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Screw Compressor Package

Grasso SP1 XCB - 5B

Project PIEDRAS NEGRAS


Build number 13377
Product Description

GEA Refrigeration Technologies

GEA Refrigeration Germany GmbH


Holzhauser Strae 165
13509 Berlin
Germany
Phone: +49 (0)30 - 43 592 600
Fax: +49 (0)30 - 43 592 - 778

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COPYRIGHT
All Rights reserved.
No part of this publication may be copied or published by means of printing, photocopying, microfilm
or otherwise without prior written consent of

GEA Refrigeration Germany GmbH

herein after called manufacturer. This restriction


also applies to the corresponding drawings and diagrams.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


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TABLE OF CONTENTS
1
2
3
4
5
6

REQUIREMENTS OF WATER QUALITY (NON CORROSIVE WATER)


1.1 Water quality requirements, parameters
OPERATING LIMITS
LUBRICATING OILS FOR SCREW COMPRESSORS
3.1 Lubricating oil selection list
CONDITIONS FOR REFRIGERANT CONNECTIONS
CONDITIONS FOR LUBRICATING OIL CONNECTIONS
MAIN COMPONENTS

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

5
6
8
12
13
25
26
30

Product Description | Specification and Main components


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GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


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Requirements of water quality (non corrosive water)

REQUIREMENTS OF WATER QUALITY (NON CORROSIVE


WATER)

for Refrigerating and Air-Conditioning Systems, overland operation

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Requirements of water quality (non corrosive water)

1.1

Product Description | Specification and Main components


Main part

Water quality requirements, parameters

All water bearing components of GEA Refrigeration Germany GmbH give an optimum performance and maximum protection from corrosion, if you meet all recommended limiting values of VDI 3803 issue 2010-02 (Tab.
B3) for non-corrosive water and adequate water conditioning.
Hint!
If you dont meet following rules for limiting values of noncorrosive water GEA Refrigeration
Germany GmbH can not give warranty for water contacted components.
All components are designed for use with non-corrosive water. Water and glycol brine analysis is essential in protecting system components. Analyses prior to start up will prevent corrosion.
Following are shown required limiting values of VDI 3803, for use of carbon steel components in non corrosive
water systems.
Appearance

clear, without sediments

Colour

colourless

Odour

without

pH-level at 20C

7.5 - 9.0

Electrical conductivity

LF

mS/m

< 220

Ca2+, Mg2+

mol/m

< 0.5

General hardness, for stabilization

GH

< 20

Carbonate hardness without hardness stabilizer

KH

<4

Chloride

Cl

g/m

< 150

Sulphur

SO4

g/m

< 325

Active biological components

KBE

per ml

< 10,000

Soil alkali

Thickness factor

EZ

2-4

The use of carbon steel and cast iron required in the most of applications water conditioning with corrosion inhibitors.
The use of stainless steel requires very special monitoring of water in apply to Chloride contents (risk of stress
crack and pitting corrosion).

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

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Requirements of water quality (non corrosive water)

Hint!
Recommend for use of plate heat exchangers in refrigerant circuit
< 100 ppm Cl for the use of 1.4301 and maximum 40 C wall temperatures in the plate heat
exchanger
< 200 ppm Cl for the use of 1.4401 and maximal 100 C wall temperature in the plate heat
exchanger

fig.1:

Corrosion resistance in presence of chlorides

log (Chlorid contents mg/kg)

Wall temperature (C)

Hint!
Manufacturer recommendation: Use uncontaminated cooling agents and cooling media, in
particular in chillers and the use of plate heat exchangers.
The media quality needs to be assured through an appropriate filter on the inlet to the heat
exchanger. The mesh for such a filter needs to be 0.9 mm!
Should the chiller need to remain in operation during filter cleaning, double filters need to be
used. Pressure loss through the filter need to be taken into consideration on the building side
when configuring the pump.
GEA Refrigeration Germany GmbH recommends enlisting the services of a reputable water conditioning company.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

OPERATING LIMITS

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OPERATING LIMITS

The screw compressors can be operated under the most varied operating conditions within the given limits of
application according to the requirements involved. The limits of application listed below for the screw compressors are based on the operational principle of the screw compressor and thermodynamic ratios and are based
on practical operating conditions and design. The tabulated data apply for single, two-stage and heat pump operation. Depending on the compressor the manufacturer selected, the specific operating conditions limitations may
occur within the parameters in the table.
Hint!
For specific operations the selection and evaluation will takes place in the manufacturer's
compressor selection program "KAB COM" or "GUD".
Caution!
To avoid "zero flow" in the compressor, which can damage the compressor, the minimum
control slide positions in the manufacturer's compressor selection programs "KAB COM" or
"GUD" need to be adhered to.
"Minimal control slide position <value>% accepted start."
If the value entered is "> 0", then a limitation of the control slide path has to be done put in
place in coordination with the manufacturer. The path limitation can be set created mechanically with a stop sleeve or by installing virtual controls (virtual stop sleeve) on the compressor.
28 bar
Maximum permitted pressure

bar g.

max.

or
52 bar

Pressure ratio (p / p0)

min.

>1.5

Pressure difference (p - p0)

bar

min.

>0.8

Suction temperature (compressor inlet)

t0h

min.

> - 60

Discharge temperature (compressor


outlet)

te

max.

<120

p0: Suction pressure


E/G *)

Compr. frame size

M/N *)

C/D

Max. driving power (kW)

Max nominal torque **)

H/L
28 bar

52 bar

150

150

220

60
Hz

180

180

Nm

500

500

50
Hz

28 bar

52 bar

300

300

530

265

360

360

640

700

960

960

1700

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


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OPERATING LIMITS

E/G *)

Compr. frame size

M/N *)

C/D

H/L
28 bar

52 bar

28 bar

52 bar

Max. allowable speeds


(rpm)

min-1

6000 /
4500 1)

6000 /
4500 1)

6000 /
4500 1)

4500

4500

4500

minimum speed limits

min-1

1000

1000

1000

1000

1000

1000

R/ S/ T

V/ W /Y

Z/ XA

XB/ XC/
XD

XE/ XF

530

530

1250

1250

1800

3000

60
Hz

640

640

1500

1500

2160

3600

Max nominal torque **)

Nm

1700

1700

4000

4000

5750

9500

Max. allowable speeds


(rpm)

min-1

3600

3600

3600

3600

3600

3600

minimum speed limits

min-1

1500

1500

1500

1500

1500

1500

1)

for compressors with integrated oil pump.

Compr. frame size

Max. driving power (kW)

*) In
**)

50
Hz

the size E/G and M/N the compressors have different drive shaft ends.

When running the compressor the maximum torque falls by 25% as opposed to electrical drives.

The nominal maximum driving power is the upper limit determined by the shaft end. For reasons of bearing loads
mentioned maximum driving power will not be achieved by all delivery flow sizes available within a compressor
type. The examination is done in the compressor selection program.
For more information see chapter regarding compressor model designation.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

OPERATING LIMITS

Product Description | Specification and Main components


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Hint!
All of the following requirements must be observed!
Compressors for a discharge pressure up to 52 bar are equipped with housings made of a
material of higher strength and are fitted with special components.
Minimal overheating at suction side: "Wet" operation to be avoided.
For p = p - po 4 bar an external oil pump to be taken for frame sizes C to N.
For p = p - po 4 bar for compressors in the LT with Vi settings range a functional oil pressure of p oil p0+ 4,5 bar needs to be maintained.
For 8 gas vibration protection is required.
For CO2 usage the use of a completely electrified oil pump for injection and function oil
needs to be checked in all types of compressors depending on the operating conditions; in
types Z to XF a partially electrified oil pump or completely electrified oil pump can be examined for the function oil depending on the operating conditions.
The discharge temperature te must be 10 K above the condensing temperature (te tc + 10 K).
Due to the solubility of refrigerant in the oil following applies:

for Ammonia:

te toil + 5 K;

te toil + 10 K, when using a PAG oil (dissolving of refrigerant in the oil).

For R22, R134a, R404A, R407C, R410A, R507, CO2, natural gas, carbohydrate molecules:

te toil + 10 K, when refrigerant is dissolved in the oil.

To determine the permitted difference between the discharge temperature (te) and oil
intake temperature (toil) the set viscosity and the solubility diagram for the refrigerant-oil
pair from the lubrication supplier need to be adhered to.
If oil viscosity is 7...the 70 cSt needs to provided for the oil solubility. Take into account the
drop in viscosity due to refrigerant dissolved in the oil!
Limits for temperature differences will be considered in compressor selection programs.
The oil temperature at the compressor inlet must be at least 18C, the oil must be preheated
if necessary.
The rate of temperature change at compressor suction side should not exceed 0.1 K/s.
Direction of rotation: view of compressors driving shaft: clockwise.
For individual cases outside the permitted speed coordination needs to made with the manufacturer.

10

Maximum permitted pressure

p0

Suction pressure

Pressure difference (p - p0)

Pressure ratio (p / p0)

t0h

Suction temperature (compressor inlet)

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

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te

Discharge temperature (compressor outlet)

tc

Condensing temperature

toil

oil inlet temperature into the compressor

OPERATING LIMITS

Notes:
1. During tests of a certain application case, all the conditions specified in the table must be considered and
adhered to.
2. Should the given limits not be adhered to in individual cases, then the manufacturer needs to be contacted.
3. In addition to the operation limits listed the operating conditions relevant to the compressor type need to be
taken into account (e.g. start routine, oil pressure, oil quantity etc.)
4. Depending on the requirements of refrigeration economizer operation proceeds between the 100% and
approx. 70% control slide positions.
5. If R134a is used as a refrigerant with liquefaction temperature of > 60 C the manufacturer needs to be
contacted.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

11

LUBRICATING OILS FOR SCREW COMPRESSORS

12

Product Description | Specification and Main components


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LUBRICATING OILS FOR SCREW COMPRESSORS

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


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3.1

LUBRICATING OILS FOR SCREW COMPRESSORS

Lubricating oil selection list

Special refrigeration oils must be used for Grasso screw compressors. The selection of the oils depends on the
chemical properties of the oil, the refrigerants, the operating conditions of the plant and the required oil viscosity
during startup and run. After inquiring with the compressor manufacturer, oils other than those listed in the table
may also be used. Further information on listed oils, are given in the data sheets and diagrams of the oil manufacturer. For refrigeration compressors special refrigeration oils have to be used. The selection depends on the
refrigerant, viscosity (at least 7 cSt for oil temperature before entering the compressor), evaporating temperature
(pour point) and requirement made of the oil separation behaviour (flash point, viscosity).
Basis of the lubricating oils and used abbreviations
M

Mineral oil

M*

Mineral oil with special treatment (hydrocracked oil)

AB

Alcylbenzene

PAO

Polyalphaolefin

Polyolester

PAG

Polyalcyl glycol

"X"-"Y" Mixed oil from previous base oils


Table 1: Lubricating oils for R717 (Ammonia)
(recommended especially if minimum oil carry over is important)
Manufacturer

Type of oil

Basis

Viscosity
at
40C in cSt

Flash point Pour point


in C
in C

Remark

NSF
grade 1)

CPI
1009-68

M*

68

226

-40

H2

CPI
1008-68

M*

64.9

240

-39

H2

Klber
Summit
RHT 68

M*

68

240

-39

M*

68

232

-39

M*

58

236

-42

CPI

Klber
Lubrication

Shell

Shell
Refrigeration Oil

H2
Hydrotreated

S2 FR-A68
Petro Canada

Reflo 68A

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

H2

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LUBRICATING OILS FOR SCREW COMPRESSORS

Product Description | Specification and Main components


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Table 1: Lubricating oils for R717 (Ammonia)


(recommended especially if minimum oil carry over is important)
Manufacturer

Type of oil

TEXACO

Capella
Premium

Basis

Viscosity
at
40C in cSt

Flash point Pour point


in C
in C

M*-PAO

67

262

-42

M*

68

230

-33

M*

68

230

-36

M-PAO

62

250

-48

M*

60.6

249

-56

Remark

NSF
grade 1)

Mogul
Paramo

Komprimo
ONC 68

TOTAL

Fuchs

Lunaria
NH 68
Reniso
Ultracool 68

NXT
Next Lubricants

NXT-717

1)

Application area in food-processing industrie according to NSF (National Sanitation Foundation, www.nsf.org)

H1: Applicable in all food-processing environments where there is the possibility of incidental food contact.

H2: Applicable in all food-processing environments where there is no possibility of incidental food contact.

14

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


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LUBRICATING OILS FOR SCREW COMPRESSORS

Table 2: Lubricating oils for DX Chiller with R717 (Ammonia)


Manufacturer

CPI

Fuchs

Mobil

Type of oil

Basis

Viscosity
at
40C in cSt

CPI
412-100
Reniso
PG 68

Zerice S32

Flash point Pour point


in C
in C

PAG

98

226

-40

PAG

62

230

-35

AB

32

154

-33

Remark

NSF
grade 1)

Please contact
manufacturer

1)

Application area in food-processing industrie according to NSF (National Sanitation Foundation, www.nsf.org)

H1: Applicable in all food-processing environments where there is the possibility of incidental food contact.

H2: Applicable in all food-processing environments where there is no possibility of incidental food contact.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

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LUBRICATING OILS FOR SCREW COMPRESSORS

Product Description | Specification and Main components


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Table 3: Lubricating oils for R717 (Ammonia) and R22


Manufacturer

Type of oil

40C in cSt

Remark

NSF
grade 1)

56

180

-34

for R22
only

28

260

-30

for R717
only

PAO

69

233

-60

for R717
only

PAO

46

268

-51

for R717
only

H1

Zerice S32

AB

32

154

-33

Zerice S68

AB

68

174

-27

PAO

68

266

-45

for R717
only

H1

AB-PAO

64

211

-54

68

200

-42

46

195

-42

AB

68

190

-33

PAO

68

260

-57

for R717
only

H1

46

195

-42

68

200

-39

Aircol
AMX 68
Aircol 2294

CPI

Flash point Pour point


in C
in C

Aircol 299

Castrol

Basis

Viscosity
at

CPI
4600-46F

Gargoyle
Arctic SHC
226E
Gargoyle
MOBIL

Arctic
SHC NH 68
Gargoyle
Arctic 300
Gargoyle
Arctic C
Heavy
Reniso
S68
Reniso
Synth 68

Fuchs
Reniso
KS 46
Reniso
KC 68

16

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


Main part

LUBRICATING OILS FOR SCREW COMPRESSORS

Table 3: Lubricating oils for R717 (Ammonia) and R22


Manufacturer

Type of oil

Basis

Viscosity
at
40C in cSt

Shell
Refrigeration Oil

Flash point Pour point


in C
in C

Remark

AB

46

180

-42

AB

68

190

-39

46

226

-36

for R717
only

PAO

44

252

-51

for R717
only

68

175

-34

for R22
only

AB-PAO

62

245

-54

for R717
only

NSF
grade 1)

S4 FR-V 46
Shell
Shell
Refrigeration Oil
S4 FR-V 68
Lunaria
NH 46
TOTAL

Lunaria
SH 46
Lunaria
FR 68

Petro Canada

Reflo
Synthetic
68A

H1

1)

Application area in food-processing industrie according to NSF (National Sanitation Foundation, www.nsf.org)

H1: Applicable in all food-processing environments where there is the possibility of incidental food contact.

H2: Applicable in all food-processing environments where there is no possibility of incidental food contact.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

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LUBRICATING OILS FOR SCREW COMPRESSORS

Product Description | Specification and Main components


Main part

Table 4: Lubricating oils for R134a; R404A; R407C; R410A; R507


Manufacturer

Type of oil

Basis

40C in cSt
Aircol SW
68

Flash point Pour point


in C
in C

68

245

-39

Aircol SW
220

220

250

-27

Solest 68

64

266

-43

125

262

-27

216

271

-27

53

270

-51

80

275

-39

91

288

-39

170

260

-24

220

240

-38

66

230

-42

94

230

-42

68

230

-36

Castrol

CPI

Viscosity
at

Remark

NSF
grade 1)

Solest 120

Solest 220
Reniso
Triton

H2

SE 55
Reniso
Triton
SEZ 80
E
Fuchs

Reniso
Triton
SEZ 100
Reniso
Triton
SE 170
Reniso
PAG 220

PAG

Shell
Refrigeration Oil S4
FR-F 68
Shell

E
Shell
Refrigeration Oil S4
FR-F 100
EAL

MOBIL

18

for R134a
only

Arctic 68

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


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LUBRICATING OILS FOR SCREW COMPRESSORS

Table 4: Lubricating oils for R134a; R404A; R407C; R410A; R507


Manufacturer

Type of oil

Basis

Viscosity
at
40C in cSt

EAL
Arctic 100
Planetelf
ACD 100FY
TOTAL

Flash point Pour point


in C
in C

105

250

-30

100

270

-30

150

272

-36

Remark

NSF
grade 1)

E
Planetelf
ACD 150FY

1)

Application area in food-processing industrie according to NSF (National Sanitation Foundation, www.nsf.org)

H1: Applicable in all food-processing environments where there is the possibility of incidental food contact.

H2: Applicable in all food-processing environments where there is no possibility of incidental food contact.
Hint!
When using high-viscosity oils with high refrigerant solubility after initial fill of the plant a sufficient mixture from refrigerant and oil has to be provided before start-up the screw compressor.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

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LUBRICATING OILS FOR SCREW COMPRESSORS

Product Description | Specification and Main components


Main part

Table 5: Lubricating oils for natural gas and hydrocarbon compounds

Castrol

at 40C

Pourpoint

in cSt

in C

in C

68

234

-21

CPI
1515-68

65

224

CPI
1515-100

103

260

62

229

PD 68

CPI
1516-68

CPI

Viscosity

Flash
point

ManufacType of oil
turer

Basis

PAG

CPI
1516-100

92

260

CPI
1516-150

153

260

CPI
4600-68

60

271

CPI
4600-100

106

271

CPI
9001-68

69

241

For high temperature


application and for feed
gas control compressors
for gas turbines

108

260

CPI
1507-68

62

231

CPI
1507-100

89

260

Glygoyle
11

85

226

20

H2

H2
For heavy hydrocarbons,
for hydrocarbon cooling
applications in range of
high pressure/ low temperature
-45
For natural gas and propane

PAG

S3 R68

H2

for feed gas control compressors for gas turbines

CPI
9001-100

Corena

for natural gas compression

-34

PAG

Shell

grade 1)

For propane refrigerant


plants or volatile hydrocarbons, where the danger of
stronger dilution or condensation does not exist

Glygoyle
22

NSF

For heavy hydrocarbons,


where strong dilution or
condensation will occur

PAO

MOBIL

Remark

177

229

68

240

-41

For natural gas

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


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LUBRICATING OILS FOR SCREW COMPRESSORS

Table 5: Lubricating oils for natural gas and hydrocarbon compounds

ManufacType of oil
turer

Shell Gas
Compressor Oil

Viscosity
at 40C

Flash
point

Pourpoint

in cSt

in C

in C

PAG

190

262

-30

For natural gas and propane

PAG

142

280

-48

For natural gas, propane


and volatile hydrocarbons

-46

For natural gas, for feed


gas control compressors
for gas turbines and hydrocarbons

Basis

Remark

NSF
grade 1)

S4 PV 190

TOTAL

Klber
Lubrication

DACNIS
LPG 150

2)

Summit
NGSH-100

PAO-E

140

250

1)

Application area in food-processing industrie according to NSF (National Sanitation Foundation, www.nsf.org)

H1: Applicable in all food-processing environments where there is the possibility of incidental food contact.

H2: Applicable in all food-processing environments where there is no possibility of incidental food contact.

2)

Product rebranded fom "TOTAL Primera LPG 150" into "TOTAL DACNIS LPG 150".

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

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LUBRICATING OILS FOR SCREW COMPRESSORS

Product Description | Specification and Main components


Main part

Table 6: Lubricating oils for CO2-application


Manufacturer

Type of oil

Basis

40C in cSt
CPI
4624-46F

CPI
4624-68F
Reniso
C 85 E
Reniso
C 130 E
Reniso
C 170 E
*

Flash point Pour point


in C
in C

Remark

NSF Grade 1)

46

H1

68

H1

PAO
CPI

Fuchs

Viscosity
at

E*

278

-42

E*

136

-27

E*

170

-30

complete
miscible

H2

attend to
the miscibility gap

During application of Polyolester: t oil inlet t discharge - 4K

1)

Application area in food-processing industrie according to NSF (National Sanitation Foundation, www.nsf.org)

H1: Applicable in all food-processing environments where there is the possibility of incidental food contact.

H2: Applicable in all food-processing environments where there is no possibility of incidental food contact.
Hint!
When using high-viscosity oils with high refrigerant solubility after initial fill of the plant a sufficient mixture from refrigerant and oil has to be provided before start-up the screw compressor.

22

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


Main part

LUBRICATING OILS FOR SCREW COMPRESSORS

Table 7: Use of O-ring elastomer in screw compressors depends on refrigerant and lubricant:
Oil
Refrigerant
M

M*

CR/
HNBR

CR/
HNBR

CR

R134a, R404A, R407C, R410A,


R507, R23

M*-

AB-

AB

PAO

CR/
HNBR

CR

HNBR

CR

CR/
HNBR

CR

CR

CR

HNBR

R290 (propane), R1270 (propylene)

HNBR

HNBR

R744 (Carbon dioxide CO2)

CR

HNBR

CR

R717 (ammonia)
R22

PAO

PAO

PAG

Abbreviations used for the elastomers:


CR Chloroprene (Neoprene caoutchouc)
HNBR Hydrogenated nitrile butadiene caoutchouc
Hint!
If natural gas and hydrocarbon compounds are used as compression medium (Tabelle
5;page 20), O-ring elastomer should be requested from the manufacturer depending on the
operation condition.
Hint!

The pour point describes the cold fluidity of an oil and represents a non-guaranteed guide value
for the minimum evaporating temperature. [The pour point is defined as the temperature at which
the fluidity of an oil decreases to an extent that it does not leave a jar within 5 sec under certain
conditions.]

Compressors are equipped with suitable elastomers at the sealing point, which are selected
dependent on the refrigerant and lubricant. (Table 7; page 23)

When selecting the type of oil, the compatibility of the sealant material used in the compressor for
o-rings (elastomer quality) must be taken into consideration in addition to the refrigerant. (Table
7; page 23)

Not all the listed oil types can be used for an existing compressor. It is absolutely necessary to
assign the oil grade depending on the elastomer used, even if the refrigerant is the same.

Oil grades are not always compatible with each other (cannot be mixed).

Changing from one oil type to another can lead to disruptions in the operation of the compressor
and to leakages at the sealing points. The compressor manufacturer should always be contacted
before changing the oil type.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

23

LUBRICATING OILS FOR SCREW COMPRESSORS

Product Description | Specification and Main components


Main part

Caution!

24

The specified range of viscosity of the lubricating oil upstream of the compressor has to
be observed in any case. At the same time, it must be noted that refrigerant/oil combinations are possible in which, dependent on the pressure and temperature in the oil separator of the package, the refrigerant dissolves in the oil. This leads to a reduction of the viscosity of the pure oil and to the formation of foam when the solution equilibrium is altered
due to pressure reduction or temperature increase. In this case, the oil must be cooled by
a minimum temperature difference, which is calculated in the compressor selection programme for the given operating conditions. The compressor may only be operated if the
oil entry temperature is complied with in accordance with the compressor selection programme!

The oil separation behaviour of the types of oil given in the Table can vary greatly (e.g.
influence of oil vapour pressure, oil viscosity, solubility, final compression temperature).

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


Main part

CONDITIONS FOR REFRIGERANT CONNECTIONS

CONDITIONS FOR REFRIGERANT CONNECTIONS


Filter mesh size

Port

[m]

Remarks

Suction nozzle
Discharge nozzle
Series SH, MC:
100 m

Economiser port

Liquid injection
Port

During pressure equalisation after stopping of the compressor, care should be taken to prevent foreign matter which
are bigger than the mesh size in the suction filter from getting into the compressor together with refrigerant vapour
flowing back from the plant components arranged downstream of the compressor.
The operating range is between control slide positions of
100% and 70% depending on operating conditions. At partload operation, care should be taken to maintain the projected intermediate pressure.

Series LT:
140 m

Refrigerant injection should only be used in conjunction


with inertia-free temperature measurement on the compressor discharge side (Delay time k<10 s). When operating
with refrigerant injection, the regulating valve should be
sized to ensure that no liquid refrigerant enters the oil separator downstream.

Caution!
Liquid (refrigerant or oil) can lead to destruction of the filter at the suction and economizer
connection.
Hint!
Due to the working principle of screw compressors dynamic pressure rates, input speed multiplied by number of lobes of male rotor, exist at compressor connections. The dynamic pressure rates and the static pressures at connections interfere with each other. Pay attention to
the active load when calculating the pipework layout.

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

25

CONDITIONS FOR LUBRICATING OIL CONNECTIONS

Product Description | Specification and Main components


Main part

CONDITIONS FOR LUBRICATING OIL CONNECTIONS


Type

Function, purpose

Oil

Volume flow

Oil pressure *)**)

pum
p

Qoil

poil

l/min
min
C, D,
E, G
H, L,
M, N

P, R,

functional oil1)

without

functional oil2)

without

Oil injection

without

functional oil3)

with

bar

max

Oil viscosity

Filter

Filtration
mesh

mm2/s

max

ma
x

min

max

p+3.55)

80

70

154)

p+3.55)

80

70

15

p-2.5

p+3.55)

10
0

70

100

p+0.5

p+4

80

70

15

p-2.5

p+3.55)

10
0

70

140

80

70

15

min

see hints

p+0.55)

page 29

p-4.5
p+0.55)

see hints

toil

p-2,5

page 29

see hints

S, T
Oil injection

without

page 29

Chamber 16) p+0.5... 4.5


Capacity control

with

Chamber 26)p0+7
Chamber 36) p04.5

balancing piston
heat pump
V, W, Y functional oil3)

without

10

20

with

p-1.5

10
0

70

15

p+0.5

p+4

80

70

15

p-2.5

p+3.55)

10
0

70

140

80

70

15

10
0

70

15

see hints
Oil injection

without

page 29

Chamber 16) p+0.5... 4.5


Capacity control

with

Chamber 26) p0+7


Chamber 36) p04.5

balancing piston
Heat pump

26

without

15

25

p-1.5

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


Main part

Type

Function, purpose

CONDITIONS FOR LUBRICATING OIL CONNECTIONS

Oil

Volume flow

Oil pressure *)**)

pum
p

Qoil

poil

l/min
min
Z, XA;
XB,
XC,
XD,

functional oil3)

bar

max

with

toil

Oil viscosity

Filter

Filtration
mesh

mm2/s

min

max

ma
x

min

max

p+0.5

p+4

80

70

15

p-2.5

p+3.55)

10
0

70

140

80

70

15

10
0

70

15

see hints
Oil injection

without

page 29

XE, XF
Chamber 16) p+0.5... 4.5
Capacity control

with

Chamber 26) p0+7


Chamber 36) p04.5

balancing piston
Heat pump

without

20

35

p-1.5

Discharge pressure [bar.g]

poil

Oil pressure [bar.g]

p0

Suction pressure [bar.g]

toil

Oil temperature [C]

Qoil

Volume flow rate oil [l/min]

Viscosity [mm/s] = [cSt]

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

27

CONDITIONS FOR LUBRICATING OIL CONNECTIONS

Product Description | Specification and Main components


Main part

poil

oil pressure at the respective connection point of the compressor

Discharge pressure

1)

functional oil flow

For bearing, shaft seal, balance piston, oil injection and internal oil pump
(for capacity control and Vi setting)

2)

functional oil flow

For bearings, shaft seal, balance piston, oil injection and internal oil pump
(for capacity control and Vi setting)

3)

functional oil flow

4)

oil filter in compressor

5)

Oil pressures when using an external oil pump

6)

Chambers 1,2 and 3 are defined in schematic diagram overleaf

*)

Values may deviate depending on the operating conditions. The requirements in the manufacturer specifications for operating conditions need to be adhered to.

**)

After start-up of the compressor drive motor, a failure of the oil pressure poil is permissible for 10 sec
within the first minute, and afterwards for 6 sec.

For bearings, cam seals, balance pistons, capacity control, Vi setting

Hint!
Due to the screw compressors working principles, dynamic pressure points occur proportionally to the drive speed multiplied by the number of teeth on the male rotor on the connection
with the screw compressor. These dynamic pressure effects occur in concert with the static
pressure on the connections. These loads need to be included when designing the connection
pipes.

28

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

Product Description | Specification and Main components


Main part

CONDITIONS FOR LUBRICATING OIL CONNECTIONS

Hints for the oil circuit


Hint!
1. "KAB COM" and "GUD" compressor selection programs from the manufacturer shall be used for
selection and testing the screw compressor for the operating conditions. It gives additional information about the oil circuit of the compressor and application limits of the compressors belonging to the series SH and MC with integral oil pump. The compressor selection program explains
what operating conditions will require an external oil pump for the functional oil circuit (external
oil pump required).
2. The oil volume flows needed to safely operate the compressor will be indicated in the compressor selection program based on operating conditions. The oil pump shall be measured so that
the swept volume reaches the value of
Voil pump = K V functional oil.
K= 1.25 for ammonia
K = 1.4 for all other media to be pumped
In the Grasso selection programme the terms
- Functional oil flow
- Total oil flow
are used.
3. LT Series
Hydraulic chambers for capacity control and Vi adjustment:
The hydraulic chamber for capacity control and Vi adjustments shall be supplied via solenoid
valve blocks that are flanged on the compressor housing. The pressures entered in the table
Chapter 5, page 26via the functional oil pressure as well as from the regulating valves integrated in the blocks.

Schematic diagram: hydraulic chambers for capacity control and Vi adjustment.


1, 2 : Hydraulic chambers for capacity control
1, 2, 3 : Hydraulic chambers for combined Vi-partial load adjustment

GEA Refrigeration Germany GmbH | PD_1 | Generated 04.08.2014

29

Main Components

31

Product Description | Specification and Main components


Main part

MAIN COMPONENTS
990563

oil separator

990336

oil management center

990361

oil filter

Tschan

coupling

990340

oil heater

990333

suction filter

HS Cooler

refrigerant cooled oil cooler

990293

pressure transducer

990294

pressure transducer

990215

resistance thermometer

990308

overflow valve

990320

stop valve

990380

stop valve

990394

check valve

990415

quick acting valve

990423

insert for thermostatic 3-way-valve

990354

level switch

990362

pressure gauge

990373

test point selector switch

990359

solenoid valve

990421

safety pressure limiter

990290

fixator

990262

levelmount elements

GEA Refrigeration Germany GmbH | PD_1 | Generated 17.09 .2014

PRODUCT DESCRIPTION
MAIN PART
Oil separators

1.3

OIL SEPARATOR

The oil separators design is standardised.

The oil separators are used in screw compressor


packages and chillers of Medium and Large series,
single stage and DuoPack designs.

1.1

Construction

Nominal sizes are defined according to the project


and depends on oil separators size as well as used
compressor type.

Function

Changing the fine oil separation cartridges

The oil separator is selected depending on the project conditions, the refrigerant used, the oil brand
used, and the degree of separation required.

Oil separators with diameters of 508 mm ...


1400 mm: The cartridges for oil fine separation are
replaced through the refrigerant outlet port.

Oil separators with oil fine separation cartridges are


used as standard version for all refrigerants.

For this purpose, remove the pipe bend mounted on


the oil separator.

Oil separation
Caution!

The refrigerant-oil mixture is led into the lower part of


the vertical oil separator.

Compensate the pressure and remove


the refrigerant before starting the replacement!

There, the first step of oil separation is performed.


The lower part of the oil separator is also used as an
oil receiver.

Afterwards, follow the Maintenance Instructions for


screw compressor units.

The fine separation of the aerosol-type oil portion


from the refrigerant is carried out in the upper part of
the oil separator by means of coalescing cartridges.

Equipment of Grasso screw compressor packages/ chillers

The oil separated in the fine separation section of


the oil separator is returned to the low-pressure side
via the connection for oil return.

1.2

Oil separator diameter


(in mm)

max. number of oil fine


separation cartridges

508

4 x type I

610

7 x type I

711

9 x type I

813

13 x type I

914

16 x type I

1016

19 x type I

1200

19 x type I

1400

19 x type I

Maintenance

The oil fine separation cartridges should be replaced


at the latest after 20000 hours of operation or after
three years.
An earlier replacement is required if an increased
amount of oil is splashed (oil is recharged at unusually short intervals).

GEA Refrigeration Germany GmbH

_990563_pd_mp_gbr_1_.doc
16.04.2012

PRODUCT DESCRIPTION
MAIN PART
Oil separators

1.3.1

Oil separator 508, 610, 711, 813, 914

View

fig. 1:

View of oil separators 508, 610, 711, 813, 914

N1

Refrigerant inlet

N2

Refrigerant outlet

N3

Overflow valve/ dafety calve

N4a

Oil outlet to oil cooler

N4b

Oil outlet to OMC-block (oil filter)

N5

Gas pulsation protection

N6

Oil return from from oil fine separation stage to the low pressure side

N7

Oil drain

N8

Oil heater

N9

Sight glass oil fine separation stage

N10

Sight glass oil level in oil receiver

N11

Measuring line/ bypass line SFC - check valve

N12

Pressure transmitter discharge pressure

N13

Level controller MIN

N14

Level controller MAX

N15

Oil temperature oil receiver

N16

Safety pressure limiter

N17

Oil temperature - discharge temperature

N18

Pressure test

N19

Level controller MID

_990563_pd_mp_gbr_1_.doc
16.04.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Oil separators

Spare parts - for NH3-Standard

Spare part

Grasso Ident

Dimensions

Quantity

Fine oil separation cartridge


(optionally)

362698044 (N)
362698047 (N)

O-Ring refrigerant inlet flange NB 100 (for units of Medium series)

762925137 (N)

125 x 5

O-Ring refrigerant inlet flange NB 150 (for units of Large series)

762925149 (N)

180 x 5

O-Ring refrigerant outlet, oil separator diameter 508

762925159 (N)

230 x 5

O-Ring refrigerant outlet, oil separator diameter 610, 711, 813, 914 762998098 (N)

330 x 5

2, 3

Gasket, refrigerant outlet, when connecting combined stop/check


valve

Nominal flange diameter NB 40

763000048

TG40/ EN1514-1

Nominal flange diameter NB 50

763000049

TG50/ EN1514-1

Nominal flange diameter NB 65

763000050

TG65/ EN1514-1

Nominal flange diameter NB 80

763000051

TG80/ EN1514-1

Nominal flange diameter NB 100

763000052

TG100/EN1514-1

Nominal flange diameter NB 125

763000053

TG125/EN1514-1

Nominal flange diameter NB 150

763000054

TG150/EN1514-1

Nominal flange diameter NB 200

763000056

TG150/EN1514-1

O-ring, refrigerant outlet with separate check valve

Nominal flange diameter NB 40

762925121 (N)

60 x 5

Nominal flange diameter NB 50

762925128 (N)

80 x 5

Nominal flange diameter NB 65

762925132 (N)

100 x 5

Nominal flange diameter NB 80

762925134 (N)

110 x 5

Nominal flange diameter NB 100

762925138 (N)

130 x 5

Nominal flange diameter NB 125

762925147 (N)

170 x 5

Nominal flange diameter NB 150

762925148 (N)

190 x 5

Nominal flange diameter NB 200

762925182 (N)

240 x 5

762925130 (N)

90 x 5

Gasket connection of level controller MAX

438698032

A20 x 24

Gasket for sight glass N9

438698077

A52 x 60

O-ring cover gasket of oil fine separation cartridge

762925132 (N)

100 x 5

Gasket for cartridge fixing

438698023 (N)

A14 x 20

O-Ring integrated check valve, oil separator diameter 508

762925155 (N)

210 x 5

O-Ring refrigerant outlet, oil separator diameter 610, 711, 813, 914 762998097 (N)

310 x 5

O-ring connection overflow valve, safety valve

(N) = HNBR-design possible, dependent on refrigerant and oil


1 Spare parts for oil separators for alternative refrigerants (freons) and for oil separators for chemical engineering on request
2 In compliance with the number of oil fine separation cartridges used (cf. Customer parts list)
3 Standard application, other designs for further refrigerants possible on request
4 Dimensions of O-ring valid only when Grasso connection- and companion flanges are used
5 In compliance with the number of oil fine separation cartridges used (cf. Customer parts list)
6 O-ring for this optional equipment type only
7 O-ring for this optional equipment type only

GEA Refrigeration Germany GmbH

_990563_pd_mp_gbr_1_.doc
16.04.2012

PRODUCT DESCRIPTION
MAIN PART
Oil separators

1.3.2

Oil separator diameters 1016, 1200 and 1400

View

fig. 2:

View of oil separator, diameters 1016, 1200 and 1400

N1

Refrigerant inlet

N2

Refrigerant outlet

N3

Safety valve/ overflow valve

N4a

Oil outlet to oil cooler

N4b

Oil outlet to OMC-block (oil filter)

N5

Gas pulsation protection

N6

Oil return from from oil fine separation stage to the low pressure side

N7

Oil drain

N8

Oil heater

N9

Sight glass oil fine separation stage

N10a

Sight glass - MIN

N10b

Sight glass - MID

N10c

Sight glass - MAX

N11

Measuring line/ bypass line SFC - check valve

N12

Pressure transmitter discharge pressure

N13

Level controller MIN

N14

Level controller MAX

N15

Oil temperature oil receiver

N16

Safety pressure limiter

N17

Oil temperature - discharge temperature

N18

Pressure test

_990563_pd_mp_gbr_1_.doc
16.04.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Oil separators

N19

Level controller MID

Spare parts - for NH3-Standard

Spare part

Grasso Ident

Dimensions

Quantity

Fine oil separation cartridge


(optionally)

362698044 (N)
362698047 (N)

O-Ring refrigerant inlet flange NB 150


(for units type P ... XA)

762925149 (N)

180 x 5

O-Ring refrigerant inlet flange NB 200


(for units type XB ... XD)

762925182 (N)

240 x 6

O-Ring refrigerant outlet

762998098 (N)

330 x 5

9, 10

Gasket, refrigerant outlet, when connecting combined stop/check valve

Nominal flange diameter NB 150

763000054

TG150/EN1514-1

Nominal flange diameter NB 200

763000056

TG150/EN1514-1

O-ring, refrigerant outlet with separate check valve

11

Nominal flange diameter NB 150

762925148 (N)

190 x 5

Nominal flange diameter NB 200

762925182 (N)

240 x 5

Nominal flange diameter NB 250

762925190 (N)

310 x 8

Nominal flange diameter NB 300

762925195 (N)

360 x 5

O-ring connection overflow valve, safety valve

762925130

90 x 5

Gasket connection of level controller MAX

762925096

A20 x 24

Gasket for sight glasses N9, N10

438698077

A52 x 60

O-ring cover gasket of oil fine separation cartridge

762925132 (N)

100 x 5

12

Gasket for cartridge fixing

438698023 (N)

A14 x 20

12

O-Ring integrated check valve, oil separator

762998097 (N)

310 x 5

13

8 Spare parts for oil separators for alternative refrigerants (freons) and for oil separators for chemical engineering on request
9 In compliance with the number of oil fine separation cartridges used (cf. Customer parts list)
10 Standard application, other designs for further refrigerants possible on request
11 Dimensions of O-ring valid only when Grasso connection- and companion flanges are used
12 In compliance with the number of oil fine separation cartridges used (cf. Customer parts list)
13 O-ring for this optional equipment type only

GEA Refrigeration Germany GmbH

_990563_pd_mp_gbr_1_.doc
16.04.2012

Product Description | OMC-Block I, Simplex filter system


Main part

1
1.1

OMC-BLOCK I, SIMPLEX FILTER SYSTEM


View

It is possible that due to special operating conditions


and installations there may be an overlapping as
regards the type selection in the predefined and optimal design and selection.
The OMC-block including the main components to
be connected can be used by external component
factories, which use Grasso screw compressors in
their products. For this, however, a coordination with
GEA Refrigeration Germany GmbH is necessary.

