Witt GP 41 Installation And Operating Instructions Manual

Content

INTRODUCTION ............................................................................................................ 4

1.1

Intended use ............................................................................................................................ 4

1.2

Safety Requirements ............................................................................................................... 4

1.3

Safety advice ........................................................................................................................... 5

1.4

Disclaimer ................................................................................................................................ 5

TERMS OF WARRENTY ............................................................................................... 6

TECHNICAL INFORMATION......................................................................................... 7

3.1

Description of types ................................................................................................................. 7

3.2

Scope of delivery ..................................................................................................................... 7

3.3

Order information ..................................................................................................................... 8

3.4

Codes / certificates / approvals ............................................................................................... 8

TECHNICAL DATA ........................................................................................................ 9

4.1

General information ................................................................................................................. 9

4.2

Motor data ................................................................................................................................ 9

4.3

Materias ................................................................................................................................. 11

4.4

Pressure range ...................................................................................................................... 11

4.5

Dimensions ............................................................................................................................ 12

4.6

Sectional Views ..................................................................................................................... 15

4.7

Parts list ................................................................................................................................. 19

4.8

Spare part sets ...................................................................................................................... 22

4.9

Description of operation ......................................................................................................... 23

4.10

Performance characteristic table ........................................................................................... 23

APPLICATIONS............................................................................................................24

5.1

General .................................................................................................................................. 24

5.2

Determination of the delivery head ........................................................................................ 25

5.3

Determination of the required flow ........................................................................................ 25

5.4

Adaptation to plant requirements .......................................................................................... 26

INSTALLATION REQUIREMENTS...............................................................................27

6.1

Pump arrangement ................................................................................................................ 27

6.2

Pump connection ................................................................................................................... 27

6.3

Downleg design ..................................................................................................................... 28

6.4

Pump discharge line .............................................................................................................. 30

6.5

Protection of the pump .......................................................................................................... 30

6.6

Electrical information ............................................................................................................. 32

TRANSPORT AND STORAGE .....................................................................................32

INSTALLATION AND APPLICATION ..........................................................................33

8.1

Preparing for installation ........................................................................................................ 33

8.2

Mounting instructions ............................................................................................................. 33

8.3

Preparation of commissioning ............................................................................................... 34

8.4

Commissioning ...................................................................................................................... 35

8.5

Normal operation ................................................................................................................... 35

8.6

Pump standstill (Stand-by) .................................................................................................... 36

SERVICE AND MAINTENANCE ...................................................................................37

9.1

Removing a pump ................................................................................................................. 37

9.2

Oil level control ...................................................................................................................... 37

9.3

Oil exchange .......................................................................................................................... 39

9.4

Changing the shaft seals ....................................................................................................... 39

9.5

Changing the bearings .......................................................................................................... 42

9.6

Oil in the pump ...................................................................................................................... 45

9.7

Shipment of pump ................................................................................................................. 45

9.8

Warnings ................................................................................................................................ 46

TROUBLE SHOOTING .............................................................................................47

TH. WITT Kältemaschinenfabrik GmbH

Lukasstrasse 32, D-52070 Aachen

Tel. +49-241-18208-0, Fax. +49-241-18208-490

https://www.th-witt.com, sales@th-witt.com

State of ducumentation: April 2019

2161-601_E_2019_04

- Introduction - 4

INTRODUCTION

Please read the entire manual careful before selecting, installing, commissioning and ser-

vicing the pump.

1.1 INTENDED USE

The WITT refrigerant pump with flanged motor type GP is designed to deliver exclusively refrig-

erant liquid at its boiling point. The pump is labelled with model and design limitation for pressure

and temperature. Pump performance details are specified in chapter Fehler! Verweisquelle

konnte nicht gefunden werden. “Technical data”. The standard pump design uses an electric

motor (type B5). Other types of drive are possible, e.g. hydraulic drive motor.

1.2 SAFETY REQUIREMENTS

All of the following specified work must be carried out by knowledgeable personnel

experienced in installation and service of refrigeration systems. All personnel must

be familiar with the national legal requirements and safety regulations. All safety reg-

ulations and codes of practice concerning the use of refrigerants must be adhered

to, with special attention paid to protection clothing and wearing of safety glasses.

Service and maintenance only be carried out when the pump is stopped and the

power supply disconnected.

Under no circumstances are the indicated temperature- and pressure limitations to

be exceeded.

Important! The content of this manual must be adhered to. Deviation from the

specified conditions will make any claim for liability or warranty void.

