руководство по монтажу и обслуживанию operation
Contents
1.2.
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5. 100 kW factor Refrigerant 12 20 3 4 2 3 Air Cooler Freezer Chiller 2 16 WITT refrigerant pumps differ conventional centrifugal pump des
6. 73 20
7. 98 37 Installation operating instructions Fig 1b 1 INTRODUCTION Please read the entire manual careful before selecting installing commissioning and servicing the pump 1 1 INTENDED USE The WITT hermetic refrigerant pump type is designed to deliver exclusively refrigerant liquid at its boiling point The pump is labelled with model and design limitation for pressure and temperature The HRP refrigerant pump is designed with safety fea tures which ensures security from the escape of ammo nia in the event the stator can leaking the pump body and the complete motor housing is designed to 25 bar pres sure to contain high pressure refrigerantRe
8. 180 11 7 INSTALLATION APPLICATION All of the following specified work must be carried out by knowledgeable and trained personnel experienced in installation and service of refrigeration systems 7 1 PREPARING THE PUMP FOR INSTALLATION Before the pump is installed the following functions sh
9. 7 41 45 42 1 77 79 29 39 93 08 50 52 54 55 59 71 30 42 51 10 41 14 21 42 51 61 64 42 46 49 42 51 7 8 10 60 0 42 09 58 22 51 56 57 93 93 9 olol ole R HRP 5050 HRP 8050 N Bec Dimension Code No Weight Dimension Code No Weight No gr r 9040 2276 3764 suction casing suction intermediate piece guide vane intermediate piece 1 discharge intermediate piece return intermediate piece
10. KS 11 12 L3 rechtes Drehfeld clockwise phase sequence Thermokontakt 2A ac thermostatic bimetal Fig 8B HRP 8050 und 5040 12 2000 Old execution of HRP 8050 and HRP 5040 until 12 2000 The correct direction of rotation indicated by the cast arrow on the pump housing is obtained if the electric connections are made as detailed in the terminal box electric wiring diagram fig 8 with the phase sequence rotating clockwise The direction of the phase sequence can be measured with specific measuring equipment The electrical connection information is also available on the label inside the cover of the terminal box see fig 8 The terminal box has two sizes of cable sockets 1x PG 13 5 1x PG 9 All cable and electrical connections includ ing the terminal box have to be made
11. 2 TERMS WARRENTY order avoid accidents ensure optimum performance no modifications or conversions may be carried out to the refrigerant pump without the explicit written approval by TH WITT K LTEMASCHINENFABRIK GMBH These instructions are based on internationally standardised SI units of measurements All data and information on the operation and maintenance of the refrigerant pump is provided based on our extensive experience to the best of our technical knowledge Our liability or warranty is excluded if e information and instructions in the operating manual are ignored the refrigerant pump including accessories is operated incorrectly or is installed contrary to these installation instructions refrigerant pump is used for applications other than that for which
12. 3232 20 5040 5050 8050 32 1 10080 HRP 8050 50 HRP 5050 50 5040 30 3232 25
13. e
14. TROUBLE SHOOTING pump makes scratching noise capacity too low valves on pump open switched off on pressure difference control switched off on flow switch switched off by too high temperature switched off by too high power consumption life time of bearings too short Motor protection fuses trip noise comes from outside foreign material pump lack of refrigerant conical filter is blocked too fast reduction of the evaporating temperature impellers or intermediate pieces worn out bearings worn out rotor in contact with can direction of rotation wrong frequency of the pump too low stop valves behind the pumps closed too much gas in liquid liquid level in separator too low valves on cooler closed regulating valve not opened far enough overflow valve closed or pressure set too low contamination is blocking the piping system non return valve of an other pump
15. 6 3232 5040 5050 8050 10080 50 2 8050 60 Hz A lt 1000 3 NH3 5 2
16. Wm 6 3 DOWNLEG DESIGN The pump shall be connected vertically with the separator To prevent interference between pumps it is advised that each pump be connected individually to the separator see fig 6a When a stand by pump is planned an installation according fig 6b is recommended To avoid any vortexing the downleg here again protrudes into the separator An oil drainage dome around the suction line as shown in fig 6b can be favourable Consideration shall be given to the fact that the suction line must be installed directly to the pump avoiding additional elbows or horizontal run Any gas accumulation in the suction line and particularly in valves attached to the pump must be avoided Gas bubbles should be able to flow back to the separator unhindered counter to the liquid flow especially when the pump is not in operation Shut off valves in the suction line shall be sized generousl
17. 2 3 Foot mounted removing the conical suction strainer When HRP pumps are foot mounted the pump A must be installed stress free to the base frame and the piping system Special attention must be paid to the expected pipe contraction at low tem peratures For inspection and cleaning of the conical strainer it is possible to remove the flange bolts and to loosen the mounting bolts and tilt up the pump at the motor end see fig 10 For pump arrangement see for instance fig 6a 6b and 6c Flange Alignment Make sure the pump connection flange grooves and tongues are properly aligned Do not use the flange bolts to align or stretch the pipe Using flange bolts to pill together a too large gap will cause undue stress or distort the pump or the flange Do not use the mounting bolts to pull down the pump on to the frame work the cast iron mounting footpads can frac ture Prior to mounting the pump it
18. 3232 5040 HRP 5050 8050 10080 77
19. A
20. e 7 2
21. 8 2 8 SERVICE AND 8 7 REMOVING A PUMP Follow all national and local safety requirements when re moving the pump Particular care must be taken of the following Check the plant room layout exit doors so can evacuate the area quickly in case o
22. A 6 5
23. 2 2 6