1.3

Safety Instructions

This installation and operation manual is an essential


component of the OMC-block delivery. Always keep
this manual in a readily accessible place near the filter.

fig.1:

1.2

OMC-block, view

Avoid danger to life and limb of the user or third


persons

Ensure the operational safety of the OMC-block

Preclude operation failures and environmental


damages due to wrong handling and mis-use

Features

The OMC-block is a main component of the screw


compressor packages and liquid chillers of GEA
Refrigeration Germany GmbH. With its functionalities, it forms the oil circuit necessary for the respective application. This guarantees a high operational
safety of the components and all the products. The
various connection possibilities and types cover a
broad range of application. The OMC-block is combined with a standardised filter system and oil pump
units and forms the central control and operator unit
in the oil circuit.
The selection of the OMC block version depends on
the following operating conditions:

The German version of this manual is the predominant and binding version. Take care that all persons
being charged with the installation, operation, maintenance and repair of the coupling have read and
understood this manual and that all instructions contained therein are carefully observed in order to:

Type of screw compressor

The relevant instructions and regulations regarding


safety at work and environmental protection have to
be observed while transporting, mounting and dismounting the coupling.
The OMC-block shall be operated, mounted, maintained and repaired by authorized, trained and
instructed personnel only. We do not assume any liability or warranty for any damages resulting from the
use of accessories and parts that are not originally
delivered by GEA Refrigeration Germany GmbH.

1.4

Intended use

Operation with external or internal oil pump

Type of screw compressor unit / liquid chiller unit

The following conditions must be met for the intended use:

Operation as single-stage, two-stage or as DuoPack

The OMC-block must only be operated in normal


industrial atmospheres. Aggressive media may
attack the components, screws and elastic buffer
rings. So the aggressive media represent a risk
for the operational safety of the OMC-block.

The OMC-block shall only be used and operated


within the frame of the conditions as defined in
the performance or delivery contract.

Operation with external oil cooler or refrigerant


injection for oil cooling

maximum oil volume flow

Type of oil

Refrigerant

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

can be directly flange-mounted particularly


Grasso oil pump units - see separate documentation

Warning!
The OMC-block is for use at a maximum operating pressure of 28 bar g.p.
provided.

Any change in the operation conditions or service parameters requires the verification of the
design.

1.5

Storage

On receipt of the goods, immediately check that all


parts are on hand and are as ordered. Eventual shipping damages and/or missing parts have to be reported in writing.
The OMC-block can be stored in a dry place under
roof at normal ambient temperatures for a time
period of 6 months. Storage for a longer period
requires the application of a long-term preservation.
The OMC-Block must not be exposed to any aggressive products, extreme temperatures or humidity. Do
not store the OMC-block along with acids, alkaline
solutions or other caustic chemicals. The place of
storage should be dry and free from dust. The air
humidity should not exceed 65% and condensation
is not permissible

Technical data

1.6

Features of the OMC-block series:

external - particularly Grasso oil pump units see separate documentation or products of other
manufacturers

prepared for mounting a simplex filter system


with standardised oil filter element

easy replacement due to standardised flange


dimension in the block mounting and inspection
cover

low pressure drops in the OMC-block due to optimised ducting for oil distribution

universal overall system when using diverse


refrigerants and oil circuit systems

prepared for the installation of 3-way valve element with different temperature control ranges
see table "Selection range: Inserts for thermostatic 3-way valve"

simplified spare part management world-wide

simplified inventory management

Assurance of a long service interval

easy assembly on base frames due to standardised mounting points

simplified maintenance

prepared for mounting directly flange-mounted


oil pump units or external oil pump units

Fluids:

Lubricating oils with refrigerants NH3, R134a, R404A, R507 (others on request) in accordance with EN
378

Max. operating pressure:

28 bar g.p.

Max. operating temperature:

120

Oil viscosity:

approx. 30 cSt - during operation


max. 500 cSt for a short time during starting of the screw compressor unit/chiller unit

Filter element:

see separate documentation


Standard: Glass fibre filter element, mesh size 25 m

Weight (without filter):

OMC I - 32

60 kg

OMC I - 40

72 kg

OMC I - 50

84 kg

OMC I - 65

136 kg

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

Main dimensions L x W x H (in


mm)

Approval:

OMC I - 32

520 x 425 x 435

OMC I - 40

525 x 455 x 435

OMC I - 50

525 x 455 x 505

OMC I - 65

600 x 525 x 600

CE in accordance with DGRL 97/23/EC, Work's acceptance (others on request)

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.7

Function and design

The OMC-block I series is used in oil circuits with


external oil cooler.
Optionally the OMC-block can be equipped with a 3way valve element (for ensuring a minimum oil temperature when starting the compressor).

1.8

Quality and Standardization

The OMC-blocks for applications with fluids of


groups 1 and 2 are pressurized items in line with the
Pressure Equipment Directive 97/23/EC (DGRL).
They are given CE marks and approval in line with
the requirements according to category I.
Approval by classification companies and according
to non-EU regulations on request.
fig.2:
OMC-block I, construction
The view shows an OMC-block I with directly flange-mounted oil
pump unit and block mounting filter

The OMC-block includes the oil distribution system


of the oil circuit of Grasso screw compressor units
and chiller units. Necessary control and shutoff fittings are integrated in the OMC-block. Connections
for temperature and pressure sensors as well as
service ports are present. Oil pump unit and block
mounted filter are configured separately depending
upon the size of the OMC-block.

1.9

The OMC-block is not a device or component in the


sense of the ATEX product directive 94/9/EC and
therefore does not have a CE mark.
The use in potentially explosive atmospheres in
accordance with directive 94/9/EC (ATEX) is possible only on request.
In the event that the OMC-block is used in potentially
explosive atmospheres, potential compensation must
be ensured.

Numbering and abbreviations

Position numbers of the R+I flow charts and component overviews


Position number

Component

35 + 36

Oil filter housing with fine filter element see separate documentation

65

Stop valve - oil circuit (connection of oil separator)

70

combined stop/ check valve - functional oil

75

Oil pressure relief valve (adjustment of oil pump pressure)

80

Control valve injection oil with integrated check valve function

90

Stop valve - oil drain and oil charging (integrated into the oil filter housing)

110

Pressure transducer - pressure after oil pump unit (functional oil)

125

Resistance thermometer oil temperature

135

Stop valve - venting (integrated into the oil filter housing)

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

Position numbers of the R+I flow charts and component overviews


Position number

Component

215 + 216

thermostatic 3-way valve with control element

220

Stop valve - oil circuit (bypass port of the oil cooler)

395

Pressure transducer - pressure after oil filter (injection oil)

415

Stop valve - pressure transducer (pos. 110)

420

Stop valve - pressure transducer (pos. 395)

460

Stop valve - service injection oil

465

Stop valve - service functional oil


Oil pressure control valve

1675

Factory default setting 4 bar - sealed, only for Grasso SPduo with FU-controlled oil
pump unit

Connections of the R+I flow charts and component overviews


Code

Remark

A12 + C12

Functional oil Grasso SP1 and Grasso SP2

AD + CD

Functional oil Grasso SPduo

Oil injection

BB

Bore hole for fixing - 4x M16

B1

Additional oil injection

BOP

Bore hole for fixing flange-mounted oil pump unit

DP

Connection for capacity control Grasso SP2 and/or balancing piston (with oil pump pressure)

DU

Balancing piston (without oil pump pressure)

IC

Oil inlet from oil cooler

IO

Oil inlet from oil separator

Oil drain and oil charging in the oil filter housing (mounting position below)

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

Connections of the R+I flow charts and component overviews


Code

Remark

OP1

Oil pressure before oil filter

OP2

Oil pressure after oil filter (injection oil)

OP4

Oil pressure after oil pump unit (functional oil)

OPI

Suction side oil pump unit


(Connection of directly flanged oil pump of OMCI) 1 DN 32 and DN 40 // 2 DN 50 and DN
65

OPO

Discharge side oil pump unit


(Connection of directly flanged oil pump of OMCI) 1 DN 32 and DN 40 // 2 DN 50 and DN
65

OT

Temperature sensor oil temperature

S2

Service injection oil

S4

Service functional oil

TB

Bore hole stop and transportation - M16

U1 + U2

Reference line for oil pressure = final pressure

Venting in the oil filter housing (mounting position above)

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.10

Ausfhrung OMC-Block: OMC I SP1-2 with oil pump unit and simplex filter system

Application in screw compressor packages of series Grasso SP1 Medium, Grasso SP1 Large and Grasso SP2
nominal width

Grasso Ident

DN 32

352198262 (N)

DN 40

352198263 (N)

DN 50

352198264 (N)

DN 65

352198265 (N)

fig.3:

R+I flow charts OMC I SP1-2 with oil pump unit and simplex filter system

fully opened for Grasso SP2

**

Install reference line when mounting the OMC-block

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.11

Design of the OMC-Block: OMC I SP1 with oil pump unit integrated into compressor
and simplex filter system

Application in screw compressor packages Grasso SP1 medium


nominal width

Grasso Ident

DN 32

352198260 (N)

DN 40

352198261 (N)

fig.4:

R+I flow chart OMC I SP1 with oil pump unit integrated into compressor and simplex filter system

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.12

Design of the OMC-Block: OMC I SPduo with oil pump unit and simplex filter system

Application in screw compressor packages of series Grasso SPduo Medium and Grasso SPduo Large
nominal width

Grasso Ident

DN 40

352198274 (N)

DN 50

352198275 (N)

DN 65

352198276 (N)

fig.5:

R+I flow chart OMC I SPduo with oil pump unit and simplex filter system

p = 4 bar, sealed

**

Install reference line when mounting the OMC-block

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.13

Design of the OMC-Block: OMC I SPduo with oil pump unit integrated into compressor and simplex filter system

Application in screw compressor packages of the series Grasso SPduo medium


nominal width

Grasso Ident

DN 40

352198272 (N)

DN 50

352198273 (N)

fig.6:

10

R+I flow chart OMC I SPduo with oil pump unit and simplex filter system

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.14

General assembly drawings

fig.7:

OMC-Block I, general assembly drawing 1

fig.8:

OMC-Block I, general assembly drawing 2

fig.9:

OMC-Block I, general assembly drawing 3

fig.10:

OMC-Block I, general assembly drawing 4

fig.11:

OMC-Block I, general assembly drawing 5

fig.12:

OMC-Block I, general assembly drawing 6

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

11

Product Description | OMC-Block I, Simplex filter system


Main part

1.15

Types

Nominal
guide value

Oil pump integrated into


the compressor

Oil pump
External

Application in

simplex filter
system

Max. oil volume flow


(l/min)

Designation
Grasso Ident (CR)
Grasso Ident (HNBR)
OMCI-32SP1-S

DN 32

Grasso SP1

80

352198260
352198260N
OMCI-40SP1-S

DN 40

Grasso SP1

180

352198261
352198261N
OMCI-40SPD-S

DN 40

Grasso SPduo

180

352198272
352198272N
OMCI-50SPD-S

DN 50

Grasso SPduo

240

352198273
352198273N
OMCI-32SP1-S-P

DN 32

Grasso SP1

80

352198262
352198262N

DN 40

Grasso SP1
Grasso SP2

OMCI-40SP12-S-P
X

180

352198263
352198263N
OMCI-40SPD-S-P

DN 40

Grasso SPduo

180

352198274
352198274N

DN 50

Grasso SP1
Grasso SP2

OMCI-50SP12-S-P
X

240

352198264
352198264N
OMCI-50SPD-S-P

DN 50

Grasso SPduo

240

352198275
352198275N

DN 65

Grasso SP1
Grasso SP2

OMCI-65SP12-S-P
X

340

352198265
352198265N
OMCI-65SPD-S-P

DN 65

Grasso SPduo

340

352198276
352198276N

12

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.16

Main components and dimensioning of connection port


Hint!
Screwed connections with moulded profiled ring are additionally to be covered with Loctite.

OMC I SP1
OMC I SP1-2
Position number
P+I diagram

Name

Nennweite
OMC-block

OMC I SPduo
OMC I SPduo

Oil pump

External oil
pump

Compressor
integrated

Grasso Ident

Oil pump

External oil
pump

Compressor
integrated

Grasso Ident

Grasso Ident
Oil filter housing
complete with oil
filter element,

35+36

see technical documentation 990361 for overall picture

DN 32

352100411-H20-CR

Oil fine filter element

DN 50

not used

352100411-H20-HNBR
352100413-H20-CR

DN 40

36 1

Grasso Ident

352100413-H20-HNBR
352100415-H20CR

352100415-H20CR

352100415-H20CR

352100415-H20HNBR

352100415-H20HNBR

352100415-H20HNBR

not used

DN 65

DN 32

Oil inlet from oil


cooler

IC + IO

Oil inlet from oil


separator

216 4

DN 50

65 + 220

352100417-H20HNBR

352100417-H20HNBR

Tube connection 42.4x2.6

not used

Block not available

Tube connection 48.3x2.6


Tube connection
60.3x2.9
Tube connection
76.1x2.9

Tube connection 60.3x2.9


Block not available

Tube connection
76.1x2.9

Block not available

see data sheet 990423 for an overview of control elements


NB 32 - NB 65

Control elements of type DN 50 for all versions of OMC-block


1x control element for OMC-blocks DN 32 - DN 50
2x control element for OMC-block DN 65

DN 32

352100417-H20CR

DN 40

DN 65

control element
for thermostatic
3-way-valve pos.
215

352100417-H20CR

stop valve oil


cooler oil inlet

DN 40

stop valve - oil


separator oil inlet

DN 50

DN 65

AVR - DN 32

Block not available


AVR - DN 40

AVR - DN 50

AVR - DN 65

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

AVR - DN 50
Block not available

AVR - DN 65

Block not available

13

Product Description | OMC-Block I, Simplex filter system


Main part

OMC I SP1
OMC I SP1-2
Position number
P+I diagram

Name

Nennweite
OMC-block

External oil
pump
Grasso Ident

Oil pump
Compressor
integrated

OMC I SPduo
OMC I SPduo
External oil
pump

Compressor

Grasso Ident

Grasso Ident

M-90

V-135

NB 32 - NB 65

Connection and
stop valve for
venting

NB 32 - NB 65

Threaded connection M 16x1.5 in the oil filter housing for screw-in threaded
connection or prepared for direct installation of the Grasso service valve
(Grasso Ident 501306623awp63) with G1/2" connection thread (see documentation 990320)

Oil injection

DN 50

DN 65

DN 32

Tube connection 33.7x2.6

Additional oil
injection

DN 50

DN 65

DN 32

80

Tube connection
48.3x2.6
Tube connection
60.3x2.9

Threaded connection M 16x1.5

AD + CD

14

Threaded connection M 26x1.5


Threaded connection M 33x2.0

Functional oil
SPduo

Block not available

Block not available

Threaded connection M 26x1.5


Block not available

RVAK - DN 25
RVAK - DN 32

DN 50

RVAK - DN 40

DN 65

RVAK - DN 50

Threaded connection M 33x2.0

Block not available

Block not available

without valve

DN 40
Functional oil
SP1 and SP2

Tube connection
60.3x2.9

Threaded connection M 22x1.5

DN 40

DN 32

A12 + C12

Tube connection 48.3x2.6


Block not available

Control valve
Injection oil

Block not available

Tube connection 42.4x2.6

DN 40

Grasso Ident

Threaded connection M 22x1.5 in the oil filter housing for screw-in threaded
connection or prepared for direct installation of the Grasso service valve
(Grasso Ident 501306625awp63) with G1/2" connection thread (see documentation 990320)

DN 40

B1

integrated

Connection and
stop valve for oil
draining and oil
charging

DN 32

Oil pump

DN 50

Block not available


without valve

Threaded connection M 22x1.5

Block not available

Block not available

Threaded connection M 22x1.5

Threaded connection M 33x2.0

DN 65

Threaded connection M 42x2.0

DN 32

closed tight

closed tight
Block not available

closed tight

closed tight

Block not available

Block not available

Block not available

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

OMC I SP1
OMC I SP1-2
Position number
P+I diagram

Name

Nennweite
OMC-block

External oil
pump
Grasso Ident

Oil pump
Compressor
integrated

OMC I SPduo
OMC I SPduo
External oil
pump

Oil pump
Compressor

Grasso Ident

Grasso Ident

integrated
Grasso Ident

DN 40

Threaded connection M 42x2.0

DN 50

Threaded connection M 48x2.0

Block not available

DN 65

Flange AWPstandard with


groove and
spring

Block not available

Tube connection
48.3x2.6
NB 32 - NB 40
70 2

Shutable check
valve

75 2

Oil pressure control valve

1675 2

Oil pressure control valve

RVA - DN25/32

NB 50 - NB 65

RVA - DN40/50

NB 32 - NB 65

RVD - DN40/50

Block not available

without valve

without valve

OPI + OPO

NB 40 - NB 65

blind flanged

RVD - DN40/50

without valve

NB 32 - NB 40

Connection
adapter flange
component oil
pump (Oil Pump
Documentation)
or flange AWPstandard with Oring gasket tube
connection
48.3x2.6

blind flanged

Connection
adapter flange
component oil
pump (Oil Pump
Documentation)
or flange AWPstandard with Oring gasket tube
connection
48.3x2.6

blind flanged

NB 50 - NB 65

Connection
adapter flange
component oil
pump (Oil Pump
Documentation)
or flange AWPstandard with Oring gasket tube
connection
60.3x2.9

blind flanged

Connection
adapter flange
component oil
pump (Oil Pump
Documentation)
or flange AWPstandard with Oring gasket tube
connection
60.3x2.9

blind flanged

Suction side oil


pump
Discharge side oil
pump

OT-125 3

Oil temperature
connection

NB 32 - NB 65

Threaded connection M 12x1.5 or prepared for direct installation of the


Grasso temperature sensor PT100 / PT1000 (see documentation 990215 /
990216)

DP

Capacity control
connection SP2

NB 32 - NB 65

Threaded connection M 16x1.5 for screw-in threaded connection

DU

Balance piston
connection without a pump

NB 32 - NB 65

Threaded connection M 22x1.5 for screw-in threaded connection

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

15

Product Description | OMC-Block I, Simplex filter system


Main part

OMC I SP1
OMC I SP1-2
Position number
P+I diagram

Name

Nennweite
OMC-block

External oil
pump
Grasso Ident

Oil pump
Compressor
integrated

OMC I SPduo
OMC I SPduo
External oil
pump
Grasso Ident

Grasso Ident

U1 + U2

Reference line
connection oil
pressure = discharge pressure

OP1 3

Oil pressure
before oil filter

OP2 3
OP4 3

S2 3

S4 3

Oil pressure after


oil filter

Oil pump
Compressor
integrated
Grasso Ident

NB 32 - NB 65

Threaded connection M 16x1.5


for screw-in
threaded connection

NB 32 - NB 65

Threaded connection G 1/4" for screw-in thereaded connection or prepared


for direct installation of the Grasso service valve (Grasso Ident
501306625awp63) with G1/4" connection thread (see documentation 990320)
for fitting Grasso pressure sensor (see documentation 990293 / 990294) or for
direct installation of the Grasso service valve (double valve pressure sensor +
service port) Grasso Ident 501306661awp63 (see documentation 990320)

NB 32 - NB 65

Threaded connection M 16x1.5 for screw-in threaded connection or prepared


for direct installation of the Grasso service valve (Grasso Ident
501306623awp63) with tube connection 12x1.5 (see separate documentation)

Oil pressure after


oil pump

blind flanged

Threaded connection M 16x1.5


for screw-in
threaded connection

blind flanged

Service valve
Injection oil
Service valve
Functional oil

- Defined assignment of the size of the oil filter element. The use of larger oil filters on same size OMC-block is
allowed. Standard: Filter material glass fibre , 25 micron. Other filter materials on request.
2

- Component is included in the OMC-block.

- Screw-in part, not included in the scope of delivery of the OMC-block.

- Installation possibility for the 3-way valve element exists in all types of OMC. Use optional, depending on the
application.

16

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.17

Installation instructions

Installation of connecting fittings and valves


The OMC-block I is fully made from an aluminium
alloy.
Utmost care must be taken when screwing the connection fittings and valves.
It is recommended that all screw-in parts are additionally glued to the threads with a suitable adhesive
- preferably Loctite.
The max. tightening torques defined in the table
must not be exceeded.
Maximum tightening torques for screwing in Csteel in aluminium

Flange or fastening screws

Tightening torque

Valve elements

[Nm]
DN25 - DN32

M60x2

625

DN40 - DN50

M80x3

760

DN65

M100x3

890

Colour-Coding
Mark the main valves on the valve stem using colour
coding methods according to their functionality
(under the protective cap, see photo).

Tightening torque
[Nm]

M8

25

M12

85

M16

210

M20

425

Screwed connections with


moulded profile rings

Tightening torque
[Nm]

fig.13:

Marking of the main valves using colour coding methods

Valve type

Item

Colour

Isolating valve AVR

65, 220

black

combined stop/ check


valve RVA

70

red

G 1/4"

25

M12x1,5

25

M16x1,5

70

M22x1,5

130

1.18

M26x1,5

180

Information on further risks in conformance to pressure appliance directive (97/23/EG)

M33x2

250

Remaining risks which can not be avoided by the


manufacturer arise because of:

M42x2

330

M48x2

500

Control valve with integrated check valve func- 80


tion

Blue

Information on further risks

Unauthorised loosening of the screw bushing


without examination whether spindle until it stops
in the highest position was driven.

Incorrect assembly of threaded joints

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

17

Product Description | OMC-Block I, Simplex filter system


Main part

18

Dirt in the service medium may cause damage


the stem.

Ignore operating range and manufacturer rules


acc. to this component documentation.

Connecting a manometer at open valve.

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

1.19

Spare parts

Spare part positions

fig.14:

OMC-block I, spare parts view 1

fig.15:

OMC-block I, spare parts view 2

fig.16:

OMC-block I, spare parts view 3

fig.17:

OMC-block I, spare parts view 4

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

19

Product Description | OMC-Block I, Simplex filter system


Main part

Spare part positions

fig.18:

OMC-block I, spare parts view 5

fig.19:

OMC-block I, spare parts view 6

1. Spare part filter element


see item no. 36 in the table "Main components" or in the project related customer part list.
2. Spare part valve element for thermostatic 3-way-valve:
see table "Selection range of valve elements" or item no. 216 in the project related customer part list
Hint!
The OMC-block I of types DN32, DN40 and DN50 is prepared for the installation of a thermostatic 3-way-valve element DN50.
The OMC-block I DN65 is prepared for the installation of 2 thermostatic 3-way-valve elements
DN50.
3. Spare parts overview of gaskets and fastening material
Hint!
When applying HNBR use the corresponding gasket quality!

Gaskets and fastening material

Item

Quantity

Designation

OMC I - SP1-2

OMC I - SP1

OMC I - SPduo

OMC I - SPduo

External oil pump

internal oil pump

External oil pump

internal oil pump

Size / Type / Grasso Ident


DN32/ DN40/ DN50/ DN65
1

O-Ring flange fine filter

O-ring 140x5
CR-type: 762925140 // HNBR-design: 762925140N

20

O-ring flange dirt filter

not used in OMC-block I

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

Gaskets and fastening material

Item

Quantity

Designation

OMC I - SP1-2

OMC I - SP1

OMC I - SPduo

OMC I - SPduo

External oil pump

internal oil pump

External oil pump

internal oil pump

DN32/ DN40 - O-ring 45x3


3+4

1 each

Gasket flange oil cooler inlet


IC / oil separator inlet IO

CR-type: 762925068 // HNBR-design: 762925068N


DN50/ DN65 - O-ring 75x3
CR-type: 762925080 // HNBR-design: 762925080N
DN32/ DN40/ DN50 - O-ring 45x3

Gasket - flange oil injection

CR-type: 762925068 // HNBR-design: 762925068N


DN65 - O-ring 75x3
CR-type: 762925080 // HNBR-design: 762925080N
DN32
CR-type: 49400E13.5110A01 - 505698314
HNBR-type: 49400E13.5110C01 - 505698314N

6+8

Valve element stop valve item


no. 65 / stop valve item no.
220

DN40/ DN50
CR-type: 49400E15.5110A01 - 505698315
HNBR-type: 49400E15.5110C01 - 505698315N
DN65
CR-type: 49400E17.5110A01 - 505698316
HNBR-type: 49400E17.5110C01 - 505698316N
DN32 - O-ring 50x3
CR-type: 762925100 // HNBR-design: 762925100N

7+9

1 each

Gasket valve element combined stop/ check valve pos.


220

DN40/ DN50 - O-ring 75x3


CR-type: 762925080 // HNBR-design: 762925080N
DN65 - O-ring 95x3
CR-type: 762925528 // HNBR-design: 762925528N
DN32/ DN40/ DN50
CR-type: 49400E13.5110R01 505698317

10

Valve element combined stop/


check valve Pos. 70

HNBR-type: 49400E13.511CR01
505698317N
DN65

not available

CR-type: 49400E15.5110R01 505698318


HNBR-type: 49400E15.511CR01 505698318N
DN32/ DN40/ DN50 - O-ring 50x3
11

Gasket valve element combined stop/ check valve item


no. 70 or blank flange gasket

CR-type: 762925100 // HNBR-design: 762925100N


DN65 - O-ring 75x3
CR-type: 762925080 // HNBR-design: 762925080N

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

21

Product Description | OMC-Block I, Simplex filter system


Main part

Gaskets and fastening material

Item

Quantity

Designation

OMC I - SP1-2

OMC I - SP1

OMC I - SPduo

OMC I - SPduo

External oil pump

internal oil pump

External oil pump

internal oil pump

DN32
CR-type:
49400B13.5110D0
1 - 505698319

Valve element oil pressure


reg. valve Pos. 75 (SP1-2)

HNBR-type:
49400B13.511CD0
1 505698319N
DN40/ DN50/
DN65
CR-type:
49404B15.5110D0
1 505698323

not available

HNBR-type:
49404B15.511CD0
1 505698323N
DN32

Spring for valve insert, separately

Type: 562070
505698473
DN40/50/65
Type: 562055
505698474

12

not available

not available
DN32
CR-type:
49400B13.5110D0
1 505698324
Valve element oil pressure
regulating valve Pos. 1675
(SPduo)
1

HNBR-type:
49400B13.511CD0
1 505698324N

Attention: Spare part, default


setting (differential pressure)
4 bar on site. Sealing after
installation necessary.

DN40/ DN50/
DN65

not available

CR-type:
49404B15.5110D0
1 505698325
HNBR-type:
49404B15.511CD0
1 505698325N
DN32

Spring for valve insert, separately

Type: 562070
505698473
DN40/50/65
Type: 562055
505698474

13

22

Gasket valve-element oil


pressure regulating valve item
no. 75 (SP1-2) or item no.
1675 (SPduo) or blank flange
gasket

DN32 - flat sealing ring 56x64x1.5 - AFM30 - 438698207


DN40/ DN50/ DN65 - flat sealing ring 76x84,8x1.5 - AFM30 - 438698208

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

Gaskets and fastening material

Item

Quantity

Designation

OMC I - SP1-2

OMC I - SP1

OMC I - SPduo

OMC I - SPduo

External oil pump

internal oil pump

External oil pump

internal oil pump

DN32/ DN40
CR-type: 49400E13.5110K01
505698321

14

Valve element control valve


item no. 80

HNBR-type: 49400E13.511CK01
505698321N

not available

DN50/ DN65
CR-type: 49400E15.5110K01
505698322
HNBR-type: 49400E15.511CK01
505698322N
DN32/ DN40 - O-ring 50x3

15

Gasket valve-element control


valve item no. 80 or blank
flange gasket

CR-type: 762925100 // HNBR-design: 762925100N


DN50/ DN65 - O-ring 75x3
CR-type: 762925080 // HNBR-design: 762925080N

16

Valve element thermostatic


3way-valve item no. 215/216

17

Gasket valve element thermostatic 3-way-valve item no.


215/216

DN50, see data sheet 990423


Selection and element dependent on the application and the operating conditions
DN32/ DN40/ DN50/ DN65 - O-ring 95x3
CR-type: 762925528 // HNBR-design: 762925528N
DN32/ DN40 - sealing ring nominal size
22
CR-type: 762998222 // HNBR-design:
762998322

18

Gasket connection functional


oil SP1 and SP2
A12 + C12

DN50 - sealing ring nominal size 33


CR-type: 762998223 // HNBR-design:
762998323

not available

DN65 - sealing ring nominal size 42


CR-type: 762998243 // HNBR-design:
762998343
DN32 - not available
DN40 - sealing ring nominal size 42

19

Gasket connection functional


oil SPduo

CR-type: 762998243 // HNBR-design:


762998343
not available

DN50 - sealing ring nominal size 48


CR-type: 762998249 // HNBR-design:
762998349

AD + CD

DN65 - gasket flange - O-ring 45x3


CR-type: 762925068 // HNBR-design:
762925068N
Gasket connection
20+26+
31

Oil pressure before oil filter


OP1
Oil pressure after oil pump
OP4

DN32/ DN40/ DN50/ DN65 - gasket ring nominal size 14


CR-type: 762998213 // HNBR-design: 762998313

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

23

Product Description | OMC-Block I, Simplex filter system


Main part

Gaskets and fastening material

Item

Quantity

Designation

OMC I - SP1-2

OMC I - SP1

OMC I - SPduo

OMC I - SPduo

External oil pump

internal oil pump

External oil pump

internal oil pump

Sealing ring nominal size 33


CR-type: 762998234 // HNBR-design: 762998334
21+25+
30+34
34+35+
36+37+
38

Sealing ring nominal size 42


1 each

Gasket screw plug

CR-type: 762998243 // HNBR-design: 762998343


Sealing ring nominal size 48
CR-type: 762998249 // HNBR-design: 762998349
Sealing ring nominal size 56
Flat gasket 56 x 64 x 2 AFM30 - 438698209

22

Gasket connection DU

DN32/ DN40/ DN50/ DN65 - gasket ring nominal size 22


CR-type: 762998222 // HNBR-design: 762998322
DN32 - sealing ring nominal size 16
CR-type: 762998216 // HNBR-design: 762998316
DN40 - sealing ring nominal size 22

23

Gasket connection additional


oil injection B1

CR-type: 762998222 // HNBR-design: 762998322


DN50 - sealing ring nominal size 26
CR-type: 762998223 // HNBR-design: 762998323
DN65 - sealing ring nominal size 33
CR-type: 762998234 // HNBR-design: 762998334

24

Gasket connection oil temperature OT

DN32/ DN40/ DN50/ DN65 - gasket ring nominal size 12

27

Gasket connection balancing


piston without pump DP

DN32/ DN40/ DN50/ DN65 - gasket ring nominal size 16

CR-type: 762998212 // HNBR-design: 762998312

CR-type: 762998216 // HNBR-design: 762998316

Gasket connection
28+32

Service oil pressure after oil


pump S4
Service oil pressure after oil
pump S2

DN32/ DN40/ DN50/ DN65 - gasket ring nominal size 16


CR-type: 762998216 // HNBR-design: 762998316

DN32/ DN40/ DN50 - gasket ring nominal size 33


29

Gasket screw plug

CR-type: 762998234 // HNBR-design: 762998334


DN65 - sealing ring nominal size 48
CR-type: 762998249 // HNBR-design: 762998349

33

Gasket connection reference


line U2
Gasket connection oil pump
directly flange mounted

DN32/ DN40/ DN50/ DN65 - gasket ring nominal size 16


CR-type: 762998216 // HNBR-design: 762998316
O-ring 48x3
CR-type: 762925069 // HNBR-design: 762925069N

39
2

24

Gasket connection oil pump


external flange

DN32/ DN40 - O-ring 45x3


CR-type: 762925068 // HNBR-design: 762925068N

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

Product Description | OMC-Block I, Simplex filter system


Main part

Gaskets and fastening material

Item

Quantity

Designation

OMC I - SP1-2

OMC I - SP1

OMC I - SPduo

OMC I - SPduo

External oil pump

internal oil pump

External oil pump

internal oil pump

DN50/ DN65 - O-ring 75x3


CR-type: 762925080 // HNBR-design: 762925080N

40

41

Gasket connection reference


line U1 on the oil pressure
regulating valve item no. 80

DN32/ DN40/ DN50/ DN65 - gasket ring


nominal size 16
CR-type: 762998216 // HNBR-design:
762998316

Gasket connection oil pump


external flange

not available

DN50/ DN65 - O-ring 75x3


CR-type: 762925080 // HNBR-design: 762925080N

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

25

Product Description | OMC-Block I, Simplex filter system


Main part

26

GEA Refrigeration Germany GmbH | 990336_gbr_2 | Generated 19.02.2014

PRODUCT DESCRIPTION
MAIN PART
Block mounting filter

BLOCK MOUNTING FILTER

1.1

View

media may attack the components, screws and


elastic buffer rings. So the aggressive media
represent a risk for the operational safety of the
block mounting filter.

The block mounting filter shall only be used and


operated within the frame of the conditions as
defined in the performance or delivery contract.
Warning!
The block mounting filter is for
use at a maximum operating pressure of 28 bar g.p. provided.

fig. 1:

Block mounting filter

1.4
1.2

Any change in the operation conditions or service parameters requires the verification of the
filter design.

Safety Instructions

Storage

This installation and operation manual is an essential component of the filter delivery. Always keep this
manual in a readily accessible place near the filter.

On receipt of the goods, immediately check that all


parts are on hand and are as ordered. Eventual
shipping damages and/or missing parts have to be
reported in writing.

The German version of this manual is the predominant and binding version. Take care that all persons
being charged with the installation, operation,
maintenance and repair of the coupling have read
and understood this manual and that all instructions
contained therein are carefully observed in order to:

The block mounting filter can be stored in a dry


place under roof at normal ambient temperatures for
a time period of 12 months. Storage for a longer
period requires the application of a long-term
preservation.

Avoid danger to life and limb of the user or third


persons

Ensure the operational safety of the block


mounting filter

Preclude operation failures and environmental


damages due to wrong handling and mis-use

The relevant instructions and regulations regarding


safety at work and environmental protection have to
be observed while transporting, mounting and dismounting the coupling.
The block mounting filter shall be operated, mounted, maintained and repaired by authorized, trained
and instructed personnel only. We do not assume
any liability or warranty for any damages resulting
from the use of accessories and parts that are not
originally delivered by GEA Refrigeration Germany
GmbH.

1.3

Intended use

The block mounting filter must not be exposed to


any aggressive products, extreme temperatures or
humidity. Do not store the block mounting filter along
with acids, alkaline solutions or other caustic chemicals. The place of storage should be dry and free
from dust. The air humidity should not exceed 65%
and condensation is not permissible

1.5

Function and design

The block mounting filter is suitable for being directly


mounted onto OMC block of GEA Refrigeration
Germany GmbH. The block mounting filter is installed in the oil circuit of the screw packages and
chillers. The block mounting filter prevents impurities
entrained in the oil stream from entering the compressor. The streamlined casing, in conjunction with
an optimal filter surface allows low pressure drops.
The flow direction from outside to inside makes the
block mounting filter easy to maintain. The block
mounting filter can be replaced quickly and without
return of dirt.

The following conditions must be met for the intended use:

The block mounting filter must only be operated


in normal industrial atmospheres. Aggressive

GEA Refrigeration Germany GmbH

_990361_pd_mp_gbr_1_.doc
28.03.2013

PRODUCT DESCRIPTION
MAIN PART
Block mounting filter

The clean oil returns to the oil circuit via the connection B. The block mounting filter and all the connection elements are designed so that pressure peaks
as can occur, for example, when large control valves
are opened suddenly, due to the accelerated quantity of oil can be safely absorbed.
This block mounting filter is directly flanged onto the
OMC-block. Before mounting the adapter (4) is
screwed in the OMC block.
Change the filter change after start-up always by the
cover (3) with gasket (5).
Hint!
Mounting adapter
Order number: 352100418

1.6

Features

The block mounting filter has the following characteristics:

fig. 2:

Highly efficient, special filter media, compatible


with refrigeratio machine oils of viscosity grades
VG 46 and VG 6 (oils of higher viscosity grades
on request)

Absorption of the finest particles over a wide


differential pressure range

High dirt absorption capacity due to large specific filter area

Chemically resistant to the media used, in particular to ammonia

Filter elements have a high level of resistance to


collapsing

Block mounting filter, cross section

Oil filter housing

Filter element (delivered separately)

Cover

Mounting adapter

O-ring, gasket

4 pcs. of screw M20 x 80, A2-70, stainless steel

4 pcs. of screw nut M20, A2-70, stainless steel

4 pcs. of screw M20 x 55, A2-70, stainless steel


(not shown, please provide separately)

The block mounting filters consists mainly of the


main components shown in the figure. The flow
which must be filtered, comes through the connection A to the filter element (2) and here is cleaned.
The flow direction is set from the outside to the inside.

(e. g. on cold start up to p = 10 bar)

Mesh size: see Technical Data or on request

Media: refrigerant (gaseous and liquid) acc. to


EN378 and technically known refrigeration oils
(mineral and synthetic)

Calculation according to AD2000 for fluid group


1 and 2 DGRL 97/23/EC

Certificates: CE, CF, others on request

_990361_pd_mp_gbr_1_.doc
28.03.2013

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Block mounting filter

1.7

Technical data

Installation
Weight

horizontal to the OMC block


NG

80

180

240

340

kg

20

24.5

31.7

37

Filter casing

GJS 400-18LT

screws

A2-70

Maximum overpressure

bar

1 to 28

Maximum calculation temperature

-10 to +120

Filter element 1

Glass-fibre veil

resistant to refrigerant, in particular to ammonia


absolutely, not cleanable
Filter element, mesh size 20 micron

Wire mesh

nominal size, not cleanable


Wire mesh, mesh size 25 micron and 80 micron

bar

10

Housing material

Allowable pressure difference


across the filter element

1 other types on request

GEA Refrigeration Germany GmbH

_990361_pd_mp_gbr_1_.doc
28.03.2013

PRODUCT DESCRIPTION
MAIN PART
Block mounting filter

1.8

Block mounting filter, preferred types

Block mounting filter, Certification CE and CF


Litres
Filter
VG 46/48
type
l/min

Seal

Approval Type

Grasso Ident
Filter (complete)

Grasso Ident
Filter element

up to 80

CR

CE

352100410CE

352100411H20CR
352100411G25CR
352100411G80CR

080

CF

352100410CF
080-OMC-28bar

HNBR

80 - 180

180

CR

CE

352100410CE

CF

352100410CF

CE

352100412CE

CF

352100412CF

352100411H20N
352100411G25N
352100411G80N
352100413H20CR
352100413G25CR
352100413G80CR

180-OMC-28bar
HNBR

180 - 240 240

CR

CE

352100412CE

CF

352100412CF

CE

352100414CE

CF

352100414CF

352100413H20N
352100413G25N
352100413G80N
352100415H20CR
352100415G25CR
352100415G80CR

240-OMC-28bar
HNBR

240 - 340 340

CR

CE

352100414CE

CF

352100414CF

CE

352100416CE

CF

352100416CF

352100415H20N
352100415G25N
352100415G80N
352100417H20CR
352100417G25CR
352100417G80CR

340-OMC-28bar
HNBR

CE

352100416CE

CF

352100416CF

_990361_pd_mp_gbr_1_.doc
28.03.2013

352100417H20N
352100417G25N
352100417G80N

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Block mounting filter

1.9

fig. 3:

Dimensions

Dimensions of the block mounting filter

Dimensions of the filter housing


Type

Content in l

A1

A2 2

080

3.5

314

247

180

5.3

464

397

240

7.4

632

565

340

11.0

925

858

Connections for draining, venting and fixing


C1 - draining

C2 - venting

C3 - fixing

M 22x1,5

M 16x1,5

M 12

Drain valve
Ident: 501306625awp63 (OMC I block)
Ident: 501306621awp63 (OMC II block)

Vent valve
Ident: 501306623awp63 (OMC I block)
Ident: 501306639awp63 (OMC II block)

2 Measurement for removal the filter element

GEA Refrigeration Germany GmbH

_990361_pd_mp_gbr_1_.doc
28.03.2013

PRODUCT DESCRIPTION
MAIN PART
Block mounting filter

Hint!
Improved vent and drain valves of GEA Refrigeration Germany GmbH are available. See table
for order numbers. See data sheet 990320 for more information on the valves.

