AQUAGEL GPserial 03 EN 00

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Operating instructions EN

MODULAR PUMPING STATION


GPP – GPV – GPR – GPA – GPI
Serial

NEW STANDARD FOR COOLING AND TEMPERATURE CONTROL


1 WARNINGS ____________________________________________________________________________________________________________ 4
2 SERIAL NUMBER________________________________________________________________________________________________________ 6
3 NOMENCLATURE _______________________________________________________________________________________________________ 7
4 SPECIFICATIONS ________________________________________________________________________________________________________ 8
4.1 HYDRAULIC CONNECTIONS GPP/GPV ___________________________________________________________________________________ 8
4.2 HYDRAULIC CONNECTIONS GPA _______________________________________________________________________________________ 8
4.3 HYDRAULIC CONNECTIONS GPI ________________________________________________________________________________________ 8
4.4 HYDRAULIC CONNECTIONS GPR________________________________________________________________________________________ 9
5 INSTALLATION ________________________________________________________________________________________________________10
5.1 HANDLING _______________________________________________________________________________________________________10
5.2 POSITIONING _____________________________________________________________________________________________________10
5.3 ELECTRICAL CONNECTIONS __________________________________________________________________________________________12
5.4 PROBES AND SENSORS ______________________________________________________________________________________________13
5.4.1 GPP / GPV / GPA_______________________________________________________________________________________________ 13
5.4.2 GPI _________________________________________________________________________________________________________ 13
5.4.3 GPR _________________________________________________________________________________________________________ 13
5.5 WATER SPECIFICATIONS _____________________________________________________________________________________________14
5.5.1 WATER QUALITY _______________________________________________________________________________________________ 14
5.5.2 ANTIFREEZE __________________________________________________________________________________________________ 15
6 WORKING CONDITION _________________________________________________________________________________________________15
7 ALARMS _____________________________________________________________________________________________________________17
8 WEBMONITORING _____________________________________________________________________________________________________17
9 MAINTENANCE________________________________________________________________________________________________________17
10 EQUIPMENT DISPOSAL _________________________________________________________________________________________________19
11 CE DECLARATION ANNEX _______________________________________________________________________________________________19
12 REVISION ____________________________________________________________________________________________________________19

DICHIARAZIONE DI CONFORMITÀ DECLARATION OF CONFORMITY

Per la dichiarazione di conformità fare riferimento al For the declaration of conformity refer to the
documento allegato alla macchina document attached to the machine

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Symbols

Explanation of symbols used in the manual:

Follow the information accompanied by this symbol to avoid damage


Warning! to persons or equipment.

Follow the information accompanied by this symbol to avoid damage


Danger, high voltage! to persons or equipment caused by high voltage.

Follow the information accompanied by this symbol to avoid


Explosion hazard! explosions of pressurized equipment or electrical equipment.

Safety protections Use appropriate personal protective equipment.

Useful information Useful information symbol.

Links to other documents Links to other documents, not included in this manual.

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1 WARNINGS

This equipment has safety devices designed to protect the operator in any case of appropriate use and inappropriate use,
or in any event reasonably acceptable. However, getting good performance for the life of the product also depends on
correct use and adequate preventive maintenance, carefully follow and completely understand the instructions in this
manual. Safety devices are:
• Main electrical switch.
• Electrical protections of each pump.

• Failure to comply with the indications contained in this manual can cause accidents or serious
injuries.
• In order to eliminate or minimize the residual risks associated with the transport, installation,
use and maintenance of equipment it is absolutely necessary to take the precautions
explained in this manual.
• Do no operate the unit nor make any connection before having accurately read and completely
understood this manual in all its parts.
• Do not operate the unit in conditions or for applications different from those indicated in the
manual. FRIGEL cannot be held responsible for failures, or accidents due to the non respect of
this prohibition.
• Do not alter or modify, even partially, the equipment described in this instruction manual, in
particular the devices used for operator’s safety.
• It is not possible to claim rights based on data, instructions and descriptions of this user
manual.
• FRIGEL reserves the right to carry out, at any time, technical modifications for improvement
of its own products.