24. 4 8 47 DESCRIPTION OF OPERATION From the surge drum refrigerant liquid flows into the suction chamber of the pump In the suction connection a conical screen is placed A special design of the suction chamber reduces the inlet friction The pressure is increased in two stages through impellers and intermediate pieces A built in ejector is designed to provide adequate cooling of bearings and motor By the diefferential pressure in the pump some of the liquid refrigerant is bled to the back bearings through the hollow shaft On top of each intermediate piece there is a small bypass hole connecting the suction and discharge side When gas has collected in the discharge chamber it can vent through these holes to the suction chamber and from there returning to the surge drum It is important that the down leg must be designed in such a way that the pump venting can take place see chapter 6 For the HRP 3232 the design of a vertical motor shaft allows the free flow of any gas bubbles that may form Pumps with horizontal motor shaft HRP 5040 HRP 5050 HRP 8050 and
25. 0 2 WITT W 4652 0 01 interrupts control voltage motor relay when the motor temperature exceeds critical value Automatic restart after cooling down the pump must be restricted Start up should only be allowed after investigation of the cause of the motor trip and inspection of the refrigeration system Experience has shown that the following are the most likely causes the bearings are worn too many cycles gt 6 hr there is too much dirt in the pump which can block the inlet filter or the internal circular screen there is oil contamination inside the pump too low flow rate through the pump cavitation Moisture in the terminal box caused by improperly sealed cable connection Faulty power supply A pressure differential switch with time delay during start up shall be used when there is insufficient discharge pressure The controller s
26. 7 6 STAND BY 74 55 PROCEDURE check record pressures system if the pressure difference is smaller than expected the pump may be rotating in the wrong direction The pump should rotate clockwise when facing pump suction end cover Check proper rotation by measuring phase se quence lf itis necessa
27. 5B e 5 dynamisch AADA SARAAN A SNA NAA RRA statisch static dynamisch statisch static 5 3 ADAPTATION PLANT REQUIREMENTS Fig 5 shows different plant oprating conditions The de livery head H is shown in relation to the required plant capacity Q Performance curve characteristics of the refrigerant pump are shown in fig 5A The different points W mark the varying plant conditions that may occur during operation If the required liquid flow does not correspond with the available pump capacity then the liquid flow to the system can be adjusted as follows pump capacity too large switch pump multi pump application liquid bypass valve fig 5B speed control of the pump fig 5C pump capacity too small e switch on an extra pump fig 5D installa larger pump Bypass System bypass system dynamisch statisch 17 6
28. 1 2 8 1 2 75 1
29. gt 6 30 15 4
30. 60
31. 6 1 1
32. 4 8050 10080 3 4 3 TECHNICAL INFORMATION 3 1 DESCRIPTION OF TYPES Five hermetic pump types are available HRP3232 5040 HRP 5050 HRP8050 and HRP means Hermetic Radial Pump The numbers give the inlet and outlet pipe connection size in DN the first two three digits give the size of the suction connection while the last two digits give the size of the discharge connection 3 2 SCOPE OF DELIVERY All HRP pumps model GF are complete with canned motor conical strainer and counter flanges only for HRP 3232 additional oil drain valve type 10 G GB PN 40 is included Optional Equipment 2 x EA with stop valves on suction side discharge side discharge side with vent valve pr
33. 3232 10 40 2 EA 69 V 3 3 3232 HRP 5040 5050 8050 10080 2
34. 11 13 6 6 10 1 4 1 2
35. 1 A 2 4 Switch Autom K lteanforderung 15 13 2 request K3T K6 cooling freigabe N 18 14 safety switch for manual operating 21 j K6 7 22 7 11 St rung XX quittieren 14 12 95 13 Motorschutz Q1 7 14 Overload protection 96 7 L B1 B2 11 Thermistor Ausl seger t 13 Thermistor motor protection unit A NNNNA K N 1 2 14 12 Sensor 14 1 2 3 4 15 altleiter EE EE Pi PTC thermistor 9 34 18 St rung 1 8 13 14 15 16 8 Str mungsw chter flow indicator MS96 12 R 2 6 7 2 type HRP3232 seit since 01 12 2000 5040 1 1 1 1 1 8050 2 4 5 K6 A2 A2 A2 A2 A2 A2 N N N N N N N N N NH3 Pumpe ein Impuls Pause I P berwachung Inpuls Pause St rung St rung Kaltleiter Kaltleiter NH3 Pump on impulse break i b supervise impulse break Kaltleiter Diff Druck Ausl seger t PTC thermistor 15 30s Zeit time ca 3min fault fault PTC thermistor motor PTC thermistor pr diff switch Steuerung mit Str mungsw chter control with flow indicator protection unit Informationszeichnung presentatio
36. 1 12 2000 Fig 7 Recommended electrical wiring diagram old execution until 1 12 2000 U V W L1 L2 L3 rechtes Drehfeld clockwise phase sequence Thermistor U 2 5 Fig 8A K B Wiring information inside terminal box 8 8 1 13 5 1 54 Abb Fig 9 unacceptable cable connection B 9
37. INSTALLATION INSTRUCTIONS To ensure trouble free operation some basic rules need to be applied to the installation of the HRP Pumps 6 7 PUMP ARRANGEMENT The installation must be designed as compact A as possible below the separator or low pressure receiver Allow sufficient access space around the pumps for removing or replacing the pump servicing valves setting pressure difference control inspection and cleaning the conical strainer Also allow space for normal frost ice accumulation around the pump Vertical distance between bottom of the A separator to the pump centre shall be at least 1 m Greater distance will make the pump less sensitive to system pressuere fluctuations suspended mounting of the pumps with threaded bars of at least 180 mm length is recommended HRP 5040 HRP5050 HRP8050 and HRP10080 should be aligned horizontally wheres the HRP 3232 should be aligned vertically Please consider that A condensate trip tray can easily be placed and cleaned The conical suction line filter can be cleaned easily Stress in the piping system is avoided 6 2 PUMP CONNECTION The top connection of the suction line to the separator can be made with an elbow or a down pipe with vortex breaker When designing the vertical down pipe special attention must be taken that any oil which may settle does not drain i
38. 2000 69 WITT 1 2 0 lt 2 5 Table 3 Under circumstances shall the maximum velocity in the downleg exceed 0 3 m s The conical suction filter that comes with the pump must be fitted at all times to protect the pump from any contamination 6 4 PUMP DISCHARGE LINE The design of the discharge line is less critical to the system operation A liquid velocity of 1 5 m s is normally recommended A non return valve this is usually a combined stop check valve type discharge line is required when several pumps are connected to one discharge manifold the static head to the coolers is high In application with a non return valve or solenoid valve liquid may be trapped When this liquid is warmed up the pressure increases rapidly to an unacceptable value and the piping may fracture Adequate precautions must be taken by the installer to