1.10 Spare parts

Hint!

Use the Grasso Ident overview "Block mounting


filter, preferred types" to order the replacement filter
elements.

When must the filter element be replaced or cleaned?


The oil filter element is to be replaced
by the user as specified in the maintenance instructions for the total product from GEA Refrigeration Germany
GmbH.
Loss in pressure during operation is
monitored by the internal control
including a preliminary alarm function
for preventative replacement.
The following applies as a guide value
for replacement: The filter element
should be replaced after every 5000
operating hours or once each year.

Table: Grasso Ident gasket (O-ring) of the housing cover and OMC-block mounting flange
Gasket (O-ring) for item 5

Grasso Ident

140 x 5 CR

762925140

140 x 5HNBR

762925140N

1.11 Installation and Maintenance


Filter installation
1. Compare operating overpressure with the specification on the rating plate.
2. Remove plug on the filter inlet and outlet.

Changing the filter element

3. Screw the adapter (4) in the OMC block.

1. Shut off the Screw Package/ Chiller and relieve


the pressure on the filter side.

4. Mount filter housing to the OMC-block with


screws M 20x55 (4 pieces), stainless steel A270.

2. Remove the filter cover by loosening the four


cover screws.

Ensure that installation occurs without mechanical tension. Take the removal height and length
of the filter element into consideration.

3. Remove the filter element by slightly turning the


mounting pin in the filter head.

5. Assemble the filter element (2).

4. Check the O-ring and support ring in the filter


bowl for damage and correct positioning. Replace parts if required.

6. Close the housing (1) with cover (3) by using


gasket (5), screws (6) and screw nuts (7).

5. Replace glass fibre element, clean or replace


wire mesh.
The efficiency of the cleaning depends on the
type of dirt and the level of differential pressure
before replacing the filter element. If, after replacing the filter element, the differential pressure is more than 50% of the value before replacing the filter element, wire mesh must also
be replaced.
6. Check whether the type designation/ Grasso
ident number on the replacement element
matches the type designation/ Grasso Ident
number on the filters rating plate.
7. Place the replaced or cleaned filter element back
on the mounting pin by turning it slightly.

_990361_pd_mp_gbr_1_.doc
28.03.2013

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Block mounting filter

8. Reposition the filter cover and tighten the four


cover screws. Ensure that installation occurs
without mechanical tension.
9. Vent the housing of the block mounting filter.

1.12 Quality and Standardization


The block mounting filter for applications with fluids
of groups 1 and 2 are pressurized items in line with
the Pressure Equipment Directive 97/23/EC (DGRL).
They are given CE marks and approval in line with
the requirements according to category II and III.
Approval by classification companies and according
to non-EU regulations on request.

Use in potentially explosive atmospheres in accordance with directive 94/9/EC (ATEX)


The block mounting filters are not devices or components in the sense of directive 94/9/EC and therefore do not have a CE mark. The design is suitable
for use in group II category 2 in line with DIN 13463.
In the event that the block mounting filters are used
in potentially explosive atmospheres, potential compensation must be ensured.

GEA Refrigeration Germany GmbH

_990361_pd_mp_gbr_1_.doc
28.03.2013

BAWL 011-GBR-0
02/2008

Installation and Operation Manual TSCHAN


Torsionally Rigid Coupling

POSIMIN - NZN, NZNmin

TSCHAN GmbH
Telefon: +49(0) 6821 866 0

Zweibrcker Strae 104


Telefax: +49(0) 6821 883 53

D-66538 Neunkirchen-Saar
www.tschan.de

Table of Contents
Chapter

Page

1
2

Safety Instructions ............................................................................................................ 2


Function............................................................................................................................ 3
2.1
Intended Application .................................................................................................. 3
3 Storage ............................................................................................................................. 3
4 Construction ..................................................................................................................... 4
5 Technical Data.................................................................................................................. 6
6 Installation ........................................................................................................................ 7
6.1
Instructions to be observed prior to Installation ......................................................... 7
6.2
Finish Bore ................................................................................................................8
6.3
Mounting of Coupling................................................................................................. 9
7 Coupling Alignment......................................................................................................... 11
7.1
Angular Misalignment Kw ....................................................................................... 11
7.2
Axial MisalignmentKa ............................................................................................. 12
7.3
Radial Misalignment Kr .......................................................................................... 12
8 Operation........................................................................................................................ 13
9 Maintenance ................................................................................................................... 16
9.1
Disk Pack Inspection ............................................................................................... 16
9.2
Replacement of Disk Packs..................................................................................... 16
10 Disposal ......................................................................................................................... 17
11 Manufacturers Declaration ............................................................................................ 18

1 Safety Instructions
This installation and operation manual is an essential component of the coupling
delivery. Always keep this manual in a readily accessible place near the coupling. The German version of this manual is the predominant and binding version.
Take care that all persons being charged with the installation, operation, maintenance and
repair of the coupling have read and understood this manual and that all instructions contained therein are carefully observed in order to:
- avoid danger to life and limb of the user or third persons,
- ensure the operational safety of the coupling,
- preclude operation failures and environmental damages due to wrong handling and misuse.
The relevant instructions and regulations regarding safety at work and environmental protection have to be observed while transporting, mounting and dismounting the coupling.
Make sure that suitable handling and transportation means are at disposal.
The coupling shall be operated, mounted, maintained and repaired by authorized, trained and
instructed personnel only.
In the interest of further development, we reserve the right to carry out modifications serving
the technical progress.

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

-2-

We do not assume any liability or warranty for any damages resulting from the use of accessories and parts that are not originally manufactured by TSCHAN GmbH.

2 Function
The TSCHAN-Coupling POSIMIN is a torsionally rigid steel disk coupling. It compensates
for angular, radial and axial shaft misalignments within defined ranges. The coupling transmits torque without backlash through flexible steel disks loaded in tension.
The spacer can be radially mounted and dismounted without having to move the connected
machines. The distance dimension E between the flange hubs can then be used, for example, to service connected machines.
When the spacer is dismounted, a check of the rotational direction of the drive can
easily be performed.
The coupling is suitable for use in every direction of rotation and installation position. For applications involving other than horizontal position, it may be necessary to support the spacer.
Please consult TSCHAN GmbH, if this has not been considered when selecting the coupling.

2.1

Intended Application
The coupling must only be operated in normal industrial atmospheres. Since aggressive
media may attack the coupling components, screws and elastic buffer rings, they represent a risk for the operational safety of the coupling. Consult TSCHAN GmbH in such
cases.
In order to ensure trouble-free and reliable operation, the coupling has to be sized according to the design specifications, e.g. according to DIN, part 2, (or acc. to catalogue
TSCHAN POSIMIN), with a service factor appropriate for the service conditions.
Except for the production of a finish bore with keyway, no further modifications are allowed to be carried out on the coupling!
The coupling shall only be used and operated within the frame of the conditions as defined in the performance or delivery contract.
Any change in the operation conditions or service parameters requires the verification of
the coupling design.

3 Storage
On receipt of the goods, immediately check that all parts are on hand and are as ordered.
Eventual shipping damages and/or missing parts have to be reported in writing.
The coupling parts can be stored in a dry place under roof at normal ambient temperatures
for a time period of 6 months. Storage for a longer period requires the application of a longterm preservation. (Please consult TSCHAN GmbH in this respect.)
The disk packs are made of stainless spring steel. They must not be exposed to any aggressive products, extreme temperatures or humidity. Do not store the disk packs along with
acids, alkaline solutions or other caustic chemicals. The place of storage should be dry and
free from dust. The air humidity should not exceed 65% and condensation is not permissible.

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

-3-

4 Construction

Fig. 1 Construction POSIMIN

1
2
3
4
5

NZN, NZNmin

N-hub, part 475


Fitted bolt
Spacer
Hexagon nut
Steel disk pack of NZN-design

Important notes:
The spacer, part 3, is delivered with fitted disk packs, part 5, as an easy-to-mount unit.
Balanced assemblies are match marked. For balanced couplings, the fitted bolts and nuts
are weight balanced. These sets must not be mixed with bolt sets of other couplings!

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

-4-

Ring type disk pack


up to size 260

Link type disk pack


as of size 330

NZN-design:
Disk pack with alternate short and long protruding
bushes used to fit the disk pack to the spacer.
NN-design:
Disk pack with short bushes.

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

-5-

5 Technical Data

Fig. 2 Construction POSIMIN

Table 1
Size
NZN
NZNmin

NZN, NZNmin

Technical Data:
TCnom
[Nm]

TCpeak
[Nm]

nmax
[rpm]

d1 max
[mm]

80

166

13900

28

110

200

11500

38

10

150

270

10300

45

21

360

650

8100

55

42

500

900

7200

65

66

900

1600

6100

75

105

1400

2500

5700

80

168

2400

4300

5150

85

260

2900

5200

4900

90

330

4400

8000

4300

100

520

5200

9400

4030

110

660

7700

13900

3650

115

840

8300

15000

3450

125

1200

15000

27000

2900

145

1650

18000

32400

2600

170

2500

28000

50400

2250

200

3200

32000

57600

2100

225

bawl011-gbr-0

E Standard
Emin
50
42
60
42
70
42
86
55
106
55
126
65
130
70
140
80
160
85
170
105
190
105
200
120
220
120
250
160
300
160
350
200
400
200

L1
[mm]

D3
[mm]

D4
[mm]

30

39

69

7,8

35

53

83

7,8

40

63

93

7,8

50

77

118

10,7

60

91

133

10,7

70

105

156

11,6

75

112

168

12

12,5

80

118

186

13

13,4

90

128

196

13

13,4

100

139

222

18

22,8

110

154

237

18

22,8

115

158

262

20

24,4

125

174

278

20

24,4

145

197

330

25

32,0

170

232

365

25

32,0

200

269

425

30

38,0

225

304

460

30

38,0

POSIMIN -NZN, -NZNmin

S1
[mm]

S2
[mm]

m
[kg]
1,0
1,0
2,0
1,9
2,9
2,7
5,8
5,6
9,0
8,5
14,0
13,2
17,9
17,1
23,0
22,0
29,0
28,0
41,0
40,0
52,0
50,0
65,0
62,0
80,0
75,0
128,0
120,0
180,0
171,0
288,0
275,0
382,0
365,0

-6-

The torques TCnom and TCpeak are valid for:


Ambient temperatures of 30C up to +150C
Operation within the range of the specified alignment values.
Weights are specified for couplings without bores in the hubs.
For determining the size of the coupling according to DIN 740, part 2, (or to catalogue
POSIMIN) various factors have to be taken into account:
the temperature factor S in case of higher temperatures,
the start-up factor Sz depending on the frequency of starts,
the shock factor SA, SL depending on the service conditions.
For circumferential speeds above 30 m/s, referred to the outer diameter of the coupling, we
recommend balancing the coupling parts.
Spacers, which are longer than the standard E-dimension, should be balanced in each case.

6 Installation
6.1

Instructions to be observed prior to Installation

Danger of injuries!
Disconnect the drive before carrying out any work on the coupling!
Secure the drive against unintentional re-start and rotation!
Incorrectly tightened bolts can cause serious personal injuries and
property damages.

If possible, assemble the coupling outside of the danger zone. Take


care that suitable transportation means are at disposal and that the
transportation ways are free of obstacles.
In compliance with accident prevention regulations, you are
obliged to protect all freely rotating parts by means of permanently
installed guards against unintentional contact and falling down objects.
To avoid sparks, the covers for couplings used should be made of
stainless steel!
As a minimum, the covers have to fulfil the requirements of protection type IP2X.
The covers have to be designed to prevent dust from depositing on
the coupling.
The cover must not contact the coupling or impair the proper function of the coupling.

Make sure that the speeds, torques and ambient temperatures as stated in chapter 5
Technical Data are not exceeded.
The maximum permissible bore diameters must not be exceeded.
Check whether the shaft-hub connections safely transmit the occurring operating torques.
The standard tolerance of TSCHAN for finish bores is fit H7.
Standard keyways comply with DIN 6885, sheet 1.
Check the dimensions and tolerances of shafts, hub bores, keys and keyways.
bawl011-gbr-0

POSIMIN -NZN, -NZNmin

-7-

Set screws as required.

6.2

Finish Bore

The following procedure has to be followed to produce a finish bore in a coupling hub:
Clean and remove all preservatives from the
coupling hubs.
Mount the coupling hub in between the surfaces
marked with and carefully align the hub.
The values for d1max as listed in table 1 are valid
for keyed connections according to DIN 6885/1
and must not be exceeded.
Select the bore fit so that an interference fit such
as H7/m6 results when mating it with the shaft
tolerance.
Axially lock the hub, for example by means of a
setscrew on the back of the hub above the keyway.
Consult TSCHAN GmbH in case of other shaft-hub connections.

The stated maximum bore diameters are valid for keyed connections according to DIN 6885/1 and must not be exceeded.
If these values are exceeded, the coupling can break.
Flying off coupling fragments are a danger to life!

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

-8-

6.3

Mounting of Coupling

Prior to installation, carefully clean


the bores of the coupling hubs and
the shaft ends. The surfaces must
be clean, dry and free of grease.
For larger couplings use suitable
mounting tools and hoisting devices
such as cranes or pulley blocks.
Mount the coupling hubs in the
proper position on the shaft ends
(Fig. 3).

Fig. 3

Note:
To facilitate mounting, the hub can be uniformly heated to 80C to 120C.
Warning!
Always wear heat-resistant gloves to protect yourself against injuries due to hot coupling components!

Mount the hubs in such a manner


that the shaft end is flush with the
inner bore opening (Fig. 4). Projecting shaft ends prevent radial mounting and removal of the spacer. Observe deviant agreements, which
may exist!
When tightening setscrews, secure
them with an adhesive, such as e.g.
Loctite 222, to prevent the screws
from working loose and dropping
out.

Fig. 4

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

-9-

Before mounting the spacer, perform


an initial alignment over the hub
flanges by using an appropriate tool,
e.g. a straightedge. The shaft ends
should be flush with each other.
The hub flanges must be parallel to
each other. Refer to chapter 7 Coupling
Alignment.
Check correct distance dimension E.
See Fig. 5 and chapter 7 Coupling
alignment.
The bearing surfaces of the fastening
elements on the flanges and disk
Fig. 5
packs must be clean, dry and free of
grease.
Place the spacer with the bushed
disk packs between the hubs. (Fig.
6). This has to be done in such a
manner that the fitted bores repose
in the recesses of the mating part.
Install the fitted bolts through the
disk packs into the fitted bores. The
nuts have to rest on the flange (Fig.
6).
Attention: The NZN-min design only
allows to mount the fitted bolts from
the hub side.
Use the fitted bolts
and nuts as they
were delivered, i.e.
Fig. 6
slightly oiled. Do not
clean or additionally lubricate the fastening elements !
Slightly tighten the nuts by hand.
Tighten the nuts progressively one after the other in small increments until the tightening
torque MA stated in table 2 is reached. Secure the fitted bolts against turning!
Align the coupling according to the instructions given in chapter 7 Coupling Alignment.

Table 2

Tightening torques MA of nuts in slightly oiled delivery state:

Size
Fitted bolt
MA [Nm]

10

21

42

66

105

168

260

M6x22
14

M6x22
14

M6x22
14

M8x30
33

M8x30
33

M10x35
66

M12x40
115

M16x46
250

M16x46
250

Size
Fitted bolt
MA [Nm]

330

520

660

840

1200

1650

2500

3200

M20x65
490

M20x65
490

M24x72
840

M24x72
840

M30x92
1700

M30x92
1700

M36x110
2800

M36x110
2800

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

- 10 -

7 Coupling Alignment
Danger of injuries!
Disconnect the drive before carrying out any work on the
coupling.
Secure the drive against unintentional re-start and rotation!
Note:
Accurate alignment of the coupling prolongs the lifetime of the disk
packs and reduces the risks when operating the coupling.
It is of utmost importance to observe the recommended alignment
values. Exceeding the permissible misalignment values results in
coupling damages and failures!
-

When aligning the cold equipment take into account the expected thermal growth of the
components, so that the permissible misalignment values for the coupling are not exceeded in operation.
Be aware that the coupling under misalignment imposes restoring forces on the adjacent
shafts and bearings. Take into account that the larger the misalignment, the greater the
restoring forces will be.
In special cases with high demand on quiet running or high rotation speeds it is possible
that, in the three displacement levels, an alignment accuracy of 0,1mm is necessary.
If the coupling is mounted in a closed housing / casing so that a subsequent alignment is
not possible anymore, it must be guaranteed that the geometry and fit accuracy of the
contact surfaces in operation aligns the shafts exactly within the mentioned tolerances.

7.1

Angular Misalignment Kw

Measure one complete rotation


(360) on the face of the outer diameter. Determine the largest deviation Kw1 and the smallest deviation Kw2 (Fig. 7). Calculate the angular misalignment:
Kw = Kw1 Kw2.
When aligning, observe the max.
permissible angular misalignment
Kwmax acc. to table 3.

Fig. 7

Table 3
Size
Kwmax
[mm]

Angular Misalignment:
3

10

21

42

66

105

168

260

330

520

660

840

0,12

0,14

0,15

0,2

0,2

0,25

0,3

0,3

0,3

0,35

0,4

0,4

0,45

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

1200 1650 2500 3200


0,6

0,6

0,7

0,8

- 11 -

Axial Misalignment Ka

7.2

Before installing the spacer measure


the actual length dimension E of
the spacer over the bushes of the
disk packs (Fig. 8).
Set the distance between the flange
hubs to a dimension between E and
(E + e) acc. to table 4. Do not exceed the tolerances stated in
table 4.

Fig. 8

Recommended Tolerance Values e for Mounting Dimension E:

Table 4
Size

10

21

42

66

105

168

260

330

520

660

840

1200

1650

2500

3200

e
[mm]

0,1

0,1

0,1

0,1

0,1

0,2

0,2

0,2

0,25

0,25

0,25

0,3

0,35

0,4

0,4

0,5

0,55

ATTENTION!
Make sure not to fall below the dimension E, as otherwise it is not possible to mount
the spacer radially!
If larger axial displacements are to be anticipated during operation, e.g. due to thermal
growth, the coupling can be mounted with axial pre-stretch to account for the expected
growth. This item has to be discussed with TSCHAN GmbH, if it has not been considered
when designing the coupling. In service, the coupling shall run in unconstrained manner with
dimension E.

7.3

Radial Misalignment Kr
Measure one complete rotation
(360). Determine the largest deviation Kr1 and the smallest deviation Kr2
(Fig. 9).
Calculate the radial misalignment Kr
= 0,5 x (Kr1 Kr2). Observe the preceding sign of the measured values.
When aligning, observe the maximum permissible radial misalignment
in dependence of the mounting dimension E Krmax = E/1000 [mm].
For verification purposes, this measurement should also be performed on
the second coupling half.
The alignment must be corrected in
case of any deviations.

bawl011-gbr-0

Fig. 9

POSIMIN -NZN, -NZNmin

- 12 -

8 Operation
When operating the coupling, its specific technical data have to be carefully observed (see
chapter 5 Technical Data). These values must never be exceeded without the prior written
approval by TSCHAN GmbH.
In order to ensure trouble-free and reliable performance of the coupling, the coupling has to
be designed according to the selection specifications, e.g. according to DIN 740, part 2, (or
acc. to catalogue POSIMIN), with a service factor appropriate to the service conditions.
Any change in the service conditions or service parameters always necessitates the verification of the coupling design!
Danger of injuries!
Disconnect the drive before carrying out any work on the coupling!
Secure the drive against unintentional re-start and rotation!
Improperly tightened screws may cause parts to fly off what leads
to most serious personal injuries and property damages!
Before putting the coupling into operation, check the alignment and
all screwed connections for correct tightening torque and firm fit!
Before starting up the equipment, install all protective guards in
order to avoid unintentional contact with freely moving or rotating
parts.
To avoid sparks, the covers for couplings used should be made of
stainless steel!
The covers have to comply with protection type IP2X as a minimum.
The cover shall be designed to prevent dust from depositing on
the coupling parts.
The cover must not touch the coupling and must not impair the
proper function of the coupling.

While operating the coupling, pay attention to:


Changes in operating noises
Vibrations

Attention!
Disconnect the drive immediately, if any irregularities are observed while operating
the coupling!
Identify the cause for the problem using table 5 Operation Faults and Possible Causes
and correct the fault.
The listed problems are some examples to assist you in troubleshooting.
All the machinery components and operation modes have to be considered for the
determination and correction of faults!

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

- 13 -

Table 5
Trouble
Running
noises/
vibrations

Disk pack
damages

Operation Faults and Possible Causes:


Cause
Risk Warning
Alignment fault Increased restoring
forces on shafts
and bearings of the
connected machines.

Correction
- Disconnect drive
- Remove cause for alignment fault
- Re-align coupling
- Check disk packs for damages such
as cracks, dents or similar damages,
and replace them, if necessary
Damaged disk Disk breakage,
- Disconnect drive
packs
spacer can fly out - Check coupling components for
damages and replace parts, if necessary
- Check alignment
- Verify coupling design
- Replace disk packs
- Verify balance state of plant components and correct it, if necessary
Unbalance
Vibrations, disk
- Disconnect drive
breakage
- Check disk packs for damages, such
as cracks, dents or similar damages,
and replace them, if necessary
- Verify balance state of plant components and correct it, if necessary
Loose screw
Spacer can fly out - Disconnect drive
connections
- Check coupling parts for damages,
replace parts, if necessary
- Verify alignment of coupling
- Tighten nuts with the specified
tightening torque
Alignment faults Increased restoring - Disconnect drive
forces on shafts
- Remove cause for alignment fault
and bearings of the - Re-align coupling
connected ma- Replace disk packs
chines
- Verify balance state of plant components and correct it, if necessary
Overloading
Disk breakage,
- Disconnect drive
due to very high spacer can fly out - Verify coupling design in cooperation
torque
with TSCHAN GmbH
- Replace coupling
- Install larger coupling, if necessary
Contact with
Disk breakage,
- Disconnect drive
aggressive
spacer can fly out - Check coupling parts for damages
products
and replace parts, if necessary
- Replace disk packs
- Verify balance state of plant components and correct it, if necessary
- Verify alignment of coupling
- Prevent contact with aggressive
products

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

- 14 -

Trouble

Cause
Risk Warning
Torsional vibra- Disk breakage,
tions in the
spacer can fly out
drive line

bawl011-gbr-0

Correction
- Disconnect drive
- Analyse and eliminate cause for torsional vibrations
- Check coupling parts for damages
and replace parts, if necessary
- Verify coupling alignment

POSIMIN -NZN, -NZNmin

- 15 -

9 Maintenance
The torsionally rigid disk coupling POSIMIN only requires little maintenance during operation.
On the occasion of routine inspections or maintenance of the equipment, check:
alignment of coupling,
state of disk packs,
firm fit of all fastening elements at the disk packs.
Remove dust deposits from coupling parts and disk packs.

9.1

Disk Pack Inspection


Danger of injuries!
Disconnect the drive before carrying out any work on the
coupling!
Secure the drive against unintentional re-start and rotation!
Visually inspect the disk packs after 2000 hours, however after 3 months at
latest, after the first start-up. If this first inspection does not reveal any
damages such as cracks or dents on the disks, further inspections may be
conducted at regular intervals of 4000 hours, however, at least once a year,
provided that the operation modes and service conditions of the equipment
are not altered.
If damages of the disk packs are already detected on the occasion of this
first inspection, verify whether the cause for the problem is listed in table 5
Operation faults. It is essential to adapt the inspection intervals to the prevailing operation conditions.
Under special operation conditions it may be necessary to perform inspections and maintenance operations at shorter intervals than stated.

9.2

Replacement of Disk Packs


Danger of injuries!
Disconnect the drive before carrying out any work on the
coupling!
Secure the drive against unintentional re-start and rotation!

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

- 16 -

Secure the spacer against falling


down.
Remove the fastening elements
from the disk packs.
Radially lift out the spacer along with
the disk packs of the hub flanges.
For larger couplings use appropriate
tools and lifting devices such as
cranes or blocks and tackles (Figure
10).
Carefully remove the damaged disk
packs making sure not to damage
the fitted bores in the flanges.
Check the coupling parts for
damages.
Fig. 10
Install the new disk packs of NZNdesign with the protruding bushes to the spacer. Take care that the bushes do not get
canted, and press the bushes into the flange of the spacer in a simultaneous and uniform
manner.
For further way of proceeding, see chapter 6 Coupling Installation.
Verify the alignment of the coupling according to chapter 7 Coupling Alignment.

Warning!
Before putting the equipment into service, all safety guards must
be installed to prevent unintentional contact with freely rotating
parts.
To avoid sparks, the covers for couplings used should be made of
stainless steel.
The covers have to fulfil the requirements of protection type IP2X
as a minimum.
The covers have to be designed to prevent dust from depositing
on the coupling parts.
The cover must not touch the coupling and impair the proper
operation of the coupling.
We do not assume any responsibility or warranty for any damages resulting from the use of
accessories or spare parts, which have not originally been manufactured by TSCHAN GmbH.

10 Disposal
Disposal of the parts must be arranged in accordance with the regulations and laws of the
country where the equipment is installed.

bawl011-gbr-0

POSIMIN -NZN, -NZNmin

- 17 -

11 Manufacturers Declaration
Compliant with the EC Machinery Directive 98/37/EC Annex II B

We herewith declare that the


torsionally rigid shaft couplings of type

POSIMIN - NZN, NZNmin


described in this operation manual are intended for installation in a machine,
and that it is only allowed to put them into service after it has been determined
that the machine into which these components will be installed, complies with
the regulations of the EC-Directive.

Neunkirchen, 15.02.2008
Norbert Telaar
General Manager

TSCHAN GmbH
Telefon: +49(0) 6821 866 0

Zweibrcker Strae 104


Telefax: +49(0) 6821 883 53

i. V. Volker Carl
Design Manager

D-66538 Neunkirchen-Saar
www.tschan.de

PRODUCT DESCRIPTION
MAIN PART
Flange mounted oil heater PN40

OIL HEATER, FLANGE MOUNTED HEATER

DN 80, DIN EN 1092-1, form C (spring), for use in oil separators diameter > 1016 mm, PN40

1.1

fig. 1:

View

Oil heater (flange mounted oil heater, form C), view

unheated

Heating bundle (1.4571) welded-in

Connection housing IP 54

DN80 PN63 DIN EN 1092-1, form C (spring)

Hint!
The installation must be professionally made according to the intended use with the required
means and tools.

Required gasket material - preferably Teflon strip - must be provided by the customer.
The heater is equipped with an overheating protection to protect against overheating (also in case of low oil level).

1.2

Technical specifications

Flange:

DN80 PN40, EN 1092-1

Flange material:

Steel C22.8

Sealing surface:

Form C, spring EN 1092-1

Enclosure:

IP 54 (DIN 40050 / IEC 529)

Voltage:

depending on demand 110 V - 690 V

Capacity:

depending on demand

Thermal safety:

Class 1 (VDE 0721 T2/9.83 Sect. E)

Temperature controller:

Type 716 RU (20C - 150C) preadjusted (by factory) to 60C

GEA Refrigeration Germany GmbH

_990340_pd_mp_gbr_1_.doc
19.04.2012

PRODUCT DESCRIPTION
MAIN PART
Flange mounted oil heater PN40

Temperature limiter:

Safety temperature limiter Heat Therm, Type 602031/81 (20C - 150C)


fixe adjusted to 150C

Test pressure:

40 bar g.p.

Tubular heating element:

Stainless steel 1.4571, welded into flange plate

Number of tubular heating elements: depending on demand 2- 3 pieces, diameter 8.5 mm


Length of tubular heating elements:

depending on demand 900 1700 mm

Spacer discs:

Diameter 60 mm

Connection housing:

120 x 120 x 105 mm plastic

Cooling section between flange


plate and housing:

80 mm

Green signal lamp:

= Heating

Red signal lamp:

= Failure active

Type plate:

GEA Grasso

Hint!
Controller, limiter as well as signal lamps wired to terminals for directly switching.
The connecting diagram is placed in the cover of heater.

1.3

Application

The heating element serves for heating refrigerating oils that are mixed with ammonia or other alternative refrigerants.
Danger!
Do not use in hazardous areas!

Use

1.4

Installation length (mm)

Oil separator (diameter in mm)

900

1016, 1200

1300

1400, 1600

1700

1800, 2000, 2200

Electrical connection

The electrical connection to the terminals provided must be carried out with cables or leads to VDE 0250 or VDE
0282, cross section for connection according to the current consumption (VDE 0100 Part 523) min. 1.5 mm.
The sealing ring of the lead-in must match the cable diameter.
The feed cables must be protected with fuses.

_990340_pd_mp_gbr_1_.doc
19.04.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Flange mounted oil heater PN40

1.4.1

Circuit diagrams

Circuit diagram: 232024:19000


Voltage: > 400 V, 2-phase

fig. 2:

Circuit diagram of oil heating (232024)

H1

Failure (red)

H2

Heating (green)

Circuit diagram: 232025:19000


Voltage: 380 V - 440 V, 2-phase

fig. 3:

Circuit diagram of oil heating (232025)

H1

Failure (red)

H2

Heating (green)

GEA Refrigeration Germany GmbH

_990340_pd_mp_gbr_1_.doc
19.04.2012

PRODUCT DESCRIPTION
MAIN PART
Flange mounted oil heater PN40

Circuit diagram: 232026:19000


Voltage: 110 V - 240 V, 1-phase, max. 16 A

fig. 4:

Circuit diagram of oil heating (232026)

H1

Failure (red)

H2

Heating (green)

Circuit diagram: 232027:19000


Voltage: 110 V, 1-phase, max. 20 A

fig. 5:

Circuit diagram of oil heating (232027)

H1

Failure (red)

H2

Heating (green)

_990340_pd_mp_gbr_1_.doc
19.04.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Flange mounted oil heater PN40

1.5

Settings

The oil heater is equipped with one temperature controller and one temperature limiter as well as with function
indicators "Operation / Failure".
The required oil temperature can be adjusted on the adjustment pin of the temperature controller (in the connecting housing).
The operating mode "Heating" is indicated by the green signal lamp.
When the heating is off, the signal lamp does not light up.
In case of a failure (temperature on the heating elements too high) the safety temperature limiter switches the
heating permanently off and the red signal lamp indicating "Failure" lights up.
After cooling down, the limiter can be reset by pressing the red Reset button; the red signal lamp goes out.
In this case the cause of the failure must be determined and eliminated.

1.6

Maintenance, Repair

No particular maintenance work is required for proper operation.


Check the temperature control units for correct functioning annually.
Check the electrical connections for their firm fixing annually.
Hint!
Repairs must only be carried out by the specialized electric staff!

1.7

Ident numbers
Installation
length

Amperage

Circuit diagram

Grasso Ident

2000 W
2200 W
2370 W
2660 W

900 mm

5,26 A
5,50 A
5,71 A
6,04 A

232025:19000

677398826

460 V-2Ph
480 V-2Ph
500 V-2Ph

2020 W
2200 W
2390 W

900 mm

4,4 A
4,6 A
4,8 A

232024:19000

677398827

690 V-2Ph

2200 W

900 mm

3,2 A

232024:19000

677398828

200 V-1Ph
220 V-1Ph
230 V-1Ph
240 V-1Ph

1665 W
2020 W
2200 W
2400 W

900 mm

8,3 A
9,2 A
9,6 A
10,0 A

232026:19000

677398829

220 V-2Ph

2200 W

900 mm

11,0 A

232025:19000

677398841

110 V-1Ph

2200 W

900 mm

20,0 A

232027:19000

677398830

380 V-2Ph
400 V-2Ph
415 V-2Ph
440 V-2Ph

1980 W
2200 W
2370 W
2660 W

1300 mm

5,2 A
5,5 A
5,7 A
6,04 A

232025:19000

677398831

Voltage

Capacity

380 V-2Ph
400 V-2Ph
415 V-2Ph
440 V-2Ph

GEA Refrigeration Germany GmbH

_990340_pd_mp_gbr_1_.doc
19.04.2012

PRODUCT DESCRIPTION
MAIN PART
Flange mounted oil heater PN40

1.8

Voltage

Capacity

Installation
length

Amperage

Circuit diagram

Grasso Ident

460 V-2Ph
480 V-2Ph
500 V-2Ph

2020 W
2200 W
2390 W

1300 mm

4,4 A
4,6 A
4,8 A

232024:19000

677398832

690 V-2Ph

2200 W

1300 mm

3,2 A

232024:19000

677398833

200 V-1Ph
220 V-1Ph
230 V-1Ph
240 V-1Ph

1665 W
2020 W
2200 W
2400 W

1300 mm

8,3 A
9,2 A
9,6 A
10,0 A

232026:19000

677398834

200 V-2Ph

2200 W

1300 mm

11,0 A

232025:19000

677398842

110 V-1Ph

2200 W

1300 mm

20,0 A

232027:19000

677398835

380 V-2Ph
400 V-2Ph
415 V-2Ph
440 V-2Ph

2710 W
3000 W
3230 W
3600 W

1700 mm

7,13 A
7,5 A
7,8 A
8,2 A

232025:19000

677398836

460 V-2Ph
480 V-2Ph
500 V-2Ph

2755 W
3000 W
3255 W

1700 mm

6,0 A
6,25 A
6,5 A

232024:19000

677398837

690 V-2Ph

3000 W

1700 mm

4,3 A

232024:19000

677398838

200 V-1Ph
220 V-1Ph
230 V-1Ph
240 V-1Ph

2270 W
2745 W
3000 W
3270 W

1700 mm

11,3 A
12,5 A
13,0 A
13,6 A

232026:19000

677398839

200 V-2Ph

3000 W

1700 mm

15,0 A

232025:19000

677398843

110 V-1Ph

3000 W

1700 mm

27,3 A

232027:19000

677398840

Spare parts
Spare part

Grasso Ident

Temperature controller 716 RU

677398558

Temperature limiter Heat Therm

677398560

Sealing ring form TG 80, EN 1514-1

763000051

_990340_pd_mp_gbr_1_.doc
19.04.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
SUCTION FILTER COMBINATION SFC

SUCTION FILTER COMBINATION SFC

1.1

View

1.4

Safety Instructions

This installation and operation manual is an essential


component of the suction filter combination SFC
delivery. Always keep this manual in a readily
accessible place near the suction filter combination
SFC.
The German version of this manual is the
predominant and binding version. Take care that all
persons being charged with the installation,
operation, maintenance and repair of the coupling
have read and understood this manual and that all
instructions contained therein are carefully observed
in order to:

fig. 1:

1.2

Avoid danger to life and limb of the user or third


persons

Ensure the operational safety of the suction filter


combination SFC

Preclude operation failures and environmental


damages due to wrong handling and mis-use

The relevant instructions and regulations regarding


safety at work and environmental protection have to
be observed while transporting, mounting and
dismounting the coupling.

Suction filter combination SFC, view

General Information

The suction filter combination SFC variants described


in this document are only used in applications with
the compressor sizes R, S and T. For other SFC types
see separate documentation.

1.3

The suction filter combination SFC shall be operated,


mounted, maintained and repaired by authorized,
trained and instructed personnel only. We do not
assume any liability or warranty for any damages
resulting from the use of accessories and parts that
are not originally delivered by GEA Grasso GmbH.

Features

The suction filter combination SFC is a main component


of the screw compressor packages and liquid chillers
of GEA Grasso GmbH. This component is designed
and conceptually prepared for use in products with
sizes of series Large (compressor P-XF). The suction
filter combination SFC guarantees a high operational
safety of the components and all the products.

1.5

The following conditions must be met for the


intended use:

The suction filter combination SFC must only be


operated in normal industrial atmospheres.
Aggressive media may attack the components,
screws and elastic buffer rings. So the aggressive
media represent a risk for the operational safety
of the suction filter combination SFC.

The suction filter combination SFC shall only be


used and operated within the frame of the
conditions as defined in the performance or
delivery contract.

The various connection possibilities and types cover a


broad range of application.
The selection of the suction filter combination SFC
version depends on the following operating
conditions:

Screw compressor size


Nominal width on plant side
Refrigerant mass flow according to operating
conditions
Refrigerant

The suction filter combination SFC can be used by


external component factories, which use Grasso
screw compressors in their products. For this,
however, a coordination with GEA Grasso GmbH is
necessary.

Refrigeration / Grasso

Intended use

Warning!
The suction filter combination SFC is
for use at a maximum operating
pressure of 28 bar g.p. provided.

Any change in the operation conditions or


service parameters requires the verification of
the design.

_990333_pd_mp_gbr_1_.doc
27.07.2010

PRODUCT DESCRIPTION
MAIN PART
SUCTION FILTER COMBINATION SFC

1.6

Storage

1.8

On receipt of the goods, immediately check that all


parts are on hand and are as ordered. Eventual
shipping damages and/or missing parts have to be
reported in writing.

The construction of the suction filter combination


SFC is a combination of a suction filter and a valve
plate. The valve plate is equipped with a check valve
function and is controlled by the suction filter
element.

The suction filter combination SFC can be stored in a


dry place under roof at normal ambient
temperatures for a time period of 6 months. Storage
for a longer period requires the application of a
long-term preservation.

Hint!

The suction filter combination SFC must not be


exposed to any aggressive products, extreme
temperatures or humidity. Do not store the suction
filter combination SFC along with acids, alkaline
solutions or other caustic chemicals. The place of
storage should be dry and free from dust. The air
humidity should not exceed 65% and condensation is
not permissible.

1.7

Technical data

Media

Operating
temperature

Refrigerant in accordance with


EN 378
e.g. NH3 (ammonia), R134a,
R404a, R507,
others on request
acid refrigeration machine oils
-60 / +120C

Operating pressure,
-1 / 28 bar g.p.
max.
Approval

CE mark in line with the


Pressure Equipment Directive
(DGRL 97/23/EG)
Work's acceptance,
other approvals on request

Housing material
Seals

Standard: CR
Optional: HNBR please note
(N) after Grasso Ident number

Mesh size

140 m

Filling

25 Litres

Weight

115 kg

Function and design

Only the sizes described in this document


have integrated an additional sop valve
function.

The suction filter combination SFC prevents dirt


particles entrained in the intake stream from
entering the screw compressor unit. The flow
through the suction filter element is from the inside
to the outside. It is designed so that monitoring is
not required. The filter element can be cleaned.
The check valve function prevents a pressure
equalisation with the LP side of the plant and
simultaneous prevents a reverse rotation of the
screw compressor.
The additional integrated stop valve function ensures
the suction side isolation of the component for the
maintenance of suction filter.
Design features are:

Check valve function is freely movable, even in


part-load positions of the compressor a pulsation
of the valve plate will be prevented.

Secured closing by defined valve plate control


using hot gas from the high pressure side of
refrigeration plant

Cleaning or replacing the suction filter element is


also possible at closed valve. Use the cover
opening of suction filter combination SFC.

_990333_pd_mp_gbr_1_.doc
27.07.2010

Refrigeration / Grasso

PRODUCT DESCRIPTION
MAIN PART
SUCTION FILTER COMBINATION SFC

fig. 2:

Code

Suction filter combination SFC

Remark

Outlet to the compressor. The sizing is dependent on the connection/ the size of the compressor.

