GEA Geneglace F15, Contractor'S Manual

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Page 3: ...Environmental Instructions 6 3 1 Safety rules 6 3 2 Protection of the Environment 6 4 Safety of pressure vessel 7 5 Installation and Handling of the F15 and F30 8 6 Dimensions and Connections of the F15 and F30 9 6 1 Positioning the machine 10 6 2 Mountings 10 6 3 Ice level safety detection 11 7 Connections 12 7 1 Specifications 12 7 2 Hydraulic connections 13 7 3 Electrical connection 13 7 4 Conn...

Page 4: ...e 27 12 1 Maintenance schedule 27 12 2 Routine maintenance 28 12 3 Replacement of worn parts 29 13 F15 and F30 Refrigeration Diagrams 30 14 Troubleshooting 31 15 Exploded view 32 15 1 F15 Generator 32 15 2 F30 Generator 33 16 Commissioning Check List 34 17 Operational Measurement sheet 36 17 1 Measurement Points for F15 or F30 Generator 37 18 Adjustment of torque limiter 38 19 Adaptating of Water ...

Page 5: ...een subjected to a test for long lasting quality Nevertheless if you discover a manu facturing fault and in order to protect your GENEGLACE machine please do not attempt a repair but contact us as soon as possible Any reproduction of all or part of this notice is subject to prior permission The information contained in this notice is subject to modification without prior notice In order to update ...

Page 6: ...instructions concerning handling with complete safety The layout will tell you about the overall dimensions of your GENEGLACE the procedure to follow for choosing the best location for it in relation to its environment and finally all information concerning accessibility for future service and maintenance Connections In order to make all the hydraulic elec trical and cooling connections correctly ...

Page 7: ...rules Non observance of the safety rules can also result in physical danger equipment danger or pollution of the environment Failure to observe the safety rules will result in the loss of rights to damages or compensation 2 4 Operating range Electrical supply as indicated on the manufacturer s rating plate and in accordance with current standards Safety rules General danger Risk of burning Electri...

Page 8: ...ools is provided Operation of the machine without this guard is prohibited The operation of manual valves is strictly reserved for maintenance personnel with the necessary skills risk of spurting of fluids under pressure In the event of a general power failure protect yourself against any risk when the power returns unintended start ing keep personnel away from dangerous areas Operation of the mac...

Page 9: ...les EU directives and any special requirements of the country concerned 4 1 1 2 Location When used in extreme conditions for example in an aggressive atmosphere in extreme outside temperatures etc take adequate protective measures Where appropriate it is advisable to consult Geneglace Warning x Geneglace ice generators are designed to be installed in the low pressure sides of refrigeration systems...

Page 10: ... 05 73 81 ZAC de la Forêt 9 rue des Orfèvres 44840 Les Sorinières France COMMERCIAL LAND BASED Generator F15 Edition date GENEGLACE may change this document whitout prior notice 29 01 2009 JPM 0 0 V 90 kg B A C H1 I L H2 H3 D2 D E F D1 a c K Øi ØG 1 2 b 3 a Net weight Installation Minimum clearance for service Handling Tightness seal around the boring 1 Raising of the floor to avoid accidental wat...

Page 11: ...s Sorinières France COMMERCIAL LAND BASED Generator F15 Edition date Cancels and replaces the document of 20 08 2004 GENEGLACE may change this document whitout prior notice 29 01 2009 JPM 0 0 V Generator F30 Minimal clearance for disassembly See Installation and handling section mm Length Item Description Qty Dimensions Overall Open crate Full crate Dimensions Item Width Height Volume Net weight G...

Page 12: ... machine Fig 512 Optional chute easily removable for mainte nance of generator Important Risks of freezing during machine downtime protect the base of the pump and valve float by means of a heater housed in the base This device will only be effective for an air tem perature of 10 C to 5 Cmaximum for a period of 12 to 24 h Beyond that it is preferable to drain the machine if it is stopped Also prot...