39. 1 1 25 4 1 2 A
40. SERVICE MANUAL 1 eher 2 eais 2 12 2 13 3 14 3 2 TTT 4 3 5 3 1 5 32 2 5 3 3 5 5 4 1 6 21 6 42 6 43 022222 77 7 44 7 45 8 4 6 12 47 14 48 14
41. 1 4 Under circumstances the indicated tem perature and pressure limitations to be ex ceeded Important The content of this manual must be A adhered to Deviation from the specified condi tions will make any claim for liability or warrenty void 1 3 SAFETY ADVICE The pump is designed for use in industrial refrigeration systems of primary refrigerant Evaporating refrigerant is used to cool motor and bearings Any gas that forms in the pump is discharged to the pressure side The electrical power consumption of the pump is low in relation to the refrigeration capacity due to the effect of the latent heat of th
42. 58 09 8 3 3 5040 5050 8050 10080 FAS 4 3232 DIN 2635 2512 WITT 8 3 GENERAL ADVICE COMPRESSOR OIL IN THE PUMP 8 3 1 When too much oil flows into the pump from A the separator the pump will not operate prop erly or may be damaged Oil prevents sufficient cooling of the bearings resulting in an unacceptable overheating of the pump Only the built in thermistor provides adequate safety Oil can be drained through a WITT 10 stop valve
43. refrigerant pumps designed especially for this WITT purpose principle of a pump system is Ha 4 shown fig 4 4 Fig 4 principle of pump recirculation system 15 WITT
44. 5040 8050 220 V 7 2000 1 2 2 5 WITT 2 2951 000101 0 2951 000201 It is recommended the control panel incorporates Auto switch for use during commissioning maintenance operations It is important to take care that during manual operation of the pump all safety devices in
45. 8 4 is recommended open repair the pump Preferably send the pump repairing to your supplier or to the factory if required request a replacement pump Repairs should only use factory supplied assem blies and be fitted by specially WITT trained per sonnel During the training a repair manual will be supplied by the manufacturer 8 5 WARNINGS WITT HRP pumps are of the canned type All rotating parts including bearings and motor rotor are in direct contact with the refrigerant Any unusual running conditions other than stable operation will have an influence on moving parts particularly the bear ings Dirt oil and large pressure fluctuations may shorten the lifetime of the bearings WITT HRP pumps are for refrigeration systems A only Read these instructions completely before selecting using or servicing these pumps Only knowledgeable trained refrigeration mechan ics should install operate or service these pumps Stated temperature and pressure limits should not be exceeded Special attention must be paid to the national rules concerning the available materials Pump should not be removed unless system has been evacuated to zero pressure All local rules to refrigeration systems and electric control and installation systems must complied with 32
46. piece 2 150 2162 000031 1862 discharge casing 2162 000307 4020 DN40 2162 000022 2540 0150 0150 0150 280 079 6 25 M8 275 12 55 2162 000014 2162 000006 2162 000010 2162 000128 2162 000083 5112 000004 5112 000026 5111 000065 2080 8260 2980 1740 497 7 109 11 13 bearing casing stator casing motor cover can complete parts 11 13 bearing cover socket head cap screw socket head cap screw hexagon head cap screw 6660 2720 1660 541 7 74 107 0150 2162 000301 2162 000303 2162 000317 2162 000320 5112 000004 5112 000042 5111 000091 N 6 hexagon nut 5151 000034 30 M12 5151 000035 15 6 hexagon head screw 25 12 55 5111 000065 6 hexagon nut 12 5151 000035 15 wood 5144 000007 3 4 30 5144 000007 3 earthing screw 5112 000030 M4 x 10 5112 000030 long socket head sc
47. 18 6 1 18 6 2 PUMP 18 6 3 DOWNLEG DESIGN 19 64 PUMP DISCHARGE 20 6 5 SAFETY AND ELECTRICAL 1 20 7 INSTALLATION AND 27 7 1 PREPARING THE PUMP FOR INSTALLATION 27 7 2 MOUNTING INSTRUCTIONS 27 73 PRIOR 28 74 COMMISSIONING 29 75 DURING NORMAL OPERATION 29 7 6 PUMP STANDSTILL 29 8 SERVICE AND 30 81 30 82 SHIPPING OF 30 83 GENERAL ADVICE 31 84 32 EE 32 Tel 49 241 18208 0 Fax 49 241 18208 49 Data valid from 2003 All rights reserved subject to alterations without notice Our terms of delivery are valid for all sales Montage und HRP 5040 Fig 1a 1
48. 32 manufacturer Witt K ltemaschinenfabrik GmbH Lukasstrasse 32 52070 Aachen Germany 2003 R P OPERATION amp CONTENTS 1 2 1 1 INTENDED 2 12 SAFETY REOUIREMENTS 2 13 3 DISCLAIMER 3 2 TERMS 44 2 444440 4 3 TECHNICAL INFORMATION 5 31 DESCRIPTION 5 32 5 33 ORDERINFORMATION 5 34 CODES CERTIFICATES 5 6 41 GENERAL INFORMATION 11111111 6 4 2 ELECTRICAL DATA 6 7 44 PRESSURE RANGE 7 8 40 PARTS OS Toscar i i 11 47 SECTIONAL VIEW OF THE 12 48 DESCRIPTION OF OPERATION 14 49 PERFORMANCE CHARACTERISTIC 14 5 APPLICATIONS n se 15 51 15 5 2 DETERMINATION THE REQUIRED 16 5 3 ADAPTATION PLANT 17 6 INSTALLATION
49. DIN ISO 12944 5 200 7001 44 25 25 27 5 AD Merkblatt HP30 4 19 2 25 50 10 18 75 10 60 40 5040 40 60 AD Merkblatt 4 19 2 40 50 10 30 10 60 43 MATERIALS Pump housing GGG 40 3 Stator steel copper Rotor steel aluminium Bearings PTFE Shaft 1 35 Motor can 1 4313 Or 1 4059 Impellers GX22CrNi17M Main bolts 8 8 Counter flanges P355NL1 or 22 8 Bolts for counter flanges 8 8 Gaskets soft gasket asbestos free Transformer oil Shell Diala D Painting system W 9 1 9 2 W 9 1 W 9 2 2 k epoxy finish according
50. prepared to 4 2 3232 5040 5050 8050 10080 DESCRIPTION HEN 22 e motor power with Ss bei R22 Nominal motor power with R22 1 0 RP 12 Bad Bd Bad Bad Baad Band 60 Hz 3 460 V 4 0 HEES Nominal motor power with N 2 Measure the maximum current during commissioning the overload protection to this value not exceed the value 5 E 1 9 D kw Lach 43 40 3 1 35 1 4313 1 4059 22 17 8 8 355 1 22 8 8 8 Shell Diala D W 9 1 W 9 2 W 9 1 W 9 2 2
51. 41 42 bearing sleeve 41 bush 42 2 43 bearing strips 2x43 2x44 retaining disc 2x44 2162 000127 2162 000126 241 7 2162 000126 37 2162 000127 4 6 4 6 SECTIONAL VIEW THE PUMP FIG 3a HRP 5040 HRP 5050 HRP 8050 HRP 10080 01 3191 83 24 02 03 04 05 84 25 32 06 07 10 13 45 41 44 43 42 64 52 62 22 08 64 51 58 38 4 Va 2 D 5122541 57 58 38 SC 21 61 1 A 4 49 ee RS Wees 1 H ZN 58 38 AN 1 Se 35 AN J 42 43 41 Detail 44 optional 46 47 48 28 78 78 77 13 5 1 9 54 55 H 1 4 160 01 014 1 2