Inlet from the LP side of the plant


The nominal size is dependent on the operating conditions of the compressor components

Venting/ bypass port via valve plate with check valve function - M 16x1,5

Port for local temperature indication on suction side - M 12x1,5

Port for local pressure indication on suction side - G 1/4"

Bypass port via valve plate with check valve function - M 16x1,5

Additional port M 16x1,5 - preferably at oil return Grasso SPduo

Hot gas port for pressurizing the valve plate with check valve function

Port for the outflow of the overflow valve

1.9

Quality and Standardization

1.10

The Suction filter combination SFC for applications


with fluids of groups 1 and 2 are pressurized items in
line with the Pressure Equipment Directive 97/23/EC
(DGRL). They are given CE marks and approval in line
with the requirements according to category I.
Approval by classification companies and according
to non-EU regulations on request.
The Suction filter combination SFC is not a device or
component in the sense of the ATEX product directive
94/9/EC and therefore does not have a CE mark.
The use in potentially explosive atmospheres in
accordance with directive 94/9/EC (ATEX) is possible
only on request.
In the event that the Suction filter combinations SFC
are used in potentially explosive atmospheres,
potential compensation must be ensured.

Refrigeration / Grasso

Types

Suction filter combination SFC for application in


screw compressor packages with screw compressors
type R, S and T
nominal width

Grasso Ident 1

SFC DN 175/125-CR-CE

638298577

SFC DN 175/125-HNBR-CE

638298577N

SFC DN 175/150-CR-CE

638298578

SFC DN 175/150-HNBR-CE

638298578N

incl. CE mark in line with the Pressure Equipment Directive (DGRL)

_990333_pd_mp_gbr_1_.doc
27.07.2010

PRODUCT DESCRIPTION
MAIN PART
SUCTION FILTER COMBINATION SFC

1.11 Fitting

Caution!

The filter is installed in the pipe taking into account


the direction of flow and allowing sufficient
clearance for removing the filter element.

When carrying out maintenance,


always inspect the sealing ring (Oring) of the cover for mechanical
damage and replace it if necessary.

The direction of flow is indicated by an arrow on the


housing and is arranged as follows:
Flange opposite cover:

inlet

Flange at right-angles to filter cover:

outlet

7. Reassemble all parts with the new or cleaned


filter element following the same procedure in
reverse order.

1.13 Cleaning the filter element

Hint!
The components of the filter are fully
assembled at the factory, so that the filter
only needs to be opened at the end of
the maintenance interval.

1.12 Changing the filter element


The maintenance interval for changing or cleaning
the filter element is specified by the manufacturer of
the refrigeration system.

The metal-gauze element used in the filter can be


cleaned and reused several times before it has to be
changed.
Manual cleaning
Immerse the soiled metal-gauze element in a clean,
grease-dissolving liquid, then blow it through with
compressed air from the outside inwards. Here it is
important to place a cylindrical part possibly
wrapped in corrugated cardboard inside the
element to catch the dirt particles.

The contamination level and mechanical condition of


the filter element must be inspected at least once a
year.

Caution!
Never use wire brushes for cleaning.

Before opening the filter, always make sure the filter


housing is not under pressure.
Caution!
Refrigerant may leak out on opening the
filter. The safety data sheets for the
refrigerants in question must be
consulted and any prescribed protective
measures observed.

Ultrasonic cleaning
Metal gauzes with a mesh size of <= 40 m can only
be cleaned in an ultrasonic bath.
Hint!
To avoid fatigue failures of the metal
gauze, strainer elements should be
replaced with new, original filter
elements after being cleaned 4 5 times.

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.

1.14 Spare parts

4. Twist the element away from the cover to


release the bayonet catch.

Spare part

Grasso Ident

5. Detach the element from the cover.

Spare part kit

638298581
638298581N

6. Allow the element to drain off into a suitable


container.

consisting of the following:


Filter element
O-ring filter element
O-ring cover seal

_990333_pd_mp_gbr_1_.doc
27.07.2010

Refrigeration / Grasso

HS-Cooler
Intercambiador de calor de alto rendimiento

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000
1000-3999 y 77008499

Tipo/Nmero de dibujo:
dibujo
Nmero de pedido:
pedido
Nmero de serie:
Cliente:
Nmero de pedido de cliente:
Proyecto:
HS-Cooler GmbH Wittenburg
Sdring 2
D-19243 Wittenburg
Tel.: +49(0)38852 2336-0
Fax: +49(0)38852 2336-25
E-Mail: production@hs-cooler.de

KS20-FEP-112 L1200
A14-17136
A14-17136A + B
GEA Ref. Germany GmbH
134900

Amtsgericht Schwerin HRB 6456


Sitz der Gesellschaft: Wittenburg
Geschftsfhrung:
Stefan Garbe
E-Mail: sales@hs-cooler.de

Bank: Sparkasse Mecklenburg


Mecklenburg-Schwerin
Konto: 163 000 6498
BLZ:140 520 00
IBAN: DE70140520001630006498
SWIFT: NOLADE21LWL
USt-IdNr.:
IdNr.: DE 812788082
Internet: www.hs
www.hs-cooler.de

NDICE
Pgina
(1)Generalidades

Instalacin/Puesta en funcionamiento
Servicio tcnico
Garanta
Conservacin
Transporte
Regulaciones medioambientales

3
3
3
3
3
3

(2)Construccin
Haz de tubos
Carcasa
Colectores

4
4
4

(3)Funcionamiento

Instalacin
Atornilladuras
Placa de caractersticas
Puesta en funcionamiento
Indicaciones de funcionamiento
Puesta fuera de servicio/Parada del aparato

(4)Mantenimiento

Inspecciones peridicas
Desmontaje
Montaje
Limpieza

4
5
6
6
6
6

7
7
8
9

(5)Problemas/Resolucin de fallos

No se alcanza el rendimiento
Tubos no hermticos
Puntos de laminacin/soldadura no hermticos
Juntas no hermticas
Reparaciones/Piezas de repuesto

9
9
9
9
10

(6)Anexos

11
12
13

(7)Dibujo/Lista de piezas/Hoja de datos

15

Montaje de la chapa deflectora del haz de tubos


Ampliacin del captulo (4) Mantenimiento

La empresa HS-Cooler GmbH Wittenburg declina cualquier responsabilidad por los errores derivados de una utilizacin del producto
contraria a las normas. Nos reservamos el derecho a realizar modificaciones en el presente manual, sin previa notificacin, en caso
de que obtengamos nuevas informaciones aplicables

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 2

Versin: 01.11.2010

(1) Generalidades

Instalacin/Puesta en funcionamiento
Consulte el manual de instrucciones (incl. dibujos/listas de piezas/hoja de datos) antes de la
instalacin/puesta en servicio del intercambiador de calor.

Servicio tcnico
Para cualquier pregunta relacionada con el servicio tcnico, pngase en contacto con nuestra
empresa, nuestro distribuidor o la parte contratante. Cuando desee pedir alguna pieza de
repuesto, deber especificar siempre la referencia de la mquina y de la pieza. Las listas de
piezas y los dibujos que se adjuntan contienen todos los datos necesarios.

Garanta
Los derechos de garanta se aplicarn conforme a lo especificado en nuestras condiciones
generales relativas al suministro y a los pagos siempre y cuando, de forma individual, no se haya
acordado otra cosa al respecto. Tras la entrega debe comprobarse si la mercanca presenta daos
del transporte. Estos daos deben documentarse claramente en el albarn de entrega. Adems,
hay que informar inmediatamente a HS-Cooler y al transportista.
Para realizar mejoras en piezas defectuosas deber contar siempre con nuestra aprobacin. En
caso de que las circunstancias lo impidiesen, podr prescindirse de esta aprobacin. En este caso
deber avisarnos inmediatamente de ello en cuanto sea posible.
En principio, todas las modificaciones de las condiciones de trabajo debern contar con nuestra
aprobacin por escrito. Si no se respeta este manual de instrucciones y se utilizan piezas de
repuesto no originales, esto puede provocar la prdida de los derechos de garanta.

Conservacin
En condiciones normales, las superficies interiores de los aparatos se conservan durante un
perodo de seis meses. Pasados seis meses deber realizarse una proceso de conservacin.
Tenemos a su disposicin lquido antioxidante y las indicaciones de seguridad pertinentes. El
material de conservacin es compatible con cualquier lubricante mineral. Sin embargo, si fuese
necesario su eliminacin, podr realizarse con los disolventes conocidos (compruebe su
compatibilidad con el material). Los aparatos debern guardarse siempre en habitaciones
cerradas. Deber evitar la formacin de condensacin por oscilaciones en la temperatura.

Transporte
Evite cualquier dao al aparato. Para transportar el aparato sin embalaje con palancas, deber
tener suficientes eslingas de transporte y colocarlas alrededor de la carcasa de la estructura. En
caso de intercambiadores de calor aislados, para la elevacin hay que usar los ojales de elevacin
soldados. Observe el peso sin carga del aparato que est indicado en la placa o en la hoja de
datos vigente.

Regulaciones medioambientales
El montaje y el funcionamiento del intercambiador de calor deben realizarse de acuerdo con las
leyes y disposiciones medioambientales del lugar de instalacin. En la eliminacin del aparato
deben tenerse en cuenta las disposiciones de eliminacin de residuos vigentes, estatales y
regionales.

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 3

Versin: 01.11.2010

(2) Construccin

Haz de tubos
El haz de tubos se compone de dos placas de tubos opuestas con tres ranuras cada una. En la
placa de tubos, los tubos de refrigeracin estn mandrilados o soldados. Entre las placas de la
parte exterior del tubo la superficie se ampla en forma de lminas unidas con los tubos en unin
continua. Sobre toda la longitud lateral de este conjunto de lminas se encuentran ranuras que
sirven para alojar las bandas de obturacin. En este conjunto de lminas puede instalarse diversas
chapas deflectoras. En las chapas deflectoras hay una ranura fresada que sirve para alojar uno o
dos anillos por lminas (segn el ancho de la ranura). Cada junta trica interna de las ranuras de
las placas de tubos cierra hermticamente la carcasa cuando el aparato est montado. Las
ranuras externas sirven para obturar los colectores. De esta forma, se impide que los lquidos se
mezclen en caso de que se daen las juntas facilitando as la localizacin de la fuga. En la ranura
central de la placa de tubos se encajan planchas que sujetan la placa de tubos cuando el aparato
est montado y permiten una dilatacin por calor de la placa colocada enfrente. La fijacin debe
estar situada en el lateral de las tomas para los aparatos de dos conductos. En todo caso, este
lado se marca en la fbrica con una F en la brida de la carcasa en la zona del apoyo M1 o M2.
Cuando el aparato est en funcionamiento, la sujecin debe estar colocada en este lado.

Carcasa
La carcasa es la parte que alberga el haz de tubos y forma el compartimento de presin exterior.
Se compone de piezas terminales o anillos con brida, soldados con el tubo envolvente mediante
una soldadura redonda. Las piezas terminales pueden colocarse de tal modo que las tomas de
aceite se encuentren en un lado o bien giradas 180 de frente. El tubo de revestimiento es un tubo
de precisin con tolerancias pequeas. Est prohibido realizar modificaciones en la carcasa.
A la entrada de las piezas terminales o los anillos con brida, la ranura interna de las placas de
tubos se encuentra obturada mediante juntas tricas. Trate esta zona con especial cuidado a fin
de mantener el efecto de la obturacin.

Colectores
Dependiendo del modelo, los colectores se componen de diversos materiales (vase lista de
piezas). Constituyen, junto al haz de tubos, el compartimento de presin del refrigerante y estn
fijados en la carcasa mediante cuatro tornillos. En un lado del aparato, se colocan chapas entre el
colector y la carcasa para sujetar la placa de tubos. En el otro lado, se encuentran discos que
conforman un espacio de separacin.
En el modelo de un solo conducto se colocan dos colectores idnticos uno frente al otro. En la
versin de dos conductos, se encuentra en un lado del aparato un colector con dos tomas y en el
otro lado una tapa de inversin. Para obturar las dos cmaras del colector en la parte de la
conexin se introduce un separador de plstico en la placa de tubos. El separador sirve para
obturar el espacio entre la placa de tubos y el colector con el aparato montado, y reparte as el
lquido de los tubos a travs del aparato.
En los colectores resistentes al agua salada pueden instalarse nodos sacrificiales.

(3) Funcionamiento

Instalacin
Retire las tapas protectoras de las tomas. Si falta la tapa en una conexin, deber
comprobar que sta no se haya introducido en la conexin y que no haya cuerpos
extraos en el aparato.

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 4

Versin: 01.11.2010

No puede haber cuerpos extraos en las entradas de las tomas.


Conecte los tubos sin tensin, para garantizar que el funcionamiento del aparato no se
pueda ver afectado por altas tensiones mecnicas o trmicas no permitidas.
Antes de integrar el intercambiador de calor en el sistema hay que asegurarse de que las
superficies de obturacin y las juntas estn libres de suciedad, araazos o daos.
Los conductos que se conectan mediante rosca slo pueden enroscarse hasta una
profundidad de rosca mxima usable.
Todos los circuitos deben estar construidos de tal forma que no pueda penetrar la
suciedad en ellos. Se recomienda la instalacin de colectores de suciedad y los filtros
correspondientes.
Los conductos deben estar colocados correctamente para que no se pueda crear ningn
colchn neumtico.
El montaje puede realizarse en vertical u horizontal.
Todas las atornilladuras deben ser fcilmente accesibles, para lo cual es importante que
haya espacio suficiente. En especial, deber observarse que haya espacio suficiente para
estirar el haz de tubos. Para conocer el espacio que se necesita tener para estirar el haz
de tubos, consulte el dibujo.
La conexin de los conductos y el sentido de la corriente puede consultarse en el dibujo y
la hoja de datos adjuntos.
Antes de la puesta en funcionamiento, deber vaciar completamente el aire del aparato.
Durante la fijacin del intercambiador de calor hay que tener en cuenta una posible
expansin longitudinal del aparato por calentamiento.
No podr realizar ninguna soldadura ni ninguna otra modificacin en el aparato.
En caso de sistemas exigentes con el grado de limpieza, antes de la puesta en servicio
del intercambiador de calor hay que enjuagar bien el aparato pasando por alto el
consumidor.
Los obturadores de reduccin slo pueden colocarse en la salida del intercambiador de
calor.
Los intercambiadores de calor son recipientes a presin diseados y construidos para
condiciones de diseo y funcionamiento especiales. La presin y la temperatura
mxima/mnima indicadas en la placa de caractersticas no deben superarse nunca. Todo
el sistema est bajo la responsabilidad del constructora de la instalacin/explotador y debe
disponer de los sistemas de seguridad y control necesarios para conservar estos
parmetros de servicio. Aqu se incluyen, entre otros, vlvulas de seguridad, recipientes
de expansin, limitadores de temperatura de seguridad, ventilaciones, evacuaciones, etc.
Hay que respetar las prescripciones especiales del pas de emplazamiento.
Los intercambiadores de calor o los sistemas unidos con este sistema conductor de
electricidad deben estar conectados con un cable de cobre (seccin de 16mm) con la
lnea de toma de tierra. Hay que fijarse que las zonas de conexin de la cinta de conexin
estn libres de colores u otros materiales elctricamente aislantes.
Al trabajar con vapor hay que procurar que no se formen serpentines de vapor por la
formacin de condensacin. En concreto, solo deben utilizarse vlvulas reguladoras
adecuadas. La derivacin de condensacin debe producirse a travs de trampas de vapor
adecuadas.

Atornilladuras
Para garantizar el funcionamiento seguro y la duracin de los elementos de conexin, las
atornilladuras deben apretarse solamente con del par de fuerzas y mediante la cruz. El par de
fuerzas debe aumentarse gradualmente hasta el valor mximo. En la tabla que se muestra a
continuacin podr ver los niveles de par de apriete de los tornillos utilizados. Los valores
indicados pueden verse afectados por diversos factores que pueden aumentarlos o disminuirlos.
Las roscas de los tornillos deben lubricarse con un lubricante adecuado.

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 5

Versin: 01.11.2010

Conexin entre carcasa/obturacin/cierre

Conexin de la brida de unin

Tipo

Tornillo/
Resistencia

Par de apriete
[Nm]

Tornillo/
Resistencia

Material de la
rosca

Par de apriete
[Nm]

K10

M8 / 8.8

12

M8 / 5.6

GG25/Aluminio

10

KK12/KA12

M10 / 8.8

23

M10 / 5.6

GG25/Aluminio

20

K12/KS12/KK12/KW12

K20/KS20/KK20/KW20

K25/KS25/KW25

K35

M12 / 5.6

40

M10 / 5.6 / 8.8

Acero

23

M12 / 8.8

86

M12 / 5.6 / 8.8

Acero

40

M16 / 5.6

100

GG25/Aluminio

30

M16 / 8.8

210

Bronce

30

M20 / 5.6

190

GG25/Aluminio

75

M20 / 8.8

410

M24 / 5.6

330

M24 / 8.8

710

M12 / 5.6

M16 / 5.6

M24 / 5.6

Bronce

75

Acero

100

Acero

300

Placa de caractersticas
La placa de caractersticas se encuentra en el lateral del aparato y est totalmente unida a l. La
placa de caractersticas no debe quitarse.

Puesta en funcionamiento
Llene el aparato con el lquido previsto por ambos lados y compruebe la estanqueidad de todo el
sistema. Primero debe crearse la corriente del lquido fro. Luego se crea lentamente la corriente
del lquido caliente. Ambos circuitos del intercambiador de calor deben purgarse. Despus de
alcanzar los parmetros de servicio (presin y temperatura), el aparato debe purgarse de nuevo y
debe realizarse un control de posibles fugas. Deben respetarse los caudales de la hoja de datos
puesto que, de lo contrario, existe un riesgo elevado de corrosin/erosin del intercambiador de
calor. No podr ponerse en marcha el aparato sin que est circulando el lquido fro. Hay que
evitar las oscilaciones bruscas de temperatura, as como los golpes de presin. Antes de aadir un
aditivo (inhibidor) a uno de los lquidos, compruebe siempre la resistencia en relacin a los
materiales del intercambiador de calor (segn la lista de piezas).
Para instalaciones refrigeradas por agua:
Si el ajuste de la circulacin se realiza mediante una regulacin, recomendamos que se regule el
aceite, especialmente cuando el sistema tenga que funcionar con agua salada y agua dulce.
La regulacin de la corriente de agua de refrigeracin ha de acordarse con nuestra fbrica, dada la
importancia de factores como el material del tubo y la calidad del refrigerante.
La utilizacin de aditivos de agua de refrigeracin debe acordarse siempre con nuestra fbrica.

Indicaciones de funcionamiento
Mientras el aparato est en funcionamiento, deber observarse, utilizando las medidas
apropiadas, que se mantienen los parmetros indicados previstos. Si los aparatos de reserva
cuentan con una guarnicin de conmutacin, deber observar que la conmutacin se produce de
forma peridica (cada 2 o 3 das) o que, durante un tiempo, el aparato se carga diariamente con
toda la cantidad de agua. La lnea de compensacin entre ambos aparatos debe mantenerse
siempre abierta durante el funcionamiento, con tal de proteger el aparato desmantelado de la
sobrepresin. La lnea de compensacin debera cerrarse nicamente al desmontar un ventilador
para que no salga ningn lquido al exterior.

Puesta fuera de servicio/Parada del aparato


Si se detiene el funcionamiento del aparato durante un corto perodo de tiempo (hasta cuatro
das), podr estar lleno. Si el intercambiador de calor no se utiliza durante un perodo prolongado
de tiempo (ms de 4 das), es necesario vaciarlo por completo y secarlo con aire comprimido

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Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 6

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caliente. Si el aparato ha funcionado con un lquido corrosivo, esta medida (vaciar y secar) ya
debe realizarse incluso con un tiempo de parada de un da. Adems, despus del vaciado hay que
enjuagar el aparato con agua clara.
En caso de peligro de heladas, hay que evitar que los lquidos se congelen adoptando las medidas
necesarias.

(4) Mantenimiento

Inspecciones peridicas
Por regla general, los aparatos de la empresa HS-Cooler son seguros y requieren poco
mantenimiento. Sin embargo, es necesario realizar inspecciones peridicas a fin de conseguir un
funcionamiento duradero y seguro. En general, predominan las inspecciones en la parte del tubo.
La parte del revestimiento tiende menos a ensuciarse, por lo que ha de ser el operario el que
decida cundo ha de tener lugar la inspeccin.
Al funcionar con agua salada hay que instalar nodos sacrificiales en los colectores. En la
fase inicial, los nodos deben comprobarse cada 3 meses. Si los nodos se agotan,
debern ser reemplazados por otros. En caso de que se registre un consumo
excesivamente rpido de los nodos, deber revisarse la calidad del agua y la diferencia
de potenciales del sistema. Inspeccin de la parte del revestimiento del intercambiador de
calor cada 6 meses.
La parte del tubo del aparato deber limpiarse por lo menos una vez al ao. Evite el
ensuciamiento excesivo de los tubos. Debern acortarse los perodos de las inspecciones
cuando los barcos estn trabajando en el puerto o en aguas sucias durante un largo
perodo de tiempo, y si el operario lo considera oportuno.
El aparato deber estar sometido a revisiones visuales externas en perodos de tiempo
cortos para determinar la existencia de fugas u otros problemas. La obturacin de junta
trica permite clasificar con exactitud las fugas y determinar el trabajo que su eliminacin
puede significar.

Desmontaje

Atencin: Anexo B: Consulte la ampliacin del captulo (4) Mantenimiento


/Desmontaje/Desmontaje sin estirar el haz de tubos

Para desmontar el aparato, proceda de la siguiente manera:


Bloquee todos los conductos.
Ambos medios deben enfriarse hasta la temperatura ambiente.
Vace el aparato por el lado del tubo y, si resulta necesario desmontar el haz, hgalo
tambin por la parte del revestimiento.
Retire los conductos por la parte del tubo.
Retire los colectores / la tapa. Para ello, deber aflojar los 4 tornillos que unen la carcasa y
el colector. Entre el colector y la tapa se encuentran 4 chapas de fijacin o placas de
apoyo. Al montar el aparato, stas debern montarse de nuevo en el mismo sitio. Para
ello, observe la marca de la brida de la carcasa.
Si desea desmontar el aparato sin estirar el haz de tubos deber desmontar en primer
lugar el colector / tapa sin chapas de fijacin para asegurar el haz de tubos y evitar que se
mueva, antes de retirar las chapas de fijacin. Para ello, podr utilizar un conjunto nuevo
de chapas de fijacin u otros dispositivos auxiliares similares.
Desmontaje sin estirar el haz de tubos

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 7

Versin: 01.11.2010

Retire las juntas tricas de la ranura exterior de las placas de tubos y fije el haz de tubos
contra la carcasa con cuatro tornillos y las cuatro chapas de fijacin en la ranura central de
la placa. Ahora podr revisar y limpiar de forma mecnica el lateral del tubo. La parte del
revestimiento puede quedar sin presin.
Desmontaje estirando el haz de tubos
Retire las juntas tricas de la ranura exterior de las placas de tubos. En una de estas
placas se indica la posicin del montaje en relacin a la carcasa. En el borde de la placa y
en la brida colindante de la carcasa se ha colocado la mitad de una cruz. Compruebe esta
seal. Ha de desplazar el haz de tubos (en caso necesario, ayudndose de una
herramienta auxiliar) hasta que la junta trica de la ranura interna sea visible. Retire la
junta trica de la ranura interior. Extraiga el haz de tubos tirando de l en el sentido
contrario. Deber retirar con cuidado el haz de tubos de la carcasa, sin que el conjunto de
lminas resulte daado. Si es posible, cuelgue el haz de tubos utilizando eslingas de
transporte de gran superficie. No dae las ranuras de alojamiento de las juntas tricas.
Al desmontar aparatos colocados verticalmente siempre hay que garantizar mediante las
medidas adecuadas que el haz de tubos no caiga hacia abajo tras soltar las chapas de
fijacin. Se recomienda preparar un juego adicional de chapas de fijacin y empezar el
desmontaje en el lado donde no hay ninguna chapa de fijacin. Primero debe fijarse all el
haz. Despus de desmontar el segundo colector, puede procederse a estirar el haz de
forma controlada. Al proceder al montaje, slo se permite utilizar una chapa de fijacin que
deber colocarse en la parte de la marca.

Montaje
El montaje sigue la secuencia inversa al desmontaje. Adems deben tenerse en cuenta los
siguientes puntos:
En principio hay que utilizar juntas nuevas y limpiar las superficies de obturacin.
Observe la marca para montar el haz de tubos de la forma correcta (marca "X").
Observe la marca para montar las chapas de fijacin de la forma correcta (marca "F").
Si en el lateral del haz de tubos hay bandas obturadoras, slo deben cambiarse en caso
de que estn daadas. Al introducir el haz de tubos observe que las bandas obturadoras
no se descolocan ni se comban. Antes de proceder al montaje del haz de tubos, las
bandas obturadoras deberan engrasarse. Para ello puede utilizarse el lquido de
funcionamiento. Las bandas obturadoras deberan tener efecto sobre toda la longitud del
haz de tubos.
Compruebe los posibles daos en los anillos de lminas en la ranura de la chapa
deflectora. Al montar las chapas deflectoras hay que presionar los anillos de lminas por
toda la extensin para que el haz pueda empujarse en el revestimiento. Como ayuda de
montaje puede usarse una tira de chapa (disponible a travs de HS-Cooler) o un medio
similar. El montaje del haz en el revestimiento se explica de nuevo en el anexo A de este
manual de instrucciones.
Lubrifique las juntas tricas con aceite adecuado para juntas tricas.
Al introducir la placa absorbente de tubos en las superficies de obturacin, asegrese de
que no corta las juntas tricas. Los colectores / tapas deben colocarse paralelos a las
placas de tubos y deslizarse de forma uniforme sobre la junta trica, observe tambin al
realizar esta operacin, que la junta no se corta.
En los aparatos de dos entradas, deber colocarse en el lado del colector una brida
separadora de plstico en la placa de tubos. Tambin en este lado se instalarn
posteriormente las chapas de fijacin.
Al montar los colectores de dos entradas asegrese de que el separador est
correctamente montado.
Si los tornillos y tuercas vuelven a utilizarse, antes deben comprobarse ante cualquier
posible dao.
A continuacin prosiga tal y como se describe en el punto Funcionamiento.

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 8

Versin: 01.11.2010

Limpieza
Las pequeas impurezas de la parte de los tubos pueden limpiarse de forma mecnica. Para ello,
desmonte el aparato tal y como se describe en el captulo Desmontaje sin estirar el haz de tubos
y limpie y aclare la parte interior de cada tubo con un cepillo de nylon (no utilice cepillos de metal).
Si se encuentran depsitos muy agarrados e impurezas grandes no las elimine con violencia en
ningn caso. En caso de depsitos muy agarrados hay que limpiar el haz de tubos mediante
procedimientos qumicos. Esto puede realizarse lavando el haz de tubos con el aparato montado o
mediante inmersin con el aparato desmontado. Este tipo de limpieza slo puede ser llevada a
cabo por personal especializado. Utilice slo disolventes adecuados. Para su seleccin puede
consultar la lista de piezas del intercambiador de calor. Observe los materiales de la brida
separadora de plstico y las juntas tricas con el aparato montado.
Si en la referencia del tipo (ejemplo: KS12-BCN-821C L1000) hay una C en el lugar 11 se trata de
un haz de tubos revestido. Para protegerlos contra la corrosin, la parte interior de los tubos del
haz est provista de un revestimiento cermico. No dae ni destruya este revestimiento al
desmontar el haz ni al realizar trabajos de limpieza. Utilice solamente cepillos de limpieza de nylon
o productos de limpieza autorizados. En caso de duda, dirjase a nuestro departamento de
atencin al cliente.

(5) Problemas/Resolucin de fallos

No se alcanza el rendimiento
Compruebe que todas las temperaturas y las corrientes de material concuerdan con los
datos del proyecto (consulte la hoja de datos).
Hay cuerpos extraos en el conducto o en el aparato que provoquen taponamientos?
El haz de tubos est montado correctamente? Compruebe la marca "X".
La brida de plstico est montada de la forma correcta en el colector de dos entradas?
La chapa de fijacin est colocada en este lado?
Todos los compartimentos de presin estn sin presin?
La parte de los tubos o del revestimiento estn excesivamente sucias (depsitos
gruesos)?
Ms del 10% de los tubos son ciegos?

Tubos no hermticos
Si tiene la sospecha de que en los tubos hay una fuga, proceda tal y como se indica en
Desmontaje sin estirar el haz de tubos. La parte del revestimiento puede quedar sin presin.
Despus de limpiar las placas de tubos podr determinar en qu tubo est la fuga cuando salga el
lquido. El tubo no hermtico debe cerrarse por ambos lados. HS-Cooler GmbH ofrece juegos de
reparacin para ello. Pueden cerrarse como mximo el 10% de los tubos sin que se produzca una
reduccin considerable en el rendimiento. No podr desmontarse el tubo defectuoso.

Puntos de laminacin/soldadura no hermticos


Si al revisar los tubos no hermticos determina que hay algn punto de laminacin que presenta
una fuga, podr laminarlo con una herramienta especial. Si existe un punto de soldadura de los
tubos que no es hermtico, entonces puede soldarse de nuevo. Sin embargo, slo personal
instruido puede llevar a cabo este trabajo. Dado que la existencia de este tipo de faltas no es
frecuente, se recomienda que se lleve a cabo una revisin del haz completo en nuestra fbrica.

Junta trica no hermtica

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 9

Versin: 01.11.2010

Si entre el colector / tapa y la carcasa se determina la existencia de una fuga, esto significar que
una junta trica de la placa de tubos est defectuosa. Podr determinarse cul es la ranura de la
placa que presenta el fallo dependiendo del tipo de lquido soltado. Si se detecta un fallo en la
parte de los tubos, proceda tal y como se indica en Desmontaje sin estirar el haz de tubos. Si se
detecta un fallo en la parte del revestimiento, proceda tal y como se indica en el punto
Desmontaje estirando el haz de tubos. Naturalmente, en este caso no debe retirarse
completamente el haz de tubos de la carcasa. Monte la junta trica tal y como se describe en el
punto Montaje.

Reparaciones/Piezas de repuesto
Las reparaciones slo podrn ser llevadas a cabo por tcnicos instruidos. Se recomienda, sin
embargo, que se realicen a travs de nuestro taller. Las piezas de repuesto pueden pedirse en
nuestra empresa directamente indicando el nmero del dibujo. Dirjase para ello a nuestra fbrica
central o a nuestra oficina de ventas.

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 10

Versin: 01.11.2010

(6)Anexos

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 11

Versin: 01.11.2010

- Ergnzung zu Kapitel Wartung/Demontage/Demontage ohne Herausziehen des


Rohrbndels. Bei Zusammenbau mssen die Fixierplatten wieder an der richtigen
Seite des Wrmetauschers eingebaut werden - siehe dazu die Bedieungsanleitung!
- Addition to chapter Maintenance/Dismounting/Dismounting without
remove the test bundle. During assembly the fixing plates have to be
assembled to the correct side of the heat exchanger see the instruction manual!
- En complment du chapitre maintenance/dmontage/dmontage sans
tirer vers lextrieur le faisceau tubulaire . Lors de lassemblage les dalles de
fixation doivent tre encastres dans le ct exact de lchangeur de chaleur - voir cet
effet linstruction dexploitation.
- Complemento al captulo Mantenimiento/Desmontaje/Desmontaje sin
extraer el haz de tubos. Al realizar el montaje, las placas fijadoras se han
de volver a colocar en el lado correcto del intercambiador de calor - ver para ello las
instrucciones de servicio.
- Completamento del capitolo Manutenzione/Smontaggio/Smontaggio senza
estrazione del fascio tubolare. Nella fase di assemblaggio, le piastre di fissaggio
devono essere rimontate sul corretto lato dello scambiatore di calore vedi a questo
proposito le istruzioni per luso!
- Suplemento do captulo Manuteno/Desmontagem/Desmontagem sem
extraco do feixe de tubos. No momento da montagem, as placas de fixao
devero ser outra vez aplicadas no lado correcto do permutador trmico -- consulte o
manual de instrues!

- Aanvulling bij het hoofdstuk


Onderhoud/demontage/
demontage zonder uittrekken van
de buizenbundel. Bij de montage
moeten de fixeerplaten opnieuw aan de
correcte zijde van de warmtewisselaar
worden ingebouwd zie ook de
gebruiksaanwijzing!
- Komplettering av kapitel
Sktsel/demontage/
demontage utan att dra ut rrpaketet.
Vid sammansttningen mste
fixerplattorna ter monteras p rtt sida
av vrmevxlaren - se bruksanvisningen
om detta!
- Supplement til kapittel
Vedlikehold/demontering/
demontering uten uttrekking av
rrbunt. Ved sammensetting m
posisjoneringsplatene monteres p
korrekt side av varmeveksleren - se
bruksveiledningen!
- Tydennys lukuun Huolto/
Purkaminen/purkaminen ilman
putkinipun ulosvetmist. Koottaessa
on kiinnityslevyt asennettava taas
oikein lmmnvaihtimen sivulle katso
kyttohje!
-
//

-



!
- Uzupenienie do rozdziau
Konserwacja/Demonta/
Demonta bez wycigania wizki rurowej.
Przy montau, pyty ustalajce musz zosta
znowu wbudowane po waciwej stronie
wymiennika ciepa patrz: Instrukcja obsugi!
- Dodatek k poglavju
- Vzdrevanje/Demontaa/
demontaa brez izvleka snopa cevi. Pri
sestavi je potrebno fiksirne ploice spet
vgraditi nazaj na pravilni strani toplotnega
izmenjevalnika glejte k temu navodila
za upravljanje!
- Dodatok ku kapitole
drba/demont/demont
bez vyahovania zvzku trubiek.
Pri monti je potrebn fixan dosky
znovu namontova na sprvnu stranu
vmennka tepla pozri v tejto svislosti
nvod na obsluhu!

B
1.

2.

Stand: 15.11.2010

3.

4.

5.

6.

7.

8.

9.

10.

Stand: 15.11.2010

(7)Dibujo/Lista de piezas/Hoja de datos

Manual de instrucciones e instalacin


Serie KS/K/KK/KW estndar/ Serie EXOT 1000-3999 y 7700-8499
Pgina 15

Versin: 01.11.2010

Pos.

Quantity

Unit

Description

Part/Standard Number

pc.

Shell

pc.

Tube bundle

pc.

Bonnet 3" SAE

KL20-F-021

S235JRG
AD-W1 (3.1)

pc.

Fixation plate

KL20-0-108

Steel galv.

pc.

Clamp bracket

KL20-0-109

Steel

pc.

Hex bolt

ISO 4017 - M16 x 40 - 8.8

Steel galv.

pc.

Hex nut

ISO 4032 - M16 - 8

Steel galv.

pc.

Washer

DIN 125 - A 17

Steel galv.

GS20

Remark

- 2

RL20 - E P - 1 1 2

pc.

H bolt
b lt
Hex

ISO 4014 - M16 x 130 - 8


8.8
8

Steel galv.
AD-W7 (stamped)
verification required for
yield stress at 100C

10

pc.

Hex nut

ISO 4032 - M16 - 8

Steel galv.
AD-W7 (stamped)

11

20

pc.

Washer

DIN 125 - A 17

Steel galv.

12

pc
pc.

Type plate

Aluminium

DRAW

DATE

NAME

02.12.99

Garbe

CHECK 02.12.99 Graulich

Parts list

NORM

Steel + 1/8"

3.5.01

Garbe

SYM

REVISION

DATE

NAME

K S 2 0 - FEP - 1 1 2
FILE: Parts list KS20.xls

Sheet
1 of 1

Pos.

Quantity

Unit

Description

pc.

Tubesheet

178

pc.

Tube LR = L + 68mm

7.5mm x 0.5mm

1.4404
AD-W2 (3.1)

L/1.1

pc.

Fin 1.1

KL20-0-104

Aluminium

pc.

O-Ring

KL-1522

Neoprene

pc.

S li strip
Sealing
ti

L x 13 x 3

N
Neoprene

pc.

Baffle

KL20-0-106

Aluminium

pc.

Sealing bonnet

KL20-0-117

PE 1000

DRAW

Part/Standard Number

KL20 - E - 062

DATE

NAME

04.11.99

Garbe

CHECK 04.11.99 Graulich

Remark

1.4301
AD-W2 (3.1)

Parts list

NORM

R L 2 0 - EP - 1 1 2
SYM

REVISION

DATE

NAME

FILE: Parts List RL20-E#-###.xls

Sheet
1 of 1

HS-Cooler GmbH
Suedring 2
D-19243 Wittenburg
Tel. +49 (0) 388 52 23 36 0
Fax. +49 (0) 388 52 23 36 25
email: sales@hs-cooler.de

Cliente

GEA Refrigeration Berlin

Fecha

02.05.2014

Proyecto

Piedras Negras 2 - 179,6kW

Oferta

B14-24528-02

Tipo

KS 20 - F E P - 1 1 2 - L1200

Nivel de presion

Pieza lateral
Fluido

Generalidades

ISO VG 68 + NH3

Lateral de tuberia
R 717

Capacidad calorifica

kW

Temperatura de entrada

80

32

Temperatura de salida

50

32

Corriente de masa

kg/s

0,16

Caudal

m/h

12,5

Perdida de presion
Superficie de
transmission

bar

0,17

0,01

38,46

4,7

Temperatura max.

100

100

Presion max.

bar

30

30

Fouling

179,6

mK/kW

21,4

mm

219,1

Numero de deflectores

Numero de tubos

178

Diametro de los tubos

mm

8,0 x 0,5

Largo de los tubos

mm

1200

kg

146

Capacidad de reserva
Diametro de caja

Vias
Peso(v)
Contenido

dm

23,6

13,3
Material

Tubos

1.4404

Placas de tubos

1.4301

Laminas

Aluminio

Deflector

Aluminio

Anillos en'O'

NEOPRENE

Tapas

Ferro

Pieza lateral

Ferro

Conexiones

Notas

HS Cooler Calculator F 3.2

---

DN80

SAE3"

HS-Cooler GmbH
Suedring 2
D-19243 Wittenburg
Tel. +49 (0) 388 52 23 36 0
Fax. +49 (0) 388 52 23 36 25
email: sales@hs-cooler.de

Cliente

GEA Refrigeration Berlin

Fecha

02.05.2014

Proyecto

Piedras Negras 2 - 212,3kW

Oferta

B14-24528-03

Tipo

KS 20 - F E P - 1 1 2 - L1200

Nivel de presion

Pieza lateral
Fluido

Generalidades

ISO VG 68 + NH3

Lateral de tuberia
R 717

Capacidad calorifica

kW

Temperatura de entrada

80

32

Temperatura de salida

50

32

Corriente de masa

kg/s

0,19

Caudal

m/h

14,7

Perdida de presion
Superficie de
transmission

bar

0,2

0,01

38,46

4,7

Temperatura max.

