenser on the pressure side of thepump.Arrange a dirt trap immediately upstream of thecondenser (recommended mesh size 0.9 mm).Optionally temperature controllers to measurethe cooling medium inlet temperature (item2145) or cooling medium outlet temperature(item 2140) in heat pump applications areoffered in the standard controlled variables. Thetemperature controller including the weldedsleeve are delivered separately and the installerwill install them in the pipe system.Check the water quality.

• Water treatmentIndustrial water usually contains dissolved orsolid matter that causes corrosion or dirt layersto develop or encourages the growth of algae.The water for the condenser and evaporator cir-cuits should be treated chemically to minimisesuch undesirable effects. In order to avoidincreasing maintenance costs as a consequenceof additional applications for removing dirt layersor exchanging corroded components, a watertreatment specialist should be consulted.

11.6 Electrical connection

Danger!


The chiller has been designed for plug-in and reliableautomatic operation.All connections must be carried out according to thecurrent installation regulations.Connections to the chiller must be flexible and free ofloads.

Hint!

Dimensioning of the inlet pipe cross-sections must be according to DINVDE 100 Part 520.

Before starting work, make sure that all parts to beconnected are de-energised, e.g. by removing themain fuse in all phases or installing a jumper wire.The insulation resistance of the electrical tools andfixtures and wiring is to be checked. The connectionmay only be undertaken if this value lies in the allow-able range.Connections and almost all external connections arepre-wired at the factory.

Warning!

Produce the earth connection accord-ing to the designation in the generalassembly drawing. See chapter "Des-ignation of the earth connection".

The electrical consumers and sensor must be con-nected according to the circuit diagram. All electricalconnections must be made according to the circuitdiagram, e.g.

– Compressor drive motor

– Compressor control supply

– Oil heater

Hint!

Some external components, such asthe second EMERGENCY STOPswitch, the ammonia sensor and thefans of the machine room, must beconnected by the system erector onsite.Check that terminal screws (in theswitching cabinet) are tight.



11.7 Paint and insulation

Damage to the paint and insulation during transportand installation must be carefully repaired.

PaintingCoating system S 2.15 acc. to EN ISO 12944-5 forenvironmental conditions C2 acc. to EN ISO12944-2.Designed for room temperatures of 5 °C up to 40 °C.Colour of chiller paintwork: RAL 5014 dove blueColour of control cabinet paintwork: RAL 7035Colour of casing paintwork (optional): RAL 7035 lightgrey

InsulationStandard insulation with housing for suction line andevaporator in 19 mm Armaflex.Standard insulation without housing for cold systemcomponents in PUR/Alu.The insulation is basically designed for an ambienttemperature of 20 °C and a humidity of 70 %.

11.8 Start-up procedure

The following procedures should be completed in thesequence in which they are described:

11.8.1 Checking the electrical connec-tion

Danger!


Check that all electrical work has been carried out inaccordance with the standards (e.g.protective earth,insulation, shielding, covers). If necessary, an earthconnection must be provided.

11.8.2 Leak test

Hint!

See type plate for permissible operat-ing pressure.

The necessary safety precautions should be takenbefore performing the leak test.An approx. 3-hour pressure drop test with dry nitro-gen is used for the test. Test pressure: 7 bar

A pressure drop of 2% is allowed during the 3 hours.Fluctuations in the ambient temperature must betaken into account.

Caution!

Checking devices which could bedamaged by the specified test pres-sure must be removed or blockedbefore the leak test is performed.

A record should be kept of the pressure test, notingthe pressure in the pipes tested, the ambient temper-ature and the outside temperature in the shade athourly intervals.The removed measuring and control instrumentsshould be reinstalled after completion of the leak testand if there are no leaks in the package/chiller.

Test strategyDry nitrogen is used as the test medium. After reach-ing the test pressure, the pressure drop is measuredvia the differential pressure measurement. This mayonly change by 0.02 bar within an hour. If the displaydevice does not indicate a leakage through foam for-mation, the system is sealed.

Testing devicesA pressure gauge with an accuracy of 0.5% over theentire measuring range, with a digital resolution of0.01 bar must be used for the measurement.The testing described here is based on pressuregauges with pressure gauge and LEAK mode fromKeller.

Display devicesA foaming agent must be used as the means to indi-cate leakages. A solution of 50 parts water and 1part detergent can be used as the foaming agent.Leaks are detected through formation of foam. Aleak detection spray can be used in problem areas.

Carrying out the test

1. Wet all connecting joints (welded seams, flangeconnections, screw fastenings, etc.) with foamingagent. Remedy any leaks detectable from thenoticeable formation of foam.

11.8.3 Drying, vacuum

After the leak tightness test has been completed, theplant must be evacuated and undergo a vacuum testfor 3 hours. Evacuation is used to remove air andmoisture from the plant.A vacuum pump must be used for evacuation.


Start-up


The permissible increase in vacuum is maximum6.66 mbar over a period of 3 hours.

fig.28: Vacuum required to remove moisture from refrigeratingplants

X Room or Wall temperature in °C

Y Vacuum in mbar

A Vacuum required to remove moisture fromrefrigerating plants

Measured values have to be checked and recordedhourly after reaching the required vacuum. After thevacuum pressure, the temperatures in the machinehouse and the outdoor temperature in shade mustbe entered in the log. After the vacuum test, thepressure compensation must be carried out withNH3.

Warning!

Shut the oil pump during evacuation!

See also "Evacuation on refrigerant side" in thechapter "Maintenance work".



11.8.4 Operating position of valves

For the positions of the manually controllable fittings for the operation of the package/chiller, see the P+I dia-gram.The layout and symbols used in the P+I diagram comply with the specifications of EN 1861, July 1998 Issue.

Caution!

The valves must be in operating position prior to the start-up of the package / chiller. Trouble-free operation is only possible in this manner!

fig.29: Stop valve open

Stop valve open during normal operation

fig.30: Stop valve closed

Stop valve closed during normal operation

fig.31: Check valve

Check valve during normal operation

fig.32: Shuttable check valve

Shuttable check valve open during normal operation


Start-up


fig.33: Control valve

Control valve adjusted:

– Start-up

– when operating conditions change

fig.34: Shuttable check valvewith integrated control function

Shuttable check valve with integrated control function open dur-ing normal operation

fig.35: Solenoid valve

Controlled by the controller (e.g. GEA Omni)

fig.36: Change-over valve

Change-over valve (3-way valve), opened from below in arrowdirection

fig.37: Oil pressure control valve

Operating position: shutΔp x,x ± x bar control pressure to be set vis-à-vis reference pres-sure (see P+I diagram)

Caution!

An oil pressure being set too high or too low may result in serious compressor damage oreven the total breakdown of the compressor after just a short period of operation!



fig.38: Overflow valve, safety valve

Overflow valve, safety valve

fig.39: Pressure controlled check valve

controlled self-sufficient

fig.40: Quick acting valve, spring-loaded

manually operated if necessary

fig.41: Charging valve, drain valve

– ½” connections

– with cap

fig.42: Service valve

– Connection Rp ¼”

– For pressure gauge and pressure transmitter


Start-up


fig.43: Oil temperature limiter

controlled autonomously using control element

fig.44: Temperature controlled control valve

Autonomous control via sensor

11.8.5 Oil charge

Caution!