52. safety switch for cooling manual operating 15 33 K4T K1 21 Ge e 34 13 ab 01 12 2000 Ss ge 22 ersetzt durch 5 21 21 6 7 7 from 01 12 2000 replaced with 22 22 thermistor ou 95 13 M M 96 14 Overload protection Thermoswitch i ANANN AN F1M 13 13 2 B1 1 2 3 4 K1 K6 15 14 14 P Sech 0 18 o o 33 5 1 8 13 14 15 16 34 Str mungsw chter 13 flow indicator MS96 12 R K5 2 6 7 ta 1 1 1 1 1 1 1 1 K1 K2M 5 K6 K7 K8 A2 A2 A2 A2 A2 A2 A2 A2 N N N N N N N N N N Anforderung K hlung NH3 Pumpe ein Impuls Pause I P berwachung Inpuls Pause Thermokontakt St rung St rung request cooling Pump impulse break i b supervise impulse break i O Str mung Thermokontakt 15 30s Zeit time ca 3min thermoswitch indicator thermoswitch OK fault fault Informationszeichnung presentation of information Diese Zeichnung zeigt die von der Fa Witt empfohlene Steuerung der K ltemittelpumpen Typ HRP5040 8050 bis 1 12 2000 recommended wiring diagram refrigerant pump type HRP5040 8050 Datum 30 11 2000 HRP 5040 HRP 8050 Zeichn Nr 3 16128 0342 001 001s Modelle bis until 01 12 2000 Blatt 1
53. 180 5040 5050 HRP 8050 10080 3232 6 2 30 40
54. SHIPPING OF THE PUMP When pump has returned to supplier or the factory be sure the pump is free of refriger ant dirt and oil The risk of damages to goods or the environment by leaking oil during transport is at the senders risk When returning the pump it is important that full information is provided stating the reason and cause of failure Always return the conical suction filter in actual conditionas found when the pump was opened with the pump 30 8 3 8 3 1 WITT 10 10 38
55. guide vane intermediate piece 2 discharge casing bearing casing stator casing motor cover can compl parts 11 13 bearing cover socket head cap screw socket head cap screw hexagon head cap screw 2162 000020 2162 000028 2162 000033 2162 000038 2162 000034 2162 000024 2162 000016 2162 000008 2162 000012 2162 000129 2162 000083 5112 000004 5112 000025 5111 000066 3684 3854 4080 2880 10550 3640 3055 497 7 N 126 hexagon nut 5151 000035 5151 000034 30 hexagon head cap screw M12 x 55 5111 000065 M12 x 55 5111 000065 hexagon nut 5151 000035 5151 000035 1 5144 000007 M4 x 10 5112 000030 wood srew for conn box earthing screw long socket head cap screw set screw gasket suction flange gasket discharge flange gasket casing intermediate pieces gasket can end gasket motor cover 98 60 15 60 15 4 30 5144 000007 3 4 10 5112 000030 1 5112 000024 54 8 3 O 1 se Wees Se BCE ch 730 5121 000004 5632 000028 5632 000026 33 5632 000023 30 40 0 5 5632 000004 50 58 0 3 5632 000027 30 40 0 5 5632 000004 O ring 10 11 2 5 5642 000024 11x2 5 5642 000024 metal gasket 1 4 screw plug 14 20x1 5 5641 000002 14 20x1 5 5641 000002 2162 000079 2162 000078 2162 000080 2162 000081 7 15 15 3 1 30 1 4 3 1 1 1 3 1 6114 000006 10 32 35 50 5 2162 000082 35 50 5 2162 000082 9 475 2
56. 2 el e LE 15 15 5 2 5 3 17 6 18 6 1 HACOCA 18 6 2 18 63 1 64 20 6 5 20 7 27 71 27 7 2 HACOCA 27 1 3 28 rE 29 75 29 7 6 29 8 30 8 1 30 8 2 HACOCA 30 9 3 31 8 4 HACOCA 32 8 5
57. 25 1 1 13 27 1 1 1 15 27 15 12 13 54 screw protection bearing sleeve bearing bush bearing strip retaining disc bearing disc N N 38 5712 000002 radial impeller 1 475 2162 000043 557 radial impeller 2 2162 000044 513 circlip ring 5541 000002 2 temperature switch 2162 000071 25 resistor transformer stator cable insulating plastic tube cable protective tube supporting sleeve supporting sleeve safety screw plug 1 4 cable inlet nipple shaft 1324 15000 1 1324 9832 000001 2162 000066 1 6346 000003 1 6346 000003 2162 000100 1 21622000100 2162 000054 52 1 2an 2162 000164 25 90 2162 000164 194 1 298 21620005 6 21622000065 5116 000009 13 5116 000009 2162 00007 7 2162000087 13 27 gt gt rotor 2162 000068 3700 balancing disc 2162 000058 2600 2162 000058 260 connecting box compl 1 2162 000075 243 backup fuse for PTC resistor 71 2591 000101 1 2591 000101 1 sensor wire 77 6111 000063 1 6111 000063 sensor wire insulation I 6346 000001 1 6346 000001 1 sensor connecting cover 15 2162 000077 15 sensor inlet nipple 2
58. DIN ISO 12944 5 with a total nominal thickness of 200 um RAL 7001 4 4 PRESSURE RANGE 25 bar models Design pressure 25 bar inside pump housing motor can and stator housing 27 5 bar with air under water AD Merkblatt HP30 4 19 2 Test pressure Allowable pressure range 25 bar between 50 10 18 75 bar between 10 60 C 40 bar models except HRP 5040 Design pressure 40 bar inside pump housing motor can and stator housing 60 bar with oil AD Merkblatt HP30 4 19 2 Test pressure Allowable pressure temperature rating 40 bar between 50 10 30 bar between 10 60 C 45 5040 5050 8050 10080 540 520 555 260 310 355 283 349 351 362 228 234 255 302 145 145 145 5050 8050 5040 10080 28 m 15 105 5 ON ES SS 10 GB Modell A AE 10 GB Modell 2 45 DIMENSIONS Modell 4 5 4 5 DIMENSIONS 3232 DIN 2635 2512 424 Modell GF 3 Modell Die oben aufgef hrten Armaturen sind above mentioned valves ausschlie lich f r die are only for 25 bar 25 Ausf h
59. even as possible The required refrigerant flow is calculated by the evaporating refrigerant in the low side evaporators times the recirculation rate pump ratio The re circulation rate depends on the type of evaporator equipment and operation conditions The larger the duty loading rate the greater the recommended re circulation factor Typical re circulation rates and pump capacities per 100 kW cooling capacity are RE CIRCULATION RATES AND PUMP CAPACITY 100 kW B m h Recirculation flow 100 including circulation rate Table 2 5 3 5 Q 5 W
60. which can be installed in place of the lower 1 4 srew plug in the suction chamber Prior to installing the EA 10 you have to make sure that the metall gasket 38 see sectional drawing fig 3 has been removed counternut of the 10 needs to be screwed down entirely to mount the valve When the valve is screwed in you fix the EA with the counter nut in the chosen position When the oil is to be drained while the pump housing is still under pressure a quick closing action valve must be used in addition to the drain valve Oil from the discharge chamber or in between the interme diate pieces can only be partly removed from the pump At low temperatures when oil flow is slow the pump must be warmed up on the outside with warm water to lower the viscosity of the oil making it flow more easily The oil return system from the surge drum should be checked or modified to prevent further oil contamination of the pump 8 3 2 DAMAGED ROTOR CAN You cannot automatically detect whether the rotor can is damaged or is leaking since the stator housing is designed at the same compressive strength To find out whether refrigerant has penetrated into the stator housing loosen carefully the 1 4 screw plug the motor cover 09 Always wear personal protective safety clothes especially safety glasses Use a leak detector or if NH3 was used you will simply smell whether refrigerant is present in the t