100

100

Presion max.

bar

30

30

Fouling

212,3

mK/kW

16,4

mm

219,1

Numero de deflectores

Numero de tubos

178

Diametro de los tubos

mm

8,0 x 0,5

Largo de los tubos

mm

1200

kg

146

Capacidad de reserva
Diametro de caja

Vias
Peso(v)
Contenido

dm

23,6

13,3
Material

Tubos

1.4404

Placas de tubos

1.4301

Laminas

Aluminio

Deflector

Aluminio

Anillos en'O'

NEOPRENE

Tapas

Ferro

Pieza lateral

Ferro

Conexiones

Notas

HS Cooler Calculator F 3.2

---

DN80

SAE3"

PRODUCT DESCRIPTION
MAIN PART
PRESSURE TRANSMITTER AKS 33

1.1

Advantages

View

Disigned to meet A/C and refrigeration demands


without compromising control accuracy concerning:
1. Tough environment

Vibration

Shock during operation and transport

Humidity and ice formation

Temperature variations

Corrosive media like ammonia gases and


salt mist

2. Convenient performance
fig. 1:

Pressure transmitter AKS 33 ... GEA Grasso, Dimensions

4 to 20 mA signal

0.3 % typical accuracy

0.2 % typical linearity

3. Perfect system integrity

Compact design

Mx. working pressure see table

Temperature compensation for suction line

G 1/4 ", threaded

Enclosure: IP 65 with plug

4. Application
fig. 2:

1.2

Pressure transmitter AKS 33 ... GEA Grasso, view

Pressure transmitter AKS 33

AKS 33 is a series of absolute transmitters with 4 20 mA standard signal, developed to meet demands
in A/C and refrigeration.
AKS 33 utilizes the proved piezoresistive measuring
principle, which has been used for decades in pressure transmitters.
The pressure difference is a sealed gauge. This
means that atmospheric pressure variations have no
influence on regulating accuracy. A must in accurate
low pressure regulation.
All materials in contact with the refrigerant ans materials for the housing are AISI 316L stainless steel.
No soft gaskets, all environmental sealings are
made through laser weldings only.

1.3

Suction pressure control

Compressor capacity control

Evaporator pressure detection

Oil pressure control

Technical data

Electrical specifications
Nominal output
signal
Supply voltage

10 ... 30 V DC, polarity protected

Voltage dependency

< 0.05 % FS/ 10 V

Current limitation

28 mA (typ.)

Max. load [RL]

[RL] = (Supply voltage -10 V)


/ 0,02 A []

AKS 33 has a 4 to 20 mA output and is available


with DIN elbow connector.

GEA Refrigeration Germany GmbH

4 ... 20 mA

_990293_pd_mp_gbr_1_.doc

PRODUCT DESCRIPTION
MAIN PART
PRESSURE TRANSMITTER AKS 33

Operating conditions

Thermal sensitivity

Temperature
limits

- 40 C to 85 C

The AKS 33 is calibrated to limit ambient temperature influence on the regulating accuracy.

Compensated
temperature
range

LP: - 30 C 40 C
HP: 0 C 80 C

Pressure transmitters to be used at low temperature


conditions, e.g. in suction lines, are calibrated at
30C to +40C. In this way control accuracy is optimized in a temperature range of 30C to +40C.

Transport temperature range

- 50 C to 85 C

Electrical connection

Enclosure (plug
design)

IP 65, EN 60529

Insulation

> 100 M, at 100 V DC

CE mark

Interference emission / interference immunity acc. to DIN 610006, Declaration of conformity


fig. 3:

Two-wire, 4 ... 20 mA

Mechanical characteristics
Electrical connection

Elbow connector Pg9 DIN EN


175301-803 (DIN 43650) Type of
construction A, colour: grey

Wetted parts,
material

EN 10088-1, 1.4404 (AISI316L)

Casing

EN 10088-1, 1.4404 (AISI316L)

Weight

0.2 kg

Media

HFC, CFC, HCFC, ammonia

Mechanical
connection

G 1/4A with max. 25 Nm


Moulded profiled ring DIN 386914-CR: Grasso Ident 762998214
Moulded profiled ring DIN 386914-HNBR: Grasso Ident
762998314

1.4

Pressure transmitter AKS 3000, electrical connection

Supply "+"

Supply "-"

not used

connected to transmitter housing

Maximum operating pressure /overload range


0 ... + 7 bar (a) min. 25 bar g.p.
0 ...+13 bar (a) min. 40 bar g.p.

Pressure ranges, Ident numbers

Designation

Pressure range

Grasso Ident

Pressure transmitter AKS 33 GEA Grasso 7

0 ... 7 bar abs.

632198021D

Pressure transmitter AKS 33 GEA Grasso 13

0 ... 13 bar abs.

632198034D

_990293_pd_mp_gbr_1_.doc

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
PRESSURE TRANSMITTER AKS 3000

1.1

Advantages

View

Disigned to meet A/C and refrigeration demands


without compromising control accuracy concerning:
1. Tough environment

Vibration

Shock during operation and transport

Humidity and ice formation

Temperature variations

Corrosive media like ammonia gases and


salt mist

2. Convenient performance

fig. 1:

Pressure transmitter AKS 3000 ... GEA Grasso, Dimensions

4 to 20 mA signal

1 % typical accuracy

0.5 % typical linearity

3. Perfect system integrity

Compact design

Mx. working pressure see table

Temperature compensation for suction line

G 1/4 ", threaded

Enclosure: IP 65 with plug

4. Application

fig. 2:

1.2

Pressure transmitter AKS 3000 ... GEA Grasso, view

Pressure transmitter AKS 3000

1.3

AKS 3000 is a series of absolute transmitters with 4


- 20 mA standard signal, developed to meet demands in A/C and refrigeration.
AKS 3000 utilizes the proved piezoresistive measuring principle, which has been used for decades in
pressure transmitters.
The pressure difference is a sealed gauge. This
means that atmospheric pressure variations have no
influence on regulating accuracy. A must in accurate
low pressure regulation.
All materials in contact with the refrigerant and materials for the housing are AISI 316L stainless steel.
No soft gaskets, all environmental sealings are
made through laser weldings only.
AKS 3000 has a 4 to 20 mA output and is available
with DIN elbow connector.

GEA Refrigeration Germany GmbH

High pressure control

Compressor capacity control

Evaporator pressure detection

Oil pressure control

Technical data

Electrical specifications
Nominal output
signal

4 ... 20 mA

Supply voltage

10 ... 30 V DC, polarity protected

Voltage dependency

< 0.2 % FS/ 10 V

Current limitation

28 mA (typ.)

Max. load [RL]

[RL] = (Supply voltage -10 V) /


0,02 A []

_990294_pd_mp_gbr_1_.doc

PRODUCT DESCRIPTION
MAIN PART
PRESSURE TRANSMITTER AKS 3000

Thermal sensitivity

Operating conditions

The AKS 3000 is calibrated to limit ambient temperature influence on the regulating accuracy.

Temperature
limits

- 40 C to 80 C

Compensated
temperature
range

LP: - 30 C 40 C // HP: 0 C
80 C

Pressure transmitters to be used at low temperature


conditions, e.g. in suction lines, are calibrated at 10C to +20C. In this way control accuracy is optimized in a temperature range of 0C to +80C.

Transport temperature range

- 50 C to 85 C

Electrical connection

Enclosure (plug
design)

IP 65, EN 60529

Insulation

> 100 M, at 100 V DC

CE mark

Interference emission / interference immunity acc. to DIN 610006, Declaration of conformity


fig. 3:

Mechanical characteristics
Electrical
connection

Elbow connector Pg9 DIN EN


175301-803 (DIN 43650) Type of
construction A, colour: grey

Wetted parts,
EN 10088-1, 1.4404 (AISI316L)
material
Casing

EN 10088-1, 1.4404 (AISI316L)

Weight

0.2 kg

Media

HFC, CFC, HCFC, ammonia

Mechanical
connection

G 1/4A with max. 25 Nm


Moulded profiled ring DIN 3869-14CR: Grasso Ident 762998214
Moulded profiled ring DIN 3869-14HNBR: Grasso Ident 762998314

1.4

Pressure transmitter AKS 3000, electrical connection

Two-wire, 4 ... 20 mA

Supply "+"

Supply "-"

not used

connected to transmitter housing

Maximum operating pressure /overload range


0 ...+21 bar (a) min. 40 bar g.p.
0 ...+25 bar (a) min. 40 bar g.p.
0 ...+35 bar (a) min. 40 bar g.p.
0 ...+41 bar (a) min. 60 bar g.p.
0 ...+51 bar (a) min. 60 bar g.p.
0 ...+61 bar (a) min. 80 bar g.p.

Pressure ranges, Ident numbers

Designation

Pressure range

Grasso Ident

Pressure transmitter AKS 3000 GEA Grasso 21

0 ... 21 bar abs.

632198022D

Pressure transmitter AKS 3000 GEA Grasso 25

0 ... 25 bar abs.

632198125D

Pressure transmitter AKS 3000 GEA Grasso 32

0 ... 35 bar abs.

632198035D

Pressure transmitter AKS 3000 GEA Grasso 41

0 ... 41 bar abs.

632198042D

Pressure transmitter AKS 3000 GEA Grasso 51

0 ... 51 bar abs.

632198150D

Pressure transmitter AKS 3000 GEA Grasso 61

0 ... 61 bar abs.

632198160D

_990294_pd_mp_gbr_1_.doc

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Compact resistance thermometer Pt100, class A, 4-20 mA

1.1

General Information

Compact screw-in resistance thermometers GEA Grasso-406 Pt100A - 4 20 mA with replaceable measuring unit
are used for measuring the temperature of the media in compressors, pressure vessels and pipelines for all refrigerants acc. EN 378-1, lubricating oils, water and brine.
By means of an electronic evaluation unit the temperature sensors convert the temperature of the media at the
measuring points into 4 ... 20 mA output signals.
The thermometers are screwed into the measuring points without an additional immersion tube.
Danger!
Do not remove the complete screw-in resistance thermometer (casing with well inclusive of
the measuring unit) when the compressor or the vessel or the pipeline are pressurised.
In case it is not possible to shut off the respective part of the system and to release pressure
you may remove the measuring unit by unscrewing the plug head and the union nut with the
plug base plate and the associated O-ring seal and replace them. (spare part see table of
Ident numbers)
Measuring units with the associated well may be replaced separately without pressure release and dismantling of the casing.

The GEA Grasso-406 screw-in resistance thermometers do not require any adjustments.
The high-quality sensor technology guaranties that the accuracy of the factory setting is maintained irrespective of
the operating conditions.

1.2

fig. 1:

View

Screw-in resistance thermometer GEA Grasso-406 Pt100A, 4-20 mA, view

GEA Refrigeration Germany GmbH

_990215_pd_mp_gbr_1_.doc
26.06.2012

PRODUCT DESCRIPTION
MAIN PART
Compact resistance thermometer Pt100, class A, 4-20 mA

fig. 2:

1.3

Screw-in resistance thermometer GEA Grasso-406 Pt100A, 4-20 mA, cross section

Specifications - compact screw-in resistance thermometer Pt100

Performance
error of measurement

0.5C
especially calibrated for Pos. (2040) only: 0.15C

Electrical
Supply voltage

10 ... 35 V DC polarity reversal protection, overvoltage and short circuit


protection

standard output signal

4 ... 20 mA, two-wire connection

interference emission / interference


immunity

EN 50082 - (IEC 801)

Physical
connecting head / connector

DIN- bent connector GSP/GDM (black)

temperature sensor / circuit

Pt100 class A DIN EN 60751 / 2-wire circuit

integrated transducer / output signal 406-transducer at plug base plate with coupler socket / 4 20 mA
casing type / well type

(diameter, material)
22 mm / 1.4571
6 mm / 1.4571

screw-in gudgeon, thread

M12 x 1,5 DIN 3852-E

fitting length L in mm

30, 60, 90, 120 mm

_990215_pd_mp_gbr_1_.doc
26.06.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Compact resistance thermometer Pt100, class A, 4-20 mA

seal

enclosed refrigerant and lubricating oil resistant seal - ring sealing section
DIN 3869-12

media resistance

all refrigerants acc. EN 378-1, lubricating oils, water and brine

operating pressure range

0 ... 63 bar a

application temperature range

-60C ... +140C

mounting position / mounting torque

any / max. 25 Nm

weight [g], length 30 / 60 / 90 / 120


[mm]

112 g / 116 g / 120 g / 124 g

Protection type

IP 65 acc. to DIN 40 050

CE mark

1.4

Specifications - analogue transducer type 406 for Pt100A

The type 406 is an analogue transducer for Pt100 class A measuring resistors according to DIN En 60751. It converts the temperature related resistance of the sensor very precisely in linear relation with the temperature into a
standard electrical signal of 4 20 mA.
The transducer is fixed on a GSP-DIN plug base plate.
input / sensor connection

1x Pt100A 2-wire circuit

output

4 20 mA current loop

current limit

23 mA.

measured current

0.8 1 mA (depends upon sensor resistance)

loop voltage

10 35 V DC, polarity reversal protection

permissible residual ripple

< 10%

sensor fracture

> 20 mA

sensor short circuit

< 4 mA

temperature range balance

- 60C + 140C measuring range

humidity

< 95% relative humidity

electrical connections

poles 1 (+) and 2 (-) loop

EMV emission

EN 6100063:2001

EMV interference immunity

EN 6100063:2001

GEA Refrigeration Germany GmbH

_990215_pd_mp_gbr_1_.doc
26.06.2012

PRODUCT DESCRIPTION
MAIN PART
Compact resistance thermometer Pt100, class A, 4-20 mA

pin assignment, sensor setting


The controllers are set at the factory for the temperature range of 200K /from to/ -60C ... +140C and protected against unintentional readjustment.

fig. 3:

pin assignment with plug base plate without encasement

fig. 4:

electronic unit - external pin assignment

Input circuit of the sensor


The transducer is operated with a two-wire circuit.
The resistance of the conductors has very little (virtually no) influence on the measuring result since these conductors are extremely short and have equal lengths, they consist both of the same material and have the same
cross-section.
Output circuit of the sensor
The current loop establishes a series circuit of the transducer and the display/evaluation elements.
In this circuit the transducer limits the current in correspondence with the input signal. The transducer itself consumes maximum 4 mA.
Protection
The analogue transducer is completely enclosed in a casting compound for improving its protection against moisture and oil and its vibration resistance. It is screwed into the casing with an O-ring seal.

_990215_pd_mp_gbr_1_.doc
26.06.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Compact resistance thermometer Pt100, class A, 4-20 mA

1.5

Fitting lengths, standard Ident numbers

Compact screw-in resistance thermometer GEA Grasso - 406, Pt100A


Installation
length L
(mm)

Weight m
(g)

Resistance thermometer
Pt100A - 4 ... 20 mA, M12x1,5

Measuring unit (spare part)


Pt100A - 4 ... 20 mA

30

112

630498243E

630498117E

60

116

630498246E

630498118E

90

120

630498249E

630498119E

120

124

630498252E

630498120E

150

128

630498245E

630498128E

180

132

630498258E

630498132E

Ring sealing section


Mechanical connection ring section

Ident number

DIN 3869 - 12 - CR

762998212

DIN 3869 - 12 - HNBR

762998312

Fitting position of ring section


M12x1,5 with max 25 Nm

fig. 5:

correct fitting position of ring section (detail X)

GEA Refrigeration Germany GmbH

_990215_pd_mp_gbr_1_.doc
26.06.2012

PRODUCT DESCRIPTION
MAIN PART
Safety group - block (A)

System A - design: 1x overflow valve (22 bar g.p.) NB 15 - 65 +


2x safety valve (23 bar g.p.) NB 15 - 40 with 1x change-over valve NB 15 - 40

fig. 1:

Safety group - block, design type with 1x overflow valve, 2x safety valve and 1x change-over valve

Safety valve

Overflow valve

Change-over valve

nominal width
Safety valve

nominal width
Overflow valve

nominal width
Change-over valve

Gaskets material

Grasso Ident

15

15

15

CR

501398650

15

15

15

HNBR

501398650N

15

20

15

CR

501398651

15

20

15

HNBR

501398651N

15

25

15

CR

501398652

15

25

15

HNBR

501398652N

15

32

15

CR

501398653

15

32

15

HNBR

501398653N

15

40

15

CR

501398654

15

40

15

HNBR

501398654N

15

50

15

CR

501398655

15

50

15

HNBR

501398655N

15

65

15

CR

501398656

15

65

15

HNBR

501398656N

20

15

20

CR

501398657

GEA Refrigeration Germany GmbH

_990308_pd_mp_gbr_1_.doc
17.04.2012

PRODUCT DESCRIPTION
MAIN PART
Safety group - block (A)

nominal width
Safety valve

nominal width
Overflow valve

nominal width
Change-over valve

Gaskets material

Grasso Ident

20

15

20

HNBR

501398657N

20

20

20

CR

501398658

20

20

20

HNBR

501398658N

20

25

20

CR

501398659

20

25

20

HNBR

501398659N

20

32

20

CR

501398660

20

32

20

HNBR

501398660N

20

40

20

CR

501398661

20

40

20

HNBR

501398661N

20

50

20

CR

501398662

20

50

20

HNBR

501398662N

20

65

20

CR

501398663

20

65

20

HNBR

501398663N

25

15

25

CR

501398664

25

15

25

HNBR

501398664N

25

20

25

CR

501398665

25

20

25

HNBR

501398665N

25

25

25

CR

501398666

25

25

25

HNBR

501398666N

25

32

25

CR

501398667

25

32

25

HNBR

501398667N

25

40

25

CR

501398668

25

40

25

HNBR

501398668N

25

50

25

CR

501398669

25

50

25

HNBR

501398669N

25

65

25

CR

501398670

25

65

25

HNBR

501398670N

32

15

32

CR

501398760

32

15

32

HNBR

501398760N

32

20

32

CR

501398761

32

20

32

HNBR

501398761N

32

25

32

CR

501398762

_990308_pd_mp_gbr_1_.doc
17.04.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Safety group - block (A)

nominal width
Safety valve

nominal width
Overflow valve

nominal width
Change-over valve

Gaskets material

Grasso Ident

32

25

32

HNBR

501398762N

32

32

32

CR

501398763

32

32

32

HNBR

501398763N

32

40

32

CR

501398764

32

40

32

HNBR

501398764N

32

50

32

CR

501398765

32

50

32

HNBR

501398765N

32

65

32

CR

501398766

32

65

32

HNBR

501398766N

40

15

40

CR

501398767

40

15

40

HNBR

501398767N

40

20

40

CR

501398768

40

20

40

HNBR

501398768N

40

25

40

CR

501398769

40

25

40

HNBR

501398769N

40

32

40

CR

501398770

40

32

40

HNBR

501398770N

40

40

40

CR

501398771

40

40

40

HNBR

501398771N

40

50

40

CR

501398772

40

50

40

HNBR

501398772N

40

65

40

CR

501398773

40

65

40

HNBR

501398773N

NB 15 - 65

PN 25 (PN 40 on request)

compact assembly, prepared for the installation on the standard GEA Refrigeration Germany GmbH oil
separator

standard safety valves with change-over valve for oil separators protection
set value of safety valves = see P+I diagram and parameter list

Overflow valve, backpressure-independent, bypass from discharge- to suction side


set value of overflow valve = see P+I diagram and parameter list

additional safety valve protection due to bursting discs (optional)

easy mounting

flanges according to DIN/ ANSI or on request

GEA Refrigeration Germany GmbH

_990308_pd_mp_gbr_1_.doc
17.04.2012

PRODUCT DESCRIPTION
MAIN PART
Service Valves

1.3

SERVICE VALVES WITH RISING STEM

Specification

HRS types, metallic-back seal

1.1

Safety Instructions
Hint!

Valves that have been damaged during transport or storage must not be
installed.

No axial forces, bending or torsional


moments should act upon the valves.

Valves must not be used as fixing


points for pipes.

In the case of gase welding or brazing, the flame may not reach the
valve.

Cap

Screw bushing

Any kind of soiling has to be kept


away from the inside of the valve.

Stem

The valves may not be detached


before the pipe has been depressurized, sucked off.

fig. 1:

Service valve, straight form

Information on further risks in conformance to


pressure appliance directive (97/23/EG)
Remaining risks which can not be avoided by the
manufacturer arise because of:

Unauthorised loosening of the screw bushing


without examination whether spindle until it
stops in the highest position was driven

Incorrect assembly of threaded joints

fig. 2:

Dirt in the service medium may cause damage


the stem

Cap

Screw bushing

Ignore of operating range and manufacturer


rules acc. to this operating instruction

Stem

Service valve, angle type (on request only)

Remaining risks of "double valves" which can not be


avoided by the manufacturer arise because of:

The specification of the valves complies with EN


12284 of the casing:

1.2

Connecting system components at open valve

E = angle type // D = straight form

Application

Service valves are suitable for being employed in the


refrigerant cycles for refrigerating plants.

GEA Refrigeration Germany GmbH

Valve type HRS E (D)

Connection inlet/outlet

Manufacturer

Flow direction

_990320_pd_mp_gbr_1_.doc
17.04.2012

PRODUCT DESCRIPTION
MAIN PART
Service Valves

1.4

fig. 3:

Double valves

Double valve M16x1,5

Cap

Screw bushing

Stem

Blind plug

fig. 4:

Double valve R 1/4"

Cap

Screw bushing

Stem

Blind plug

_990320_pd_mp_gbr_1_.doc
17.04.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Service Valves

Caution!
The system components may only be connected or replaced after venting and closing the
valve, especially for double valves (see fig. 4, valves with double-system connections) and with
control through one spindle. For venting the screw SW10 (see figure) is used.

The specification of the double valves complies with EN 12284 of the casing:

Type valve

Connection inlet/outlet

Manufacturer

Flow direction

1.5

Technical characteristics

Media of operation:

Refrigerants acc. to EN 378 part 1, e.g. ammonia, R22, R134a, propane,


butane, CO2 and mixtures with refrigerating oil, neutral, gaseous and liquid
media cold brine basing on glycol

Temperature limits:

-60C to +150C

Permissible ambient temperature:

- 50C to +50C

Pressure stage:

63 bar

Housing material:

Selection of material acc. to EN 12284, AD-W 10


C22.8 // 1.0460 (steel)
X6CrNiMoTi17.12 2 // 1.4571 (stainless steel) or any equivalent

Mounting position:

individual

Leakage to the outside:

<5 g/a (refrigerant per year)

Table acc. to AD 2000


PS

DN

TS (MWT) [C]

-60*

-60**

-10

+50

+150

63

8-15

PS (MWP) [bar]

47,25

63

63

63

63

** kind of straining I // * kind of straining II (acc. to AD 2000 W10, EN 12284)

1.6

Functional description

Hint!

Service valves are operated by a handwheel or by


ratchet. They are shut off clockwise in viewing direction towards the operating element and are opened
counter-clockwise. The valves are shut-off devices
and may only be operated in "shut-off" or "open"
position. When opening the valve, the stem has to
be moved to the limit stop into the top position (completely open). The valves are equipped with a back
sealing. When the valve is completely open, is it
possible to replace the screw bushing with the
sealing.

GEA Refrigeration Germany GmbH

The screw bush is taped with left-hand


thread.
In case of extrem high temperatures
the valve has to be handled with protective gloves (danger of burning!).

_990320_pd_mp_gbr_1_.doc
17.04.2012

PRODUCT DESCRIPTION
MAIN PART
Service Valves

1.7

installation

1.8

Before installing the valves, the pipelines and the


components have to be cleaned.

Maintenance

Service valves are maintenance-free. Replacement


of stem sealing is possible.

The deviation from the squareness and parallelism


of the pipe connection may be not higher than 1.
Valves that have been damaged during transport or
storage are not allowed to installed. After the protective caps (at the connection ends) have been removed the valves can be welded on or installed in
any desired directions. For recommended flow direction see the stamp arrow at the valve housing. During the weld on procedure the valve stem has to be
in the central position. After the installation has been
performed, check whether the handwheel runs
smoothly within its entire lift range. The thread of the
cap must not be painted and has to be greased.

Replacing the stem sealing (during operation of


the system):
1. Screw off the cap. across flat dimension = 22
2. Move the stem by means of the uppermost position.
3. Unscrew the screw bushing the right. across
flat dimension = 14
Hint!
Pay attention to any leaking refrigerant remaining. The screw
bushing should be kept loosely in
the cover until the pressure has
equalized totally. Only then
should it be unscrewed completly.

For disassembling the valve sufficient space has to


be provided on the side of the cover.

4. Clean the stem.


5. Lubricate the screw bushing with lowtemperature grease (e.g. RENAX UNITEMP 2)
or any other appropriate lubricant and tighten
clockwise.
6. For leakage test move the stem into central position and coat the area screw bushing/stem with
afoam.
Stem turning moment = 15 Nm

_990320_pd_mp_gbr_1_.doc
17.04.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
Service Valves

1.9

Transport and storage

1.10 Spare parts

Transport

A spare parts order includes the Screw bush with the


corresponding seals.

The valves have to be transported shockproofed.

The replacement order must contain:

Storage
The storage must be carried out in dry rooms. It is
important that the plugs of the connecting pieces are
not damaged. Pollution of any kind must be kept
away from the inside of the fitting. The steel version
of the valves is galvanized to protect against corrosion.

Quantity

Designation according to illustration (valve type,


see valve housing)

Stock number: Grasso Ident 501306658

Year of construction of the fitting

Example for ordering: 3 pieces, screw bushing HRS


025, Grasso Ident 501306658, year of construction:
06/2009

1.11 Connection combinations - Grasso Ident


HRS 26 - technical progress, 2010, used in the products of the GEA Grasso GmbH
HRS 25 - use on request
HRS 25 / HRS 25 - stainless steel version on request
Stop valves
Outlet

Accessories 1

Designation

Grasso Ident

M16x1,5 conical

M18x1,5 RA12

1+2

HRS E AC/A84
DN8 PS63

501299036awp63

M18x1,5 RA12

M18x1,5 RA12

1+2

HRS E A84/A84
DN8 PS63

501306611awp63

Inlet

Accessories 1

M26x1,5 RA18

1+2

M26x1,5 RA18

1+2

HRS E AS4/AS4
DN8 PS63

501306613awp63

M30x2 RA22

1+2

M30x1,5 RA22

1+2

HRS E AT4/AT4
DN8 PS63

501306614awp63

AE 18x3

1+2

G 1/2" RA12

1+2

HRS E E4/AN4
DN8 PS63

501306620awp63

AE 18x3

G 1/2" RA12

HRS E E4/AN2
DN8 PS63

501306621awp63

M16x1,5 conical

G 1/2" RA12

1+2

HRS E AC/AN4
DN8 PS63

501306622awp63

M16x1,5 conical

G 1/2" RA12

HRS E AC/AN2
DN8 PS63

501306623awp63

M22x1,5 conical

G 1/2" RA12

1+2

HRS E AD/AN4
DN8 PS63

501306624awp63

M22x1,5 conical

G 1/2" RA12

HRS E AD/AN2
DN8 PS63

501306625awp63

AE 18x3

G 3/4" RA18

1+2

HRS E E4/AP4
DN10 PS63

501306626awp63

AE 18x3

G 3/4" RA18

HRS E E4/AP2
DN10 PS63

501306627awp63

M22x1,5 conical

G 3/4" RA18

1+2

HRS E AD/AP4
DN8 PS63

501306628awp63

GEA Refrigeration Germany GmbH

_990320_pd_mp_gbr_1_.doc
17.04.2012

PRODUCT DESCRIPTION
MAIN PART
Service Valves

Outlet

Accessories 1

Designation

Grasso Ident

M22x1,5 conical

G 3/4" RA18

HRS E AD/AP2
DN8 PS63

501306629awp63

R 1/4" conical

G 1/4" inside

HRS E AG/AH
DN8 PS63

501306630awp63

R 1/4" conical

G 3/8" inside

HRS E AG/AM
DN8 PS63

501306631awp63

R 1/4" conical

G 1/2" RA12

1+2

HRS E AG/AN4
DN8 PS63

501306632awp63

R 1/2" conical

G 1/2" RA12

1+2

HRS E AX/AN4
DN8 PS63

501306633awp63

R 1/2" conical

G 1/2" RA12

HRS E AX/AN2
DN8 PS63

501306634awp63

HRS E A84/AN2
DN8 PS63

501306637awp63

Inlet

Accessories 1

M18x1,5 RA12

1+2

G 1/2" RA12

G 1/2" RA12

1+2

M16x1,5 conical

HRS E AN4/AC
DN8 PS63

501306638awp63

G 1/2" RA12

M16x1,5 conical

HRS E AN2/AC
DN8 PS63

501306639awp63

M16x1,5 conical

G 1/4" inside

HRS E AC/AH
DN8 PS63

501306640awp63

M16x1,5 conical

G 3/8" inside

HRS E AC/AM
DN8 PS63

501306641awp63

Designation

Grasso Ident

Explanation: 1 = pipe nut // 2 = welding taper bush // 3 = blind nut

Double valves
Inlet

Accessories

Outlet

Accessories

M16x1,5 conical

2x G 1/2" RA12

E2460F07C5ANN022

501306660awp63

R 1/4" conical

1x G 1/4" inside
1x M18x1,5 RA12

02B60F07G5AH8022

501306661awp63

R 1/4" conical

1x R 3/8" inside
M18x1,5 RA12

02B60F07G5AM8022

501306662awp63

_990320_pd_mp_gbr_1_.doc
17.04.2012

GEA Refrigeration Germany GmbH

AVR_26300 08.08.2012

APS 06.30 10.1

Betriebsvorschrift
Armaturen fr die Kltetechnik

Operating Instructions
Valves for refrigeration

Absperrventile mit steigender Spindel

Shut off Valves with rising stem

AVR Typenvertreter:

AVR types example:

mit elastischer PTFE-Ring Abdichtung an der Spindel

with PTFE-ring seal on the stem

263, 264, 26G Deckel geflanscht

263, 264, 26G cover flanged

263 1, 264 1, 26G A Deckel geflanscht und

263 1, 264 1, 26G A cover flanged and

verlngert

extension

Inhaltsverzeichnis

Seite

Contents

Page

1. bersicht der Bauarten

1. Survey of Types

2. Technische Kennwerte

2. Technical Characteristics

3. Sicherheitshinweise

3. Safety Instructions

4. Anwendung

4. Application

5. Funktionsbeschreibung

5. Functional Description

6. Einbau

6. Installation

7. Wartung

7. Maintenance

8. Transport und Lagerung

8. Transport, Storage

9. Garantie

9. Warranty

10. Ersatzteile

10. Spare parts

11. Kennzeichnung

10

11. Specification

10

12. Hinweis auf Restgefahren

10

12. Information on risks

10

990380

GEA AWP GmbH


1 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

APS 06.30 10.1

1. bersicht der Bauarten

Typ / type

1. Survey of types

DN25 - 250

263 00, 264 00, 26G 00


263 10, 264 10, 26G A0

Spindel
stem cmpl
Flachdichtring K
flat sealing-ring K

Gewindestift
headless pin
DN 80 - 200

Handrad
handwheel
Kappe
cap

Flachdichtring S
flat sealing-ring S

DN 10 - 32
Sitzdichtung S verschraubt
seat sealing-ring S screwed
DN 40 - 150
Sitzdichtung S eingepresst
seat sealing-ring S pressed

Abstreifring
scraper
Flachdichtring R
flat sealing ring R

Schraubbuchse
screw bushing

Flachdichtung SB
flat sealing-ring

Typ / type

DN300 400
mit Ventiltellerentlastung / with balancing valve disc

263 00, 264 00


PTFE-Ring
PTFE-ring seal

DN 200 - 400
Sitzdichtung S verschraubt
Seat sealing-ring S screwed

O-Ringe B
o-ring seals B

O-Ringe A
o-ring seals A

Kappe
cap

Handrad
handwheel
Flachdichtring S
flat sealing-ring S

Spindel kpl.
Stem cmpl.

Flachdichtring R
flat sealing-ring R

Flachdichtring K
flat sealing-ring K

990380

GEA AWP GmbH


2 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

APS 06.30 10.1

2. Technische Kennwerte

2. Technical characteristics

Gehusewerkstoff
Auswahl nach DIN EN12284, AD-2000 Reihe W
St: P235GH, S235JR, S355J2
TT: P215NL, P255QL, P355NL1, G20Mn5QT
NIRO: X5CrNi18-10 , GXCrNiMoNb19-11-2
oder gleichwertige

body material selection of material according to


German DIN EN12284, AD-2000 Reihe W,
St: P235GH, S235JR, S355J2
TT: P215NL, P255QL, P355NL1, G20Mn5QT
NIRO: X5CrNi18-10, GXCrNiMoNb19-11-2
or any equivalent

bei Verwendung von Schrauben der


Festigkeitsklasse 8.8

by using screws 8.8

PN

TB (MWT) [C]

-60*

-40*

-25*

-10

+50

+150

25
40
63

PS (MWP) [bar]

5
8
12,6

12,5
20
31,5

18,7
30
47,2

25
40
63

25
40
63

25
40
63***

-10

+50

+150

25
40
63

25
40
63

bei Verwendung von Schrauben der


Festigkeitsklasse A2-70

by using screws A2-70

PN

TB (MWT) [C]

-60*

-60**

25
40
63

PS (MWP) [bar]

18,7
30
47,2

25
40
63

*** G20Mn5QT =43bar/ GXCrNiMoNb19-11-2 =50bar


** Beanspruchungsfall I (TT, Niro)
* Beanspruchungsfall II ( nach AD2000-W10,
EN 12284) (ST)

Zulssiger Umgebungstemperaturbereich (C)


-50 bis +50

25
40
63***

*** G20Mn5QT =43bar/ GXCrNiMoNb19-11-2 =50bar


** kind of straining I (TT, Niro)
* kind of straining II ( after AD2000-W10,
EN 12284) (ST)

permissi ble ambient temperature range (C)


-50 to +50

Betriebsmedien

working media

Kltemittel EN 378 Teil 1, z.B.NH3, R22, R134a, Blends


und Gemische mit Kltemaschinenl, neutrale, gasfrmige
und flssige Medien Khlsole auf Glycol-Basis,

cold brine basing on glycol refrigerant EN 378 p. 1 and


mixtures with refrigerator oil, neutral, gaseous and liquid
media, cold brine basing on glycol
flow factor (m3/h)

Durchflusswert KVS
Typ / DN

25

263/26G

12,7

264

13,8

32

40

50

65

80

100 125 150

200

250

300

18,6

30,0

42,0

66,5

109,0

151,0

245,0

22,2

37,0

53,5

80,0

159,0

231,0

373,0

350

400

352,0

526,0

800,0

960,0

1340,0

1930,0

464,0

1049,0

1180,0

1416,0

2120,0

3140,0

Einbauanlage beliebig, Durchflurichtung sollte eingehalten


werden

mounting position in any desired position, the flow direction


should be observed

Leckage nach auen,


Sitz (g/a) <5 Kltemittel im Jahr

leakage outward,
seat (g/a) <5 refrigerant per year

GEA AWP GmbH

990380
3 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

APS 06.30 10.1

3. Sicherheitshinweise

3. Safety instructions

! Ventile mit Transport- oder Lagerschden drfen nicht


eingebaut werden.
! Ventile:

mssen frei von Achskrften, Biege- und


Torsionsmomenten sein

drfen nicht als Fixpunkte von Rohrleitungen


dienen.
! Bei Autogenschweiung oder Hartltung darf die Flamme
das Ventil nicht berhren.
! Verunreinigungen jeglicher Art mssen vom Innenraum
der Ventile ferngehalten werden.
! Schlieen oder ffnen der Ventile mit einer Handradgabel
oder sonstiger hebelarmverlngernder Gegenstnde ist
unzulssig, da dies zur Beschdigung der Sitzdichtung
fhren kann.
! Demontage bzw. Ausbau der Ventile nur bei druckloser,
abgesaugter und ausreichendbelfteter Rohrleitung.

! Valves that have been damaged during transport or


storage must not be installed.
! Valves:

no axial forces, bending or torsional moments


should act upon the valves.

must not be used as fixing points for pipes


! In the case of gase welding or brazing, the flame may not
reach the valve.
! Any kind of soiling has to be kept away from the inside of
the valve.
! It is not allowed to open or close the valves by means of a
hand wheel wrench or any other devices for extending the
lever arm, as this may damage the seat sealing.
! The valves may not be disassembled or detached before
the pipe has been depressurized, sucked off and
adequately ventilated.

4. Anwendung

4. Application

AWP-Absperrventile sind geeignet fr den Einsatz in


Kltemittelkreislufen fr Industrie-Klteanlagen.

AWP-Shut off valves are suitable for being employed in


the refrigerant cycles for industrial refrigerating plants.

5. Funktionsbeschreibung

5. Functional description

AWP-Absperrventile sind durch ein Handrad zu bettigen.


Die Ventile werden mit Blickrichtung auf das Handrad
rechtsdrehend geschlossen und linksdrehend geffnet. Die
Ventile sind Absperrarmaturen und drfen nur in "Auf"-oder
"Zu"-Stellung gefahren werden. Beim ffnen des Ventils ist
die Spindel bis zum Anschlag in die oberste Stellung zu
fahren (voll geffnet). Die Ventile sind mit einer
Rckdichtung ausgerstet (Flachdichtring R).
Bei voll geffnetem Ventil ist der gefahrlose Austausch
der Dichtelemente (O-Ringe A, B, PTFE-Ringe) an der
Spindel, durch Herausschrauben der Schraubbuchse
mglich.
Bei extremen Temperaturen ist das Ventil mit Schutzhandschuhen zu bedienen.
Die Bettigung des Absperrventils gegen eine eingeschlossene Flssigkeit ist zu vermeiden, da es durch die
Bewegung der Spindel zur Volumennderung kommt. Dies
bedingt
eine
unzulssige
Druckzunahme
im
abgeschlossenen Rohrabschnitt. Das Schlieen der
Absperrventile in Flssigkeitsleitungen hat in Reihenfolge
zu einem Behlter mit Gasvolumen zu erfolgen.

AWP-Shut off valves are actuated by a hand wheel. They


are shut off clockwise in viewing direction towards the
operating element and are opened counterclockwise. The
valves are shut-off devices and may only be operated in
"shut-off" or "open" position. When opening the valve, the
stem has to be moved to the limit stop into the uppermost
position (completely open). The valves are equipped with a
back sealing (flat sealing ring R).
When the valve is completely open, it is possible to replace the sealing elements (O-rings, A, B, PTFE-ring) at
the stem safety by unscrewing bushing.
In case the flow medium reaches extreme temperatures,
the valve must be handled with protective gloves, -danger
of burning-.
Actuating the valve against a liquid in a closed section
should be avoid, as the motion of the stem sauses a change in volume within the valve body. This, in turn, causes an
inadmissible increase of pressure in the closed pipe
section. Valves in pipes for liquids have to be shut off in
direction towards a vessel containing gas.

! DN 300 bis 400 mit Ventiltellerentlastung!

! DN 300 to 400 with balancing valve disk!

6. Einbau

6. Installation

Vor Einbau der Ventile sind Rohrleitungen und Anlagenteile


zu subern.
-bitte beachtenDie Abweichung von der Parallelitt bzw. Rechtwinkligkeit
der Anschweienden bzw. Flanschdichtflchen darf 1 nicht
berschreiten. Anschluflansche mssen achsengleich
sein. Ventile mit Transport-und Lagerschden drfen nicht
eingebaut werden. Nach dem Entfernen der Rohrstopfen
knnen die Ventile in beliebiger Lage eingeschweit bzw.
montiert werden. Die Durchflurichtung (siehe Pfeil auf
Kennzeichenschild) sollte eingehalten werden. Eine
entgegengesetzte Durchflurichtung ist bis DN250
zulssig, die Leistungsangaben gelten dann nicht.

Before installing the valves, the pipelines and the components have to be cleaned.
-please noticeThe deviation from the parallelism or squareness of the
welding ends or, as the case may be, the sealing surfaces
of the flanges must not exceed 1. The connecting f langes
have to be coaxial. Valves that have been damaged during
transport or storage must not be installed. After the
protective caps have been removed, the valves can be
welded on, or installed in any position.
An opposite flow direction is permitted up to DN 250, the
performance figures do not apply then.

990380

GEA AWP GmbH


4 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

Ab DN300 sollte die Durchflurichtung


folgende Differenzdrcke eingehalten werden.
DN

300

350

400

4,5

3,5

p(bar)

APS 06.30 10.1

ber

DN300 should flow from the


following differential pressures are maintained.

Bei Anwendung moderner Schweiverfahren (z.B.