Check the oil type to be filled! Seecontract / project or recommendationof GEA Refrigeration Germany GmbH.

The vacuum present in the screw compressor pack-age/chiller before pressure compensation may beutilised for charging the package with oil. A separateoil charging pump is required after the pressure com-pensation and for refilling with oil.The stop valve oil draining or oil filling (090) must beconnected with the oil charging tank.Before charging with oil, switch the valves to theoperating position.Open the stop valve (090) until the oil level hasreached the top third of the sight glass assembly inthe oil separator sump. During operation of the pack-age, the oil level should only reach the lower third ofthe sight glass assembly.The oil separator is generally charged with oil via theoil cooler.When charging with oil for the first time, oil must alsobe charged via the service valve (135) too. To thisend, the stop valve (065) must then be closed.

Caution!

Due to the use of selected compo-nents, the refrigerating machine oilstend to absorb more moisture. There-fore, when charging a compressor theoil should be allowed to come intocontact with air for a short time only.The contents of an opened drum haveto be used up within one working day,provided the drum is properly closedbetween charging.

11.8.6 Pressure compensation with thecooling system

Re-establish the vacuum. Carry out pressure com-pensation via the service stop valve (285).

11.8.7 Checking the fault monitoring

1. Disconnect the incoming feeder of the compres-sor driving motor from the supply mains forchecking the safety devices (e.g. removeLV/HBC fuse links).

2. Apply voltage to the control.



3. Check the built-in pressure transducer andresistance thermometer for correct wiring.To do so, loosen the relevant contacts. The mes-sage "Broken wire <sensor XXX>" appears onthe display of the control. Check that the displayis correct after the contact has been re-estab-lished.Further information can be found in the con-troller manual.

4. Check limit values.Limit value = see parameter list

5. Switch on the chiller from the controller.

6. Set the motor current limitation acc. to nominalmotor data. See parameter list!

11.8.8 Adjustment of oil pressure

(for external oil pump)The correct oil pressure must be set in the "Parame-ters" menu of the control before the compressordrive motor and the screw compressor package/chiller may be started.Setting value = see parameter list

Warning!

Oil pressure which is set too high ortoo low may result in serious compres-sor damage or even total breakdownof the compressor after even a shortperiod of operation!

During operation, the regulation of the oil pressure iscarried out fully automatically by the speed control ofthe oil pump. Slight deviations of the displayed oilpressure are normal during the switch-on phase ofthe compressor.

11.8.9 Checking the direction of rotationof the drive motor

Warning!

The coupling must not yet connect themotor and compressor!

– Secure the electric switchgear so as to preventthe compressor drive motor from being switchedon accidentally.

– With the control slide in the MIN or MAX position,it should be possible to rotate the compressorshaft easily and smoothly by hand. When check-ing the direction of rotation of the compressordriving motor pay attention to the conditions forswitching the compressor on.

fig.45: Motor direction of rotation

A Compressor

B Motor

– The compressor drive motor is started directlyand then switched off again by forcing the digitaloutputs.

Hint!

Prior to the start-up of the compressordrive motor, the manufacturer's infor-mation, e.g. on the lubrication of themotor, must be followed at all costs.

– If the direction of rotation of the motor is incor-rect, it should be corrected while the electricswitchgear is secured to prevent the motor frombeing switched on accidentally. Then the motormust work for at least 1 hour, unencumberedand free from errors. This is important in order todry out residual moisture in the motor (causedduring transport or storage).

– The coupling protection must be in place duringthis start-up period as required by the laboursafety regulations.

– After checking the direction of rotation of thedrive motor, the coupling may be connected withthe motor.

11.8.10 Mounting the coupling

1. The electric switchgear is secured to prevent itfrom being switched on accidentally.


Start-up


2. Mount the coupling while observing the instruc-tions of the separate documentation.

3. The values for radial and angular deviationsgiven in the coupling documentation must bechecked and corrected if necessary. The axisdistance between the compressor drive motorand the compressor must be checked.

4. The real values have to record at data sheet ofcoupling documentation. Please send back acopy of the filled data sheet to:GEA Refrigeration Germany GmbHHolzhauser Straße 16513509 BerlinFax: +49 (0)30 - 43 592 759

Caution!

Observe the maintenance instruction!Regrease the coupling at the prescri-bed intervals if scheduled in the main-tenance instruction for the coupling!

11.8.11 Checking the water circuits

Check that the cooling and cold water pumps arerunning and the shut-off fittings in the cooling watercircuit are in their operating positions.If a cooling water controller is installed, this must beset under project conditions so that the condensingand oil temperature lies within the allowable range.

11.8.12 Charging refrigerant

Warning!

In order to charge the refrigerant, thecompressor must be ready for opera-tion!

1. Connect the refrigerant reservoir to the fillingvalve.

2. Open the charging valve.

3. Carefully open the container valve and perform apressure compensation.

4. Close the valve.

5. Check the plant for leaks again.

6. Start the compressor.

7. Open the container valve.

8. Draw refrigerant into the circuit at a low com-pressor capacity.

9. Close the reservoir valve when the suction pres-sure nears the required values. Let the compres-sor continue to run until the refrigerant has beencompletely distributed in the circuit. Based on thevalues, you can now assess whether additionalrefrigerant has to be charged or not.

Hint!

If necessary, repeat refrigerant charg-ing until suction pressure reaches therequired value.

10. In case of a separate refrigerant circuit for oilcoolers:Keep the injection valve into the compressorclosed to increase the discharge temperatureduring the filling process in order to betterassess the refrigerant quantity in the oil circuit.

11. After the charging process has been completed,close the charging valve and cylinder valve.

12. Drain and dismantle the charging line.



11.8.13 Initial startup

On completion of the work described above, thechiller can be started up in accordance with the oper-ating instructions for control (GSC TP).

1. Switch on the control voltage of the compressorcontrol device.

2. Remedy and acknowledge existing fault mes-sages.

3. Select operating mode "Manual + Manual (1)".

4. Switch on the chiller.

11.8.14 Checking the oil cooler

Oil cooling with refrigerant-cooled oil coolerNo regulation or inspection necessary.

11.9 Start-up after long standstill periods

1. Inserting the main fuse

2. Switching on the control unit according to theoperating manual.

3. Checking all parameters on the control unit dis-play. See parameter list.

4. Checking the settings of all control and safetydevices.

11.10 Restarting after approx. 1 yearstandstill

• Change the oil filter inserts (see maintenanceinstruction).

• Switch on the oil heater at least one hour beforestarting the screw compressor package/chiller.

• Open the stop valve on the suction side and thepressure side (or check valves which can beshut off).

• If fitted: Open the stop valves (or shuttable checkvalves) in the suction line of the economiser.

• If fitted: Open the refrigerant supply to the ther-mosyphon - oil cooler.

• If fitted: Open the manual stop valve of the refrig-erant injection.

• Remove all non-condensable gases by venting.To this end, check the condensing pressure andtemperature (see parameter list).

• Check the oil collection sump and drain if neces-sary.