5 - Introduction -

1.3 SAFETY ADVICE

The pump is designed for use in industrial refrigeration systems using primary refrigerants.

It is very important that everybody responsible for the safe operation and

maintenance of the plant reads this manual.

The coupling protection must be in place at all times! (see chapter 8.2.2)

If you have any problems please do not hesitate to call our service department, who will be glad

to assist you.

Make sure the ground area around the pump is clear, e.g. no incoming electric power cables. If

you cannot avoid such obstruction, they should be marked with two-coloured warning tape (warn-

ing sign).

Correctly retighten all screw connections after mainte-nance and repair work.

If you have to disassemble any safety devices for maintenance and repair make sure that upon

completion of said work the re-assembly and correct functioning is checked.

When operating at low temperatures (< 0°C) freeze bites can occur when the surface is touched.

Therefore always wear appropriate protection clothing.

1.4 DISCLAIMER

Even when using the pump for the intended purpose it cannot be entirely excluded that a danger

may remain during its working lifetime.

Translations have been made to the best of our knowledge. We are unable to accept any liability

for er-rors in translation.

We reserve the right to change descriptions, graphs and technical information due to future de-

velopment of the refrigerant pump.

- Terms of warrenty - 6

TERMS OF WARRENTY

In order to avoid accidents and ensure optimum performance, no modifications or conversions

may be carried out to the refrigerant pump without the explicit written approval by TH. WITT

KÄLTEMASCHINENFABRIK GMBH.

These instructions are based on internationally standardised SI units of measurements.

All data and information on the operation and maintenance of the refrigerant pump is provided

based on our extensive experience and to the best of our technical knowledge.

Our liability or warranty is excluded, if:

 information and instructions in the operating manual are ignored,

 the refrigerant pump including accessories is operated incorrectly or is installed contrary to

these installation instructions

 the refrigerant pump is used for applications other than that for which it was intended,

 safety devices are not used or disconnected

 there have been modifications made without written approval

 the safety regulations are not adhered to

 the refrigerant pump including its filters and required safety devices has not been maintained

or repaired correctly with respect to frequency or competence this includes the use of ap-

proved spare parts.

Opening the pump within the warranty period will void all implied or explicit

guarantees!

It is recommended to return the pump to the supplier for repair or order an exchange pump.

When exchanging any parts respective spare parts only genuine spare parts are to be used.

Equipment must be used in accordance with the instructions in this manual.

7 - Technical Information -

TECHNICAL INFORMATION

3.1 DESCRIPTION OF TYPES

Six WITT refrigerant pumps with flanged motor are available:

GP 41, GP 42, GP 51, GP 51a, GP 52 and GP82.

Pumps can be delivered with or without standard flange-motor. To select your model please see

table below.

3.2 SCOPE OF DELIVERY

GP… model 1 Replacement (bare shaft) pump with

- gasket for flanges

- coupling part on the pump side

GP… model 2 Pump as model 1 with

- complete coupling

- motor connection

GP… model 4 Pump as model 2 with

- 1 motor 1500 min-1 for NH

3

Please specify for model 2 the motor size for correct selection of the motor

coupling (and if required to be supplied with the intermediate ring for the motor

flange).

The standard motor can be replaced by other sizes in accordance with the mo-

tor selec-tion data sheet.

Optional Equipment

 Counter flange, suction side with screws, nuts and gasket

 Counter flange, pressure side with screws, nuts and gasket

 Shut off valve EA … suction side with counter flange, screws, nuts and gasket

 Shut off valve EA … pressure side withcounter flange, screws, nuts, gasket and deaeration-

valve EA 10 GB (manometer connection)

 Strainer KS .. P suction side, including shut-off device, with counter flange, screws, nuts and

gasket

 Non return / shut off valve ERA ... pressure side, with counter flange, screws, nuts and gasket

and deaeration valve EA 10 GB (manometer connection) pipe Ø 17,2 and hand regulating

valve EE6 (loose)

 NH3 manometer with stand B for 0 - 12,5 bar

 NH3 manometer with stand B for 0 - 25 bar

 Strainer KS ... L

- Technical Information - 8

3.3 ORDER INFORMATION

Please specify the following data when ordering a pump:

 refrigerant

 type GP 41, GP 42, GP 51, GP 51a, GP 52 or GP82

 For models 2 the required coupling size (or motor size of the motor to be fitted later)

 For models 4 the selected motor

 Voltage and frequency.