WIG, CO2) werden die Ventile zum Einschweien nicht
demontiert. Das Handrad ist in Mittelstellung zu bringen.
Die Befestigungsschrauben und Muttern sind ber
Kreuz und gleichmig anzuziehen.
Nach dem Einbau ist die Leichtgngigkeit des Handrades im
kompletten Hubbereich zu berprfen. Das Deckelgewinde
zum Aufschrauben der Kappe hat farbfrei zu bleiben und ist
zu fetten (z.B. mit RENAX UNITEMP 2).
- bitte beachtenZur Demontage des Einsatzes ist gengend Platz auf
der Deckelseite vorzusehen.
DN 25

32

40

50

65

80

With modern welding processes (s u c h as TIG, CO2shielded metal-arc), the valves are not disassembled for
welding.
The fastening bolts and nuts have to be tightened crosswise
and evenly. After the installation has been performed, check
whether the hand wheel runs smoothly within its entire lift
range.
The thread of the cover for unscrewing the cap must not be
painted and has to be greased (e.g. with RENAX UNITEMP
2).
-please noticeFor disassembling the valve sufficient space has to be
provided on the side of the cover.

100 125 150 200 250 300 350

400

mm 115 115 130 130 145 170 170 240 270 425 600 800 1200 1200

7. Wartung

7. Maintenance

AWP-Absperrventile arbeiten wartungsfrei. Treten Mngel


im Funktionsverhalten auf, ist eine Reparatur mglich.
Whrend der Garantiezeit drfen Reparaturen nur durch
AWP bzw. mit dessen Einverstndnis durchgeschultes
Instandhaltungspersonal des Betreibers der Anlage
vorgenommen werden.

AWP-Shut off valves are maintenance-free. In case any


defects in the functional performance of the valves occur,
they can be repaired. During the term of warranty, repairs
may only be carried out by the AWP or -with his consent by
specially-trained maintenance personal working for the
plant operator.

Sicherheitshinweise beachten

Safety instructions please notice

Auswechseln der Spindelabdichtung

Replacing the stem sealing

(bei Betrieb der Anlage)

(During operation of the system)

1.

1.

Kappe abschrauben
DN
SW

25 - 32 40 - 65 80 - 100 125 - 150


24

32

41

Screw off the cap

200 400

50

60

2.

Spindel mittels Handrad bis zum Anschlag in die


oberste Stellung fahren.

2.

Move the stem by means of the uppermost


position.

3.

Schraubbuchse links herum herausschrauben.

3.

Screw off the screw bushing counter-clockwise.

Auf eventuell austretendes restliches Kltemittel


achten. Bis zum vlligen Druckausgleich
Schraubbuchse lose im Deckel belassen.
Erst danach vllig herausschrauben

DN

25 - 32

40 - 65

SW

22

27

80 100 125 - 150


32

46

The screw bushing should be kept loosely in


the cover until the pressure has equalized totally.
Only then should it be unscrewed completely.

200 400
55

4.

O-Ringe A, B, PTFE-Ring und Abstreifring


entfernen und durch neue ersetzen.
Flachdichtring SB aus dem Einbauraum im
Deckel entfernen.

4.

Remove the o-ring seals A, B, PTFE-ring and the


scraper and replace them by new ones. Remove
flat sealing ring SB from the seal housing in the
cover.

5.

Spindel subern.

5.

Clean the stem.

6.

Neuen Flachdichtring SB in Deckel einlegen.


Schraubbuchse mit Kltefett (RENAXUNITEMP2)
bzw. gleichwertiges einfetten und handfest
anziehen.

6.

Insert a new flat sealing-ring SB into the cover.


Lubricate the screw bushing with low-temperature
grease (RENAXUNITEMP 2) or any other appropriate lubricant and fasten it finger tight.

7.

Zur Dichtheitskontrolle ist die Spindel in Mittelstellung zubringen und der Deckelbereich mit
Schaummitteln einzupinseln.

7.

For leakage test move the stem into central


position and coat the cover area with a foaming
agent.

990380

GEA AWP GmbH


5 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

APS 06.30 10.1

Auswechseln Flachdichtring S und R bzw.


Spindel kpl.

1.

Replacing the flat sealing ring S and R, or


stem cmpl.

Ventil bis Anschlag ffnen. Deckelschrauben


ISO 4762 und EN 24014 lsen.

1.

Open the valve up to the limit stop. Loosen the


cover screws ISO 4762 and EN 24014.

!
!

Auf eventuell austretendes restliches Kltemittel achten.


Bis zum vlligen Druckausgleich Deckelschrauben lose im
Gehuse belassen. Erst danach vllig herausschrauben.

Schrauben
screws

DN 25

32

40

50

65

80

100 125 150 200 250 300 350 400

10

12

16

16

16

16

18

24

24

24

ISO 4762
SW 6

20

20

24

30

36

46

EN 24014

2.

Deckelschrauben herausschrauben und Deckel


einschlielich
Innenteile
am
Handrad
herausziehen.

3.

Handrad von der Spindel abschrauben und die


Spindel nach Entfernen des Gewindestiftes
(DN80 bis 200) aus dem Deckel herausdrehen.

4.

Flachdichtring R herausnehmen und ersetzen.

5.

DN 25 bis 32:
Ventiltellerschrauben abschrauben und Flachdichtring S herausnehmen.
DN 40 bis 150:
Durch geeignete Verfahren
(Feilen, Sgen) Entfernen der Sicken am
Ventilteller, so dass die Scheibe und der
Flachdichtring S abgenommen werden knnen.
DN 200 bis 400:
Ventiltellerschrauben abschrauben und Flachdichtring S herausnehmen.
Schrauben
screws
EN 24014

3.

Screw the handwheel from the stem and turn the


stem out of the cover after having removed the
headless pin (only DN 80 to 200).

4.

Remove the flat sealing ring R and replace it.

5.

DN 25 to 32:
Unscrew valve-disc plate and draw out the flat
sealing-ring S.
DN 40 to 150:
Remove crimps from the valve plate by means of
suitable methods (such as filling, sawing) so that
the washer and the flat sealing ring S can be
taken off.
DN 200 to 400:
Unscrew valve-disc plate and draw out the flat
sealing-ring S.

200-400

M
SW

6x20
10

Einlegen des neuen Flachdichtringes S,


Sicherung durch Scheibe und Eindrcken der
Sicken durch geeignete Verfahren (z.B.
Handhebelpresse), bzw. Ventil

100

30

Unscrew cover screws and draw out the cover


including internal parts by means of the
handwheel.

DN

Vor der Montage sind alle Einzelteile der Ventile zu


reinigen, die Spindel und der Deckel einzufetten.
Anschlieend wird noch ein Flachdichtring K eingelegt, der
Deckel aufgesetzt und mit den Schrauben gleichmig und
ber Kreuz angezogen.

30

2.

6.
6.

The cover screws should be kept loosely in the body until


the pressure has equalized totally. Only then should it be
unscrewed completely.

Insert a new flat sealing ring S, secure it by


means of the washer and reproduce the crimps
by means of appropriate methods, e.g. hand lever
press, or valveplate screws tightening.

Before mounting, clean all component parts of the valves;


grease stem and the cover.
Afterwards another flat sealing ring is inserted, the cover is
put back in its place and is tightened by means of the
screws evenly and crosswise.

DN

25

32

40

50

65

80

8x25

8x25

8x25

8x25

8x25

10x30 12x35 16x45 16x45 16x45 20x60 20x60 24x65

125

ISO 4762
SW

150

200

250

300

350

400
30x80

EN 24014

25

25

25

25

16

18

24

24

24

30

30

36

46

425

730

1450

Anziehdrehmoment / tightening moment [Nm] (8.8)


25

49

85

210

990380

210

210

425

GEA AWP GmbH


6 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

APS 06.30 10.1

8. Transport und Lagerung

8. Transport, Storage

AWP-Absperrventile werden stogeschtzt, mit Folie


abgedeckt transportiert. Die Lagerung hat in trockenen
Rumen zu erfolgen. Es ist auf den unversehrten
Verschluss der Anschlussstutzen zu achten.
Verschmutzungen jeglicher Art mssen vom Innenraum
ferngehalten werden. Die auenliegenden Flchen der
Armaturen sind mit einem Korrosionsschutzanstrich fr
trockene Lagerung bei Raumtemperatur versehen, der
mindestens 1 Jahr wirksam ist. Der Korrosionsschutzanstrich BISPHENOL-A-Epoxidharz ist ein guter
Haftvermittler fr Deckanstrichstoffe auf 1- und 2Komponenten-Basis.

During transport, AWP-Shut off valves are protected


against shocks and covered with plastic sheeting. They
should be stored in dry rooms. Care has to be taken that
the plugs of the connecting pieces are not damaged. Any
kind of soiling has to be kept away from the inside of the
fitting. The external surfaces of the valves are provided with
a layer of anticorrosive paint for dry storing at room
temperature, which remains effective for at least 1 year.
The anticorrosive paint which BISPHENOL-A-Epoxidharz
is a good bonding agent for one or two-pot finishing coating
paints.

9. Garantie
Die Garantieleistung fr Erzeugnisse ist entsprechend den
vertraglichen Bestimmungen im Liefervertrag festgelegt.

10. Ersatzteile
Ersatzteile entsprechend Bild Seite 2:
Ersatzteilbestellung: (muss enthalten)
Anzahl

Bezeichnung entsprechen Bilder fr Typ

Bestell-Nummer

Nennweite der Armatur

Baujahr der Armatur

9. Warranty
The warranty services for our products have been defined
incompliance with the regulations stipulated the contract of
delivery.

10. Spare parts


Spare parts according to the illustration sheet page 2:
Ordering Spare parts: (an order must contain):
quantity

designation according to illustration sheet page 2

stock number

nominal diameter of the fitting

year of construction of the fitting

Example for ordering


3 pieces, stem cmpl. AVR, 263 00
263 00E13.5060001,
DN32, 05/2010

Bestellbeispiel:
3 Stck, Spindel kpl. AVR, 263 00
263 00E13.5060001,
DN32, 05/2010

990380

GEA AWP GmbH


7 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

APS 06.30 10.1


Handrad / handwheel

Kappe / cap

DN

Bestellnummer
stock number

Abmessung
dimension

DN

Bestellnummer
stock number

Abmessung
dimension

25
32
40
50
65
80
100
125
150
200
250
300
350
400

163 00E13.5 280 00 3


163 00E13.5 280 00 3
163 00E15.5 280 00 3
163 00E15.5 280 00 3
163 00E15.5 280 00 3
163 00E18.5 280 00 3
163 00E18.5 280 00 3
163 01.20.5 280 00 3
163 01.21.5 280 00 3
163 01.23.5 280 00 3
163 01.23.5 280 00 3
163 01.23.5 280 00 3
163 01.23.5 280 00 3
163 01.23.5 280 00 3

120 x 11/14
120 x 11/14
140 x 12/16
140 x 12/16
140 x 12/16
180 x 14/22
180 x 14/22
300 x 22/26
400 x 22/26
600 x 28/46
600 x 28/46
600 x 28/46
600 x 28/46
600 x 28/46

25
32
40
50
65
80
100
125
150
200
250
300
350
400

164 02.13.3 180 00 3


164 02.13.3 180 00 3
164 02.15.3 180 00 3
164 02.15.3 180 00 3
164 02.15.3 180 00 3
164 02.19.3 180 00 3
164 02.19.3 180 00 3
164 02.21.3 180 00 3
164 02.21.3 180 00 3
164 02.23.3 180 00 3
164 02.23.3 180 00 3
164 02.23.3 180 00 3
164 02.23.3 180 00 3
164 02.23.3 180 00 3

M36
M36
M52
M52
M52
M60
M60
M76
M76
M80
M80
M80
M80
M80

Flachdichtring K / flat sealing ring K AFM30

x 2,0
x 2,0
x 3,0
x 3,0
x 3,0
x 3,0
x 3,0
x 3,0
x 3,0
x 3,0
x 3,0
x 3,0
x 3,0
x 3,0

Flachdichtring S / flat sealing ring S PTFE

DN

Bestellnummer
stock number

Abmessung
dimension

DN

Bestellnummer
stock number

Abmessung
dimension

25
32
40
50
65
80
100
125
150
200
250
300
350
400

163 01.13.4 146 00 3


163 01.13.4 146 00 3
163 01.15.4 146 00 3
163 01.15.4 146 00 3
163 01.17.4 146 00 3
163 01.18.4 146 00 3
163 01.19.4 146 00 3
163 01.20.4 146 00 3
163 01.21.4 146 00 3
163 01.23.4 146 00 3
163 01.24.4 146 00 3
263 01.25.4 146 00 3
263 01.26.4 146 00 3
263 00B27.4 146 00 3

43 x 49,0 x 1,5
43 x 49,0 x 1,5
62 x 68,8 x 1,5
62 x 68,8 x 1,5
76 x 84,8 x 1,5
94 x 105 x 1,5
115 x 129 x 1,5
140 x 159 x 1,5
170 x 188,5 x 2,0
240 x 259 x 2,0
296 x 320 x 2,0
338 x 366 x 2,0
370 x 400 x 2,0
440 x 478 x 2,0

25
32
40
50
65
80
100
125
150
200
250
300
350
400

163 01.13.2 144 00 3


163 01.13.2 144 00 3
163 01.15.2 144 00 3
163 01.15.2 144 00 3
163 01.17.2 144 00 3
163 01.18.2 144 00 3
163 01.19.2 144 00 3
163 01.20.2 144 00 3
163 01.21.2 144 00 3
163 01.23.2 144 00 3
164 02.24.2 144 00 3
263 02.25.2 144 00 3
263 02.26.2 144 00 3
263 00B27.2 144 00 3

20,2 x 33,8
20,2 x 33,8
32,2 x 47,8
32,2 x 57,8
55,2 x 71,0
68,0 x 89,0
86 x 109
112 x 134
130 x 163
185 x 218
230 x 275
289 x 322
322 x 355
361 x 398

Flachdichtring SB / flat sealing ring SB AFM30

Flachdichtring R / flat sealing ring R PTFE

DN

Bestellnummer
stock number

Abmessung
dimension

DN

Bestellnummer
stock number

Abmessung
dimension

25
32
40
50
65
80
100
125
150
200
250
300
350
400

363 02.13.4 143 00 3


363 02.13.4 143 00 3
164 02.15.4 143 00 3
164 02.15.4 143 00 3
164 02.15.4 143 00 3
164 02.18.4 143 00 3
164 02.18.4 143 00 3
164 02.21.4 143 00 3
164 02.21.4 143 00 3
164 02.23.4 143 00 3
164 02.23.4 143 00 3
164 02.23.4 143 00 3
164 02.23.4 143 00 3
164 02.23.4 143 00 3

25
32
40
50
65
80
100
125
150
200
250
300
350
400

164 02.10.2 145 00 3


164 02.10.2 145 00 3
264 00.17.2 145 00 3
264 00.17.2 145 00 3
264 00.17.2 145 00 3
164 02.18.2 145 00 3
164 02.18.2 145 00 3
164 02.21.2 145 00 3
164 02.21.2 145 00 3
164 02.23.2 145 00 3
164 02.23.2 145 00 3
164 02.23.2 145 00 3
164 02.23.2 145 00 3
164 02.23.2 145 00 3

14
14
16
16
16
20
20
28
28
35
35
35
35
35

x 25,5 x 2,0
x 25,5 x 2,0
x 26,9 x 2,0
x 26,9 x 2,0
x 26,9 x 2,0
x 32,9 x 2,0
x 32,9 x 2,0
x 45,9 x 2,0
x 45,9 x 2,0
x 54,9 x 2,0
x 54,9 x 2,0
x 54,9 x 2,0
x 54,9 x 2,0
x 54,9 x 2,0

x 3,0
x 3,0
x 4,0
x 4,0
x 4,0
x 5,0
x 5,0
x 6,0
x 6,0
x 6,0
x 6,0
x 6,0
x 6,0
x 8,0

990380

16
16
20
20
20
26
26
36
36
45
45
45
45
45

x 21,6 x 2,0
x 21,6 x 2,0
x 33,9 x 2,0
x 33,9 x 2,0
x 33,9 x 2,0
x 40,0 x 3,0
x 40,0 x 3,0
x 52,0 x 3,0
x 52,0 x 3,0
x 70,0 x 3,0
x 70,0 x 3,0
x 70,0 x 3,0
x 70,0 x 3,0
x 70,0 x 3,0

GEA AWP GmbH


8 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

APS 06.30 10.1


Schraubbuchse kpl. / screw bushing cmpl.

Spindel kpl. / stem cmpl.

Spindel kpl. / stem cmpl.

DN

Typ / type: 263 00, 264 00

Typ / type: 263 10, 264 10

25
32
40
50
65
80
100
125
150
200
250
300
350
400

Bestellnummer / stock number

163 00E13.8 142 001


163 00E13.8 142 001
163 00E15.8 142 001
163 00E15.8 142 001
163 00E15.8 142 001
163 00E18.8 142 001
163 00E18.8 142 001
163 00E21.8 142 001
163 00E21.8 142 001
163 00E23.8 142 001
163 00E23.8 142 001
163 00E23.8 142 001
163 00E23.8 142 001
163 00E23.8 142 001

O-Ring A / o-ring seal A


DN

Bestellnummer
stock number

25
32
40
50
65
80
100
125
150
200
250
300
350
400

73 75 91
73 75 91
73 75 59
73 75 59
73 75 59
73 75 25
73 75 25
73 75 96
73 75 96
73 75 97
73 75 97
73 75 97
73 75 97
73 75 97

263 00E13.5 060 00 1


263 00E13.5 060 00 1
263 00E15.5 060 00 1
263 00E15.5 060 00 1
263 00E17.5 060 00 1
263 00E18.5 060 00 1
263 00E19.5 060 00 1
263 00E20.5 060 00 1
263 00E21.5 060 00 1
263 00E23.5 060 00 1
263 00B24.5 060 00 1
263 02.25.5 060 00 1
263 02.26.5 060 00 1
263 00B27.5 060 00 1

CR75

O-Ring B / o-ring seal B


Abmessung
dimension

14
14
16
16
16
20
20
28
28
35
35
35
35
35

x3
x3
x3
x3
x3
x3
x3
x5
x5
x5
x5
x5
x5
x5

DN

Bestellnummer
stock number

25
32
40
50
65
80
100
125
150
200
250
300
350
400

73 75 22
73 75 22
73 75 01
73 75 01
73 75 01
73 75 03
73 75 03
73 75 16
73 75 16
73 75 27
73 75 27
73 75 27
73 75 27
73 75 27

PTFE-Ring / PTFE-ring seal


DN

Bestellnummer
stock number

25
32
40
50
65
80
100
125
150
200
250
300
350
400

72 84 00
72 84 00
72 84 01
72 84 01
72 84 01
72 84 02
72 84 02
72 84 03
72 84 03
72 84 04
72 84 04
72 84 04
72 84 04
72 84 04

263 10E13.5 060 00 1


263 10E13.5 060 00 1
263 10E15.5 060 00 1
263 10E15.5 060 00 1
263 10E17.5 060 00 1
263 10E18.5 060 00 1
263 10E19.5 060 00 1
263 10E20.5 060 00 1
263 10E21.5 060 00 1
263 10E23.5 060 00 1
-

Abmessung
dimension

Abstreifring / scraper
Abmessung
dimension

14 x 19
14 x 19
16 x 21
16 x 21
16 x 21
20 x 25
20 x 25
28 x 28
28 x 28
35 x 36,8
35 x 36,8
35 x 36,8
35 x 36,8
35 x 36,8

/3,9
/3,9
/3,9
/3,9
/3,9
/3,9
/3,9
/5,9
/5,9
/6,0
/6,0
/6,0
/6,0
/6,0

CR75

22 x 2
22 x 2
22 x 3
22 x 3
22 x 3
28 x 3
28 x 3
40 x 3
40 x 3
50 x 3
50 x 3
50 x 3
50 x 3
50 x 3

NBR85

DN

Bestellnummer
stock number

Abmessung
dimension

25
32
40
50
65
80
100
125
150
200
250
300
350
400

73 98 55
73 98 55
73 98 38
73 98 38
73 98 38
73 98 41
73 98 41
73 98 54
73 98 54
73 75 37
73 75 37
73 75 37
73 75 37
73 75 37

14 x 20 x 5
14 x 20 x 5
16 x 22 x 5
16 x 22 x 5
16 x 22 x 5
20 x 28 x 7
20 x 28 x 7
28 x 36 x 7
28 x 36 x 7
35 x 43 x 7
35 x 43 x 7
35 x 43 x 7
35 x 43 x 7
35 x 43 x 7

990380

GEA AWP GmbH


9 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

AVR_26300 08.08.2012

APS 06.30 10.1

11. Kennzeichnung

11. Specification

Die Kennzeichnung der AWP-Absperrventile erfolgt


entsprechend EN12284.

The specification of the AWP-shut off valves complies with


German Standard EN12284

Kennzeichenschild auf Gehuse

PS

[bar]

- maximal zulssiger Betriebsberdruck


permissible working pressure

DN

[mm]

- Nennweite
nominal diameter

EN 12284

Specification label of the casing

- Kltemittelarmaturen, Sicherheitstechnische Festlegungen,


Prfung, Kennzeichnung
European Standard: refirigerant valves; requirements, testing,
marking

12. Hinweis auf Restgefahren entsprechend


der Druckgerterichtlinie (97/23/EG)

12. Information on risks in conformance to


pressure appliance directive

Vom Hersteller nicht zu vermeidende Restgefahren


bestehen durch:

Remaining risks which cannot be avoided by the


manufacturer arise because of:

Unbefugtes Lsen des Deckels whrend des


Betriebes bzw. Lsen der Schraubbuchse ohne
Aktivierung der Rckdichtung

Unauthorized loosening of the cover during


operation or removing of the screw bushing
without activation of the back sealing

Unsachgeme Montage von


Flanschverbindungen (Eingangs- und
Ausgangsflansch, Deckel)

Incorrect assembly oft he flange connections


(inlet and outlet flange, lid)

Verschmutzungen im Betriebsmedium bzw.


Unsachgemer Umgang mit Einbauteilen
knnen zu Beschdigungen an der Sitzdichtung
fhren

Dirt in the service medium or inappropriate


handling of the internal fittings may cause
damage to the seat seal

Ignore of the operating range and manufacturer


rules acc. to this operating instruction

Nichtbeachtung der Einsatzgrenzen und


Herstellervorschriften entsprechend dieser
Betriebsvorschrift

990380

GEA AWP GmbH


10 / 10

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

Betriebsvorschrift
Armaturen fr die Kltetechnik

Operating Instructions
Valves for refrigeration

Rckschlagventile in Klemmbauweise

Check Valves clamp construction

RVZ Typenvertreter:

RVZ types example:

313 91, 313 93, 313 95

313 91, 313 93, 313 95

ohne integrierte Dmpfung

without integrated damping

313 92, 313 94, 313 96

313 92, 313 94, 313 96

mit integrierter Dmpfung

with integrated damping

315 92, 315 94, 315 96

315 92, 315 94, 315 96

mit integrierter Dmpfung (ber-Kopf-Einbau)

with integrated damping (overhead installation)

316 92, 316 94, 316 96

316 92, 316 94, 316 96

mit integrierter Dmpfung und Linearkugellager

with integrated damping and linear ball bearing

319 92, 319 94, 319 96

319 92, 319 94, 319 96

mit integrierter Dmpfung und Linearkugellager


(ber-Kopf-Einbau)

with integrated damping and linear ball bearing


(overhead installation)

IRV

IRV

312 92

312 92

fr Einbau im labscheider

for installation in oil separator

Inhaltsverzeichnis

Seite

Contents

Page

1. bersicht der Bauarten

1. Survey of Types

2. Technische Kennwerte

2. Technical Characteristics

3. Sicherheitshinweise

3. Safety Instructions

4. Anwendung

4. Application

5. Funktionsbeschreibung

5. Functional Description

6. Einbau

6. Installation

7. Wartung

7. Maintenance

8. Transport und Lagerung

8. Transport, Storage

9. Garantie

9. Warranty

10. Ersatzteile

10. Spare parts

11. Kennzeichnung

11. Specification

12. Hinweis auf Restgefahren

12. Information on risks

990394

GEA AWP GmbH


1/9

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

1.

bersicht der Bauarten / Survey of types

313 91, 313 93, 313 95


ohne integrierte Dmpfung/without integrated damping

313 92, 313 94, 313 96


mit integrierter Dmpfung / with integrated damping

315 92, 315 94, 315 96


mit integrierter Dmpfung (ber-Kopf-Einbau)/with integratet damping (overhead installation)

316 92, 316 94, 316 96


mit integrierter Dmpfung und Linearkugellager/with integrated damping and linear ball bearing

319 92, 319 94, 319 96


mit integrierter Dmpfung und Linearkugellager/with integrated damping, linear ball bearing (overhead instllation)

31292 fr Einbau im labscheider/for installation in oil separator

DN 40 - 150
Ventilteller
valve plate

Druckfeder
pressure spring

Fhrungsbuchse
guide bush

Sicherungsring
locking ring
O-Ring
o-ring seal

Typ / type:
313 91
313 93
313 95
ohne Dmpfung
without damping

312,313,315,316,319 (92)
313,315,316,319 (94)
313,315,316,319 (96)
mit integrierter Dmpfung
with integrated damping
und Linearkugellager
and linear spindle bearing

DN 200 - 350

Ventilteller
valve plate
Sicherungsring
locking ring
Fhrungsbuchse
guide bush
O-Ring
o-ring seal
Druckfeder
pressure spring
GEA AWP GmbH

990394
2/9

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

2. Technische Kennwerte

2. Technical characteristics

Gehusewerkstoff
Auswahl nach DIN EN12284, AD-2000 Reihe W
St: P235GH, S235JR, S355J2
TT: P215NL, P255QL, P355NL1
NIRO: X5CrNi18-10
oder gleichwertige

body material selection of material according to


German DIN EN12284, AD-2000 Reihe W,
St: P235GH, S235JR, S355J2
TT: P215NL, P255QL, P355NL1
NIRO: X5CrNi18-10
or any equivalent

PN

DN

TB (MWT) [C]

-60*

-60**

-10

+50

+150

25
40
63

40-350
40-350
40-150

PS (MWP) [bar]

25
40
63

18,7
30
47,2

25
40
63

25
40
63

25
40
63

* Beanspruchungsfall I (TT, Niro)


** Beanspruchungsfall II (ST)

* kind of straining I (TT, Niro)


** kind of straining II (ST)

Zulssiger Umgebungstemperaturbereich (C)


-50 bis +50

permissi ble ambient temperature range (C)


-50 to +50

Betriebsmedien
working media

Kltemittel EN 378 Teil 1, z.B.NH3, R22, R134a, Blends


und Gemische mit Kltemaschinenl, neutrale, gasfrmige
und flssige Medien Khlsole auf Glycol-Basis,

cold brine basing on glycol refrigerant EN 378 p. 1 and


mixtures with refrigerator oil, neutral, gaseous and liquid
media, cold brine basing on glycol.

Durchflusswert KVS (m3/h)


DN

flow factor (m3/h)

40

50

65

80

100 125 150

38,0

62,5

93,0

135,0 180,0 310,0 480,0

200

250

300

350

680,0

980,0

1370

2030

Einbauanlage

mounting position

Typ / type: 313 91, 313 93, 313 95


ohne Dmpfung

Typ / type: 313 91, 313 93, 313 95


without damping

nur waagerecht [+/-15]

only horizontal [+/-15]

Typ / type: 312(313,316) 92, 313(316) 94, 313(316) 96


mit Dmpfung

Typ / type: 312(313,316) 92, 313(316) 94, 313(316) 96


with damping

senkrecht [+/-15] mit Strmung von unten nach oben und


waagerecht

vertical [+/-15] with upward flow direction and ho rizontal

Typ / type: 315(319) 92, 315(319) 94, 315(319) 96


mit Dmpfung

Typ / type: 315(319) 92, 315(319) 94, 315(319) 96


with damping

senkrecht [+/-15] mit Strmung von oben nach unten und


waagerecht

vertical [+/-15] with downward flow direction and horizontal

ffnungsdruck [bar]

opening pressure [bar]

waagerecht
0,02 bis 0,04 (voll geffnet
0,1 bis 0,15)

vertical
0,025 (completely open 0,20)

senkrecht
0,025 (voll geffnet 0,20)
Leckage nach auen,
Sitz <15g Kltemittel im Jahr bei p=10 bar ber
Ventilteller

horizontal
0,02 to 0,04 (completely open
0,1 to 0,15)

leakage outward,
seat <15g refrigerant per year p=10 bar above the valve
plate

990394

GEA AWP GmbH


3/9

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

3. Sicherheitshinweise

3. Safety instructions

! Ventile mit Transport- oder Lagerschden drfen nicht


eingebaut werden.
! Ventile:

mssen frei von Achskrften, Biege- und


Torsionsmomenten sein

drfen nicht als Fixpunkte von Rohrleitungen


dienen.
! Bei Autogenschweiung oder Hartltung darf die Flamme
das Ventil nicht berhren.
! Verunreinigungen jeglicher Art mssen vom Innenraum
der Ventile ferngehalten werden.
! Demontage bzw. Ausbau der Ventile nur bei druckloser,
abgesaugter und ausreichendbelfteter Rohrleitung.

! Valves that have been damaged during transport or


storage must not be installed.
! Valves:

no axial forces, bending or torsional moments


should act upon the valves.

must not be used as fixing points for pipes


! In the case of gase welding or brazing, the flame may not
reach the valve.
! Any kind of soiling has to be kept away from the inside of
the valve.
! The valves may not be disassembled or detached before
the pipe has been depressurized, sucked off and
adequately ventilated.

4. Anwendung

4. Application

AWP-Rckschlagventile sind geeignet fr den Einsatz in


Kltemittelkreislufen fr Industrie-Klteanlagen.
Sie werden druck- und saugseitig der Verdichter eingesetzt
bzw. in Rohrleitungen in denen nur eine Strmungsrichtung
zugelassen ist.

AWP-check valves in clamp construction are suitable for


being employed in the refrigerant cycles for industrial
refrigerating plants.
They are installed on the pressure or on the suction side of
compressors, or in pipes, for which only one direction of
flow is permitted.

5. Funktionsbeschreibung

5. Functional Description

AWP-Rckschlagventile sind selbstttig arbeitende


Sperrorgane.
Sie werden durch den Druck des Betriebsmediums unter
dem Ventilteller geffnet (siehe auch Seite 3).
Bei Stillstand bzw. Umkehr der Strmung schliet das
Rckschlagventil selbstttig, untersttzt durch die
Federkraft bzw. durch das Eigengewicht des Ventiltellers.

AWP-check valves are automatically working locking units.


They are opened by virtue of the pressure the working
medium exerts upon the valve plate.
As soon as the flow is interrupted or the flow direction is
reversed, the valve locks automatically. The locking function
is supported by the elastic force of the spring or by the
valve plate's own weight.

Typ 313 91, 313 93, 313 95 besonders fr waagerechten


Einbau geeignet, da ohne Dmpfung. Bei senkrechtem
Einbau mit Strmung von unten nach oben und geringem
Leistungsbedarf <40%, kann dieser Typ zum Schwingen
neigen.

Type 313 91, 313 93, 313 95 is specially suited for


horizontal mounting, because it is not equipped with a
damping device. In the case of vertical installation with
upward flow direction and low power requirement < 40%
this type tends to vibrate.

Typ 312(313,316)92, 313(316) 94, 313(316) 96 besonders


fr senkrechten Einbau mit Strmung von unten nach
oben geeignet. Durch das Vorhandensein einer
Dmpfungseinrichtung ist dieser Typ besonders fr stark
schwankenden Leistungsbedarf geeignet. Selbst geringste
Strmungsgeschwindigkeiten bringen den Ventilteller nicht
zum Schwingen.

Type 312(313,316)92, 313(316)94, 313(316)96 is


specially suited for vertical mounting with upward flow
direction. By virtue of a damping device, this type is
especially suitable if the power requirement varies greatly.
Even the lowest flow speed does not cause the valve plate
to vibrate.

Typ 315(319) 92, 315(319) 94, 315(319) 96 besonders fr


senkrechten Einbau mit Strmung von oben nach unten
geeignet.
Die Dichtheit des Abschlusses hngt entscheidend vom
Differenzdruck ber dem Ventilteller ab.
Die Abdichtung am Ventilsitz erfolgt durch einen
Flachdichtring aus Teflon.
Um ein einwandfreies Funktionsverhalten zu gewhrleisten
ist darauf zu achten, dass die tatschliche minimale
Durchfluleistung (z.B. bei Teillast) nie kleiner wird als 20%
der maximalen, nennweitenbezogenen Ventilleistung
bezogen auf einen Druckverlust von 0,1 bar.

Type 315(319) 92, 315(319) 94, 315(319) 96 is specially


suited for vertical mounting with downward flow
direction.
The tightness of the sealing depends mainly on the
differential pressure above the valve plate.
The valve seat is sealed by a flat sealing ring, made of
Teflon.
To assure an impeccable valve function the real minimum
flow (e.g. at part load) should not go below 20% of
maximum valve capacity at 0,1 bar pressure drop.

GEA AWP GmbH

990394
4/9

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

6. Einbau

6. Installation

DN 40-150

DN200-350

Zubehrteile

Accessories

Sechskantmuttern
hexagon nut

Vorschweiflansche
welding neck flange

O-Ringe
o-ring seals

O-Ringe
o-ring seals

Sechskantschrauben
hexagon head cap screw

Sechskantschrauben
hexagon head cap screw

Vor Einbau der Ventile sind Rohrleitungen und Anlagenteile


zu subern. Das Ausblasen der Rohrleitungen nach Einbau
der Ventile kann zur Beschdigung des TeflonFlachdichtringes am Ventilteller fhren und ist unzulssig.

Before installing the valves, the pipes and the system parts
have to be cleaned. It is not allowed to blow through the
pipes after having installed the valves, as it can harm the
flat sealing ring made of Teflon at the valve plate.

-bitte beachtenAls Klemmflansche werden Vorschweiflansche nach DIN


EN 1092-1 in den Druckstufen PN25, PN40, PN63 und
Flansche nach ASME B16.5 300lbs, 600lbs verwendet.
Die Abweichung von der Parallelitt bzw. Rechtwinkligkeit
der Flanschdichtflchen darf 1 nicht berschreite n.
Anschluflansche mssen achsengleich sein.
Ventile mit Transport- und Lagerschden drfen nicht
eingebaut werden.
Nach dem Entfernen der Rohrstopfen / Folie knnen die
Ventile montiert werden.
Die Durchflurichtung (siehe Pfeil auf Kennzeichenschild) ist einzuhalten.

-please noticeWelding neck flanges according DIN EN 1092-1, in the


compression phases PN25, PN40, PN63 and flange to
ASME B16.5 300lbs, 600lbs are used as clamping flange.
The deviation from the parallelism or squareness of the
sealing surfaces of the flanges must not exceed 1.
The connecting flanges have to be coaxial.

-bitte beachtenDie Sechskantschrauben und Muttern sind ber Kreuz und


gleichmig anzuziehen.

-please noticeThe hexagon head cap screws and nuts have to be


tightened crosswise and evenly.

Um ein Herausfallen der O-Ringe aus den Nuten whrend


der Montage der Rckschlagventile zu vermeiden, sind
diese mit Kltefett in die Nuten einzulegen.

The O-ring seals should be inserted into the grooves


together with low-temperature grease in order to prevent
them from falling out of the grooves during the assembly of
the check valves.

Valves that have been damaged during transport or storage


must not be installed.
After the protective caps / sheeting have been removed, the
valves can be installed.
The flow direction (see arrow on the specification label)
has to be observed.

GEA AWP GmbH

990394
5/9

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

7. Wartung

7. Maintenance

AWP-Rckschlagventile arbeiten wartungsfrei.


Treten Mngel im Funktionsverhalten auf ist eine Reparatur
mglich.
Whrend der Garantiezeit drfen Reparaturen nur durch
den Hersteller bzw. mit dessen Einverstndnis durch
geschultes Instandhaltungspersonal des Betreibers der
Anlage vorgenommen werden.
Demontage bzw. Ausbau der Ventile nur bei druckloser,
abgesaugter und ausreichend belfteter Rohrleitung.

AWP-check valves are maintenance-free.


In case any defects in the functional performance of the
valves occur, they can be repaired.
During the term of warranty, repairs may only be carried out
by the manufacturer or - with his consent - by speciallytrained maintenance personnel working for the plant
operator.
The valves may not be disassembled or detached before
the pipe has been depressurized, sucked off and
adequately ventilated.

Demontage

For disassembly

Nach dem Lsen der Sechskantschrauben sind so viele


Schrauben zu entfernen, bis sich das Ventil aus den
Klemmflanschen herausdrehen lt.

First release the hexagon head cap screws. Then remove


as many screws as are necessary for being able to turn the
valve out of the clamping flanges.

ben die Klemmflansche einen zu hohen Druck auf das


Rckschlagventil aus, sind diese mit einer geeigneten
Vorrichtung auseinander zu drcken.

In case the clamping flanges exert too much pressure on


the check valve, loosen the flanges using a suitable device.

Sicherungsring nach DIN 472 mit geeigneter MontageZange DIN 5256 ZGJ entfernen.
Vorsichtig Fhrungsbuchse zusammen mit der Druckfeder
und dem Ventilteller aus dem Gehuse herausnehmen.

Remove the locking ring according DIN 472 by means of


suitable pliers DIN 5256 ZGJ.
Remove the guide bush carefully together with the pressure
spring and the valve plate from the body.

Montage

Assembly

Vor der Montage sind alle beschdigten Teile entsprechend


Ersatzteilbersicht (siehe Pkt.10) auszuwechseln. Alle
Einzelteile sind zu reinigen. Fhrungsflchen leicht mit
kltebestndigem l (z.B. ANTICORIT 5F ) einlen.
Druckfeder auf Fhrungsbuchse stecken und Ventilteller
vorsichtig in die Fhrungsbuchse einfhren.

Before performing the assembly, exchange all damaged


parts according to 10. "Spare parts". Clean all components.
Please wet the surfaces of guidance surface with an oil,
which is resistant against low temperature
(e.g. ANTICORIT).
Place the pressure spring onto the guide bush carefully.

Vormontierte Einheit, bestehend aus:

Ventilteller

Druckfeder

Fhrungsbuchse
vorsichtig in das Gehuse einfhren und mit Sicherungsring
DIN 472 gegen ein Herausfallen sichern.

Insert this pre-assembled unit, which consists of:

valve plate

pressure spring

the guide bush


into the body carefully and secure it against falling out with
a locking ring DIN 472.

Einbau in die Rohrleitung siehe 6. Einbau.

For installation into the pipes see 6. Installation.

8. Transport und Lagerung

8. Transport, Storage

AWP- Rckschlagventile werden stogeschtzt, mit Folie


abgedeckt transportiert. Die Lagerung hat in trockenen
Rumen zu erfolgen. Es ist auf den unversehrten
Verschluss
der
Anschlussstutzen
zu
achten.
Verschmutzungen jeglicher Art mssen vom Innenraum
ferngehalten werden.
Die auenliegenden Flchen der Armaturen sind mit einem
Korrosionsschutzanstrich fr trockene Lagerung bei
Raumtemperatur versehen, der mindestens 1 Jahr wirksam
ist.
Der Korrosionsschutzanstrich BISPHENOL-A-Epoxidharz
ist ein guter Haftvermittler fr Deckanstrichstoffe auf 1- und
2- Komponenten-Basis.

During transport, AWP check valves are protected against


shocks and covered with plastic sheeting.
They should be stored in dry rooms. Care has to be taken
that the plugs of the connecting pieces are not damaged.
Any kind of soiling has to be kept away from the inside of
the fitting.
The external surfaces of the valves are provided with a layer of anticorrosive paint for dry storing at room temperature,
which remains effective for at least 1 year.
The anticorrosive paint which BISPHENOL-A-Epoxidharz
is a good bonding agent for one or two-pot finishing coating
paints.