61. 7 6 PUMP STANDSTILL STAND BY A During periods of pump standstill only one valve may be closed preferably the discharge valve When the suction and discharge valves are closed at the same time trapping cold liquid in the pump the pressure will increase rapidly as the liquid warms up to an unacceptable high value This increase in pressure can very quickly damage the pump If there is oil contamination during standstill of A the pump the oil must be drained from the pump before restarting the pump otherwise a malfunction may occur which can lead to pump failure which may lead to the failure of the pump WITI 29 8 8 1
62. HRP 10080 are equipped with a sensor behind the bearing filter to detect wear of the bearings While the pump is at stand still at connection position 77 on the outside of the pump you can measure the electrical resistance through the shaft If there is a short circuit i e down to earth the bearings are worn and the pump should be sent in for repair Transformer oil is used in the stator housing between the motor can and the outside casing This oil is useful to prevent moisture entering the stator conducts the motor heat away to the outside casing A thermistor is integrated in the stator windings to sense any abnormal rise in temperature The thermistor stops the pump at a critical temperature to protect the motor bearings from being damaged 4 8 PERFORMANCE CHARACTERISTIC TABLE 50 Hz 3 x 400 V BbICOTA LIQUID HEAD H in m PRESSURE DIFFERENCE Ap in bar NH3 to EVAPORATING TEMPERATURE to 2 369 440 722 900 5 2 3 98 474 778 969 637 4 5 5 5 45 5 5 6 2 4 0 0 0 0 0 0 1 1 3 3 5 5 7 2 2 4 8 10 15 25 20 35 4 4 5 55 6 65 270 FLOW V in HRP 5050 HRP HRP 3232 5040 HRP 8050 13 2 13 0 12 6 12 2 12 0 30 0
63. prevent any liquid from becoming trapped 6 5 SAFETY AND ELECTRICAL INFORMATION To prevent damage to the special pump shaft bearings the installer must ensure that the pumps are not allowed to run dry To ensure the pump is protected and stops if there is insufficient refrigerant to feed the pumps the following equipment must be provided in the electric control circuit of the motor An overload protection switch shall protect the pump when the set current amps consumption is exceeded Maximum setting must be less than the value stated on the name data plate All HRP pump models are since 12 2000 equipped with PTC resistors in the motor windings The required PTC motor control relay e g INT 69 V can be supplied by WITT The built in PTC resistor is connected to clamp terminals 1 and 2 U lt 2 5 V This PTC resistor must be connected otherwise the warranty is void 20
64. the circuit are connected and in good working condition Nil Voltage Bearing Condition Test For the horizontal pump models it is possible to detect bearing wear during pump stand still The external end of the sensor wire under the cap 77 can be used to measure the electrical resistance When a closed circuit with the pump housing is observed the bearings are worn and the pump must be sent to the supplier for repair Electrical Connection PTC Resistors Until 12 2000 the thermal protection of HRP 5040 and HRP 8050 was obtained using a thermoswitch klixon which was connected with 220V see wiring information fig 7c Since 12 2000 all pumps are fitted with PTC resistors in the motor windings which are connected at clamp terminals 1 and 2 with U lt 2 5 V The required PTC motor control can be supplied by WITT Pumps with PTC resistors are marked on the name plate with a K before the serial number The clamp terminals 1 and 2 are protected by a picofuse 62 mA art no 2591 000101 and an additional connection 0 art no 2591 000201 There is a spare picofuse 62 mA inside the cover of the terminal box see below 21924220 93425 Glassicherung Picofuse 62 mA D 5 lt ap lt The following drawings show electrical wiring recommendationsfor HRP pumps 22 1
65. to IP 54 e 9 b Fig 9 b Correct connection with loop electrical cable It is important that all electrical cables are connected with a loop to the terminal box see fig 9 b By using a loop any condensate that may run along the cable is prevented from running into the terminal box The terminal box must be sealed at all times to prevent dirt and moisture to come in also touching of the connections has to be avoided The length of the loop shall be of sufficient length to enable the tilting and moving of the pump during inspection and replacement of the conical strainer in the pump suction connection 26 7 7 1 77
66. 00082 38 5712 000001 4 5 7 5 5712 000001 4 1 radial impeller 1 2162 000313 175 111 2162 000040 300 2 radial impeller 2 111 2162 000041 273 ring 18 5541 000001 1 temperature switch 1020 2162 000071 25 2162 000164 25 90 2162 000164 25 663 4980 1 0 Ltr 139 9832 000001 2162 000065 6346 000003 2162 000100 2162 000053 883 9340 transformer oil stator cable insulating plastic tube cable protective tube supporting sleeve 0 75 Ltr 9832 000001 139 2162 000318 6346 000003 2162 000100 80 45 2162 000053 1 154 1 80 x 45 154 alaa 1 5 AIO wwo wa AINI Supporting sleeve safety _ 2162 000085 2162 000085 screw plug 1 4 5116000009 13 5116 000009 13 cable inlet nipple 2162 000087 27 2162 000087 27 Ban shaft rotor
67. 162 000086 27 2162 000086 27 counterflange suction side 6411 000142 1625 1194 127 15 12 17 54 6411 000141 M12x180 5122 000014 M12 5151 000035 15 Mi 5151 000035 030 13 3 5161 000019 12 30 13 3 5161 000019 O 54 counterflange discharge side threaded bar hexagon nut limpet washer suction strainer bearing filter ejector O 250 125 2196 000002 280 160 2196 000003 57 57 2162 000084 57 57 2162 000084 2162 000136 8 2162000136 assemblies 2162 00091 3168 2162 00115 25520 2162 00115 2162 00052 3670 2162 00052 2162 000077 lt I 5 S 79 bearing casing with parts 7 41 45 E30 E42 51 77 79 29 39 93 stator with parts 08 50 52 54 55 59 71 30 42 51 with parts 10 41 14 21 E30 E42 51 shaft with rotor with parts 61 64 42 46 49 E30 E42 51 Replacement motor assembled with parts A7 A8 A10 A60 E30 E42 09 58 22 51 56 57 2162 A00091 3168 A A 25520 3670 2 7200 2162 00009 7200 2162 00113 2162 00007 45040 7 8 0 0 6 8 2162 00004 45040 joints wear small parts 2 31 1x32 9 33 1x34 1x35 3x38 set of gaskets number x no 3