• Switch on the compressor and observe the oper-ating instructions of the electrical switchgear.Make a screw compressor package/chiller testrun in order to test the sensor and actor technol-ogies (for operation and indicating precision).


Start-up


12 OPERATING THE CHILLER

12.1 Important information for the opera-tor

The chiller must be only be operated by trained andqualified personnel who are familiar with the contentsof the operating manual for Grasso liquid chillers.The safety regulations for the refrigeration plant mustalways be observed in order to prevent damage tothe compressor unit and injury to operating person-nel.

Hint!

The chiller is operated via the controlpanel of the control. In the event thatthe Grasso GSC TP control is con-tained in the scope of delivery, theoperating personnel must have knowl-edge of the contents of the completedocumentation for the control. Thedocumentation for the controller ispart of the product documentation.

12.2 Requirements for switching on

The chiller has been designed for automatic opera-tion; the control controls the switching of the com-pressor and its capacity adjustment.There is no need for constant adjustment and obser-vation of the system in automatic operation. The nec-essary steps for switching on the chiller are given inthe documentation of the control.If the chiller is controlled manually, it must be oper-ated from the refrigerator room. In particular, therepair and maintenance instructions must be com-plied with.The following prerequisites must be fulfilled forswitching on the chiller:

1. The main current must be available and switchedon.

2. The chiller must be sufficiently filled with refriger-ant and oil.

3. The valves must be in their operating positions.

4. The oil level in the oil separator must be withinthe allowable range.

5. The cooling and cold water pumps must be inoperation.

6. The supply of cooling water or coolant to the oilcooler must be ensured.

7. The oil must be sufficiently heated by the oilheater in the oil separator.

Hint!

The oil heater can be energised whenthe chiller is shut down. It is then auto-matically switched off when the chilleris started and switched on when it istaken out of service. If the ambienttemperature is below 5°C, the oilheater must be switched on at leastone hour before the compressorchiller is started.

8. The rated current limitation has been set accord-ing to the motor rating.

® The chiller can be switched on according to theoperating manual of the control.

Operating the chiller Operating Manual | Grasso BluAstrumChiller with Screw Compressors


12.3 Overview of the operating modes

Modes Signal for …

Name Remark Start/Stop Capacity +/-

0 Service Oil pump by itselfCompressor motor blocked

1 Manual+ Manual

Manual control via Touch Panel (TP) Manual Manual

2 Manual + Auto Manual Start/Stop via TP and full automatic localcapacity control

Manual Auto

3 Auto + Auto Full automatic start/stop and local capacity control Auto Auto

4 Remote+ HW (cont)

Start/stop and capacity demand via digital contacts(hardware) from a remote master controller. The GSCTP derives from the continuous +/- signals the pulsesfor capacity (indirect).

External Externalcontinuous

5 Remote+ HW (pulse)

Start/stop and capacity demand via digital contacts(hardware) from a remote master controller. The mas-ter also generates the +/- signals as pulses for control-ling the slide capacity directly.

External Externalpulses

6 Remote+ HW (loc.SW)

Start/Stop from a remote master controller via digitalcontacts (hardware). The GSC TP controls the outputdepending on a local setpoint (TP) and from this set-point also automatically switches the product ON/OFF.

External+ setpointdeviation

LocalSetpoint

7 Remote+ HW (ext.SW)

Start/Stop from a remote master controller via digitalcontacts (hardware). The GSC TP controls the outputdepending on an external setpoint (analog input) andfrom this setpoint also automatically switches theproduct ON/OFF.

External+ setpointdeviation

RemoteSetpoint

8 Remote+ Net (cont)

Start/stop and capacity demand via network from aremote master controller. The GSC TP derives fromthe continuous +/- signals the pulses for controlling thecapacity (indirect).

Network Networkcontinuous

9 Remote+ Net (pulse)

Start/stop and capacity demand via network from aremote master controller. The master also generatesthe +/- signals as pulses for controlling the capacitydirectly.

Network Networkpulses


Operating the chiller


Modes Signal for …

10 Remote+ Bus (loc.SW)

Start/stop from a central master controller via a bussignal. The GSC TP controls the output depending ona local setpoint (TP) and from this setpoint also auto-matically switches the product ON/OFF.

Network+ setpointdeviation

LocalSetpoint

11 Remote+ Bus (net.SW)

Start/stop from a central master controller via a bussignal. The GSC TP controls the output depending onan external setpoint sent externally via the networkand from this setpoint also automatically switches theproduct ON/OFF.

Network+ setpointdeviation

NetworkSetpoint

12.4 Setting of setpoint and limiting val-ues as well as safety devices

Caution!

The correct setting of all setpoint andlimiting values is a prerequisite for thesafe operation of the chiller.

For the setting of the setpoint and limiting values, the

1. details (steps) in the control operating manualand

2. the project-related data areinstrumental. The program-based setpoint and limit-ing values as well as the setting values of the safetydevice are given in the project-based parameter list.The parameter list is part of the documentation of thecontroller.

Hint!

Adaptations must be made to the localconditions on site.

12.5 Operation of the chiller

Caution!

Familiarise yourself with the controldocumentation.Contact the GEA Refrigeration Tech-nology GmbH technical customerservice if you require assistance.

The chiller is operated via the control (standard:GSC TP).

In the standard version, the GSC TP is mounteddirectly on the chiller, but can optionally also beinstalled in a control centre.The GSC TP consists of the control with operatorkeypad and display unit (touch panel), indicator lightsfor "Running", "Warning" and "Alarm", the emer-gency stop button, the output relays and the casing.All switching, operating and control actions are car-ried out via this touch panel. The touch panel is theinterface between the operator and the control.

The GSC TP performs the following functions asstandard:

– Display of all important physical and technicalparameters, e.g. pressure, temperature, motorcurrent, capacity, number of operating hours,operating mode and status signals,

– automatic startup and shutdown of the chillerand capacity control dependent on the parame-ters corresponding to the application (e.g. thesuction pressure or an external temperature),

– Monitoring of all operating parameters,

– Compressor capacity limitation if the measureddischarge pressure, suction pressure, secondaryrefrigerant temperature or motor current indicatean overload,

– Fault memory with date and time,

– Wire failure detection for all analogue input sig-nals,

– Password protection to prevent unauthorisedaccess to important parameters,

– Non-volatile saving of program,

– MPI communication with a master controller(optionally via Profibus-DP, Modbus RTU orModbus TCP).



12.6 Equipment Protocol

Hint!

Owners and operators of refrigerationequipment with filling levels of morethan 3kg of refrigerant are required tokeep an equipment protocol underEN378 Part 2.The technical customer service at GEARefrigeration Germany GmbH offerssupport in maintaining the equipmentprotocol.The equipment protocol needs to bestored for at least five years after man-ufacture and presented to the relevantauthorities upon request.

The equipment protocol needs to include the follow-ing information:

1. Service and maintenance work

2. Proof of a regular leak tightness test

3. Type and quantity of filled or recovered refriger-ant including quantity balanceIf recovered refrigerant is used then the

– Analytical findingsand

– Source of the recovered refrigerantneed to be given

4. Quantity and type of the filled and recovered oilincluding quantity balance

5. Changes to and replacement of components

6. Regular and routine inspections with results anddates

7. Longer shut-down periods

8. Identification of the company of the technicalstaff that carried out the servicing/ maintenance.

Hint!