GEA AWP GmbH


6/9

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

9. Garantie

9. Warranty

Die Garantieleistung fr Erzeugnisse ist entsprechend den


vertraglichen Bestimmungen im Liefervertrag festgelegt.

The warranty services for our products have been defined


incompliance with the regulations stipulated the contract of
delivery.

10. Ersatzteile

10. Spare parts

Ersatzteile entsprechend Bild Seite 2


Zubehrteile siehe Bild Seite 5

Spare parts according to the illustration sheet page 2


For accessories see picture page 4

Ersatzteilbestellung: (muss enthalten)


Anzahl

Bezeichnung entsprechen Bilder fr Typ

Bestell-Nummer

Nennweite der Armatur

Baujahr der Armatur

Ordering Spare parts: (an order must contain):


quantity

designation according to illustration sheet page 2

stock number

nominal diameter of the fitting

year of construction of the fitting

Bestellbeispiel:
4 Stck, O-Ring, RVZ, 313 91
73 75 40,
DN150, 05/2007

Example for ordering


4 pieces, o-ring, RVZ, 313 91
73 75 40 ,
DN150, 05/2007

Ventilteller / valve plate


Bestellnummer /
stocking number
Typ 313/315
313 91(92)K14.5 125 001
313 91(92)K15.5 125 001
313 91(92)K17.5 125 001
313 91(92)K18.5 125 001
313 91(92)K19.5 125 001
313 91(92)K20.5 125 001
313 91(92)K21.5 125 001
313 91(92)E23.5 125 001
313 91(92)E24.5 125 001
313 91(92)E25.5 125 001
313 91(92)E26.5 125 001

DN
40
50
65
80
100
125
150
200
250
300
350

Druckfeder / pressure spring


Bestellnummer /
stocking number
Typ 316/319
------------------------316 91(92)K19.5 125 001
316 91(92)K20.5 125 001
316 91(92)K21.5 125 001
316 91(92)E23.5 125 001
316 91(92)E24.5 125 001
316 91(92)E25.5 125 001
316 91(92)E26.5 125 001

Fhrungsbuchse / Guide bush

DN
40
50
65
80
100
125
150
200
250
300
350

Bestellnummer /
stocking number
Typ 313/315
307 91(92).14.5 521 01 2
307 91(92).15.5 521 01 2
307 91(92).17.5 521 02 2
307 91(92).18.5 521 00 2
307 91(92).19.5 521 44 2
307 91(92).20.5 521 00 2
313 91(92)K21.5 521 00 2
307 91(92).23.5 520 02 1
307 91(92)B24.5 520 00 1
313 91(92)E25.5 520 00 1
307 91(92)B26.5 520 08 1

Bestellnummer /
stocking number
Typ 313
56 20 56
56 20 56
327 02.13.8 233 00 3
139 11.13.8 233 00 3
139 11.14.8 233 00 3
307 91.21.8 233 01 3
307 91.21.8 233 02 3
307 91.23.8 233 00 3
307 91.24.8 233 00 3
307 91.25.8 233 00 3
56 20 33

Bestellnummer /
stocking number
Typ 316
------------------------309 91E19.8 233 00 3
295 00E17.8 233 00 3
295 00E17.8 233 00 3
309 91E23.8 233 00 3
309 92E24.8 233 00 3
309 92E25.8 233 00 3
309 91E26.8 233 00 3

Ventileinsatz kpl. / valve


Insert cmpl.
Bestellnummer /
stocking number
Typ 316/319
------------------------316 92K19.5 521 00 1
316 92K20.5 521 00 1
316 92K21.5 521 00 1
316 92E23.5 521 00 1
316 92E24.5 521 00 1
316 92E25.5 520 00 1
316 92E26.5 520 00 1

Bestellnummer /
stocking number
Typ 313
313 91(92)K14.5 110 00 1
313 91(92)K15.5 110 001
313 91(92)K17.5 110 001
313 91(92)K18.5 110 001
313 91(92)K19.5 110 001
313 91(92)K20.5 110 001
313 91(92)K21.5 110 001
313 91(92)E23.5 110 001
313 91(92)E24.5 110 001
313 91(92)E25.5 110 001
313 91(92)E26.5 110 001

Bestellnummer /
stocking number
Typ 316
------------------------316 92K19.5 110 001
316 92K20.5 110 001
316 92K21.5 110 001
316 92E23.5 110 001
316 92E24.5 110 001
316 92E25.5 110 001
316 92E26.5 110 001

GEA AWP GmbH

990394
7/9

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

Zubehrteile

Accessoires

Fr Ausfhrung mit Flanschen nach DIN EN 1092-1 Typ 11


B1 / C22.8 und Rundringabdichtung

For execution with flanges according to DIN EN


1092-1 type 11 B1/C.22.8 and round ring sealing

DN 40-150 = PN 40

DN
40
50
65
80
100
125
150
200
250
300
350

DN 200-350 = PN 25

Vorschweiflansche /
Welding neck flanges

Sechskantschrauben /
hexagon head cap screws

Bestellnummer /
stocking number
263 50.14.5 031 10 4
263 50.15.5 031 10 4
263 50.17.5 031 10 4
263 50.18.5 031 10 4
263 50.19.5 031 10 4
263 50.20.5 031 10 4
263 50.21.5 031 10 4
263 50.23.5 031 10 4
263 50.24.5 031 10 4
263 50.25.5 031 10 4
263 50.26.5 031 10 4

Anzahl
Number
4
4
8
8
8
8
8
24
24
32
32

Flansch / flange
EN 1092-1
Typ 11
PN25
PN40
PN63
ASME B16,5
300 lbs
600 lbs

Sechskantmuttern /
hexagon nut
Abmessung
dimension
M16 x 130
M16 x 150
M16 x 150
M16 x 180
M20 x 200
M24 x 210
M24 x 220
M24 x 60
M27 x 60
M27 x 60
M30 x 65

Anzahl
Number
4
4
8
8
8
8
8
-----

Dichtflchenbezeichnung
Sealing surface designation
Form B1
Form C

Schrauben-/ Muttern-Gewinde
Screw-/ nuts-thread
Metrisch
Metric

RF

Metrisch / Zoll
Metric / zoll

990394

Abmessung
dimension
M16
M16
M16
M16
M20
M24
M24
-----

GEA AWP GmbH


8/9

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

RVZ_313 10.03.2014

APS 06.30 07.1

11. Kennzeichnung

11. Specification

Die Kennzeichnung der AWP-Absperrventile erfolgt


entsprechend EN12284.

The specification of the AWP-shut off valves complies with


German Standard EN12284

Kennzeichenschild auf Gehuse

PS

[bar]

- maximal zulssiger Betriebsberdruck


permissible working pressure

DN

[mm]

- Nennweite
nominal diameter

EN 12284

Specification label of the casing

- Kltemittelarmaturen, Sicherheitstechnische Festlegungen,


Prfung, Kennzeichnung
European Standard: refirigerant valves; requirements, testing,
marking

12. Hinweis auf Restgefahren entsprechend


der Druckgerterichtlinie (97/23/EG)

12. Information on risks in conformance to


pressure appliance directive

Vom Hersteller nicht zu vermeidende Restgefahren


bestehen durch:

Remaining risks which cannot be avoided by the


manufacturer arise because of:

Unsachgeme Montage von Flanschverbindungen

Verschmutzungen im Betriebsmedium bzw.


Unsachgemer Umgang mit Einbauteilen
knnen zu Beschdigungen an der Sitzdichtung
fhren

Nichtbeachtung der Einsatzgrenzen und


Herstellervorschriften entsprechend dieser
Betriebsvorschrift

Incorrect assembly oft he flange connections

Dirt in the service medium or inappropriate


handling of the internal fittings may cause
damage to the seat seal

Ignore of the operating range and manufacturer


rules acc. to this operating instruction

GEA AWP GmbH


9/9

990394

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

SSO 08.08.2012

APS 06.30 20

Betriebsvorschrift
Armaturen fr die Kltetechnik

Operating Instructions
Valves for refrigeration

Schnellschluventil

Quick - closing valve

SSO Typenvertreter:

SSO types example:

460 62

460 62

460 64

Anschweiende am Eingang
Gewinde am Ausgang
Flansch am Eingang
Gewinde am Ausgang

Inhaltsverzeichnis

Seite

460 64

Inlet: welding ends


Oulet: threaded ends
Inlet: flanges
Outlet: threaded ends

Contents

Page

1. bersicht der Bauarten

1. Survey of Types

2. Technische Kennwerte

2. Technical Characteristics

3. Anwendung

3. Application

4. Funktionsbeschreibung

4. Functional Description

5. Einbau

5. Installation

6. Wartung

6. Maintenance

7. Transport und Lagerung

7. Transport, Storage

8. Garantie

8. Warranty

9. Ersatzteile

9. Spare parts

10. Kennzeichnung

10. Specification

11. Hinweis auf Restgefahren

11. Information on risks

GEA AWP GmbH

990415
1/6

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

SSO 08.08.2012

APS 06.30 20

1. bersicht der Bauarten

Typ / type
460 62 Eckform

1. Survey of types

DN10 - 250
Anschweiende am Eingang
Gewinde am Ausgang
Flansch am Eingang
Gewinde am Ausgang

460 64 Eckform

angle type

Inlet: welding ends


Oulet: threaded ends
Inlet: flanges
Oulet: threaded ends

Gehuse
body
Hebel
lever
O-Ring S x
o-ring seal S
Stift
pin

Dichtkolben
sealing piston

Deckel
cover

Sprengring
snap ring

O-Ring SP x
o-ring seal SP

Dichtring x
sealing ring

Druckfeder
pressure spring

Ersatzteile spare parts

2. Technische Kennwerte

O-Ring D x
o-ring seal D

Spindel
stem

2. Technical characteristics

Gehusewerkstoff
Auswahl nach DIN EN12284, AD-2000 Reihe W
St: P235GH, S355J2
TT: P215NL, P255QL, P355NL1
NIRO: X5CrNi18-10
oder gleichwertige

body material selection of material according to


German DIN EN12284, AD-2000 Reihe W,
St: P235GH, S355J2
TT: P215NL, P255QL, P355NL1
NIRO: X5CrNi18-10
or any equivalent

PN

DN

TB (MWT) [C]

-35*

25
40

15
15

PS (MWP) [bar]
PS (MWP) [bar]

** Beanspruchungsfall I (TT, Niro)


* Beanspruchungsfall II ( nach AD2000-W10,
EN 12284) (ST)

18,7
30

-35**
25
40

-10

+50

+130

25
40

25
40

25
40

** kind of straining I (TT, Niro)


* kind of straining II ( after AD2000-W10,
EN 12284) (ST)

990415

GEA AWP GmbH


2/6

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

SSO 08.08.2012

APS 06.30 20

Zulssiger Umgebungstemperaturbereich (C)


-50 bis +50

permissi ble ambient temperature range (C)


-50 to +50

Betriebsmedien

working media

Kltemittel EN 378 Teil 1, z.B.NH3, R22, R134a, Blends


und Gemische mit Kltemaschinenl, neutrale, gasfrmige
und flssige Medien Khlsole auf Glycol-Basis,

cold brine basing on glycol refrigerant EN 378 p. 1 and


mixtures with refrigerator oil, neutral, gaseous and liquid
media, cold brine basing on glycol

ffnungsdruck > 25 bar

opening pressure > 25 bar

Einbauanlage beliebig, Durchflurichtung sollte eingehalten


werden

mounting position in any desired position, the flow direction


should be observed

Leckage nach auen,


Sitz (g/a) <5 Kltemittel im Jahr

leakage outward,
seat (g/a) <5 refrigerant per year

3. Anwendung

3. Application

AWP-Schnellschluventile sind geeignet fr den Einbau


in
lablaleitungen
und
besonders
gefhrdeten
Anlagenteilen z.B.: Fllstandsanzeiger, Schauglser,
flexible Leitungen u.a.

AWP quick-closing valves are suitable for being


employed in oil drain pipeline (oil drain valve) and in system
parts which are especially exposed to danger, such as:
level indicators, viewing glasses, flexible pipes and the like

! Hinweis ! DIN 8975 Teil 6 Pkt. 5.5


In der lablaleitung ist vor dem Schnellschluventil ein
Absperrventil (AVR oder AVB) mit waagerecht angeordneter Spindel einzubauen.

! please notice ! DIN 8975 part 6, section 5.5


A shut off valve (AVR or AVB) with a horizontally disposed
stem has to be mounted in front of the quick-closing valve.

4. Funktionsbeschreibung

4. Functional description

AWP-Schnellschluventile werden durch Ziehen am


Hebel Pos.2 zum ffnen gebracht. Der unter dem
Dichtkolben Pos.10 anstehende Anlagendruck untersttzt
den ffnungsvorgang.
Die Druckfeder ist so dimensioniert, dass der Dichtkolben
bei einem anstehenden Anlagendruck > 20 bar selbstttig
ffnet.
Durch Loslassen des Hebels Pos.2 schliet der Dichtkolben
Pos.10 selbststndig.
Die Abdichtung am Ventilsitz erfolgt mit einem O-Ring S
Pos.11 aus Chloropren.

AWP quick-closing valves are opened by pulling the lever


pos.2. The system pressure acting upon the sealing piston
pos.10 supports the opening.
The pressure spring is dimensioned in a way that the
sealing piston opens automatically if the system pressure
raises > 20 bar.
If the lever pos.2 is released, the sealing piston pos.10
closes automatically.

5. Einbau

5. Installation

Vor Einbau der Ventile sind Rohrleitungen und Anlagenteile


zu subern.
-bitte beachtenDie Abweichung von der Parallelitt bzw. Rechtwinkligkeit
der Anschweienden bzw. Flanschdichtflchen darf 1 nicht
berschreiten. Anschluflansche mssen achsengleich
sein. Ventile mit Transport-und Lagerschden drfen nicht
eingebaut werden. Nach dem Entfernen der Rohrstopfen
knnen die Ventile in beliebiger Lage eingeschweit bzw.
montiert werden. Nach dem Entfernen der Rohrstopfen
knnen die Ventile in beliebiger Lage eingeschweit bzw.
montiert werden. Die Durchflurichtung (siehe Pfeil auf
Kennzeichenschild) ist einzuhalten.

Before installing the valves, the pipelines and the components have to be cleaned.
-please noticeThe deviation from the parallelism or squareness of the
welding ends or, as the case may be, the sealing surfaces
of the flanges must not exceed 1. The connecting f langes
have to be coaxial. Valves that have been damaged during
transport or storage must not be installed. After the
protective caps have been removed, the valves can be
welded on, or installed in horizontal or vertical position, in
the latter case with the cover pointing downwards.
The flow direction ( see arrow on specification label ) should
be observed.

The sealing at the valve seat is affected by a chloroprene


O-ring S pos.11.

990415

GEA AWP GmbH


3/6

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

SSO 08.08.2012

APS 06.30 20

-bitte beachtenAWP-Schnellschluventile

mssen frei von Achskrften, Biege- und


Torsionsmomenten sein

drfen nicht als Fixpunkte von Rohrleitungen


dienen

bei Autogenschweiung oder Hartltung darf die


Flamme das Ventil nicht berhren
Bei Anwendung moderner Schweiverfahren (z.B. WIG,
CO2) werden die Schnellschluventile zum Einschweien
nicht demontiert.

-please noticeAWP quick-closing valves:

no axial forces, bending or torsional moments


should act upon the valves

must not be used as fixing points for pipes

in the case of gas welding or brazing, the flame


may not reach the valve.

-bitte beachtenZur Demontage der Innenteile ist gengend Platz auf der
Deckelseite vorzusehen: > 40 mm.

-please noticeFor disassembling the inner parts has to be provided on the


side of the cover: > 40 mm.

6. Wartung

6. Maintenance

AWP-Schnellschluventile arbeiten wartungsfrei. Treten


Mngel im Funktionsverhalten auf, ist eine Reparatur
mglich.
Demontage bzw. Ausbau der Ventile nur bei druckloser,
abgesaugter und ausreichend belfteter Rohrleitung.

AWP quick-closing valves are maintenance-free. In case


any defects occur in the functional performance of the
valves, they can be repaired.
The valves may not be disassembled or detached
before the pipe has been depressurized, sucked off and
adequately ventilated.

With modern welding processes (such as TIG, CO2 shielded metal-arc), the quick-closing valves are not
disassembled for welding.

! Demontage !
Stift Pos.1 4 mm herausschlagen und Hebel
Pos.2 abnehmen.
Deckel Pos.3 vorsichtig entgegen dem Uhrzeigersinn mit einem Maulschlssel [SW 30 mm] herausschrauben

! Deckel Pos.3 steht geringfgig durch die Druckfeder


unter Spannung !

! The cover pos.3 is under slight pressure due to the


pressure spring !

Spindel Pos.6 zusammen mit Druckfeder Pos.7


und Dichtkolben Pos.10 aus dem Gehuse herausnehmen.
alle O-Ringe entfernen

! Montage !
Teile vorsichtig subern, keine scharfen
Gegenstnde verwenden.
O-Ring Bereiche mit etwas Kltefett z.B.:
RENAX UNITEMP 2 bestreichen und neue
O-Ringe entsprechend Bild 1 montieren.
O-Ring / o-ring
SP Pos.4
D Pos.5
S Pos.11

! Disassembly !
Knock out the pin pos.1 4 mm and remove
lever pos.2
Screw out the cover pos.3 counterclockwise by
means of a spanner [with across 30mm] carefully.

Abmessung / Dimension
8x2
26 x 3
12 x 3

Gehuseinnenraum, Dichtkolben Pos.10 und


Spindel Pos.5 im Bereich der O-Ringe SP Pos.4
leicht einfetten mit z.B.: RENAX UNITEMP 2
Spindel Pos.6 zusammen mit Druckfeder Pos.7
und Dichtkolben Pos.10 in das Gehuse
einfhren
Deckel Pos.3 vorsichtig ber die Spindel Pos.6
schieben und unter leichtem Druck mit einer
Drehung im Uhrzeigersinn in das
Gehuse
Pos.12 eindrehen.
Deckel SW 30 mit ca. 100 Nm anziehen
Hebel Pos.2 so auf der Spindel Pos.6 platzieren,
dass der Stift Pos.1 eingeschlagen werden kann.
abschlieend Funktionskontrolle

990415

Remove stem pos.6 together with pressure spring


pos.7 and sealing piston pos.10 from the body.
Remove all O-rings.

! Assembly !
Clean the parts carefully, do not use any sharp
objects.
Grease the surfaces around the O-rings with a
little low-temperature grease, e.g. RENAX
UNITEMP 2 and mount new O-rings according to
figure 1.
Stck / piece
2
1
1
Grease the interior of the body, the sealing piston
pos.10 and the stem pos.5 around the O-rings SP
pos.4 slightly with e.g. RENAX UNITEMP 2.
Insert stem pos.6 together with pressure spring
pos.7 and sealing piston pos.10 into the body.
Install the cover pos.3 by pushing it over the stem
pos.6 and screw it into the body pos.12 by
exerting slight pressure and performing one turn
in clockwise direction.
Tighten the cover width across 30 with approx.
100 Nm
Place the lever pos.2 on the stem pos.6 in a way
that the pin pos.1 can be driven into the lever
final step: operational check
GEA AWP GmbH

4/6

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

SSO 08.08.2012

APS 06.30 20

7. Transport und Lagerung

7. Transport, Storage

AWP-Schnellschluventile
werden
stound
feuchtigkeitsgeschtzt transportiert. Die Lagerung hat in
trockenen Rumen zu erfolgen. Es ist auf den unversehrten
Verschluss
der
Anschlussstutzen
zu
achten.
Verschmutzungen jeglicher Art mssen vom Innenraum
ferngehalten werden. Die auenliegenden Flchen der
Armaturen sind mit einem Korrosionsschutzanstrich fr
trockene Lagerung bei Raumtemperatur versehen, der
mindestens 1 Jahr wirksam ist.
Der Korrosionsschutzanstrich auf Basis Epoxidharzester
in Verbindung mit Zinkphosphat ist ein guter
Haftvermittler fr Deckanstrichstoffe auf 1- und 2Komponenten-Basis.

During transport, AWP quick-closing valves are protected


against shocks and moisture. The fittings should be stored
in dry rooms. Care has to be taken that the plugs of the
connecting pieces are not damaged. Any kind of soiling has
to be kept away from the inside of the fitting. The external
surfaces of the valves are provided with a layer of
anticorrosive paint for dry storing at room temperature,
which remains effective for at least 1 year.

8. Garantie

8. Warranty

Die Garantieleistung fr Erzeugnisse ist entsprechend den


vertraglichen Bestimmungen im Liefervertrag festgelegt.

The warranty services for our products have been defined


incompliance with the regulations stipulated the contract of
delivery.

9. Ersatzteile

9. Spare parts

Ersatzteile entsprechend Bild Seite 2:


Ersatzteilbestellung: (muss enthalten)
Anzahl

Bezeichnung entsprechen Bilder fr Typ

Bestell-Nummer

Nennweite der Armatur

Baujahr der Armatur

Spare parts according to the illustration sheet page 2:


Ordering Spare parts: (an order must contain):
quantity

designation according to illustration sheet page 2

stock number

nominal diameter of the fitting

year of construction of the fitting

The anticorrosive paint which is based on esterified epoxy


resin in combination with zinc phosphate is a good
bonding agent for one or two-pot Finishing coating paints.

Bestellbeispiel:
3 Stck, O-Ring D, SSO
73 75 71,
DN15, 06/2005

Example for ordering


3 pieces, O-rings D, SSO
73 75 71
DN15, 06/2005

Ersatzteile:
Pos.
4
5
11
8

spare parts:
Bezeichnung
marking
o-ring SP
o-ring D
o-ring S
Dichtring
sealing ring

Bestellnummer
stock number
73 75 23
73 75 71
73 75 75
73 74 88

Abmessung
dimension
8x2
26 x 3
12 x 3
13 x 18

990415

Werkstoff
material
CR 75
CR 75
CR 85
Alu

Stck je Ventil
piece per valve
2
1
1
1

GEA AWP GmbH


5/6

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

SSO 08.08.2012

APS 06.30 20

10. Kennzeichnung

10. Specification

Die Kennzeichnung der AWP-Schnellschlussventile erfolgt


entsprechend EN12284.

The specification of the AWP quick-closing valves complies


with German Standard EN12284

Kennzeichenschild auf Gehuse

PS

[bar]

- maximal zulssiger Betriebsberdruck


permissible working pressure

DN

[mm]

- Nennweite
nominal diameter

EN 12284

Specification label of the casing

- Kltemittelarmaturen, Sicherheitstechnische Festlegungen,


Prfung, Kennzeichnung
European Standard: refirigerant valves; requirements, testing,
marking

11. Hinweis auf Restgefahren entsprechend


der Druckgerterichtlinie (97/23/EG)

11. Information on risks in conformance to


pressure appliance directive

Vom Hersteller nicht zu vermeidende Restgefahren


bestehen durch:

Remaining risks which cannot be avoided by the


manufacturer arise because of:

Unbefugtes Lsen des Deckels whrend des


Betriebes bzw. Lsen der Schraubbuchse ohne
Aktivierung der Rckdichtung

Unauthorized loosening of the cover during


operation or removing of the screw bushing
without activation of the back sealing

Unsachgeme Montage von


Flanschverbindungen (Eingangs- und
Ausgangsflansch, Deckel)

Incorrect assembly of the flange connections


(inlet and outlet flange, lid)

Verschmutzungen im Betriebsmedium bzw.


Unsachgemer Umgang mit Einbauteilen
knnen zu Beschdigungen an der Sitzdichtung
fhren

Dirt in the service medium or inappropriate


handling of the internal fittings may cause
damage to the seat seal

Ignore of the operating range and manufacturer


rules acc. to this operating instruction

Nichtbeachtung der Einsatzgrenzen und


Herstellervorschriften entsprechend dieser
Betriebsvorschrift

990415

GEA AWP GmbH


6/6

Armaturenstr. 2
17291 Prenzlau, Germany
Tel.: +49 3984 8559-0 Fax: +49 3984 8559-18
www.gea.com e-mail: info.awpvalves@gea.com

Product Description | Temperature controller


Main part

TEMPERATURE CONTROLLER

1.1

View and the principle "mixing operation"

The un-cooled oil volume flow from the oil separator


(1) is mixed with the cooled oil volume flow from the
oil cooler (2). So a specified oil volume flow temperature towards the compressor (4) is guaranteed.
Additional during the screw compressor package
start-up is guaranteed, that first un-cooled oil (from
the warm oil side) is reaching the compressor.
As a result, the oil filter is relieved (low pressure
drop) and ensures an adequate supply of oil.
The elements for thermostatic 3-way-valves operate
without maintenance. An exchange can be done only
against a new component, see article number in the
table below.
Hint!
The selection of the valve insert is
dependent on the used refrigerant.
Basically, ammonia (NH3) and all other
known refrigerant (freons) are differentiated.

fig.1:

Principle "mixing operation"

un-cooled oil from oil separator

cooled oil from oil cooler

measuring cell (dependent on temperature according to


the defined control range)

to the compressor

1.2

The types of oil (mineral or synthetic)


have no influence on the selection of
the temperature range.
The size of the valve insert must be
matching to the size of OMC-block as
well as to the size of 3-way-valve casing (see customer parts list).

Function

The element for thermostatic 3-way-valves is provided for the use in screw compressor packages and
chillers of the GEA Refrigeration Germany GmbH.
The element is generally installed

in the OMC-block (oil management center)


or

in the 3-way-valve casing.

The valve insert selection occurs by GEA Refrigeration Germany GmbH and depends on the specified
operating conditions.
The element for thermostatic 3-way-valves operates
without auxiliary power and fulfils the function of a
mixing valve.
The function is independent from operating pressure.
Based on the selected temperature range (Section 1.3, page 2), the oil temperature is automatically controlled after screw compressor has started.

GEA Refrigeration Germany GmbH | 990423_1 | Generated 13.02.2014

Product Description | Temperature controller


Main part

1.3

Specifications

Selection range for refrigerant ammonia


Diameter nominal
DN32/ DN40

DN50

Specification

Control range

mean temperature

Grasso Ident

5435P085

26 - 34C

085F / 29C

637699197

5435P095

30 - 40C

095F / 35C

637699167

5435P100

33 - 42C

100F / 37C

637699166

5435P110

38 - 47C

110F / 43C

637699168

5435P120

45 - 55C

120F / 48C

637699170

5435P130

49 - 60C

130F / 54C

637699171

5435P140

55 - 66C

140F / 60C

637699173

5435P150

60 - 71C

150F / 65C

637699175

1096P100

34 - 42C

100F / 38C

637699156

1096P105

35 - 45C

105F / 41C

637699157

1096P110

38 - 47C

110F / 43C

637699158

1096P115

40 - 50C

115F / 46C

637699159

1096P120

43 - 54C

120F / 49C

637699160

1096P130

51 - 60C

130F / 54C

637699161

1096P135

54 - 63C

135F / 57C

637699162

1096P140

57 - 66C

140F / 60C

637699163

1096P145

60 - 69C

145F / 63C

637699164

1096P150

63 - 72C

150F / 66C

637699165

Specification

Control range

mean temperature

Grasso Ident

5435X076

20 - 29C

076F / 24C

637699169

5435X085

26 - 34C

085F / 29C

637699196

Selection range for freons


Diameter nominal
DN32/ DN40

GEA Refrigeration Germany GmbH | 990423_1 | Generated 13.02.2014

Product Description | Temperature controller


Main part

Selection range for freons


Diameter nominal

DN50

Specification

Control range

mean temperature

Grasso Ident

5435X095

30 - 40C

095F / 35C

637699186

5435X100

33 - 42C

100F / 37C

637699187

5435X110

38 - 47C

110F / 43C

637699188

5435X120

45 - 55C

120F / 48C

637699190

5435X130

49 - 60C

130F / 54C

637699191

5435X140

55 - 66C

140F / 60C

637699193

5435X150

60 - 71C

150F / 65C

637699195

1096X090

27 - 35C

090F / 32C

637699198

1096X100

34 - 42C

100F / 38C

637699176

1096X105

35 - 45C

105F / 41C

637699177

1096X110

38 - 47C

110F / 43C

637699178

1096X115

40 - 50C

115F / 46C

637699179

1096X120

43 - 54C

120F / 49C

637699180

1096X130

51 - 60C

130F / 54C

637699181

1096X135

54 - 63C

135F / 57C

637699182

1096X140

57 - 66C

140F / 60C

637699183

1096X145

60 - 69C

145F / 63C

637699184

1096X150

63 - 72C

150F / 66C

637699185

GEA Refrigeration Germany GmbH | 990423_1 | Generated 13.02.2014

Product Description | Temperature controller


Main part

GEA Refrigeration Germany GmbH | 990423_1 | Generated 13.02.2014

PRODUCT DESCRIPTION
MAIN PART
Leven monitor MIN / MAX

optical level scanning as well as an electronic,


removable evaluation unit.

INT279 LN - Level monitor MIN


INT279 LX - Level monitor MAX

INT279 LN - Level monitor MIN


The relay trips 3 seconds after connecting the supply
voltage. If a level too low is detected the relay
switches off after a delay, the red LED lights. If the
level reaches the good range, the relay picks up
again after a delay, the red LED goes out. The own
monitoring system of the optics integrated into the
INT279 LN ensures increased operational reliability.
An installation check monitors the proper assembly.
If there is a fault, the relay switches off after a delay,
the red LED flashes.
INT279 LX - Level monitor MAX
fig. 1:

The relay trips 3 seconds after connecting the supply


voltage. If a level too high is detected the relay
switches off after a delay, the red LED lights. If the
level falls under the limit, the relay picks up again
after a delay, the red LED goes out. The own
monitoring system of the optics integrated into the
INT279 LX ensures increased operational reliability.
An installation check monitors the proper assembly.
If there is a fault, the relay switches off after a delay,
the red LED flashes.

View

1.2

Installation Instructions

The proper sealing at the change-over point depends


on the application case and needs to be ensured by
the user.
fig. 2:

Wiring diagram

Hint!
The unit must be connected by trained
electrical personnel. All valid European
and national standards for connecting
electrical equipment must be observed.

Mounting
1. The mounting for the electronics (especially the
glass) needs to be checked for cleanliness.
fig. 3:

Evaluation unit

Screw cap

Cable

1.1

2. Insert the evaluation unit in the screw-in unit


and screw tight by hand with the pipe nut. Make
sure that the cable outlet points down.

Dimensions (in mm)

Torque about 10Nm


3. The electrical connection needs to be carried out
according to the wiring diagram.
4. After refilling the vessel, check the seal.

Application

The optical monitoring unit is used for contactless


monitoring of the liquid level. This is accomplished by
a screw-in unit installed at the measuring point for

Refrigeration / Grasso

_990354_pd_mp_gbr_1_.doc
06.04.2011

PRODUCT DESCRIPTION
MAIN PART
Leven monitor MIN / MAX

1.3

Technical data

1.4

Screw-in units

Hint!
The sensor for level monitoring must be
in operation with a 315mA fuse
protected against a maximum current
consumption. Fuse kit (one kit per
sensor), consisting of fuse 315mA,
terminal and cable, can be ordered from
Grasso.

Supply voltage:

AC/ DC, 50Hz/ 60Hz,


24V 10%, 3VA

Permitted ambient
temperature:

-30C ... +60C

Max. medium temperature:

+120C

Delays:
Level monitoring when applying the supply voltage after
Relay on (level good)
Relay off (level too low)
Relay off (level too high)
Relay off (Alarm)

3s 1s
5s 2s, LED off
5s 2s, LED on
5s 2s, LED on
5s 2s, LED flashes

Relay:
240V AC AgNi90/10

Max. 240V AC 2,5A


C300
Min. > 24V AC/DC >
20 mA

fig. 4:

Screw-in units for level monitoring

fig. 5:

Dimensions (in mm), M20 x 1,5mm, short

Mechanical service life:

approx. 105 switching


cycles

Protection class acc. to EN


60529:

IP54 in built-in status

Connecting cable:

5 x 0,75m LiY-CY,
colour coded, L = 10m

Housing material:

PA66/ PA6, glass-fibrereinforced

Mounting:

Pipe nut

Weight:

approx. 1100g

Check base:

EN 61000-6-2
EN 61000-6-3
EN 61010-1

Seal

Application
Together with the corresponding evaluation unit,
the screw-in unit is used for non-contact detection of
fill limits and has been designed for installation in
vessels and/ or in compressors. The screw-in unit is
suitable for ammonia applications.
Installation
The proper sealing at the change-over point depends
on the application case and needs to be ensured by
the user.
The maximum torque of the screw-in unit is about
75Nm and has to be ensured by a ring spanner or a
socket key.
The glass cone must not ne damaged. The mounting
for the electronics (especially the glass) needs to be
checked for cleanliness. After refilling the vessel or
compressor, check the seal of the screw-in unit.

Exclusively the following described swrew-in units


may be used.

_990354_pd_mp_gbr_1_.doc
06.04.2011

Refrigeration / Grasso

PRODUCT DESCRIPTION
MAIN PART
Leven monitor MIN / MAX

Technical data
Permitted ambient
temperature:

-30C ... +60C

Max. ambient temperature at the glass cone:

+120C

Housing material:

Steel nickel-plated,
suitable for ammonia

Connenction thread:

M20 x 1,5mm

Width across flat:

24

Weight:

approx. 45g

Version 63bar according Pressure Equipment


Directive (97/23/EC)
max. perating pressure PS
-10C ... +120C
63bar
-60C ... -10C
48bar
Min. bursting pressure

1.5

315bar

Grasso Ident

INT279LN
Level monitor MIN

634198173

INT279LX
Level monitor MAX

634198174

Screw-in unit

634198175

Flat sealing ring


A20 x 24 x 1,5, DIN 7603
(for mounting the screwin unit)

438698032

Fuse kit (fuse 315mA,


terminal, cable)

591098897

Refrigeration / Grasso

_990354_pd_mp_gbr_1_.doc
06.04.2011

K.H.W
Bourdon Tube Pressure Gauges for
Refrigerators, case with Bayonet-lock NS 100 und 160
Application

Pressure ranges
Range of application
Accuracy
Design
Movement

Dial

Pointer
Window

Damping liquid

For refrigeration compressors, both for suction and pressure applications, with liquid filling
for measuring points subject to vibrations and
high dynamic pressure loads, no formation of
condensation
According to the used cooling agent
For static pressure 100%, for dynamic
pressure 90% of full scale
Cl. 1.0 according to DIN 16005 / EN 837-1
DIN 16064 / EN 837-1
Brass (for organic cooling agents)
Stainless steel (for inorganic cooling agents
NH3)
White pressure scale, black
temperature scale, coloured
graduations DIN 16112, 16125
Aluminium, black DIN 16099
Normal glass;
polycarbonate for gauges fitted with
auxiliary units with adjusting device,
only with organic cooling agents
System design DR:
without liquid
DRO: Glycerine 86%
System design DR:
IP 54 (EN 60529 / IEC 529)
DRC/DRO: IP 65 (EN 60529 / IEC 529)

Protection

Selection Chart

for NH3

180 (see photo above)

DRC

/ /

Suction side
Range

Pressure side
Range

Order number

DRO

11

Order number

DR

with liquid
filling

100 / 2 1 1 . 1

Order number

D R

without liquid
filling
standard

Cooling agent

Ordering example:
System
design

Pressure side
Range

R 11

+ 1.5 bar
1 + 3 bar
110 301
+ 40 C 130 30 + 60 C

R 12

+ 9 bar
1 + 15 bar
1 + 24 bar
180 601
+ 40 C 270 60 + 60 C 350 60 + 80 C

+ 5 bar
1 + 15 bar
R 12 B1 160 301
+ 50 C 280 30 + 95 C
1 +12.5 bar

100

NS 160

160

Case

R 13 B1 200

Stainl st. 1.4301, bright drawn

Stainl st. 1.4301, bright drawn

Struct. shape Direct mounting, without flange

Connection

R 21

140

R 22

210

R 113

120

Panel mounting A
Not available with electrical contact

R 114

150

Wall mounting, 3 brackets

R 123

400

Panel mounting B 1)

radial

eccentric back

Indicator

Standard

Meas. elem.

for organic cooling agents


Cu-alloy

R 134 A 420
R 402 A 530
1

R 404 A 460
11

2)

for inorganic cooling agents (NH3)


Stainless steel 1.4571
Range

33

R 500

240

R 502

220

R 22
R 12

500

R 22
R 12
R 502

600

R134 A 640
R 404 A

Special designs and auxiliary units


Note:

1)

2)

DRC/DRO 100/8 2

Design and specifications subject to change without notice


K.H.W Druckmesstechnik 70794 Filderstadt

120 15 C
1 +12.5 bar
overpr.safe 2 fold
80 + 10 C
1 + 5 bar
40 + 55 C
1 +12.5 bar
60 + 30 C
1 + 1.5 bar
30 + 75 C
1 + 5 bar
40 + 55 C
1 + 1.5 bar
30 + 55 C
1 + 9 bar
60 + 39 C
1 +12.5 bar
100 + 23 C
1 +12.5 bar
50 + 28 C
1 +12.5 bar
40 + 40 C
1 +12.5 bar
60 + 30 C
1 + 9 bar
overpr.safe 2fold
60 + 20 C
60 + 40 C
1 + 9 bar
overpr.safe 2fold
60 + 20 C
60 + 40 C
60 + 15 C
1 +12.5 bar
60 + 50 C
50 + 28 C
1 +12.5 bar

100 + 5 C
1 + 24 bar

1 + 40 bar
80 + 25 C

310
80 + 40 C
+12.5 bar
250 101
+ 100 C
+ 24 bar
1 + 40 bar
320 601
+ 60 C 370 30 + 80 C
+ 5 bar
170 301
+ 110 C
+12.5 bar
1 + 24 bar
260 101
+ 95 C 380 10 + 130 C
+ 3 bar
410 301
+ 70 C
+ 24 bar
1 + 40 bar
440 601
+ 77 C 450 40 + 100 C
1 + 24 bar
540 100
+ 50 C
+ 24 bar
470 501
+ 50 C
+ 24 bar
340 401
+ 70 C
+ 24 bar
1 + 40 bar
330 601
+ 55 C 390 40 + 80 C
1 + 24 bar

1 + 15 bar

520 60 + 60 C

510 60 + 40 C

40 + 83 C
1 + 24 bar

60 + 60 C
1 + 15 bar

620 60 + 60 C

610 60 + 40 C

40 +
60 +
1+
650 60 +
50 +
1+
r.m. at
300
60 +

NH3
230
(R 717)
60 + 30 C
other cooling agents on request

83 C
55 C
24 bar
77 C
50 C
24 bar
16 bar
50 C

60 + 60 C
60 + 35 C

For electrical contacts see Section D3.1

Nominal size NS 100

1 + 24 bar

190 overpr.safe. 2 fold 290 overpr.safe 1.6 fold 360

For special designs see D1.901

R 13

D1.155 E / 6.02

K.H.W
Bourdon Tube Pressure Gauges for
Refrigerators, case with Bayonet-lock NS 100 and 160
Structural shape/
connection location

Dimensions

11

Direct Mounting
(without flange)

13

G1/4 or G 1/2
cooling agent NH3 (R 717)

Panle Mounting A
Panel cutout
NS + 4

21

23

Panel Mounting B
3 fixation elements
Panel cutout
NS + 2

41

31
Wall Mounting
Panel
3 fixation brackets

8.5

100

101

160

Notes:

161

a1

15

15

a2

30

50

49

49

b
with electrical contact
electro-mech.
inductive
1
2
3
1
2
3
fold fold fold fold fold fold

085

104

853)

104

093

124

085

104

85

4)

093

124

d1

116

178

d2

132

196

d4

4.8

5.8

d5

4.8

5.8

h1

h2

h3

h4

Thread

NS

Standard

Measurement Chart

71

7/16 20

24

87

UNF

11
22

G1/4

23

105

7/16 20

56 5)

UNF

118

33

G1/2

DR

DRO

0.6

0,1

22

G1/2
1)

Weight
appr. kg 2)

11
22
17
22
17

1)

G1/2 with connection piece G1/4 x G1/2 S 22 as a special design (Order code 0004)
2)
System design DR (without contact)
3)
For separate circuits 93 mm
4)
Switching functions 12 and 21 104 mm; switching functions 11 and 22 124 mm
5)
Incl. gauge connection piece DIN 8916

Design and specifications subject to change without notice


K.H.W Druckmesstechnik 70794 Filderstadt

D1.155 E / 6.02

Druckmesstechnik
+ Zubehr

Operating Instructions

for mechanical Pressure and Differential Pressure Measuring Instruments with


/ without electric contacts / analogue signal output
Bourdon Tube Pressure
Gauge

Bourdon Tube Pressure


Gauge with electric
contacts

Bourdon Tube Pressure


Gauge with analogue
signal output

DR, DRO, DRC,


Diaphragm Pressure
Gauge

DRCE
Diaphragm Pressure
Gauge with electric
contacts
Figure
currently not available

DRCG

DPC
Differential Pressure
Gauge with capsule
element

DPCE
Differential Pressure
Gauge with bourdon tube

DK
Differential Pressure
Gauge with diaphragm

DKD

DRD

DMD

Capsule Element
Pressure Gauge

All Pressure and Differential Pressure Gauge are according the effective
Pressure Equipment Directive PED 97/23/EG
Karl -Heinz Weinzierl
Justus-Liebig-Strae 14
70794 Filderstadt/Plattenhardt

Telefon: 0711 / 9970999-0


Telefax: 0711 / 9970999-15
e-Mail: kweinzierl@kh-we.de

Kreissparkasse Esslingen
1
BLZ: 611 500 20
Konto: 7 500 747
Steuer Nr.: 97 148/62218

Druckmesstechnik
+ Zubehr
Safety instructions
This manual is prior to installation, commissioning and maintenance of the
equipment to read in full. Failure may lead to serious injury and / or property
damage.
K.H.W assumes no liability for property damage or personal injury, direct or
indirect or consequential damages resulting such as loss of production, based
on ignoring the instructions given in this document are due.
Only qualified personnel should work on these pressure / differential pressure
gauges.
Operating principle

The tube used here, capsule and diaphragm springs are widespread and have proven themselves due
to their robustness for many decades. The measuring element deforms under pressure in the elastic
range.
The here used tube, capsule and diaphragm springs are widespread and have proven themselves due
to their robustness for many decades. The measuring element deforms under pressure in the elastic
range.
With the aid of the movement, the mechanical deflection of the pressurized measuring element is
converted into a rotational movement. The applied pointer follows this rotation angle of 270 degrees.
This also applies for pressure gauges with electric contact/s. Here a contact arm is supplied through
the pointer over a driving pin and carried toward or away of a solid contact swing (NO / NC).
When the pressure gauge with analogue output signal by means of a built-pressure cell, the pressure
recorded directly by use of an amplifier and converted into a 4 ... 20mA signal. The measuring range
of the mechanical pressure gauge is identical to that of the integrated electrical pressure transducer.