 (Special requirements if applicable, e.g. PN 65 for HRP 3232)

If you are unsure about the selection, please provide the following additional information:

 evaporating temperature ....°C

 volume flow .... m

3

/h or capacity and re-circulation rate

 required pressure head …. m

3.4 CODES / CERTIFICATES / APPROVALS

The following certifications are available and can be downloaded from our website www.th-

witt.com:

declaration of incorporation of a partly completed machinery according to EG machinery directive,

conformity declaration according to EU- low voltage directive.

9 - Technical data -

TECHNICAL DATA

4.1 GENERAL INFORMATION

DESCRIPTION GP 41

GP 42

GP 51

GP 51a

GP 52

GP 82

Volume refrigerant side [ltr.] 1,75

1,85

4,10

5,25

7,72

Reservoir oil content [ltr.] 1,70

1,70

2,00

Flange connection [DN] 40,00

40,00

50,00

50/80

Weight [kg] for

Model 1 41,00

45,00

63,00

73,00

91,00

Model 2 48,00

52,00

75,00

92,00

110,00

Model 4 dependent

dependent

4.2 MOTOR DATA

4.2.1 Motor data for 50 Hz - 1.500 RPM

Density

[kg/dm

3

] Motor size

Power

[kW]

Voltage [V] Weight

[kg] Remark

Δ Y

GP 41

< 0,7 (NH3) 80 0,55

220 - 240

380 - 420

10 Standard

< 1,4 0,75 12

< 1,6 90S 1,1 14

< 1,8

GP 42

< 0,7 (NH3) 90S 1,1

220 - 240

380 - 420

14 Standard

< 1,4 90L 1,5 17

< 1,6

< 1,8 100L 2,2 22 Motor adapter ring ne-

cessary

GP 51

< 0,7 (NH3) 100L 3

220 - 240

380 - 420

660 - 725

28 Standard

< 1,4 112M 4 40

< 1,6 132S 5,5 66 Motor adapter ring ne-

cessary

< 1,8

GP 51a

< 0,7 (NH3) 100L 2,2 220 - 240

380 - 420

17 Standard

< 1,4

112M 4 220 - 240

380 - 420

660 - 725

40

< 1,6

< 1,8

GP 52 < 0,7 (NH3) 132S 5,5 220 - 240

380 - 420

660 - 725

66 Standard

GP 82 < 0,7 (NH3) 132M 7,5 380 - 420

660 - 725

64 Standard

- Technical data - 10

4.2.2 Motor data for 50 Hz - 1.000 RPM

Density

[kg/dm

3

] Motor size

Power

[kW]

Voltage [V] Weight

[kg] Remark

Δ Y

GP 41

< 0,7 (NH3)

80 0,37 220 - 240

380 - 420 9

< 1,4

< 1,6

< 1,8

GP 42

< 0,7 (NH3)

80

0,37

220 - 240

380 - 420

9

< 1,4

< 1,6 0,55 11

< 1,8

GP 51

< 0,7 (NH3)

100L 1,5 220 - 240

380 - 420 25

< 1,4

< 1,6

< 1,8 112M 2,2 38

GP 51a

< 0,7 (NH3)

100L 1,5 220 - 240

380 - 420 26

< 1,4

< 1,6

< 1,8

GP 52

< 0,7 (NH3) 100L 1,5 220 - 240

380 - 420 26

< 1,4 112M 2,2 38

< 1,6 132S 3 220 - 240

380 - 420

660 - 725

66 Motor adapter ring ne-

cessary

< 1,8 132M 4 82

4.2.3 Motor data for 60 Hz - 1.800 RPM

Density

[kg/dm

3

]

Motor

size

Power

[kW]

Voltage [V] Weight

[kg] Remark

Δ Y

GP 41

< 0,7 (NH3) 80 0,9

254 - 280 440 - 480

12

< 1,4 90S 1,3 14

< 1,6 90L 1,8 17

< 1,8

GP 42

< 0,7 (NH3) 90L 1,8

254 - 280 440 - 480

17

< 1,4 100L 2,6 22

< 1,6

GP 51

< 0,7 (NH3) 112M 4,8 254 - 280

460 440 - 480 40

< 1,4 132S 6,6 460 --- 66 Motor adapter ring ne-

cessary

GP 51a

< 0,7 (NH3) 112M 4,8 254 - 280

460 440 - 480 40

< 1,4 132S 6,6 460 --- 66 Motor adapter ring ne-

cessary

GP 82 < 0,7 (NH3) 132M 7,5 460 --- 64

11 - Technical data -

4.2.4 Motor data for 60 Hz - 1.200 RPM

Density

[kg/dm

3

] Motor size

Power

[kW]