Following documents, which are partof product documentation or the oper-ating manual, may be used for keepingthe equipment protocol:

1. Maintenance check list

2. Measurement protocol operatingparameter (template)

3. Data sheet oil filling (template)

4. Data sheet refrigerant fill up (tem-plate)




12.6.1 Data sheet of operating parameters for refrigerant circuit (template)

User

Refrigerant

Type of oil

Chiller - Type / ManufacturerSerial No. / Year

Compressor - Type / ManufacturerSerial No. / Year

Date / Time

Operating hours OH

Slide position %

Speed min-

1

Psuc suction pressure bar

t0 evaporating temperature °C

Pdis discharge pressure bar

Tdis compression end temperature °C

tC condensation temperature °C

Tsuc-t0 overheating 2 K

Poil oil difference pressure bar

Toil oil temperature °C

Imot compression motor current A

t W1Inlet temperature cooling medium °C

tW2 Outlet temperature cooling medium °C

t K1 Secondary refrigerant inlet tempera-ture

°C

2 Measure suction gas temperature with a suitable sensor at the compressor suction tube



tK2 Secondary refrigerant outlet tempera-ture

°C

Oil level in compressor 3

Refrigerant level in the sight glass 4 3)

Remarks

Service technician

3 Oil level needs to be visible4 Normal status: clear and bubble free




12.6.2 Data sheet oil filling (template)

User

Refrigerant

Type of oil

Chiller - Type / ManufacturerSerial number/ year

Compressor - Type / Manufac-turerSerial number/ year

Date Runninghours

Filledrecov-ered oilquantityin l

Absorbedoil quan-tityin l

Remarks(e.g. quantity balance, findings of oil analy-sis)

Servicetechni-cian



12.6.3 Data sheet refrigerant filling (template)

User

Refrigerant

Type of oil

Chiller - Type / ManufacturerSerial No. / Year

Compressor - Type / Manufac-turerSerial No. / Year

Date Runninghours

Removedrefriger-ant quan-tityin l

Refriger-ant quan-tity intakein l

Remarks(e.g. quantity balance)

Servicetechni-cian




12.7 Guide to failures, their causes and remedies

The chillers manufactured by GEA Refrigeration Technology GmbH are highly advanced, automatic andextremely efficient systems. However, failures can occur, making it difficult to maintain continuous operation orcausing part or the whole of the system to fail.

Table of malfunctions

Fault Cause Remedy

The suction pressure is too low,performance is reduced and thesystem overheats.

Slow loss of refrigerant throughleaks in the refrigerant circuit.

Check the entire system for leaks.Repair leaks, top up refrigerant ifnecessary.

Pressure sensor defective. Replace pressure sensor.

Suction filters are clogged. Clean or replace the filter insert.

The suction pressure increases andthe compressor becomes coveredwith a thick layer of hoar frost ormakes noises which indicate thepresence of liquid (refrigerant) inthe compressor.

The compressor sucks in wetsteam or liquid when it is startedup. The safety device to prevent atoo-high liquid level is not respond-ing.

Check liquid levels in the system,drain some refrigerant if necessary.Repair safety device. Check forsuperheating.

The condensation pressure is toohigh.

There is air or other non-condensa-ble gases in the refrigerant circuit.

Vent the refrigerant circuit.

The compressor(s) do(es) not startup after the system is switched onor turn(s) off immediately afterstarting

The electrical circuit is interruptedby a unit in the safety chain.

Switch on the power supply, checkthe pressure switches and replaceor set properly as appropriate.

No oil pressure is building up in thepackage/chiller. The oil circuit isdisturbed by clogged oil filters orleaks.

Replace or clean the oil filters, sealthe leaks and top up with oil.

The compressors are shut off veryoften by the maximum pressuregovernor.

The condensation pressure is toohigh.

See above.

The maximum pressure governor isdefective or set wrongly.

Remove the maximum pressuregovernor, repair it, set it correctly orreplace it.

The compressors are shut off veryoften by the minimum pressuregovernor.

The suction pressure is too low. Open all valves on the suction sideof the compressors.

The pressure governor is defectiveor set wrongly.

Remove the minimum pressuregovernor, repair it, set it correctly orreplace it.



Fault Cause Remedy

The heat transfer capacity of theevaporator decreases.

Check the evaporator for elevatedoil concentration, possibly drain oil

The package/chiller is extremelynoisy in operation.

The compressor(s) or the drivemotor(s) is/are defective.

Please call customer service formore information




13 CLEANING, MAINTENANCE, REPAIR

Hint!

The obligation for signage to prevent unintentional switch-on of the plant during cleaning,maintenance and repair must be observed.

13.1 Important information for servicepersonnel

Hint!

Heed all safety instructions in thisoperating manual. Familiarise yourselfwith the local conditions of the chillerinstallation site. Adhere to all legal andlocal regulations of health, work andfire protection, the safety regulationsfor refrigeration systems as well as theregulations which must be heededconcerning the gases to be com-pressed. Please read this operatingmanual carefully and completely priorto working on the chiller. Familiariseyourself with the special features ofthe chiller.

Caution!

There is an increased danger of slip-ping due to contact of operating mediawith the floor!

The chiller must only be serviced by appropriatelyqualified personnel. For all maintenance work, youmust comply with the maintenance instructions.The maintenance certification is issued and signedfollowing the inspection and maintenance by author-ised fitters. This serves as evidence for the mainte-nance work which has been carried out.During the guarantee period these confirmed mainte-nance certificates are also a prerequisite for anyclaims under the guarantee provided by manufac-turer.The responsible certified specialist company must beinformed if any repairs are required.All maintenance and service tasks have to be carriedout with care to preserve the functionality of thechiller. Guarantee claims will not be valid if the cus-tomer failed to follow the maintenance instructions.

13.2 Cleaning the heat exchanger

13.2.1 Mechanical cleaning

Mechanical cleaning is a maintenance measure inorder to ensure the continuous safe operation of thechiller.Components from the chiller (e.g. suction filters, heatexchangers) can be removed for manual mechanicalcleaning. To do so, follow the instructions listed inthe corresponding component documentation. Aftercompletion of the cleaning work, correctly mount thecomponent and check it for leakages.

13.2.2 Chemical cleaning

The chemical cleaning of the heat exchangers mustonly be carried out by an experienced specialistcompany. At the same time, the manufacturer'sinstructions must be observed.

Cleaning, maintenance, repair Operating Manual | Grasso BluAstrumChiller with Screw Compressors


13.3 Maintenance

The chiller must only be serviced by appropriatelyqualified operating personnel. For all maintenancework, you must comply with the maintenance check-list. The maintenance checklist is part of the productdocumentation and contains the maintenance to becarried out and the specified maintenance intervals.Moreover, all health & safety and fire prevention reg-ulations and the safety regulations for refrigerationsystems must also be observed.The maintenance checklist contains all the mainte-nance instructions and certifications for the first 10years of performance of the liquid chiller. The main-tenance certificates are completed and signed aspart of the inspection and maintenance by authorisedfitters as evidence of the work done. During the war-ranty period, these confirmed maintenance certifi-cates also serve as a precondition for possible war-ranty claims to GEA Refrigeration Germany GmbH.We advise you to sign a long-term service agree-ment with a qualified firm authorised by GEA Refrig-eration Germany GmbH to carry out the necessaryservice and maintenance work. Our service depart-ment is at your disposal whenever you need assis-tance in selecting a partner suitable for you.Contact the service department if repairs are neces-sary.