68. 2162 000319 3970 80 2162 000067 3720 balancing disc T 2162 000057 260 2162 000057 260 connecting compl 1 2162 000075 243 98 64 38 2162 000075 243 pene backup fuse for PTC resistor 71 2591 000101 1 2591 000101 1 sensor wire 77 6111 000063 1 sensor wire insulation 6346 000001 1 sensor connecting cover 2162 000077 15 sensor inlet nipple ii 2162 000086 27 counterflange suction side 6411 000104 1720 DN50 6411 000141 1194 1720 127 15 12 13 DN40 M12x180 M12 30 13x3 250 125 57 57 6411 000140 5122 000014 5151 000035 5161 000019 2196 000002 2162 000084 2162 000136 713 127 15 12 13 54 6 discharge side threaded bar hexagon nut limpet washer suction strainer bearing filter ejector bearing casing with parts HRP 3232 6 41 45 E30 E42 51 HRP 5040 7 41 45 E30 E
69. 29 9 29 4 28 7 28 0 26 1 24 2 22 4 20 1 18 2 15 0 12 5 Lg N N Wu 9021021 AIAI A 741 OO lt gt gt 5 _ N gt 1 Table 60 Hz 3 460 V LIQUID HEAD PRESSURE DIFFERENCE FLOW Hin Ap in bar V in 3232 5040 5050 8050 10080 EVAPORATING TEMPERATURE to 15 0 5 30 3 0 5 50 2 84 3 38 5 56 692 4 5 547 55 312 3 72 611 7 61 501 602 __341 406 6 67 831 546 6 57 3 69 3 98 4 26 3 69 4 40 722 9 00 5 92 7 12 3 98 4 74 7 78 9 69 6 37 746 4 26 5 08 8 34 10 38 6 83 821 16 Table 1b 5 5 APPLICATIONS 5 1 5 1 GENERAL industrial refrigeration systems pumps used K deliver refrigerant evaporators WITT hermetic
70. 42 77 79 29 39 93 stator with parts 08 50 52 54 55 59 71 E30 E42 51 08 50 52 54 55 59 71 E30 E42 51 HRP3232 50 232 without 50 with parts 10 41 14 21 E30 E42 51 10 41 14 21 E30 E42 51 c n shaft with rotor with parts 61 64 42 46 49 E30 E42 51 61 64 42 46 49 E30 E42 51 HRP 3232 ohne 49 HRP 3232 without 49 replacement motor assembled A7 A8 A10 with parts A7 A8 A10 A60 E30 A60 E30 E42 09 58 22 51 56 57 E42 09 58 22 51 56 57 joints wear and small parts x Nr set gaskets number 6411 000104 5122 000014 5151 000035 5161 000019 2196 000002 Kiesch plete assemblies N lk WIN lt 3 gt N 2162 00092 4938 2162 00090 2330 2162 00116 6360 2162 00114 17650 2162 00053 3161 2162 00051 2354 gt 2162 00118 5460 2162 00112 5880 80 2162 00005 23658 2162 00003 32550 5040 2x31 1x32 9x33 1x34 1x35 3x38 E30 2162 000170 2162 000124 HRP 3232 6x33 2x38
71. 7 41 42 2 43 2 44 241 7 ss bearing sleeve 41 bush 42 bearing strips 2x43 retaining disc 2x44 E30 2162 001200 33 2162 000125 2162 000126 241 2162 000126 3 47
72. K5 K6 A2 A2 A2 A2 A2 A2 N N N N N N N NH3 Pumpe ein Impuls Pause St rung St rung Kaltleiter Ausl seger t Kaltleiter 15 30s Zeit time ca 3min fault fault PTC thermistor PTC thermistor PTC thermistor pr diff switch motor protection unit Steuerung mit Differenzdruckschalter control with pressure differential switch Informationszeichnung presentation of information Diese Zeichnung zeigt die von der Fa Witt empfohlene und and seit since 01 12 2000 Zeichn Nr 3 16128 0342 001 007 Steuerung der K ltemittelpumpen HRP recommended wiring diagram refrigerant pump type HRP HRP 5040 und 8050 3232 5050 10080 Datum 01 12 2000 pene Fig 7b Recommended electrical wiring diagram with differential pressure switch L1 230V L1 St rung 2 4 1 chalter reset XX manual autom switch Autom Hand K1x e 2 K lteanforderung freigabe 4
73. dirt in pump stainer or at the coolers power supply not right working on only 2 phases impellers worn out oil in pump at low temperature not sufficient suction head see number 2 set value of pressure control not right hand control valves in system opened too much too quick start up or capacity steps of compressor s too quick switch off of big capacities see number 2 set value of flow switch not right suction side or discharge side closed too quick start up or capacity steps of compressor s too quick switch off of big capacities motor overloaded switching too much on off gt 6 hr dirt on strainer 92 around shaft bearings worn out especially the tail bearing rotor in contact with can too much oil in refrigerant rotor in contact with can much dirt in refrigerant flow too large much oil in low temperature refrigerant see also above points set value pressure diff control too low too much dirt in system too much gas in liquid small particles in system Moisture in the terminal box check the connections and seal the terminal box pump Pump is blocked see above 33 34
74. e liquid being utilised d It is very important that everybody responsible for the safe operation and maintenance of the plant reads this manual you have any problems please do not hesitate to call our service department our staff will be glad to assist you Avoid any tripping obstacle at ground levels e g cable If you cannot avoid such obstacles they should be marked with two coloured warning tape warning sign Retighten all screw connections after maintenance and repair work If you have to disassemble any safety devices for maintenance and repair make sure that upon completion of said work the re assembly and proper functioning is checked 1 4 DISCLAIMER Even when using the pump for the intended purpose it cannot be entirely excluded that a danger remains for the life of the user Translations are carried out to the best of our knowledge We are unable to accept any liability for translation errors We reserve the right to change descriptions graphs or other statements which are required for technical development of the refrigerant pump 2 WITT
75. essure gauge connection and socket for flow switch differential pressure switch with suction valve and discharge valve nonreturn valve discharge side with vent valve pressure gauge connection and socket for flow switch differential pressure switch PTC motor control INT 69 V 3 3 ORDERINFORMATION Please specify the following data when ordering a pump type HRP 3232 HRP 5040 HRP 5050 or HRP 8050 required specifiction Model e g GF 2 x EA or EA Refrigerant Voltage and frequency Special requirements if applicable e g PN 40 for HRP 3232 or HRP 5050 If you are unsure about the selection please provide the following additional information refrigerant type evaporating temperature C 3 required pressure head 3 4 CODES CERTIFICATES APPROVALS The following certifications are available if required declaration by the manufacturer according EG machinery directive conformity declaration according to EG low voltage directive respective EG EMV directive WI 4 d TECHNICAL DATA 41 41 GENERAL INFORMATION Seen 5 1 8 Weight pump with 43 55 8 3 117 om 54 Itr Itr kg 3 al wes cable sockets