Voltage [V] Weight

[kg] Remark

Δ Y

GP 41

< 0,7 (NH3)

80

0,44

254 - 280

440 - 480

9

< 1,4

< 1,6 0,66 11

< 1,8

GP 42

< 0,7 (NH3) 80 0,66

254 - 280

440 - 480

11

< 1,4

< 1,6 90S 0,9 13

< 1,8 90L 1,3 16

GP 51

< 0,7 (NH3) 100L 1,8

254 - 280

440 - 480

25

< 1,4

< 1,6 112M 2,6 38

< 1,8

GP 51a

< 0,7 (NH3) 100L 1,8

254 - 280

440 - 480

26

< 1,4

< 1,6 112M 2,6 38

< 1,8

GP 52

< 0,7 (NH3) 112M 2,6 254 - 280

440 - 480

38

< 1,4 132S 3,6 254 - 280

460

66 Motor adapter ring ne-

cessary

< 1,6 132M 4,8 82

< 1,8 6,6 460 --- 83

4.3 MATERIAS

Pump housing: EN-GJS-400-18-LT Motor flange: EN GJS-400-15

Coupling: Stahl Coupling bush: Kunststoff

Coupling protection: PVC Rohr transparent Ball bearings: Stahl

Shaft: C 35 Shaft seal: PTFE

Impellers: EN GJS-400-15 Main bolts 8.8

Counter flanges: P355NH Bolts for counter flanges:

8.8

Gaskets: Centellen NP Reservoir oil: MR 520

Painting system W 9.1 + W 9.2 *

* W9.1 + W9.2 = 2k epoxidy finish according DIN ISO 12944/5, RAL 7001

4.4 PRESSURE RANGE

Design pressure pump housing [bar] 16

Test pressure (air under water) [bar] 17,6

Permitted operating pressure range [bar] 16 (+50 / -10°C)

8 (-10 / -60°C)

- Technical data - 12

4.5 DIMENSIONS

4.5.1 Dimensions GP 41 / GP 42

All dimensions in mm (inch)

13 - Technical data -

4.5.2 Dimensions GP 51 / GP 51a / GP 52

All dimensions in mm (inch)

- Technical data - 14

4.5.3 Dimensions GP 82

All dimensions in mm (inch)

15 - Technical data -

4.6 SECTIONAL VIEWS

Figure 3a: GP 82 shown (Model GP 41 – GP 52 similar)

- Technical data - 16

Figure 3b: Details of bearing

Figure 3c: Detail of coupling and motor connection

17 - Technical data -

Figure 3d: Details of shaft seal

- Technical data - 18

Figure 3e: Details of strainer KS 40-P / KS 50-P

Figure 3f: Details of strainer KS 80-P

19 - Technical data -

4.7 PARTS LIST

4.7.1 parts list for pump (part 1 of 2)

GP 41/ GP 42 GP 51/ GP 51a/ GP 52 GP82

part Dimension Article-No. weight

[gr] Dimension Article-No. weight

[gr]

slide flange 11 Ø40 2161.001295 82 Ø50 2161.001296 120 Ø50 2161.001296 120

slide ring 12 Ø22 2161.001226 2 Ø28 2161.001265 3 Ø28 2161.001265 3

o-ring 13 Ø22 x 3,5 5642.ABBR01 1 Ø28 x 5 5642.ABCD01 3 Ø28 x 5 5642.ABCD01 3

pressure ring 15 Ø42 2161.001230 60 Ø42 2161.001269 40 Ø42 2161.001269 40

pressure spring 16 3 x 38 x 34 5512.WBD001 17 3 x 38 x 34 5512.WBD001 17 3 x 38 x 34 5512.WBD001 17

spring washer 17 Ø60 2161.001228 105 Ø73 2161.001267 127 Ø73 2161.001267 127

brake disc 18 Ø70 2161.001223 105 Ø86 2161.001260 23 Ø86 2161.001260 23

pressure-limitation valve 19.1 2161.002009 90 2161.002009 90 2161.002009 90

safety pressure-limitation valve 19.2 2161.001208 20 2161.001208 20 2161.001208 20

cylinder head screw with inner hex 21 M5 x 25 5112.BC41AO 5 M5 x 25 5112.BC41AO 5 M5 x 25 5112.BC41AO 5

cylinder head screw with inner hex 22 M6 x 16 5112.BC51AF 6 M6 x 16 5112.BC51AF 6 M6 x 16 5112.BC51AF 6