• Safety precautions must be observed during installation, start-up, and service due to the
presence of refrigerant-charge and high-voltage hazards. Only qualified personnel should
install, start-up, and service this equipment.
• Non-compliance of safety precautions can cause serious personal injury.
• Always wear personal protective equipment when working around components energized by
high voltage. Faulty components can explode and cause serious eye injuries.
• Ensure that electrical power is isolated from the AC main cables before handling them.
• Before performing operations on hydraulic components, make sure that wires or electrical
components are well insulated.

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For further information, please contact:

FRIGEL FIRENZE S.p.A.


Via Pisana, 316
50018 Scandicci (FI) – ITALY
http://www.frigel.com

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2 SERIAL NUMBER

Each unit is provided with an adhesive label on the right side. All the main specifications (serial number,
mechanical and electrical) of the unit are written on the label. Serial number of the unit is needed when
ordering spare parts. Never remove the label!

Fig. 1: ADHESIVE LABEL.

Each pump is supplied with a label indicating the manufacturer, type, and all nominal data.

Fig 2: PUMP IDENTIFICATION LABEL.

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3 NOMENCLATURE

NGP 1 2 3 4 5 6 7 8

1 P Pump station for process


V Pump station for process with inverter
R Pump station for recirculating
A Pump station for auxiliary process
I Pump station for auxiliary process with independent pumps

2-3 XX Size (kW processed)


05 = 500
12 = 1200
16 = 1600
24 = 2400
30 = 3000
48 = 4800

4 X Hydraulic rev. X

5 X Num. of pumps = 1 - 4

6 S Std. pressure (3 bar)


H High pressure (4 bar)

7 X Voltage/Frequency 0 = 400V/50Hz
1 = 460V/60Hz
2 = 220V/60hz
3 = 380V/60Hz
5 = 460V/60Hz UL std.
6 = 575V/60Hz UL std.
8 = 380/400/460V 50/60Hz
8 S Serial (for 3PR control panel only)

Example:

NGP P 4 8 1 4 S 0 S
Pump station GPP, size 4800, revision 1, 4 pumps, standard pressure, 400V/50Hz voltage supply, serial.

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4 SPECIFICATIONS

GP pumping station series are designed for the circulation of water, mixtures of water and ethylene glycol or propylene
glycol for cooling installations in a closed circuit. The pumping station is modular and in can be expanded easily with the
correct pump kit. Contact FRIGEL FIRENZE S.p.A. with your pump station serial number for further information.

MODEL DESCRIPTION AND TYPE OF CONTROL


The pumping group is controlled by the 3PR. The set pressure is read by a transducer mounted on the
manifold. Only the pumps necessary to maintain the set pressure are powered up. The pumps work
GPP
in turnover condition in order to guarantee an equal usage. The Pumping group is used for circulate
the cooling water of the production process(es) (See section 4.1).
The pumping group is controlled by the 3PR. The set pressure is read by a transducer mounted on the
manifold. Only the pumps necessary are powered up and inverter(s) adjust speed to maintain the set
GPV pressure. The Pumping group is used for circulate the cooling water of the production process(es)
(See section 4.1). Each pump is driven by its own inverter. Pumps are all 60 Hz designed model, except
4800 SP is 50 Hz.
Auxiliary pumping unit, used for various applications (circulation, evaporators, etc.). Deliveries of all
GPA the pumps are connected by a manifold. The 3PR logic, depending on the configuration, will switch
power on / off for the entire GP station (See section 4.2).
Auxiliary pumping unit, used for various applications (circulation, evaporators, etc.). Deliveries of all
the pumps are not connected, each pump delivery is independent from the other ones. The 3PR logic,
GPI
depending on the configuration, will switch power on / off for the entire GP station (See section 4.2)
or control individually every pump.
Group dedicated to recirculating water; only for ECODRY “D” SELF DRAIN configuration (See section
GPR
4.3).