76. f an emer gency assistance to handle and remove the pumps Wear the correct protective safety clothing as mini mum use a safety goggles and gloves in case of have a safety gas mask within easy reach Isolate the pump by switching off and locking off the electrical supply and the electrical controls label should be fixed to control panel to indicate pumps are switched off and are being worked on Note the sequence of electrical connections and disconnect the wiring trained engineer suitable qualified electrician in accordance with electrical engineering regula tions should carry out any work on electrical equipment or controls Before moving tilting pump e g access clean the conical suction filter the refrigerant must be discharged It is recommended that the refrigerant is purged to the dry gas side of the surge drum via the pressure gauge valve at the base of the discharge valce Hot water may be used on the outside of the pump to accelerate the boiling off of the liquid refrigerant Never use naked flame or open fire to warm up the pump When there is no liquid refrigerant left in the pump carefully open the slotted screw plug on the suction housing 58 by 14 turn to the pump When there is no residual pressure inside the pump the flange bolts can be carefully unscrewed Be aware of any trapped liquid or leaking valves seats 8 2
77. frigerant will not escape from the pump or through the cable connec tions Performance data of the pump are to be found in chapter 4 Technical data 1 2 5 REQUIREMENTS All of the following specified work must be car A ried out by knowledgeable personnel experi enced in installation and service of refrigeration systems All personnel must be familiar with the national legal requirements and safety regula tions All safety regulations and codes of prac tice concerning the use of refrigerants must be adhered to with special attention paid to pro tection clothing and wearing of safety glasses Service and maintenance only be carried out when when the pump is stopped and the power supply disconnected 1 3
78. hall switch the pump off as the flow drops loss of sufficient differential pressure for approximately 30 s If the pressure is not restored within 15 s after restart the pump will be switched off again This procedure can be repeated a maximum of four times After that a restart should only be made after investigation of the cause of failure and acknowledging the fault indicator The pressure differential switch does not protect the pump against closed discharge running A by pass valve adjustable is required if the system design or the evaporator installation allow closed discharge running Operating refrigerant pumps partially at or at a fully closed throttled condition is not allowed and will damage the refrigerant pump The adjustable by pass valve shall be sized DN 20 for the HRP 3232 and DN 32 for the HRP 5040 HRP 5050 and HRP 8050 To set the by pass valve select the pressure difference according table 1 for the following delivery head HRP 10080 at HRP 8050 at50 m HRP 5050 at50 m HRP 5040 at30m HRP 3232 at25m flow switch must be installed when a bypass valve is not fitted in the refrigerant circuit It is known when the bypass valve is not fitted the pump is capable of producing a differential pressure without volume flow has not been stopped by the differential pressure switch The flow switch control in the pump discharge Shall stop the flow as the flow drops below 0 2 5 See WITT informati
79. igns due to the fact that large volumes of entrained vapour gas bubbles do not completely stop delivery of the refrigerant liquid Large volumes of gas occur in the pump suction when the evaporation temperature of the plant varies during the production cycle particularly when starting the compressor pull down and during the rapid loading or unloading of cmpressor steps of capacity Large amounts of gas bubbles in the pump suction line will cause the mass flow of liquid refrigerant to be reduced Special attention has to be taken to ensure that the pump suction lines are generously sized Long periods of cavitation must be avoided as this will cause premature failure of the pump lIt is important the installation instructions in chapter 6 are correctly understood and followed OPERATIONAL LIMITATIONS HRP pump models HRP 3232 HRP 5040 HRP 5050 HRP 8050 and HRP 10080 are suitable for operation with all refrigerants at 50 HZ HRP 8050 refrigerant pumps using 60 Hz supply A are only permitted for use with low density refigerants p lt 1000 e g NH3 A horizontal separator is recommended this gives greater surface area for the settlement of any oil and stable suction head conditions 5 2 DETERMINATION OF THE REQUIRED FLOW The evaporators have to be supplied with sufficient liquid refrigerant so that The surface of the evaporators is fully used e Supply to several evaporators with ifferent duties is as
80. it was intended safety devices are not used or disconnected e there have been modifications made without written approval the safety regulations are not adhered to the refrigerant pump including its filters and required safety devices has not been maintained or repaired correctly with respect to frequency or competence this includes the use of approved spare parts Opening the pump within the warranty period will void all implied or explicit guarantees Always return the pump to the supplier for repair or order an exchange pump When exchanging any parts respective spare parts only genuine spare parts are to be used Statements in this manual shall also apply to any service fluids 3 3 1 3232 5040 5050 8050 10080 Hermetische Pumpe 3 2
81. n of information Diese Zeichnung zeigt die von der Fa Witt empfohlene Steuerung der K ltemittelpumpen Typ HRP recommended wiring diagram refrigerant pump type HRP HRP 3232 HRP 5050 HRP 10080 und and seit since 01 12 2000 Datum 01 12 2000 Zeichn Nr 3 16128 0342 001 007s HRP 5040 und 8050 Blatt 1 c pene Fig 7a Recommended electrical wiring diagram with flow switch 1 51 1 3 Pype H 0 A 2 4 Schalter Switch Autom 15 13 K6 Hand Se reques freigabe cooling 18 14 safety switch for manual operating 21 7 7 22 St rung 11 reset K7 fo 14 12 K7 L B1 B2 11 Q1 95 13 Thermistor Ausl seger t Thermistor motor protection unit 1 2 14 12 Motorschutz 96 14 Overload protection 7 GE 52 13 33 15 7 e SE KaT 7 14 34 18 St rung xx B8 Diff Druck Schalter reset Pressure 2 differential Typ type switch HRP3232 seit since 01 12 2000 HRP5040 HRP8050 A1 A1 A1 A1 A1 A1 Kar K4
82. nto the duty or stand by pump Therefore it is recommended that the suction down leg protrudes into the surge drum by 30 40 mm depending on the vessel diameter see fig 6a A standard short oil drainage dome is not suitable for connecting a pump suction down leg Do not connect two or more pumps in operation by a single common pump suction line liquid header Fig Application with two pumps operation 18 Fig 65 Application with pump operation stand by NH3 3232 Arrangement of HRP 3232 Fig 63 6b
83. on sheet W 4652 0 01 minimum level cut out switch is mounted on the separator it shall be used to switch the pump off in case of a lack of refrigerant dry run protection WITI 21 77 2000