cylinder head screw with inner hex 23 M8 x 25 5112.BH61AO 15 M8 x 25 5112.BH61AO 15 M8 x 25 5112.BH61AO 15

cylinder head screw with inner hex 24 M8 x 20 5112.BH61AJ 13 M8 x 20 5112.BH61AJ 13 M8 x 20 5112.BH61AJ 13

cylinder head screw with inner hex 25 M10 x 25 5112.BH71AO 25 M12 x 30 5112.BH81AT 39 M12 x 30 5112.BH81AT 39

cylinder head screw with inner hex 26b M10 x 35 5112.BH71AY 28 M12 x 50 5112.BH81BD 55 M12 x 50 5112.BH81BD 55

hex nut 26c M10 5151.AH7100 10 M12 5151.AH8100 15 M12 5151.AH8100 15

hex bolt 27a M16 x 55 5111.AHA1BI 110 M16 x 55 5111.AHA1BI 110 M16 x 65 5111.AHA1BS 126

hex nut 27b M16 5151.AHA100 30 M16 5151.AHA100 30 M16 5151.AHA100 30

hexagon socket screw (GP 41 & 51) 28 M16 x 100 5112.BHA1CR 186 M16 x 150 5112.BHA1E5 266 ---

hexagon socket screw (GP 42, 52 & 82) 28 M16 x 140 5112.BHA1DV 250 M16 x 220 5112.BHA1G3 320 M16 x 300 5112.BHA3IB 440

cylinder head screw with inner hex 29 M10 x 25 5112.BH71AO 25 M12 x 25 5112.BH81AO 36 M12 x 25 5112.BH81AO 36

gasket suction connection 31 40/60 x 1 5632.1B3BNI 3 50/67 x 1 5632.1BDBUI 4 77/100x1 5632.1C4CRI 6

gasket pressure connection 32 40/60 x 2 5632.1B3BNK 6 50/67 x 2 5632.1BDBUK 7 50/67 x 2 5632.1BDBUK 7

gasket intermediate piece 33 138/149x0,3 5632.1DTE44 1 180/195x0,3 5632.1EZFE8 2 180/195x0,3 5632.1EZFE8 2

gasket cover 34 70/84 x 2 5632.1BXCBK 10 80/100 x 1 5632.1C7CRI 12 80/100 x 1 5632.1C7CRI 12

gasket slide flange 35 30/40 x 0,5 5632.1ATB38 1 38/50 x 0,5 5632.1B1BD8 1 38/50 x 0,5 5632.1B1BD8 1

gasket oil pot 36 125/155x1,5 5632.1DGEAJ 20 125/155x1,5 5632.1DGEAJ 20 125/155x1,5 5632.1DGEAJ 20

gasket oil-fill screw 37 22x27x1,5 5641.A11AL0 3 22x27x1,5 5641.A11AL0 3 22x27x1,5 5641.A11AL0 3

gasket oil-drain screw 38 14x20x1,5 5641.A11AD0 1 14x20x1,5 5641.A11AD0 1 14x20x1,5 5641.A11AD0 1

seal for stop valve 39 8/14 x 8 5643.ABAP01 1 8/14 x 8 5643.ABAP01 1 8/14 x 8 5643.ABAP01 1

rill ball bearing with steel cage 41 5341.000003 240 5341.000002 380 5341.000002 380

baring bush 42 Ø45 2161.001219 130 Ø55 2161.001256 220 Ø55 2161.001256 220

tightening ring 43 Ø55 2161.001220 77 Ø63 2161.001257 95 Ø63 2161.001257 95

spring cage 44 Ø55 2161.001229 110 Ø62 2161.001268 130 Ø62 2161.001268 130

safety ring (2 resp. 4 pcs.) 45 22 x 1,2 5541.AAL120 2 28 x 1,5 5541.AAR150 3 28 x 1,5 5541.AAR150 3

disc spring 46 5 x 7,5 5712.AGF001 4 6 x 10 5712.AHH001 9 6 x 10 5712.AHH001 9

impeller 47 Ø130 2161.001243 440 Ø165 2161.001285 1170 Ø165 2161.180101 1170

shaft GP 41 / GP 51 48 Ø23 x 370 2161.001210 1085 Ø30 x 400 2161.001251 1875 Ø30 x 400 --- 1875

shaft GP 42 / GP 52 / GP 82 49 Ø23 x 410 2161.001211 1180 Ø30 x 474 2161.001252 2180 Ø30 x 590 2161.182102 2660

oil housing 50 2161.001303 3050 2161.001303 3050 2161.001303 3050

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