Warning!

Please observe the maintenanceinstruction given in the manufacturer'stechnical documentation for individualcomponents! The service and mainte-nance work and maintenance intervalsare directly matched to the compo-nents used.The manufacturers' instructions arebinding and must be observed by theclient in order to comply with the guar-antee!If the manufacturer does not specifyany special maintenance instructions,the details given in the maintenanceinstructions and the maintenancechecklist apply.

13.3.1 General instructions

Danger!

Contact with live components is pro-hibited.Maintenance work on the runningchiller is not allowable.

Work involving intervention in the refrigerant circuitmust only be carried out by qualified engineers inaccordance with the guarantee conditions.The chiller must be switched off before being dis-mantled. Before beginning the work, ensure that allcomponents subject to maintenance/servicing arede-energised (e.g.by removing the main fuse orinstallation of a short-circuit jumper).The refrigerant must be removed from the relevantparts of the system. This work must be carried outwith great care, taking into account the safety regula-tions, so that the maintenance personnel are notinjured by the refrigerant or by the refrigeratingmachine oil present in the system.Parts of the system under pressure must be com-pletely drained before opening. While carrying outthe repair, always ensure that there is completepressure compensation between the relevant pres-surised spaces and the surrounding air.During cleaning, repair or maintenance work, thechiller or its components must be protected againstthe entry of moisture in order to prevent impairmentof the function of the components.The chief principle must be to keep air and moistureentering the chiller to an absolute minimum. All for-eign substances must be kept away or elimina-ted,such as

– welding residues,

– sealing remnants,

– auxiliary materials such as grease, oil or sol-vents.

Welding and soldering work may only be performedwith the operators consent. The requisite protectivemeasures must be defined. These include:

– Personal protective measures during the open-ing of the respective part of the system,

– complete draining of the respective part of thesystem,

– Cleaning with the appropriate cleaning agents,

– Concentration measurements,

– Ensuring sufficient ventilation and venting,


Cleaning, maintenance, repair


– Performance of all welding work with the use offorming gas.

If lines that carry gas have to be opened for mainte-nance work, these lines must be in a gas-free state.



13.3.2 Repair work

Modifications and repair work may only be carriedout by qualified persons or persons with suitabletraining with the manufacturer's consent and muststrictly comply with the rules set out in the mainte-nance instruction for the components concerned.

Hint!

The following maintenance notes mustbe observed:

Only spare parts made by the original componentmanufacturer may be used for repairs and for replac-ing wearing parts. These are available from thespare parts department.

13.3.3 Repair information

Important features of the technology and productionprocess must be taken into account when repairingthe plant:

– complete sealing of all devices and pipes.

– Dryness and cleanliness of the entire plant.

– Use of welding methods causing only a minimumamount of dirt to collect in the plant.

– Pipes bent on a pipe-bending machine onlyusing refrigerating oil.

– If repairing the piping system from your ownstocks, we recommend that you use a pipe withNBK surface quality (annealed and descaled,mechanically or chemically descaled afterannealing).

– When carrying out repairs to piping systems,care should be taken to maintain the original pip-ing routes.

– Only pipes of sufficient material quality, whichare certified according to DIN 10216-2 should beused.

13.3.4 Repairs of pressure vessels sub-ject to approval inspection

Hint!

The responsible monitoring body(e.g.TÜV) must be notified in advance.

New inspection and approval is required after pres-sure vessels that are subject to approval have beenrepaired or changed. Welding may only be carriedout by approved welders with a valid welder’s card.

13.3.5 Maintenance work

13.3.5.1 Maintenance of the screwcompressor

The following maintenance work must be performedon the screw compressor at regular intervals (seemaintenance checklist):

– Measure axial play of bearings,

– Check shaft seal,

– Check primary slide movement,

– Check the adjustment of the position sensor.After 50,000running hours or in the 10th runningyear, a general check of the screw compressor isprovided by the manufacturer. Contact CustomerService in this regard.

13.3.5.2 Replacing the oil filter

Hint!

Follow the manufacturer's instructionsconcerning the correct maintenance ofthe oil filter.See component documentation.

1. Take the chiller out of service.

2. If the oil filter is very dirty, it may be necessary toreplace it outside the normal maintenanceschedule.

3. To change the oil filter insert, close the followingvalves in accordance with the P+I diagram andthe oil filter documentation:

– Stop valve in front of oil filter (item 65)

– Further stop valves in front of oil filter (ifavailable) see P+I diagram

– Stop valve function oil (item 70)

– Further stop valves after oil filter (if availa-ble), see P+I diagram

– Stop valve bypass oil cooler (optional)




4. Establish pressure compensation with theatmospheric pressure.

5. Drain oil.

6. Remove the cover of the oil filter.

7. Remove the oil filter element and properly dis-pose of it if it is highly soiled.

8. Carefully insert a new oil filter element.

9. Close the cover of the oil filter.

10. Reopen valves in accordance with point 3.

11. After the pressure has been compensated, ventthe oil filter via the vent valve.

13.3.5.3 Maintenance of suction filtercombination SFC

13.3.5.3.1 Changing the filter element

The maintenance interval for changing or cleaningthe filter element is specified by the manufacturer ofthe refrigeration system.The contamination level and mechanical condition ofthe filter element must be inspected at least once ayear.Before opening the filter, always make sure the filterhousing is not under pressure.

Caution!

Refrigerant may leak out on openingthe filter. The safety data sheets forthe refrigerants in question must beconsulted and any prescribed protec-tive measures observed.

To remove the element, proceed as follows:

1. Unscrew the cover.

2. Pull out the cover with the filter element.

3. Remove the spring wire clamp.

4. Twist the element away from the cover torelease the bayonet catch.

5. Detach the element from the cover.

6. Allow the element to drain off into a suitable con-tainer.

Caution!

When carrying out maintenance,always inspect the sealing ring (O-ring) of the cover for mechanical dam-age and replace it if necessary.

7. Reassemble all parts with the new or cleaned fil-ter element following the same procedure inreverse order.



13.3.5.3.2 Cleaning the filter element

The metal-gauze element used in the filter can becleaned and reused several times before it has to bechanged.

Manual cleaningImmerse the soiled metal-gauze element in a clean,grease-dissolving liquid, then blow it through withcompressed air from the outside inwards. Here it isimportant to place a cylindrical part – possibly wrap-ped in corrugated cardboard – inside the element tocatch the dirt particles.

Caution!

Never use wire brushes for cleaning.

Hint!

To avoid fatigue failures of the metalgauze, strainer elements should bereplaced with new, original filter ele-ments after being cleaned 4 – 5 times.