Page 13: ... device in accordance with electrical diagram 534004 In order to prevent direct action due to ice flakes falling on the switch finger the blade must be screwed into the lower end of the central shaft and positioned opposite the reamer see drawing opposite the switch and its end must be positioned in line nith and underneath on of the supporting arm of the cen tral bearing of the generator In the c...

Page 14: ...19 20 18 22 20 23 21 23 23 Required refrigeration power KW 2 33 2 33 2 33 2 33 3 4 3 4 3 4 3 4 4 9 4 9 4 9 4 9 Thermostatic expansion valve Type TX2 TS2 TX2 TS2 TX2 TS2 Orifice No 2 3 2 3 2 4 Electrical supply V 400V 3 phase N 50 Hz 60 Hz Power of reducer motor W 90 Three 90 Three Pump power single phase W 70 70 Switches Torque limiter I S L supplied not fitted Electrical diagrams Power control Pa...

Page 15: ...low therefore prevents any overflow of water through the ice descent hole and thus into the ice store The overflow water must flow into the drains as required by the regulations The drain pipe must not have a rising portion that could prevent the natural flow of water and its slope must be sufficient 7 3 Electrical connection The type of electrical power supply is stated on the rating plate attach...

Page 16: ...he phase to W1 7 3 2 Water pump The water pump operates from 220 Volts single phase and is fitted in advance with a 3 m cable However if the cable has to be changed the connections must be as follows 7 3 3 Torque limiter switch The drawing below shows the position of the torque limiter switch when the generator is operating normally 7 3 4 High level safety switch The drawing below shows the positi...

Page 17: ... siphon three metres from the rising piping Regarding the section of suction piping sloping towards the compressor a reverse siphon must be placed at the top in order to prevent any return behind of oil Where the suction piping is very long it is recommended after a section of ascending piping of sufficient size to en sure the correct oil carry over that a change is made to a larger cross section ...

Page 18: ...um ice production rate of your GENEGLACE Fig 7111 Illustration of the float valve in its closed and open positions Setting the level By turning the screw 6 adjust the water level in the base while observing the following dimensions Once the adjustment of the water level in the base has been completed lock the setting with the lock nut 5 Adjusting the flow rate Measure Adjusting the flow rate of th...

Page 19: ...ponds to the production rate of the machine see Specifi cations Note The speed of the reamer is the number of complete revolutions made by all the rotating parts in one hour At the same time check the operation of the torque limiter by causing it to trip To do this it is sufficient to trip the torque limiter by manually moving the roller of its microswitch To reset the limiter hold the reamer moto...

Page 20: ...n 8 1 4 1 Addition of salt Check that the salt addition system is operating correctly 8 2 Recommended uses In the case of an independent refrigerating system leave the power supply of the system switched on during periods of stoppage the crankase heater must remain live In the same case after a long period without electrical power power on at least 3 hours before starting up Avoid short duration r...

Page 21: ...nds on The refrigerating power applied to the generator The speed of rotation of the reamer Important The thickness of the ice does not depend on the spacing of the reamer from the drum IT IS DANGER OUS TO SPACE THE REAMER AWAY FROM THE DRUM this can cause fatigue of the bearings tripping of the torque limiter slugging and oil departure that could destroy the compressor In the factory the reamer i...

Page 22: ...t on that of the fluid solenoid valve Electrical sequences Time delay T1 Time required to fill the cylinder with refrigerant before starting production 15s to180s Ice safety detector Safety blade Switch Reset by Manual Electrical Switch Time delay T KA1 Time required for cleaning the cylinder after stopping the generator 180s Do not install a pump down on generators F15 and 30 Fig Block diagram of...

Page 23: ... the ice level detector or the clock trip the solenoid valve and the water pump stop immediately while the reamer continues to rotate for 3 minutes When this safety device is reset the start up procedure is repeated as when starting Electrical sequences When starting the ice generator the compressor the liquid feed solenoid valve water pump and reamer begin working simultaneously If the condensing...