84. ould be carried out unpack the pump and check for possible damage during Shipping and the correct scope of equipment supplied Pay special attention to the electric terminal box and the con nection of the sensor wire 77 case of any damages in form your supplier immediately Excepts sensore wire cap 78 remove all plastic caps other sealings immediately prior to and not before installa tion of the pump Check that the conical suction strainer has been supplied and that the gaskets are on both sides of the suction strainer mounting ring the gaskets must be clean and lightly covered with oil Make sure all equipment connections are clear of plastic caps and rags the piping system is to be clean and free of any moisture The HRP pumps have undergone a short mechanical test run at ambient temperature with mineral refrigerant machine oil in the factory If the pump is to be used in systems where contamination with mineral oil is not allowed i e in cases with ester oil in the system the residual oil must be removed and the pump cleaned by use of solvents 72 MOUNTING INSTRUCTIONS The HRP pumps are designed with two sets of mounting pads allowing the pump to be top or foot mounted Due to formation of condensate and to avoid thermal stress on the pump pipework top supports are preferred The top supports comprise two threaded rods these are used to lower the pump for access to the conical
85. ransformer oil 8 33 PUMP INTERCHANGEABILITY The inlet and outlet connection flanges of the HRP 5040 HRP 5050 HRP 8050 and HRP 10080 pumps are of the same sizes and diameters as FAS flanges All flanges are of a square design and have four 4 bolt holes The inlet and outlet connecting flanges of the HRP 3232 are round type DIN 2635 2512 If you want to replace WITT GP pump models with HRP pump models please contact your supplier for further infor mation WITI 31 8 4 8 5 WITT
86. rew 5112 000043 454 M16x450 5112 000024 730 screw 1 6 10 5121 000004 1 Gasket suction flange 5631 000052 55 77 1 5632 000041 40 60 2 138 149 0 3 50 58 0 3 30 40 0 5 11 2 5 14 20 1 5 5 5 40 50 20 26 52 23 20 119 1 38 5 52 1 5632 000009 5632 000019 5632 000027 5632 000004 5642 000024 5641 000002 6114 000006 2162 000079 2162 000078 2162 000080 2162 000081 5631 000038 33 5632 000019 5632 000027 5632 000043 5642 000024 5641 000002 40 50 20 2162 000079 26 52 23 2162 000078 20 119 1 2162 000080 38 5 52 1 2162 000081 10 1 4 Gasket discharge flange gasket casing intermediate pieces Gasket can end gasket motor cover O ring EA10 metall gasket for 1 4 screw plug set screw protection bearing sleeve bearing bush bearing strip retaining disc 110 132 5 2 N sch 4 bearing disc 2162 000082 38 35 50x5 2162 0
87. rung ausgelegt 59 54 59 50 71 1 13 5 1 9 4 6 4 6 SECTIONAL VIEW FIG 3 B HRP 3232 46 31 91 24 83 01 02 V 03 8 412 2 4 84 33 gt 2056 N 25 D LELT RSS S 5 haa 23 10 13 42 Cl f 32 neo 61 a 28 52 1 lr 22 JET 0 El 08 e MAR 7 44 33 43 1 57 42 24 D e D dE 34 EMILE 2 14 35 37 10 21 Parts list HRP 3232 HRP 5040 Dimension Code Weight r 5960 Dimension Code No Weight r Z 5380 suction casing 2162 000305 DN 50 2162 000018 suction intermediate piece 2162 000309 1080 2150 2162 000026 1087 1 guide piece 1 2150 2162 000030 1775 discharge intermediate piece 2162 000311 1240 return intermediate piece 150 2162 000036 2037 2 guide
88. ry switch off electrical system change over two connecting cables and test pressure difference again Close the discharge valve until the pressure difference reaches a maximum value as per table 1 and set the flow switch accordingly If you hear unusual or unfamiliar sounds from the pump switch off the pump immediately and investigate the cause When the pump operates normally check after 2 hours after 8 hours and later the pressure difference and note the measured values After a period of trouble free operation 1 to 2 weeks you should inspect the coni cal filter for dirt and contamination Depending the degree of contamination the conical filter should be regularly inspected and cleaned at planned intervals 7 5 DURING NORMAL OPERATION During normal operation the pump does not require specific maintenance there is no need to refill or to change the oil It is strongly recommended that the following items are checked frequently check the conical suction filter for contamination check the pumpre circulation pipework for oil contami nation check the pressure differential of the pump check the bearing wear listen to the running sound of the pump Crackling noise indicates oil contamination once a year or as dictated by the classification rules the pump operation settings and all safety provisions should be checked The date time and results of each inspection should be recorded together with the serial number
89. should be aligned with holes using chims and if necessary use longer threaded bars with counter nuts 7 3 TO COMMISSIONING the refrigeration system must be pressure tested vac uum tested and be fully charged with refrigerant the suction and discharge valves must be fully open the valves of the pressure differential control if fitted must be fully open the pressure differential switch if fitted must be set at a difference of at least 20 kPa above the system static height static height means liquid column pressure difference between cooler inlet and separator a sufficient volume of refrigerant must be present in the separator or low pressure receiver for a minimum running time of approxately 2 3 minutes the electrical control system including all safety controls must be pre tested prior to starting the pump Check the wiring for the correct rotation of the motor 28 7 4
90. suction strainer for cleaning or replacement without the necessity to completely remove the pump It is recommended to use threaded studding 180 mm minimum to provide sufficient length to re move the conical strainer see fig 11 Advantages of the top mounting A drip tray can be easily positioned and cleaned Thermal stress stress caused by varying temperatures 15 reduced WITI 27 10 10 6b
91. y and without reducers to enable degassing Installation of angle valves or full bore ball valves is recommended Straight through valves must be installed with stem in horizontal position ball valves should not have a reduced bore on the pump side connection Do not install any additional filters dryers etc To be sure the pump will operate even at a low pressure difference resulting in maximum A capacity the diameter of the downleg to the pump must be executed as mentioned in the table below 19 Required diameter of downleg to the pump HRP3232 HRP 5040 HRP 5050 HRP 8050 HRP 10080 3 0 3 6 4 1 5
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