13.3.5.4 Oil draining, oil filling, oilchange

13.3.5.4.1 Importance of oil change

Aged oil demonstrates an increasing loss of lubricity.Because of this, all rotating components of the com-pressor are endangered. The filter elements becomeprematurely clogged and must be cleaned andreplaced at shorter intervals.The oil in the compressor unit/chiller requires chang-ing

– if the operating time of the oil charge hasreached the technically specified oil changeinterval.

Warning!

Time periods for oil quality analysis /oil changeOil quality analysis / Oil change whenusing ammonia as the refrigerant after5,000 operating hours or at the latestafter 1 year.

– if the oil becomes unacceptably contaminateddue to a major accident (e.g. water penetrationinto the refrigerant circuit).

The degree to which oil in refrigeration plants hasaged must be checked by analysis and comparisonof the data with those of fresh oil. Oil ageing can alsobe judged from the darkening of the oil colour andthe deposits found in the oil filters. If the degree ofageing cannot be assessed reliably by laboratoryanalysis and the results of visual examination, it isadvisable to change the oil at the following intervals(see maintenance checklist).The assessment of the condition of the refrigeratingmachine oil by means of a general visual inspection(contamination) or laboratory analysis must be car-ried out:

– after 5000 operating hoursor

– at the end of one year's operationor

– after remedying major damageor

– in case of extreme darkening of the oil colour oropacity of the oil.

13.3.5.4.2 Oil change, maintenancework

Take oil samples for analysis and comparison withthe fresh oil data at regular intervals. Check the col-ouration of the oil visually and assess the degree ofcontamination.Depending on the results, the user must decidewhether to approve the postponement of filling the oiluntil the next assessment date or whether to havethe oil changed.Inadmissibly damp oil must be removed from thecompressor unit/chiller immediately.

13.3.5.4.3 Changing the oil

1. The chiller must be run for at least half an hourto reach its operating temperature before the oilcan be changed.

2. First shut down the chiller as described in theoperating instructions.




3. Open the stop valve in the bypass line aroundthe check valve on the suction side and the suc-tion-side stop valve to compensate the pressurebetween the compressor and the suction line.Then re-close the stop valves bypass and suc-tion-side stop valve. Otherwise the pressure canbe reduced by opening the vent valve on thesuction filter and then disposing of the refrigerantas specified by law.

4. Subsequently, drain the used oil through the oildraining/oil charging valves and dispose of it(Attention! Hazardous waste!). Once this hasbeen done, re-close the valve and, if possible,continue to draw off the refrigerant using a dis-posal facility until atmospheric pressure is almostreached.

5. Otherwise depressurise the chiller by openingthe vent valve - suction filter, taking into accountthe safety rules for refrigeration plants.

Caution!

Follow the safety instructions for therefrigerant, ammonia.

6. Open the drain plugs and valves on the oilcooler, oil separator and oil filter to drain anyresidual oil. The drain plugs or valves must beclosed again thereafter.

7. The filter element of the oil filter must bereplaced and the filter element of the suction fil-ter combination SFC must be replaced orcleaned.

8. Evacuate the chiller using a vacuum pump.

9. Pressurise the chiller with a slight overpressurevia the stop valve bypass check valve on thepressure side.

10. Then check all components for leakages. Thenperform a complete pressure compensation withthe pressure line followed by a repeated leakagetest of the chiller. The oil charge oil and start-upof the chiller must be accomplished in accord-ance with the operating instructions.

13.3.5.4.4 Used oil

Refrigeration machine oil drained from the circuit isno longer suitable for use in refrigeration plants. Ithas to be stored or transported in appropriately label-led containers in accordance with the legal provi-sions. The operator is responsible for its proper dis-posal.

13.3.5.4.5 Draining the oil

It may be necessary to drain the oil:

– to inspect or repair the compressorand

– if there is too much oil in the circuit.The oil must be drained in accordance with points 1to 6 of the chapter entitled "Carrying out oil change".The oil must be drained through the filling hose andinto a container suitable for waste oil.

13.3.5.4.6 Checking the oil level

The oil level is checked visually in the sight glass ofthe oil separator.The filling level should be 1/2 to 3/4 of the height ofthe sight glass.If the filling level is too low, replenish the oil. The fill-ing amount must be documented in an appropriatelog.

13.3.5.4.7 Charging with oil, toppingup with oil

See chapter "Start-up, charging with oil".

Hint!

For permissible types of oil, pleaserefer to the technical specifications.Oil removed from the compressormust not be re-used. Use only fresh oilfrom closed tanks! You must rule outmixing different types of oil.

13.3.5.5 Tightening screw fastenings

Screw fastenings of components can become loosedue to vibration or movement. Screw fasteningsmust therefore be checked regularly to ensure theyare tight and retightened if necessary.Screw fastenings must only be tightened to the maxi-mum tightening torques.Unless otherwise stated by warning signs, the tight-ening torque is dependent on the size and strengthof the screw fastening.



13.3.5.6 Checking the function of checkvalves

In order for a check valve to be effective, it is impor-tant to perform function checks at regular intervals.An inspection is carried out by checking the noisebehaviour of the valves during operation. Afterswitching off the screw compressor package, mal-function on the suction side is indicated by prolongedturning back of the compressor. Malfunction on thepressure side leads to an increase of the standstillpressure in the package to the pressure level of thesystem pressure side.

13.3.5.7 Searching for leaks on therefrigerant side / leak test

The absence of leaks is a precondition for perfectfunctioning of the compressor unit/chiller unit. Leak-ing parts or connecting elements will lead to the lossof refrigerant and oil as well as the penetration of airand moisture into the low pressure side. The site ofthe leak must therefore be located and remedied ifthere is:

– Loss of the inert gas charge (delivery state),

– Loss of the entire refrigerant chargeor

– underfilling.Lower refrigerant levels in the containers are due toloss of refrigerant as a result of leaks. For this rea-son, all pipes, connections and valve glands shouldbe checked regularly, especially in the initial periodof assembly.The most striking feature if there is a leak in the filledrefrigerant circuit is the smell of refrigerant. Theodour threshold of ammonia in the air is approx. 5ppm and thus well below the permitted MAK values.Methods of leak detection:

– Regular visual inspections.

– Smudges/dirt stains indicate leakingrefrigerant/oil mixture.

– Leak tests with nitrogen with a max. of 0.5%ammonia by volume, an elapsed time of morethan 3 hours and application of a foaming agentto all the joints with a brush. Oil-filled compres-sors or circuit sections must only be chargedwith nitrogen – not air – to generate pressure.

– Use of an NH3 leak detector.

– Ammonia produces the following colours whenleak tests are performed:

– Red litmus paper turns blue,

– Blotting paper impregnated with phenolph-thalein turns red (moisten).

Caution!

Due to the danger of explosion, oxy-gen must never be used to build upthe pressure!

Generate a test pressure in the refrigerant circuit thatmeets the intended operating pressure for the leaktightness test to determine leaks on the refrigerantside, e.g. in the case of escaped inert gas or refriger-ant. When system parts are individually tested, themaximum operating pressure indicated on therespective system part for the corresponding pres-sure chamber must not be exceeded. The use offoaming agents gives the best results at test pres-sures < 5 bar.If leaks are determined, these must be sealed imme-diately. Release the test pressure before beginningrepair! Evacuate the system after repairs are com-plete and after rechecking for leaks.