Technical data

- These are provided in the respective data sheets.


If not available: online at www.kh-we.de
- The electrical wiring diagrams are on the respective pressure gauge fixed.

Installation instructions / installation conditions on place

During installation and commissioning, the instructions of the European Standard EN 837-1/3
to note.
The pressure and differential pressure gauges are affixed vibration free and in a good readable
position. Between the pressure gauge and the pressurized line, at least one shutoff valve must
be installed, which allows a zero point check and the replacement of the device while the plant
is in operation.

Installation

It is basically to check whether the pressure gauges meet the standards EN 837-1/3 and are
designed for the intended application.
-

Installation in the normal case with the lower pressure connection; nominal 90 vertically.

For wall mounting a distance of at least 20mm from the wall must be kept out.

Karl -Heinz Weinzierl


Justus-Liebig-Strae 14
70794 Filderstadt/Plattenhardt

Telefon: 0711 / 9970999-0


Telefax: 0711 / 9970999-15
e-Mail: kweinzierl@kh-we.de

Kreissparkasse Esslingen
2
BLZ: 611 500 20
Konto: 7 500 747
Steuer Nr.: 97 148/62218

Druckmesstechnik
+ Zubehr
-

The pressure gauge is to avoid overheating, be protected from direct heat radiation (sunlight)
Is the pressure gauge filled with damping fluid, so before using the breathing hole of the plug
should be exposed.

For boilers or other critical applications, the shut-off valves have a test flange so that the
pressure gauge can be checked without removing any time.

Oscillation discharge

Oscillating or vibrating equipment a decoupling shall be made from the measuring instrument:
-

Fixing of the pressure gauge at a not swinging carrier or solid wall.

Installation of a flexible tube (capillary) from the measuring point to the pressure gauge.

The rates of standard EN 837 1/3 or values identified in the data sheet for vibration and
vibration exposure may not be exceeded.

Measuring location and piping

The pressure collection shall be provide through a piece of pipe with a minimum bore of 6mm and so
designed and arranged so that there is no possibility by the flow of the fluid to cause a wrong
measurement.
In addition the piping should be in a position to compensate for possible expansion, vibration and
thermal effects.
The installation of pressure measuring devices should preferably be to the general technical rules for
pressure gauges, for example, EN 837-2, section "Selection and installation recommendations for
pressure gauges.

Commissioning
-

The pressure PB: depending on the model, PB = 75 or 100%, is on the dial indicated by an
upside-down triangle mark. This maximum load should not be exceeded in continuous service.

Operating temperature: -20 ... +60 C, should not be exceeded. If one is in excess of
operating temperature (device temperature) appropriate precautions should be taken.

Protection and security class of the pressure gauge must have been established according the
application and the given directives.

The counterpart to the process connection has to be a perfect fit. For the sealing of the
process connection gaskets or lenses used. To attach the device to the viewer correctly a
clamping sleeve connection or a connection with union nut is provided.

Housing design, this should be suitable for the installation at a distance and readability.

Compatibility is connected to the liquid in contact to the wetted materials.

Check the material indicated on the dial. If not specified, the fluid coming into contact with the
parts made of copper alloy.

Check whether the device is designed for the prevailing environmental conditions, vibration,
pulsation, mechanical shock and surrounding atmosphere.

Karl -Heinz Weinzierl


Justus-Liebig-Strae 14
70794 Filderstadt/Plattenhardt

Telefon: 0711 / 9970999-0


Telefax: 0711 / 9970999-15
e-Mail: kweinzierl@kh-we.de

Kreissparkasse Esslingen
3
BLZ: 611 500 20
Konto: 7 500 747
Steuer Nr.: 97 148/62218

Druckmesstechnik
+ Zubehr
-

With damping fluid filled devices is to ensure that the liquid takes up more than 75% of the
housing diameter.

With damping fluid-filled devices, the air vent for pressure ranges below 10 bar is kept free.

Electrical connection: pressure gauge with analogue signal output


The electrical connection of the remote signal output is realized by L-plug connector on the left side of
the pressure gauges.
The assignment of electric connection according to the label on the pressure gauge, as shown in the
illustration below, is as follows:
L-plug connctor

external

electric values

L-plug connector

electric values

K.H.W D-70794 Filderstandt

Karl -Heinz Weinzierl


Justus-Liebig-Strae 14
70794 Filderstadt/Plattenhardt

external

L-plug connector electric values

external L-plug connector electric values

K.H.W D-70794 Filderstadt

Telefon: 0711 / 9970999-0


Telefax: 0711 / 9970999-15
e-Mail: kweinzierl@kh-we.de

Kreissparkasse Esslingen
4
BLZ: 611 500 20
Konto: 7 500 747
Steuer Nr.: 97 148/62218

Druckmesstechnik
+ Zubehr
Electrical Connection: Gauge with contact device
Teminal assignment of the L-plug connector

1 x NO (contact closes with increasing pressure)

1 x NC (contact opens with increasing pressure)

1 x NC/NO (contact changes from close ot open with


increasing pressure)

2 x NO

1 x NO and 1 x NC

2 x NC
Karl -Heinz Weinzierl
Justus-Liebig-Strae 14
70794 Filderstadt/Plattenhardt

Telefon: 0711 / 9970999-0


Telefax: 0711 / 9970999-15
e-Mail: kweinzierl@kh-we.de

Kreissparkasse Esslingen
5
BLZ: 611 500 20
Konto: 7 500 747
Steuer Nr.: 97 148/62218

Druckmesstechnik
+ Zubehr
Separators and Overload Protection

Is known to occur with aggressive, hot, highly viscous, highly contaminated or crystallizing fluids
should then depending upon the prevailing requirement of the use of separators in the form of
membrane, tube or tongue diaphragm seals.
The pressure of fluid is transferred through a separation membrane with a pressure transmission fluid
on the sensing / measuring element of mechanical/electronic pressure or differential pressure
measuring instruments. Thus, a good protection is guaranteed, including a temperature decoupling.
If the process side to expect rapid changes in pressure or pressure surges, the use of throttling
sections: capillary tubes or throttle devices for the protection of the pressure or differential pressure
measuring devices is necessary.

Hazardous fluids

Such as: oxygen, acetylene, flammable or toxic fluids, refrigerants, etc. There are special rules that
must be considered at user side.

Use in hazardous areas

Pressure gauges with limit-switch suitable for connection to intrinsically safe circuits for use in
hazardous zones 1, 2, 21 and 22 according to Directive 94/9/EC are equipped with intrinsically
safe (inductive) Contact kits and in accordance with ATEX approval II 2G / D, EEx ia / ib IIC
marked T4/T5/T6.

Mechanical pressure gauges without electrical equipment, but generally with


laminated safety glass fitted are marked with CE II2GDc - IM2c for use in hazardous
areas according to Directive 94/9/EC and EN 13463-1. (Self-confirmation)
Note for dismantling
-

Verify before removal, that no more pressure on the pressure measuring instrument is
present. As a precaution, the pressure measuring instrument release slowly.
Make sure that the temperature of the housing of the pressure gauge does not
causes burns etc.
Medium contained in the pressure may be hazardous to ones health or environment.

Review of the zero point


-

The review of the Zero Point and if possible, the adjustment shall be made at zero pressure
and in the installation position of the pressure gauge.
For differential pressure gauges the static pressure should be supplied, the impulse lines are
to close and the equalizing valve is to open.
If an adjustment pointer is present, the bayonet ring has to be removed and the zero point
corrected by adjusting the pointer position.
At Pressure-measuring instruments is a correction of the zero point at present not yet possible
on site and must be made in the factory.

Karl -Heinz Weinzierl


Justus-Liebig-Strae 14
70794 Filderstadt/Plattenhardt

Telefon: 0711 / 9970999-0


Telefax: 0711 / 9970999-15
e-Mail: kweinzierl@kh-we.de

Kreissparkasse Esslingen
6
BLZ: 611 500 20
Konto: 7 500 747
Steuer Nr.: 97 148/62218

Druckmesstechnik
+ Zubehr
Maintenance- free
The devices are generally maintenance-free when properly used.
-

It is recommended that the accuracy of pressure gauges through regular inspections is to


ensure.
All pressure gauges can be assumed that abnormal conditions were exposed, such as fire,
inappropriate measurement materials, shocks, vibration, etc. may, in order to avoid
damages, no further usage should be allowed.

Disposal

The disposal of the devices or device components and packaging materials must be made in
accordance with the relevant country-specific waste treatment and disposal requirements.

Disturbances and possible measures for mechanical pressure / differential


pressure gauges
Disturbances
No indication
Display changes slowly at
larger pressure changes

Consistant indication on
pressure changes
Display does not match to the
pressure

Possible cause
No pressure input
Check access channel. If
diaphragm seal attached:
- diaphragm could be damaged
- loss of pressure
transmission-fluid
Access channel or throttle
device closed
Pressure instrument defect

Measures
Check supplied pressure
Check pressure supply channel
Pressure measurement system
to dismount and repair / replace
by new instrument.
Check and clean if necessary
Disassembling, testing, repair /
new acquisition

Disturbances and possible measures to pressure gauge with electric contacts


or analog signal output
Disturbances
No output signal

Possible cause
Line break / no power supply

Contacts / instrument
connected incorrectly
No pressure supply
Electronics defective possibly
due to incorrect voltage /
overvoltage
See continuation on the following page

Karl -Heinz Weinzierl


Justus-Liebig-Strae 14
70794 Filderstadt/Plattenhardt

Telefon: 0711 / 9970999-0


Telefax: 0711 / 9970999-15
e-Mail: kweinzierl@kh-we.de

Measures
Check power supply and
restore
Check electrical connections,
connect properly
Check supply channel
Send pressure gauge to the
manufacturer for repair

Kreissparkasse Esslingen
7
BLZ: 611 500 20
Konto: 7 500 747
Steuer Nr.: 97 148/62218

Druckmesstechnik
+ Zubehr
Disturbances
When pressure changes no
switch function or changing
output signal is noticed
Electrical output signal or
switching function sporadic or
insufficient

Possible cause
No pressure input
Supply voltage connected
incorrectly
Contact or electronic measuring
device defect
Supply voltage too low
Line resistance or load too high
Device or zero point not well
adjusted

Measures
Check supply channel
Check electrical connectins and
connect properly
Send pressure gauge to the
manufacturer for repair
Correction of the supply voltage
to the designated value
Maximum allowable transfer
resistance or load to note
Zero point correction at place if
possible. If not return to
manufacturer for repair

Storage
Before storing of used devices they must be cleaned carefully (process fluid / device
itself) to avoid possible health damage. This is particularly necessary if the fluid is
toxic, corrosive, radioactive, carcinogen, etc.
Storing of new equipment it should be considered:
-

Keep pressure / differential pressure gauge in the original packaging

Observe the storage temperature according the given information in the data sheet

The proximity to very cold or hot places should be avoided

Vibrations, shocks should be avoided by including dropping

Moisture, corrosive gases and vapores, dust should be excluded

No flammable or explosive atmosphere locations

Maintenance

The pressure and differential pressure transmitters are maintenance free. In accordance with the
standard treatment and professional service is guaranteed for a long lifetime.
For cleaning of pressure and differential pressure gauges to a damp cleaning rag may be used
penetrated with soapy water. In hazardous areas no dry cleaning rags are allowed due to a possible
static charge of the equipment.

Maintenance, inspection, re-calibration or repair can be made only by the


manufacturers themselves or by local availability of a trained staff equipped with
appropriate tools!ail pipe

Karl -Heinz Weinzierl


Justus-Liebig-Strae 14
70794 Filderstadt/Plattenhardt

Telefon: 0711 / 9970999-0


Telefax: 0711 / 9970999-15
e-Mail: kweinzierl@kh-we.de

Kreissparkasse Esslingen
8
BLZ: 611 500 20
Konto: 7 500 747
Steuer Nr.: 97 148/62218

Germany - 17291 Prenzlau, Gewerbegebiet Ost, Strae A1


http://www.AWPvalves.com e-mail; info@AWPvalves.com

Telefon +49 (0) 3984/ 8559 - 0


Telefax +49 (0) 3984/ 8559 -18

Messstellenumschalter

Klte Klima Armaturen GmbH

measuring point switch

MSU

PN 40

Kompakte Bauweise
compact design
mehrere Messstellen variabel auf ein Manometer schaltbar
several measuring points variable switchtable at one manometer
Einsparung von Manometern und Absperrventilen
saving of manometer and shut off valves
vereinfachte Montage
simplification of assembly

15.0-15.2.cdr
MSU_dt_e02 14.05.01

990373

15.0

Germany - 17291 Prenzlau, Gewerbegebiet Ost, Strae A1


http://www.AWPvalves.com e-mail; info@AWPvalves.com

Telefon +49 (0) 3984/ 8559 - 0


Telefax +49 (0) 3984/ 8559 -18

Messstellenumschalter

MSU

Klte Klima Armaturen GmbH

measuring point switch

1
2
3
4
5
6
7
8
9
10
11
12
13

Pos.
1
2
3
4
5
6
7
8
9

10
11
12
13

15.1

Teil / part

Kappe
Handrad
Abstreifring
O-Ring A
O-Ring B
elast.PTFE-Ring
Flachdichtring SB
Spindel kpl.
Deckel

cap
handwheel
scraper
O - ring seal A
O - ring seal B
elastic PTFE - ring
flat sealing ring SB
stem cmpl.
cover

Flachdichtring R
O-Ring D
Flachdichtring S
Gehuse

flat sealing ring R


O - ring seal D
flat sealing ring S
body

990373

Material

3.2341
Stahlblech
NBR-85
CR-70
CR-70
1.4571 / PTFE
AFM - asbestfrei
1.4305
1.0038 / 1.0488
1.4305
PTFE
HNBR-70
PTFE
St 52 - 3

15.0-15.2.cdr
MSU 14.05.01

Germany - 17291 Prenzlau, Gewerbegebiet Ost, Strae A1


http://www.AWPvalves.com e-mail; info@AWPvalves.com

Telefon +49 (0) 3984/ 8559 - 0


Telefax +49 (0) 3984/ 8559 -18

Messstellenumschalter

MSU

Klte Klima Armaturen GmbH

measuring point switch

"!' 

m2

l2

l1
l4
l3

Einbaulngen / lengths in mm :
h h1 l1 l2 l3 l4 A
157

65 120 40

50

28

13

B
8

18

18

d1

d2

m1 m2 m3 m4

M12x1.5 M12x1.5 54

34

15

Varianten / variants :
Messstellenumschalter fr eine Messstelle, zwei oder drei Messstellen / weitere Messstellen auf Anfrage

measuring point switch for one measuring point, two or three measuring points /
further measuring points upon request

15.0-15.2.cdr
MSU 439 00 14.05.01

990373

15.2

EVM-NC

EVM (NC)
EVM (NC)

AC-TMP

032R9528

032R9528

Instruction
Type EVM NC/NO

EVM-NO

EVM (NO)
EVM (NO)

RI.3X.J1.02

Danfoss 01/2001

MAKING MODERN LIVING POSSIBLE

Data sheet

Pressure Control, Differential Pressure Control


and Temperature Control, type RT-E
The RT-E series consist of pressure
and differential pressure switches as well as
temperature switches. The units are designed
for industrial refrigeration and general
industrial application in explosive zones acc.
to 94/9/EC, Atex directive, explosive zone 1,
for surface equipment, category 2.
It includes usage in refrigeration systems
with ammonia, hydrocarbons and other
applications where presence of flammable
gases, vapours and mists are likely to occur.
RT-E pressure and temperature switches
for use in explosive zones incorporate SPDT
changeover switch where contact position
depends on pressure or temperature value
of the system.

Features

yy Designed for use in explosive zone 1

yy Metallised front cover without window

yy Versions with enclosure IP66

yy Gold plated contacts 1)

yy Stainless steel frame

Approvals

GOST certificate covers temperature controls only.


The certificate for pressure controls is not required

CE marked, according to EN 60947-4/-5

China Compulsory Certificate, CCC

Ex II 2G Ex ia IIC T6 Gb

GOST

CE marked acc. to PED 97/23/EC category IV,


safety equipment: RTE6AEW, RTE6AEB, RTE6AES.

DKRCC.PD.CB0.B8.02 / 520H6848

1)

990421

Data sheet
Technical data

Pressure Control, Differential Pressure and Temperature Control, type RT-E


Enclosure*

IP66 or IP54 (version with external manual reset)

Ambient temperature

-20 65 C

Cable entry

2 x Pg 13.5 Cable diameter: 6 14 mm

Contact material

Gold plated AgCdO

Contact load

Must be used with reliable means of limiting voltage


and current to prevent sparks between contact surfaces.
This could be zener diodes or EX barriers.

Contact system

Single-pole changeovers switch (SPDT)

* IP degree can only be obtained on enclosure without


fractures / damages. RT-E must be protected against
unintended impacts.

Ordering

Pressure controls for R717 1), HCFC, HFC and HC refrigerants.

Type

Regulating
range

Differential
p

Max.
working
pressure PS

[bar]

[bar]

[bar]

Code no.
Connection

Reset

G 3/8 A
+ welded nipple
6.5/10 mm

G 3/8 A

RT 112E

0.1 1.1

0.07 0.16

Auto

017-518566

RT 113E

0.0 0.3

0.01 0.05

0.4

Auto

017-519566

RT 1AE

-0.8 5.0

0.5 1.6

22

Auto

017-500966

1 10

0.3 1.3

22

Auto

017-520166

RT 5E

4 17

1.2 4

22

Auto

017-525266

RT 6AEW

5 25

34 2)

Auto

017-513866

2)

Man. (Max.)

017-513466

Man. (Max.)

017-502166

Auto

017-529866

Pressure
connection

Code no.

G 3/8 A
+weldednipple
6.5/10 mm

017D003666

RT 116E

RT 6AEB

10 28

1.5

34

RT 6AES

10 28

1.5

34 2)

RT 117E

10 30

14

42

Only types with letter A are suitable for R717


2)
Max. working pressure acc. to PED is limited to 28 bar
1)

Differential pressure controls for R717, HCFC, HFC and HC refrigerants.


Type

Regulating
range

Differential
p

Operating
range for
LP bellows

Max.
working
pressure PS

[bar]

[bar]

[bar]

[bar]

RT 260AE

0.5 4

0.3

-1 18

22

RT 262AE

0.1 1.5

0.1

-1 9

11

017D003066

Temperature controls

Type

Regulating
range
[C]

Differential p
at lowest
at highest
range setting range setting
[C]

Max. sensor
temperatur

[C]

Type of
charge

Capillary
tube
length

Code no.

[m]

[C]

RT 14E

-5 30

28

2 10

150

Adsorption

017-509866

RT 101E

25 90

2.4 10

3.5 20

300

Adsorption

017-512666

RT 107E

70 150

6 25

1.8 8

215

Partial

017-515366

RT 123E

150 250

6.5 30

1.8 9

300

Partial

017-521666

Sensor pockets of RT-E temperature controls


RT 14E, RT 107E, RT 123E, RT 101E

Brass: 017-437066

DKRCC.PD.CB0.B8.02 / 520H6848

18/8 stainless steel: 017-436966

Data sheet

Pressure Control, Differential Pressure and Temperature Control, type RT-E

Safety requirements

RT-E pressure, differential pressure


and temperature controls comply
with the requirements for explosive
atmosphere (947/23/EC), acc. to ATEX, zone 1.
Only apparatus designed, constructed and
released by Danfoss must be used for application
concerned. Danfoss can accept no responsibility
in case of alterations made on the switches or
the use of them against the Danfoss instructions.
Original Danfoss spare parts approved for use in
explosive atmosphere can only be used.

Electrical connection

Intrinsic safety
protection method

The application covers systems that must be


located within the EU or EFTA and comply with
the existing EU legislation, such as Pressure
Equipment Directive (PED) (97/23/EC),
the directive concerning potential explosive
atmosphere (ATEX) (94/9/EC), and other related
EU standards. The system where RT-E is mounted
must always comply with local directives,
legislation or any other regulation applying in
the area of installation. The Danfoss products
comply with the requirements of ATEX directive,
but Danfoss takes no responsibility for the
classification of explosive zone.

The RT-E pressure control placed in explosive


zone must always be wired through reliable
zener barrier, placed outside ex-zone, to ensure
insufficient energy supply to cause the ignition
of surrounding atmosphere by an electrical spark
or the heating of components of circuitry.

Cables and cable entries approved for the


application must be used and can not be in
contact with sharp edges. Cables must be
connected with adequate stress relief that way
that pulling forces can not be carried throug
the cable to the terminal.

The equipment to be used for electrical load


limiting must always be approved for use
in the zone concerned.

Note:
A particular system can be classified in different
zones, for different parts of the system.

EX - zone

Electrical data for intrinsically


safe specification
(for all RTE types):

Non EX - zone

Signal
Zener barrier

Installation
and maintenance

Only authorised persons, who are certified in


installing and maintaining the systems may do
the installation, maintenance and change of the
switch.
In the event of strong pulsation in the system,
bellows must be protected against fatigue failure
by use of damping coil.

DKRCC.PD.CB0.B8.02 / 520H6848

Ui: 29 V
Ii: 0.5 A
Pi: 1 W
Ci: 0.5 nF
Ii: 0.2 H

The cycle frequency of the RT-E switch must be


kept as low as possible. The vibration level must
be kept as low as possible.
Any overload of the RT-E switch must be
prevented. Overloaded or damaged apparatus
must be exchanged.

Data sheet

Pressure Control, Differential Pressure and Temperature Control, type RT-E

Design and function

Pressure control, type RT

Pressure controls
RT-E controls are similar to non-explosive version
of RT. Main design changes include stainless steel
frame and metalised front cover to keep surface
resistance below 1 Gohm.
By turning setting knob (5) the main spring (12)
can be set to balance the pressure in the bellows.
A rise in pressure compresses the bellows and
moves the main spindle (15) upwards until spring
and bellows pressure are in equilibrium.
The main spindle (15) is fitted with the guide
bush (17) and differential pressure setting nut
that together transfer the main spindle
movement to the switch (16).
RTE6AEW/B/S has double fail-safe bellows: outer
and regulating (inner bellows).

Differential pressure control, type RT

.FW

Differential pressure controls

Temperature control, type RT

An RT-E differential pressure control contains


single-pole changeover switch that makes or
breaks depending on pressure differential
between two counteracting bellows elements
(LP and HP). The bellows (4) and (24) are
respectively connected to lower pressure port
and higher pressure port. The main spring (12)
can be set for different differential pressure by
the setting disc (5). If the differential pressure
between higher and lower pressure falls, the
spindle (15) moves downwards and via the upper
guide bush (17) actuates the switch contact arm
(18). The reverse action occurs if the differential
pressure rises.

Temperature controls
The thermostatic element consists of sensor (29),
capillary tube (28) and bellows element (23).
Charge in the element reacts to temperature
variations and increases the pressure in the
bellows when temperature rises. By turning the
setting knob (5) the main spring (12) can be set to
balance the pressure in the element. A rise in
temperature of the sensor compresses the
bellows and moves the main spindle (15)
upwards until spring force and element pressure
are in equilibrium. Such movement is transferred
to the switch (16) and causes its on or off action.

DKRCC.PD.CB0.B8.02 / 520H6848

Data sheet

Pressure Control, Differential Pressure and Temperature Control, type RT-E

Settings

The range is set by using setting knob (5).


Tools must be used to set switches fitted with
seal cap. To read the range scale front cover must
be removed. On the units with adjustable
differential, differential disc (19) must be set after
removing front cover. For proper adjustment
differential roller must be used. Detailed
information can be found in RT data sheets,
non-explosive version.

19

Dimensions [mm]

RT-E housing (pressure and temperature controls)

RT-E (pressure and differential pressure controls)

RT 1AE

Danfoss A/S (AC-MCI /jmn), 2012-11

RT 6AE

DKRCC.PD.CB0.B8.02 / 520H6848

RT 260AE

RT 262AE

PRODUCT DESCRIPTION
MAIN PART
BW-Erection mounts, MS Series

ERECTION MOUNTS

1.1

Design, Function, Specifications

The BW-Erection mount MS Series is used for the vertical and horizontal alignment and fixing between driving
motor and screw compressor.
The BW-Erection mount MS Series consists of a baseplate with two fixing angles (90 staggered) and clamping
screws for horizontal alignment, one bearing screw-element including the welded adjusting and clamping screw
for vertical alignment and one ball spacer ring.

fig. 1:

BW-Erection mount MS Series, components and


dimensions

Pressure screw

Adjusting and clamping screw

spherical washer

Ball spacer ring type "p"

Motor stand

fig. 2:

Placement of the Ecection mounts, view from above

Dimensions
of symmetrical and asymmetrical designs
M
MS

12

16

20

70

12

16

20

68

56

15

II

110

16

20

24

75

58

20

II

150

16

20

24

75

58

20

III

210

24

30

36

80

60

25

III-S

220

24/ 30

36

42

95

80

30

GEA Refrigeration Germany GmbH

_990290_pd_mp_gbr_1_.doc
01.03.2012

PRODUCT DESCRIPTION
MAIN PART
BW-Erection mounts, MS Series

Technical data

Type MS ...

Vertical adjusting
screw

perm. max. adjustement torque


[Nm]

perm. max. load


[KN]

perm. max. tightening torque [Nm]

M 12

40

55

I/II

M 16

100

20

140

I/II

M 20

150

30

270

II

M 24

200

40

450

III

M 24

300

40

450

III

M 30

400

50

900

III

M 36

450

60

1600

III-S

M 42

450

60

1600

Type MS ...

Horizontal pressure screw

perm. max. torque [Nm]

M 10

25

II

M 12

35

III

M 16

60

Alignment
1. Pull out the pressure screw until the motor can be placed easy.
2. Put the driving motor down at the BW-Erection mount.
3. Align the motor neutral in the vertical plane (without tightened hexagonal bolt of clamping screw).
4. Lock the clamping screw with the below hexagonal bolt back to the mounting frame.
5. Align the motor with the horizontal clamping screws.
6. Tight the motor with the upper hexagonal bolt of clamping screw.
7. Check the result of alignment.

_990290_pd_mp_gbr_1_.doc
01.03.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
BW-Erection mounts, MS Series

1.2

fig. 3:

Fixators, Design: symmetrical

Fixators, Design: symmetrical

Grasso Ident

Type

eo

eu

573598121

MSI

12

40

45

20

30

573598122

MSI

12

40

45

30

30

573598123

MSI

12

40

45

35

30

573598124

MSI

16

40

45

30

30

573598125

MSI

16

40

45

35

30

573598126

MSI

20

40

45

30

30

573598127

MSI

20

40

45

35

30

573598131

MSII

16

60

45

35

30

573598132

MSII

16

60

45

40

30

573598133

MSII

16

60

45

45

30

573598134

MSII

20

60

45

40

30

573598135

MSII

20

60

45

45

30

573598136

MSII

24

60

45

40

30

573598137

MSII

24

60

45

45

30

573598138

MSII

24

60

45

50

30

573598139

MSII

16

80

45

40

30

573598140

MSII

16

80

45

45

30

573598141

MSII

16

80

45

50

30

573598142

MSII

20

80

45

40

30

573598143

MSII

20

80

45

45

30

573598144

MSII

20

80

45

50

30

573598145

MSII

24

80

45

45

30

573598146

MSII

24

80

45

50

30

573598147

MSII

24

80

45

55

30

573598148

MSII

24

80

45

50

30

573598149

MSII

24

80

45

55

30

GEA Refrigeration Germany GmbH

_990290_pd_mp_gbr_1_.doc
01.03.2012

PRODUCT DESCRIPTION
MAIN PART
BW-Erection mounts, MS Series

Grasso Ident

Type

eo

eu

573598150

MSII

24

80

45

60

30

573598151

MSII

20

60

45

40

30

573598152

MSII

20

60

45

40

30

573598153

MSII

12

60

45

30

30

573598154

MSII

24

80

45

30

30

573598156

MSII

24

80

45

70

30

573598161

MSIII

24

110

55

50

30

573598162

MSIII

24

110

55

55

30

573598163

MSIII

30

110

55

50

30

573598164

MSIII

30

110

55

55

30

573598165

MSIII

30

110

55

60

30

573598166

MSIII

36

110

55

55

30

573598167

MSIII

36

110

55

60

30

573598169

MSIII

24

110

55

70

30

573598172

MSIII

20

110

55

55

30

573598173

MSIII

30

110

55

20

30

573598200

MSIII

30

110

55

40

30

573598239

MSIII

36

110

55

50

40

573598240

MSIII

36

110

55

40

30

573598247

MSII

20

60

45

35

30

573598248

MSII

24

60

45

35

30

573598251

MSIII

24

130

65

65

30

_990290_pd_mp_gbr_1_.doc
01.03.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
BW-Erection mounts, MS Series

1.3

fig. 4:

Fixators, Design: asymmetrical

Fixators, Design: asymmetrical

Grasso Ident

Type

eo

eu

573598170

MSIII

20

150

110

55

55

30

573598171

MSIII

20

110

150

55

55

30

573598178

MSIII

24

110

180

55

40

30

573598179

MSIII

24

180

110

55

40

30

573598180

MSIII

24

110

150

55

55

30

573598181

MSIII

24

150

110

55

55

30

573598182

MSIII

24

110

150

55

60

30

573598183

MSIII

24

150

110

55

60

30

573598184

MSIII

30

110

150

55

55

30

573598185

MSIII

30

150

110

55

55

30

573598186

MSIII

30

110

150

55

60

30

573598187

MSIII

30

150

110

55

60

30

573598188

MSIII

36

110

150

55

55

30

573598189

MSIII

36

150

110

55

55

30

573598190

MSIII

36

110

150

55

60

30

573598191

MSIII

36

150

110

55

60

30

573598225

MSIII

30

110

150

55

40

30

573598226

MSIII

30

150

110

55

40

30

573598227

MSIII

24

110

150

55

50

30

573598228

MSIII

24

150

110

55

50

30

573598235

MSIII

36

110

150

55

40

30

573598236

MSIII

36

150

110

55

40

30

573598241

MSIII

36

110

150

55

45

30

573598242

MSIII

36

150

110

55

45

30

573598243

MSIII

24

110

150

55

30

30

573598244

MSIII

24

150

110

55

30

30

GEA Refrigeration Germany GmbH

_990290_pd_mp_gbr_1_.doc
01.03.2012

PRODUCT DESCRIPTION
MAIN PART
BW-Erection mounts, MS Series

1.4

fig. 5:

Fixators, Design: asymmetrical (S)

Fixators, Design: asymmetrical (S)

Grasso Ident

Type

eo

eu

573598192

MSIII-S

42

180

130

65

85

30

573598193

MSIII-S

42

130

180

65

85

30

573598194

MSIII-S

30

180

130

65

60

30

573598195

MSIII-S

30

130

180

65

60

30

573598196

MSIII-S

42

200

150

65

70

30

573598197

MSIII-S

42

150

200

65

70

30

573598198

MSIII-S

30

180

130

65

50

30

573598199

MSIII-S

30

130

180

65

50

30

573598201

MSIII-S

36

180

130

65

70

30

573598202

MSIII-S

36

130

180

65

70

30

573598203

MSIII-S

36

180

130

65

50

30

573598204

MSIII-S

36

130

180

65

50

30

573598205

MSIII-S

36

230

130

65

50

30

573598206

MSIII-S

36

130

230

65

50

30

573598207

MSIII-S

30

180

130

65

60

30

573598208

MSIII-S

30

130

180

65

60

30

573598209

MSIII-S

30

200

150

65

50

30

573598210

MSIII-S

30

150

200

65

50

30

573598211

MSIII-S

30

300

150

65

50

30

573598212

MSIII-S

30

150

300

65

50

30

573598213

MSIII-S

24

200

120

65

30

30

573598214

MSIII-S

24

120

200

65

30

30

573598215

MSIII-S

24

200

150

65

30

30

573598216

MSIII-S

24

150

200

65

30

30

573598217

MSIII-S

36

300

150

65

50

30

_990290_pd_mp_gbr_1_.doc
01.03.2012

GEA Refrigeration Germany GmbH

PRODUCT DESCRIPTION
MAIN PART
BW-Erection mounts, MS Series

Grasso Ident

Type

eo

eu

573598218

MSIII-S

36

150

300

65

50

30

573598219

MSIII-S

36

360

150

65

50

30

573598220

MSIII-S

36

150

360

65

50

30

573598221

MSIII-S

24

300

150

65

50

30

573598222

MSIII-S

24

150

300

65

50

30

573598223

MSIII-S

24

230

130

65

50

30

573598224

MSIII-S

24

130

230

65

50

30

573598229

MSIII-S

30

200

120

65

35

30

573598230

MSIII-S

30

120

200

65

35

30

573598231

MSIII-S

30

230

130

65

50

30

573598232

MSIII-S

30

130

230

65

50

30

573598233

MSIII-S

36

360

150

65

70

30

573598234

MSIII-S

36

150

360

65

70

30

573598237

MSIII-S

42

180

130

65

50

30

573598238

MSIII-S

42

130

180

65

50

30

573598245

MSIII-S

30

360

150

65

50

30

573598246

MSIII-S

30

150

360

65

50

30

573598249

MSIII-S

42

300

150

65

50

30

573598250

MSIII-S

42

150

300

65

50

30

GEA Refrigeration Germany GmbH

_990290_pd_mp_gbr_1_.doc
01.03.2012

Product Description | Level Mount Elements, LM Type


Main part

LEVEL MOUNT ELEMENTS, LM TYPE

for anti-vibration Installation

1.1

Standard design

fig.1:

Level Mount Elements, LM Type, Standard design

Spacer bush

Bolt head

Characteristics
Type LM

1-11

3-11

3-25

3-33

Diameter

D1)

80

Height

H1)

25

Thread size

G1)

M10

M12

Screw length

L1)

80

90

Max. mounting foot thickness

1)

43

44

Levelling height

Ni1)

15

20

Weight

(kg)

0,4

1,1

Load per element

(kg)

480

650

900

1200

763398043

763398044

763398045

763398046

763398047

763398050

763398035

763398051

Grasso Ident
Hexagonal bolt head
Grasso Ident
Square-cut bolt head

GEA Refrigeration Germany GmbH | 990262_1 | Generated 28.07.2014

120
37

32

Product Description | Level Mount Elements, LM Type


Main part

1)

all dimension values listed in mm

1.2

Special design bottom plate BA Type

fig.2:

Level Mount Elements, LM Type, Special design bottom plate (BA)

Characteristics
Type LM

3-11 BA

3-25 BA

Length

B1)

158

158

Width

A1)

90

90

Thickness

T1)

10

10

Distance between hole


centres

b1)

140

140

Bore hole

d1)

13

13

Weight

(kg)

Load per element

(kg)

650

900

763398049

763398048

Grasso Ident
1)

all dimension values listed in mm

Features

1.3
Design

Elastomer-metal-connection

Compact design

Integrated levelling system

Characteristics

GEA Refrigeration Germany GmbH | 990262_1 | Generated 28.07.2014

Product Description | Level Mount Elements, LM Type


Main part

Aktive and passive arrangements

Anti-vibration mounting, impulse absorption

Structure-borne noise insulation

Installation without holding point on foundation

Broadband loading range

Natural frequency (stat.)12 Hz 20 Hz

Fine thread

Options

Parts out of galvanized metal

Parts out of stainless stell

Elastomer as special quality

Levelling

Levelling range max. 5 - 30 mm

Materials

Elastomer piece in CR-quality with high angular flexibility, resistant to ageing and oil

Outer cap out of St W 23 or GG

Yellow enamelled metal surface

Forged clamping plate

Screw M10/ M12 acc. DIN 933, quality 8.8 zinc-coated


Caution!
The combination of level mount elements and U-type profile is equipped 1 wedge-disc for
each element!
Hint!
For Package frames with bore holes diameter 20 mm:
Install the delivered spacer bushes between frame section and screw bolt!

Type LM

1-11

3-11

Thread size

M10

M12

4-disc (wedge disc)


acc. DIN 434

11

13

Grasso Ident

542711002

542711003

Spacer bush

B0742270

B0742240

GEA Refrigeration Germany GmbH | 990262_1 | Generated 28.07.2014

3-25

3-33

Product Description | Level Mount Elements, LM Type


Main part

1.4

Installation instruction
Caution!
Pay attention to assembly!

fig.3:

Level Mount Element, LM Type, Installation instruction

Screw

Nut

Washer

Key washer

Turn!

Level

Counter!

GEA Refrigeration Germany GmbH | 990262_1 | Generated 28.07.2014