4.1 HYDRAULIC CONNECTIONS GPP/GPV

MODEL Victaulic flange PN10/16 (mm) (*)


GPP500 / GPV500 VICTAULIC FLANGE Ø 114.3 [4”]
GPP1200 / GPV1200 VICTAULIC FLANGE Ø 168.3 [6”]
GPP3000 / GPV3000 VICTAULIC FLANGE Ø 273 [10”]
GPP4800 / GPV4800 VICTAULIC FLANGE Ø 323.9 [12”]

4.2 HYDRAULIC CONNECTIONS GPA

MODEL Victaulic flange PN10/16 (mm) (*)


GPA1200 VICTAULIC FLANGE Ø168.3 [6”]
GPA1600 VICTAULIC FLANGE Ø 219.1 [8”]
GPA2400 VICTAULIC FLANGE Ø 219.1 [8”]
GPA4800 VICTAULIC FLANGE Ø 323.9 [12”]

4.3 HYDRAULIC CONNECTIONS GPI

INLET OUTLET
MODEL
Victaulic flange PN10/16 (mm) (*) Victaulic flange PN10/16 (mm) (*)
GPI1200 VICTAULIC FLANGE Ø168.3 [6”] PLANE FLANGE Ø 76.1 [2” 1/2]
GPI1600 VICTAULIC FLANGE Ø 219.1 [8”] PLANE FLANGE Ø 88.9 [3”]
GPI2400 VICTAULIC FLANGE Ø 219.1 [8”] PLANE FLANGE Ø 114.3 [4”]
GPI4800 VICTAULIC FLANGE Ø 323.9 [12”] PLANE FLANGE Ø 168.3 [6”]

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4.4 HYDRAULIC CONNECTIONS GPR

MODEL Victaulic flange PN10/16 (mm) (*)


GPR1200 VICTAULIC FLANGE Ø 168.3 [6”]
GPR1600 VICTAULIC FLANGE Ø 219.1 [8”]
GPR2400 VICTAULIC FLANGE Ø 219.1 [8”]
GPR4800 VICTAULIC FLANGE Ø 323.9 [12”]
NOTE
✓ (*) ANSI 150 lb Victaulic flange supplied for US market.

OUT

IN

Fig. 3: GPP/GPV/GPA/GPR.

OUT

IN

Fig. 4: GPI.

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5 INSTALLATION

Upon delivery, check the unit carefully (inside and outside) for shipping damage. In case of any damage, contact the carrier
immediately and call our service center.

5.1 HANDLING

Use only a pallet-jack or a forklift to lift the pumping station from the base (Fig. 4). Do not use pumps or manifolds as
lifting points. Only authorized personnel handling lift trucks can perform these operations.

Fig. 4: HANDLING

5.2 POSITIONING

• Do not block air intake(s) of the pump motor(s).


• Place the unit on a horizontal surface.
• Leave necessary space for maintenance (Fig. 5).
• Always support the connecting pipes so that there is no stress on the pump manifolds.
• Misalignment or strained piping can cause damages and unsafe working condition.

• Use the adjustable supporting feet to level the group (Fig. 6).
• The pump manifolds must perfectly align with the suction and discharge pipes.
• Tighten all flanges (Fig. 7).
• The pump station should be installed indoors and must not endure environments:
o with relative humidity above 90%;
o with strong vibrations;
o with aggressive and polluting atmospheres (sulphur and ammonia gases, saline mists, fumes,
etc..) to avoid corrosion and / or oxidation;
o exposed to the weather elements (rain, etc..).

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1 m for GP size 500/1200/3000
1.5 m for GP size 4800

Fig. 5: FREE SPACE FOR MAINTENANCE

Fig. 6: ADJUSTABLE FEET.

Fig. 7: VICTAULIC® FLANGE.

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5.3 ELECTRICAL CONNECTIONS

Make sure the door lock switch is in position 0. Connect the three phases at the respective terminals (indicated by R, S, T)
and the ground in the electrical cabinet, tighten the terminals to prevent the slippage of cables:

• Any improper installation in the main supply line can cause negative consequences for the
functioning of the machine, with serious risks of damage to components. The choice of the power
cord and its size must take into account the maximum absorbed power and all the conditions for
the installation and safety regulations in the country. (*)
• Remember that the incorrect connection to the supply voltage, incorrect voltages or frequencies
can seriously damage the machine. The tolerance of the nameplate rated power (see Section 2) is
± 10%.
• You should check that the pump rotation is correct during the start-up phase. The rotation must
correspond to the arrow printed on each box of the pump if the pump phase polarity is incorrect,
remove power, open the electrical panel and then swap the two-phase input power.
• For all electrical data (maximum power, FLA etc.), see the ELECTRICAL DIAGRAM supplied with
the machine.
• For electrical connections refer to the INTERCONNECTING WIRE DIAGRAM. In the diagram are
indicated the type and cables to be used for connections.
• All electrical connections must comply with the regulations in the country of use. These may
require the use of any security devices, cables, wiring directions different from the standards
normally provided.
• GPV only: an earth leakage current breaker must be installed in the main power supply line.
Then it must be designed for inverter applications, generally marked with the proper symbol
(see Electrical Scheme for reference).

Ps (DELIVERY
PRESSURE
GPP/GPR/GPV/GPA)

Pr (RETURN PRESSURE
GPP/GPV/GPA/GPI)

SERIAL
COMMUNICATION

POWER SUPPLY
Fig. 8: ELECTRICAL CONNECTIONS

Fig 9: ROTATION OF PUMP MOTOR

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5.4 PROBES AND SENSORS

5.4.1 GPP / GPV / GPA


In the following table, the list of sensors connected for circuits A/B/C/D for GPP and GPV, circuit C for GPA:

Sensor Description Supplied with


Ts Supply temperature GPP / GPV /GPA
Tr Return temperature GPP / GPV /GPA
Ps Supply pressure GPP / GPV /GPA
Pr Return pressure GPP / GPV /GPA
Lt Tank level GPP / GPV /GPA
Fin Filter inlet pressure (*) FILTER KIT
Fout Filter outlet pressure (*) FILTER KIT
Fmt Flowmeter kit Optional
Notes:
(*) =optional, only with “filter kit”
For description of circuits A/B/C/D please see 3PR manual.

5.4.2 GPI

In the following table the list of sensors connected to GPI for circuit C:

Sensor Description Supplied with


Ts Supply temperature GPI
Tr Return temperature GPI
Pr Return pressure GPI
Lt Tank level GPI

For description of circuits A/B/C/D please see 3PR manual.

5.4.3 GPR
In the following table the list of sensors connected to the circuit R (GPR only):

Sensor Description Supplied with


TeR Ecodry out temperature GPR
TsR Supply temperature GPR
PsR Supply pressure GPR
LtR Tank level GPR

See the P&ID for sensor locations.

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5.5 WATER SPECIFICATIONS

For further information see “Frigel Water Quality Reference Document”

5.5.1 WATER QUALITY


It is advised to use water that is not excessively hard, containing low contents of calcium ions, magnesium, silicon dioxide,
chlorine ions and ferric ions. Frigel recommends to establish a preventive water treatment program with a local water
specialist. As a general guideline we recommend to follow general std practices for CLOSED-LOOP INDUSTRIAL PROCESS
WATER SYSTEMS. Each water treatment company has their own specific approach and products. Normally the program
includes an initial flush and then corrosion and bacteria control products that are added and checked on a periodical basis.
Scale depends on the make-up water used and it is not typically critical being a closed loop system. If make-up water is
very hard and/or used for cooling process with high surface temperature (above 60 °C - 90 F), then a softener may be also
installed. Water should be tested at least every 3-4 months.

Closed Loop System Closed Loop System


Parameter
With No Aluminum Containing Aluminum

pH 8.5-10.5 7.5-8.0

Iron, Total <1.0 ppm <1.0 ppm

Copper, Free <0.1 ppm <0.1 ppm

Aluminum - < 0.1 ppm

Turbidity <20 NTU <20 NTU

Total Aerobic Bacteria < 1,000 CFU/ml < 1,000 CFU/ml

Anaerobic Bacteria (SRB) Negative Negative


Makeup water Hardness <200 ppm – NEW:50-200 ppm <200 ppm – NEW:50-200 ppm
Makeup water Conductivity < 500 μS/cm < 500 μS/cm

Target Corrosion Rates

Mild Steel < 0.5 mpy < 0.5 mpy


Copper < 0.1 mpy < 0.1 mpy
Aluminum - < 0.1 mpy
Stainless Steel < 0.1 mpy < 0.1 mpy

The above recommended values are indicative of a good water treatment and will be satisfactory in most different
scenarios. However, there could be cases where the specific requirements demand for different parameters to be
respected. Frigel cannot guarantee that following the above indications will result in an unconditionally water quality
trouble free system and strongly recommends to involve a specialist water treatment company as a consultant/service
provider.