13.3.5.8 Venting the refrigerant circuit

When air penetrates into the refrigerant circuit, thismakes itself felt in a fall-off in system performance,and the pressure gauge on the pressure side of thecompressor indicates a higher pressure compared tothe condensing temperature. Any leaking must beproperly rectified. In extreme cases, air in the circuitmay interrupt the flow of the refrigerant and causethe oil cooling to fail.There are several ways of venting the system. Dur-ing standstill of the package, the air or the NH3 airmixture is let off via the vent valves of the condenseror the suction filter in water-filled vessels.If air is contained in the mixture, the venting NH3 isabsorbed by water.

13.3.5.9 Finding and fixing leakages

Lower refrigerant levels in the containers are due toloss of refrigerant as a result of leaks. For this rea-son, all pipes, connections and valve glands shouldbe checked regularly, especially in the initial periodafter assembly, with a suitable indicator (litmuspaper, etc.).




Leakages are revealed by a change of colour andmust be sealed immediately.The supplier is not liable for losses of refrigerantcaused by a lack of or improper maintenance!

13.3.5.10 Charging and topping up withrefrigerant

13.3.5.10.1 Charging refrigerant

Liquid filling is carried out:

– after the leak tightness test and evacuation ofthe compressor unit/chilleror

– for recharging.The refrigerant is introduced in liquid form via thesystem's refrigerant draw-in valve. The vessel con-taining the refrigerant should be fixed to the chargingvalve by means of the charging line. Ensure that thefilling hose does not contain any air (e.g. by includingthe line in the evacuation process). The refrigerant isdrawn in after slowly opening the refrigerant draw-invalve and the cylinder valve.Once the circuit has been charged, the cylinder andrefrigerant draw-in valves should be closed tight. Therefrigerant charging line and the refrigerant cylindermust be removed. The system is now in normaloperation.If the refrigerant level has subsided (loss of refriger-ant blown off by safety valves or leaked out duringrepairs), the refrigerant must be topped up with thesystem running. This should only be done if the sys-tem is in operation and free from leakages.

13.3.5.10.2 Draining the refrigerant

Caution!

Refrigerant may escape.Protective clothing must be worn (eyeprotection and protective gloves).

The refrigerant must be drained:

– if the plant is overfilled,

– if the refrigerant or oil circuit is dismantled andrepaired,

– for maintenance work on the oil circuit,

– if foreign gases are detected in the plant.

The liquid refrigerant can be filled into refrigerant cyl-inders in liquid form, or suctioned off as refrigerantvapour using an extraction device.The cylinders into which the refrigerant is filledshould be evacuated and cooled in advance. A suffi-cient number of cleaned, dry and sub-cooled cylin-ders must be made available ready for use beforestarting to drain the refrigerant. The weight of theempty refrigerant cylinder must be determined.The filling line is threaded together with the refriger-ant draw-in valve and the other end fixed firmly to theclosed refrigerant cylinder. The charging valve isopened slowly. The valve on the refrigerant cylinderis then also opened slowly. Due to the hazardsinvolved, you should take care to avoid spilling anyrefrigerant.The refrigerant is weighed with a scale, rememberingthat the cylinder should only be filled to 80% of thecapacity. If this percentage is not reached and thereis still refrigerant in the system, the pressure in thecylinder can be reduced by venting the cylinder.When the cylinder is filled to 80 %, the refrigerantdraw-in valve and the cylinder valve are closed andthe next cylinder is connected. Repeat this proce-dure until all of the refrigerant is bottled. Only onecylinder must be filled at a time.The quantity of refrigerant filled must be documentedin an appropriate log. When the refrigerant has beenfilled into cylinders, the charging valve should beclosed.The remnants of refrigerant are suctioned out of thesystem until it is completely drained. The pressuremust no longer increase after the compressor hasbeen turned off.

Connections for draining refrigerantDraining the refrigerant circuit or parts of the circuitcan be carried out via the service valves provided(see P+I diagram).

13.3.5.11 Draining refrigerant circuit

Open the stop valve (2330) carefully to drain anyexisting oil out of the evaporator. Pay attention to thesafety rules of working with the refrigerant ammonia!

Danger!

Keep the safety equipment handy (pro-tective breathing mask)!Working only together with a 2nd per-son!



13.3.5.12 Refrigerant side evacuation

The purpose of evacuating the system is to removeair and moisture from the refrigerant circuit.Evacuation is required:

– after intervention in the refrigerant circuit andelimination of leaks,

– before start-up/restarting.Evacuate the chiller using a vacuum pump. Thecompressor must not be used for evacuation.During evacuation, all affected parts of the circuitshould be at least at room temperature as cold partshinder the removal of moisture.If there is still any moisture in the chiller, this will leadto a rise in pressure. Evacuation must continue untilthe pressure no longer increases. For a pressurecompensation, it is necessary for the ambient tem-perature to remain constant.

13.3.5.13 Maintenance of the compres-sor drive motor

Hint!

The compressor drive motor must bemaintained in accordance with the"Motor documentation".

Maintenance of the compressor drive motor includesthe following activities:

– Lubrication of the motorLubrication intervals and quantities according tothe "Motor documentation" or "Type plate".

– Cleaning of the motor (externally)Select a suitable cleaning agent according to the"Motor documentation".

13.3.5.14 Checking the operating parameters

Hint!

The control of the operating parameters is carried out via a Touch Panel. The checking inter-vals recommended in the table must be observed. The project-related setting values and limitsare given in the parameter list.Inform GEA Refrigeration Germany GmbH technical customer service if the parameters areoutside the allowable limits.

Parameter to bechecked

Every 24to 72hrs Weekly Monthly Remark

Discharge temperature X

Minimum superheat must not be less than 25 K.Maximum discharge temperature 100°C, in indi-vidual cases (e.g. heat pump applications) thismay be exceeded in agreement with the manu-facturer.

Oil temperature X See parameter list!The viscosity must not be less than 7 cSt atmax. speed (rpm).

Oil pressure X

The oil difference pressure to the dischargepressure must not be lower than –2 bar. In theevent of an oil difference pressure fault, a con-taminated oil filter may be the cause.

Discharge pressure X See project value (parameter list). Determinethe superheat on the pressure side by compari-son with the final discharge temperature.




Parameter to bechecked

Every 24to 72hrs Weekly Monthly Remark

Oil level in oil separa-tor X

An oil level must be visible in the sight glass atall times. If the oil level is below the bottom thirdof the sight glass, recharge oil.

Oil heater X

When compressor is shut down, the heatermust automatically start. If the thermostatic cut-out (limiter) switches off the heater, this may bean indication of an oil shortage.

Setting the safety devi-ces X See set values in the parameter list.

Number of operatinghours X

See maintenance checklist for maintenancework to be carried out according to the numberof operating hours.

13.3.5.15 Checking the earth connection

Check the function of the earth connection frequently(see the general assembly drawing and the indica-tions on the product).Only a specialist company must be commissionedwith inspections.