Page 24: ...rating conditions The following depend directly on correct adjustment of the expansion valve the filling of the generator with refrigerant fluid and thus the production of ice the evaporation pressure the superheat of suction gas the oil carry over to compressor Indirectly misadjustment of the superheat may have me chanical consequences for the generator itself and also to the compressor The therm...

Page 25: ... base of the dosing system will keep it operating correctly The purified salt used with dosing pumps must be dissolved in small successive quantities to ensure a complete melting either in cold water or preferably hot water Final mixing after complete filling of the PVC tank will ensure a homogeneous solution A dosing tube is a system for adding salt mounted in series in the case where there is no...

Page 26: ...rator The suction tube must be positioned vertically and mustn t have any swan necks on its entire length Maximum height 6 m M aximum height 1 5 m Valve drain connexion 1 inch injector pipe inlet fi lter 0 4 inch Elect Control box generateur A Fix the pump on a wall bracket type above the brine tank 1 Fix the nut and tubing sleeve A D F H on the suction and discharge tubes see the right sketch bel...

Page 27: ...s empty before replacing it apply power to the dosing pump with 1 on off switch Adjust stroke at 100 3 and the speed at 80 2 Turn the knurled knob located on 4 way valve E for a 1 4 turn and maintain it open until brine drips out of the draining tube return to bin After successful priming release the knurled knob Adjust the 2 and 3 knobs according to the ice maker as per table 1 Ensure that brine ...

Page 28: ...llustration of a possible mounting of the ILD 11 2 4 Connection to the terminal box Important In order to avoid repeated starting of the GENEGLACE it is recommended that you install manual or automatic time delayed resetting 11 3 Remote Control Options The ILD must be positioned in such a location that it prevents ice from building up inside the ice generator Position the ILD in order to avoid a b...

Page 29: ... salt or salt solution Recharge standard salt dosing system Or Filling up the brine containers for the dosing pump depending on consumption Cleaning standard salt dosing system monthly Cleaning water system Base tanks valve operation weekly Grease bearings use greasing pump Central shaft and reamer bearings Food compatible grease fulfils NSF H1 standard consult us if necessary every three months C...

Page 30: ...commend a range of products for descal ing and attacking micro organisms Important 15 2 1 Anti micro organism product PR 61 is an anti algae sanitary decontaminant product for any microbial contamination It is in the form of a clear liquid Density 1 02 PH 7 It is sanitary and not dangerous to use It is not volatile It is rapid and works on any surface It has great powers of decontamination It can ...

Page 31: ...odification example F15 01 F15 Generator Replacement of the central shaft bearings F30 02 F30 Generator Centring the central shaft Replacement of worn parts Part Frequency Coding of Data Sheets Float valve When appropriate 10 Central shaft bearings About 1095 Days 3 years 01 Centring of central shaft After replacing the bearings 02 Torque limiter 912 Days to 1095 Days 06 2 5 to 3 years Wipers Abou...

Page 32: ...de la Forêt 9 rue des Orfèvres 44840 Les Sorinières France COMMERCIAL LAND BASED Generator F15 Edition date GENEGLACE may change this document whitout prior notice 29 01 2009 JPM 0 0 V 1 3 4 5 2 Refrigerating connection made To be performed on site Weld Flare connection Screw connection Flange connection Generator F30 1 Generator 2 Suction 3 HP liquid inlet 4 Horizontal heat exchanger loose 5 Ther...

Page 33: ...ME AWAY FROM THE CYLINDER R ź ICE VERY FRAGMENTED S ź ź ROTATING PART MOTOR NOT WORKING T ź LOW OIL LEVEL IN COMPRESSOR U ź OIL LEVEL IN COMPRESSOR HIGH WHEN STARTED THEN LOW V ź DROPE IN ICE PRODUCTION RATE W ź ź ź ź ź Causes 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 LACK OF SALT 1 2 TOO MUCH SALT 2 3 FRONT WIPER SETTING LOST OR INCORRECT LEAK 3 4 REAR WIPER SETTING LOST OR INCORRECT LEAK...