NOTES:
The following general information might be interesting for the water specialists:
• Type of expansion tank = open to atmosphere.
• Temp. range = 50-95 F (10°C-60°C).

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• Recommended filtration = at least 150 microns provided by a full flow filter (preferable) or at least a side stream
by-pass.
Materials constituent Frigel equipment:
• Copper.
• Stainless steel.
• Small quantity of cast iron and galvanized steel.
• Very small quantities of brass and bronze.
• Industrial grade rubbers and gasket material in NBR, EPDM, VITON or TEFLON.

It is very important that your water treatment specialist is notified of the special materials in the cooling system that are
in contact with water. Review all the piping material and any equipment connected to the water system. The tables
above shows the ideal parameters that a water treatment specialist would like a closed system to run at. Those guidelines
are specific to the Plastic Industry and are much more stringent than the standard accepted specifications for general
closed systems, due to the extremely small diameter piping that is encountered in molds. Those “Guidelines” however
should be seen as targets and not limits. Targets are the ideal specifications that we should aim to achieve, but general
conditions of the system should also be taken into consideration. The addition of corrosive substances or the use of
particular types of water beyond these limits may cause inefficiency or breakage of components on machines. Ask FRIGEL
for further information.

5.5.2 ANTIFREEZE
In some plants antifreeze or other protective substances may be required. Follow the listed warnings:

• Contact FRIGEL FIRENZE S.p.A. if the process needs an antifreeze percentage higher than 35%: it
could cause current overload on pump motors or damage pump seals.
• Don’t use antifreeze less than 15-20%. highly diluted glycol may cause rapid deterioration of the
water creating a highly corrosive mixture.
• Check the compatibility of the any substances added to the process water with the pump seals,
for doubts, contact FRIGEL FIRENZE S.p.A.
• FRIGEL FIRENZE S.p.A. disclaims any liability for damage caused by the use of the machine under
the following conditions:
o Water quality outside the parameters specified above.
o Lack or total lack of the proper percentage of glycol.
o Any direct or indirect damages due to improper use of the machine are not covered by
the warranty of the machine in any cases.

6 WORKING CONDITION

For normal operation:

• GPP – GPV - GPA: open all valves in suction and discharge side of all pumps.
• GPR: open only the valves of the pumps used and close the valves of the pumps that will remain unused to ensure
that they do not work as a water bypass.
• Check that the voltage and the phases are correct, for all pumping stations.
• GPP/GPA/GPI: set the switches for all pumps to AUTOMATIC.
• GPR: set the switches of the pumps, in use, to ON.
• Check that the pumps can be primed: otherwise manually fill the suction side, for all pumping stations.
• Turn the power switch to ON.
• To start you need the consent of the 3PR, for all pumping stations.
• The 3PR receives an alarm from each pump’s thermal sensor individually.
• Check that there is no air in the impeller: use the air bleed screw (not present on all models) (see Fig 11).

NOTES
• GPP/GPA/GPI: if needed, the pumps can be activated manually by setting the switch of the pump(s) to MANUAL.
• At the first start up, check that the delivery pressure is consistent with the expected power consumption.

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MAIN POWER
DISCONNECT SWITCH

Fig 10: GPP/GPA/GPI SELECTOR

AIR BLEED SCREW

Fig 11: AIR BLEED SCREW

MAIN POWER
DISCONNECT SWITCH

Fig 12: GPR SELECTOR


NOTE: the GPV control panel has no selector. It is equipped with the main switch only. To set the manual control of pumps,
please refer to the proper technical documentation dealing with the variable speed drive configuration. Ask Frigel for
more information.

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7 ALARMS

If the pumps do not start, check:


• The presence of alarms on the 3PR control panel (*).
• The power to the group.