13.3.5.16 Maintenance of the switchingcabinet

Terminal screws must be checked for tightness and,if necessary, tightened at regular intervals (every5,000 operating hours or at least once per year). Thecontacts of the contactors must be checked for lossof contact material.

13.3.5.17 Insulation

Check the insulation (if present) on components,containers and piping for damage.Damaged insulation must be replaced. The insula-tion strength must be selected according to the tem-perature and humidity at the place of installation.Details on the insulation can be found in the P+I dia-gram.

Caution!

No screw connections must be usedunder the insulation if the piping isinsulated. The pipes must be welded.

13.3.5.18 Check of the tightening torqueon the adjusting elements ofthe fixing base.

The tightening torques vary depending on thestrength and size of the screw used. The values fortightening torques are to be taken from the applica-ble DIN, unless otherwise specified.

Hint!

The tightening torques for the adjust-ing elements should be obtained fromthe data sheet. The data sheet formspart of the product documentation.



14 DECOMMISSIONING

14.1 Shutdown in the event of dangeroussituations

The safety equipment of the chiller complies with EN378.By means of automatic monitoring of the individualoperating parameters, the control detects hazardoussituations in good time and automatically switches offthe chiller.The cause of the fault is then displayed on the con-trol and can then be corrected.Among other things, the concept of the chiller isbased onlow maintenance refrigerant circuits that areas well sealed as possible. However, residual risksremain, especially due to possible leaks or escapingrefrigerant or rotating drive parts.

Hint!

The EMERGENCY STOP switch in theswitching cabinet is used to switch offthe chiller quickly whenever neces-sary.

Leaking refrigerant can be detected with a gasdetector (not included in the scope of delivery). Thisdetector can be integrated into the automatic safetychain.Please consult the safety regulations within this doc-umentation for information about what to do in thecase of leaking refrigerant.

14.2 Taking out of service for a period<48 hours

Hint!

The obligation to label the plant as"Plant not in operation" must beobserved!

If the chiller is shut down for a period <48 hours, thefollowing activities must be performed:

1. Switch off the compressor in accordance with theoperating instruction for the electrical switchgear.

2. If necessary, shut down all ancillary drives.

3. Removing the main fuse.

4. If necessary, shut off the secondary refrigerant,heating agent or the cooling water supply.

5. Ensure that the venting slots of the electricmotors are covered under all circumstances!

® System has been taken out of service

Hint!

If the chiller is shut down temporarily,the valves do not need to be operated;they remain in their operating posi-tions. If there is a possibility of thetemperature in the evaporator risingabove the cooling water temperature,the cooling water supply must beinterrupted or the stop valve on thecompressor suction side must beclosed.The stop valve on the suction side ofthe compressor must also be closed ifit is possible that the temperature inthe evaporator could rise above theambient temperature of the chiller.

14.3 Taking out of service for a period<48 hours

Hint!

The obligation to label the plant as"Plant not in operation" must beobserved!

If the chiller is taken out of service for a period (>48hours), the following activities must be performed:

1. Switch off the compressor in accordance with theoperating instruction for the electrical switchgear.

2. Switch off all ancillary drives.

3. Switch off the main switch of the three-phaseelectric system.

4. Close the stop valve (or closable check valves)on the suction side and the pressure side.

5. Shut off the secondary refrigerant, heating agentor cooling water.

6. Shut off the cooling medium supply to the oilcooler. (if present)

7. Close the manual stop valve of the refrigerantinjection.

8. Switch off the oil heater.


Decommissioning


9. Shut off the remote condenser (Version (R) ofthe condenser) to prevent refrigerant displace-ments.

10. Preparation for winter operations (Version (R) ofthe condenser). See chapter "Winter Operation".

11. Ensure that the vent slits of the electric motorsare covered under all circumstances!

® The system has been taken out of service.

14.4 Measures during shutdowns

Even though the screw compressor package/ chilleris under overpressure, check the moisture content ofthe refrigerant and lubricating oil in case it is shut-down for a period longer than half a year. The mois-ture content must not differ substantially from the ini-tial values.

14.4.1 Monthly measures during shut-down

– Check that the screw compressor package/chiller is constantly under overpressure. Checkthe screw compressor package/chiller for leak-ages using a leak detector.

– Manually rotate the compressor shaft (min. 10rotations).

14.4.2 Four weeks before restarting

– Check the moisture content and ageing conditionof the refrigerating machine oil. Analyse the oilfor this purpose. Compare the results of the anal-ysis with the values for fresh oil. We recommendan oil change after 1 year (ammonia as refriger-ant) (see Maintenance Instructions).

– Check the insulation resistance of the drivemotors (see the operating manual for the electricmotor).

– Check the chiller for leakages.

14.5 Winter operations

( for version (R) of the condenser)

"Winter operating conditions" means that the outsidetemperature is lower than the temperature on the siteof the chiller installation.

In order to protect the system, unusual measures forlonger stop periods during the cold season are nec-essary.

Warning!

Close stop valves condenser outlet toreceiver; pressure compensation linebetween receiver and condenser inletmust be closed to prevent refrigerantdisplacements!

Otherwise suction pressure faults would occur duringrestarting the chiller.The valves should be motor valves, closing automati-cally when the chiller is switched off.

Decommissioning Operating Manual | Grasso BluAstrumChiller with Screw Compressors


15 DECOMMISSIONING, DISPOSAL

Preparatory measures

Hint!

The information in the chapter"Decommissioning" must beobserved.

Hint!

Care must be taken during disposaland devaluation that the various mate-rials are separated and taken for recy-cling. Disposal of component remainsand components in the domestic ref-uge or on refuse tips is not permitted.The legal regulations applicable to theplace of installation regarding the dis-posal of electrical equipment must betaken into account.Dismantled components must be dis-posed of correctly and according tolegal requirements.

– The dismantling and disposal of the package/chiller must be carried out in such a way that:

• the plant is free of voltage and is protectedagainst unintentional reconnection of thevoltage.

• Accidents to persons are prevented,

• material damage is prevented,

• uncontrolled escape of refrigerant or oil isprevented.

– Disposal and decommissioning work must onlybe carried out by personnel who are qualifiedaccording to EN 13313.

– Components may be under elevated pressureand the pressure must be released before open-ing them.

– In case of contact with refrigerant or operatingmedia, their hazardous properties (e.g. toxicity,inflammability) must be taken into account (seealso the safety data sheet for the refrigerant).Personal protective equipment compliant withEN 378-3 must be worn.

– National regulations (e.g. EN 378-4, Section 6)must be observed for the reclamation and dis-posal of refrigerants.

– National regulations (e.g. EN 378-4, Appendix A)must be observed for the reclamation and dis-posal of operating media (oil).

– No unauthorised persons must be within theinstallation area of the plant during decommis-sioning, as they could come into contact withrefrigerant.

– All components of the plant which are not to bere-used, as well as refrigerant and operatingmedia, must be stored in suitable separate con-tainers. They must be treated as waste and dis-posed of safely.

Hint!

Re-use of operating media is not pos-sible!


Decommissioning, disposal


Date post:	16-Jul-2020
Category:	Documents
Upload:	others
View:	5 times
Download:	2 times