Page 34: ...s Manual For F15 and F30 Mill 2008 11 Mod JPM 05 Page 15 Exploded view 15 1 F15 Generator This drawing is the property of Généglace it is forbidden to reproduce it or to communicate it to a third party without our permission Exploded view F15 ...

Page 35: ...enerators Manual For F15 and F30 Mill 2008 11 Mod JPM 05 Page This drawing is the property of Généglace it is forbidden to reproduce it or to communicate it to a third party without our permission 15 2 F30 Generator Exploded view F30 ...

Page 36: ...of the contact The presence of the exchanger in the suction system according to instructions The position of the bulb of the expansion valve according to instructions and the insulation thereof The connection to the overflow tube The flow regulation of the water float valve at standstill according to instructions That the water float valve has remained in operating position after having been conne...

Page 37: ... in order to obtain the pressure recommended by GENEGLACE at the time of the order Set the expansion valve to 6 8K by reference to the bulb temperature at the bulb minus the temperature of evaporation at the generator Adjusting the wipers according to instructions The level of water in the upper basin and that of the water tray base according to instructions The oil level at compressor indicator t...

Page 38: ...e a in Opposite side b in C 100 Enter the level of charge in in the left boxes J Use an electronic contact thermometer K Indiquer s il y a des fluctuations et dans quelles proportions show on the drawing And frost on the oil return heat exchanger a b Evaporating pressure bar N Corresponding temperature C N Condensing pressure bar O corresponding temperature C O M3 OTHER CONTROLS Temperature of the...

Page 39: ...Generators Manual For F15 and F30 Mill 2008 11 Mod JPM 05 Page J D L B P BAR C P BAR K N O F E H G I F Z C A mm H2O l h C mm kg h C Kg mm M 17 1 Measurement Points for F15 or F30 Generator Measurement Points for F15 or F30 Generator ...

Page 40: ...switched off and stopped see safety instructions Measure dimension A in the drawing above using a calliper gauge Subtract the following values from the measured dimension PACK 11 2 5 mm PACK 12 or generator F15 2 5 mm PACK 13 et 14 or generator F30 3 5 mm Take the G clamp and compress the stop no 2 to obtain dimension A minus the value chosen above Unscrew screw no 3 until the switch operates Remo...

Page 41: ...ncing work The dimensions are given for information only IMPORTANT The water level in the distribution bowl is obtained by the size of the water pump impeller AND by the adjustment of the overflow pipe Refer to the Initial Start Up section in the instructions concerned Cut off the hatched portion File the hatched area A F30 A 8 mm at 50 Hz F30 A 7 mm at 60 Hz Remove the hatched portion A F15 A 7 m...

Page 42: ... nuts turn the front wiper to position A and the rear wiper to position B They must remain in these positions If they do not retighten the lock nuts at the bottom under the collection tank A very thin film of water must be visible at the rear wiper 2 Positions C and D cause deformation by strong pressure on the drum Positions E and F cause water to flow into the stripping area The good condition o...

Page 43: ... de glace Ice level detector ANR 2 3 Coffret électrique Terminal of electrical panel Machine à glace Ice machine 36 37 41 Vers un Voyant Towards a light indicator RACCORDEMENT ELECTRIQUE DE L ANR ELECTRICAL CONNEXION OF THE ANR CONEXIÓN ELÉCTRICA DEL ANR 4 21 Electrical connexion of the ILD Electrical connexion of the ILD ...

Page 44: ...ning in an anti clockwise direction to bring the reamer tooth towards the cylinder Take a wedge equal to or less than 0 4mm and place it between the tooth and the cylinder Manoeuvre the reamer axis a placing the screwdriver in one of the slots until there is contact between the tooth wedge cylinder Isolate this adjustment by locking the screw v while maintaining the axis a with a screwdriver in on...

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