In case it is needed control the protection of the pump (GPP, GPR and GPA only), STRICTLY OBSERVE THE MAINTENANCE
INSTRUCTIONS, then:

• Remove the main power supply.


• Remove the protection panel.
• Check that there is no tension.
• Turn on the magnetic protection.
• Replace the cover and restore the power.

If the pump still does not start, proceed to check the pump as indicated by the pump manufacturer (see manufacturer
manual).

(*) See 3PR control panel manual.

8 WEBMONITORING

The machine can be monitored remotely from Frigel through remote monitoring panel 3PR.

See 3PR control panel manual.

9 MAINTENANCE

Maintenance of this equipment should be left to authorized service technicians, working on refrigerant
circuits requires special training and tools.
Not following safety precautions can cause serious personal injury.
Always wear personal protective equipment when working around components energized by high
voltage. Faulty components can explode and cause serious injuries.
Ensure that electrical power is isolated from the AC main-cables before handling them.
Before performing operations on hydraulic components, make sure that the wires or electrical
components are well insulated.

Few simple checks can contribute significantly to avoid problems in the life of the GP. Below a table of recommended
maintenance and time intervals.
The set of replacement parts, including the master panel, the display (user) and probes can be ordered from FRIGEL
FIRENZE S.p.A. or distributor. When ordering spare parts you must specify the serial number of the unit (see section 2).

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RECOMMENDED PREVENTIVE MAINTENANCE

MONTHLY
AS NEEDED
CHECKS

WEEKLY

YEARLY
Measure and record amp draw for each phase on each pump. X
Inspect hose clamps and/or Victaulic connections and check for tightness. X
Check pump for seal leakage, usual noise, vibration or overheating. X
Greasing shaft Bearing(s). (*) X
Check sensor readings, all electrical connections and visually inspect electrical
X
components. Remove dust from contactors and cooling fans.
GPR-GPA: make the rotation procedure. (**) X
GPV: keep air filter of electrical box cleaned. X
SPECIAL NOTES AND ADDITIONAL RECOMMENDATIONS
(*) The periodic greasing of the bearings of the pumps is specified on the nameplate on the pumps or the group itself
(Fig. 1, Fig.13).
(**) A special message from the 3PR is displayed (as a warning) to manually rotate the pump(s) to provide equal running
time to all pumps in the pump group. Switch off a pump, close inlet and outlet valves related to it, open valves of the
pump to switch on, then switch on that pump.

Refer to the wiring diagram for the description of the machine parts and part numbers.
Always provide the serial number of the machine when ordering replacement parts or assistance (see
section 2).

Be careful when servicing the metal frame and panels that can be sharp for design reasons: use protective
gloves.

Periodically grease the bearings of the pump when specified on the label (Fig. 13)

Monitor water quality. Most of the faults are due to poor water condition.

FRIGEL reserves the right to make any technical changes aimed at improvement of its products.

You cannot claim any rights on the basis of the data, instructions and descriptions in this owner's manual
and maintenance.

It is forbidden to tamper with, alter or modify, even partially, the devices covered by this manual, in
particular devices provided for the safety of persons and/or equipment. It is also forbidden to operate
differently than that described or neglecting the necessary security operations.

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Fig. 13: BEARING GREASE POINT

SENSOR DATA SHEET

SENSOR TYPE - SIGNAL RANGE REF. VALUES NOTES

1039.0 Ohm @ 10°C / 50°F


Temperature -50 ÷ 105°C No polarity
Ts, Te, Tr PT1000 cl.B 1077.9 Ohm @ 20°C / 68°F
sensor -58 ÷ 221°F issue
1116.7 Ohm @ 30°C / 86°F

Ps, Pr, Fin, Piezoelectric -0.5 ÷ 10 bar 4 mA @ -0.5 bar / -7.25 psi Polarity to be
4…20 mA
Fout pressure sensor -7.25 ÷ 145 psi 20 mA @ 10 bar / 145 psi respected

Ps ( for GPA, Piezoelectric -0.5 ÷ 6 bar 4 mA @ -0.5 bar / -7.25 psi Polarity to be
4…20 mA
GPR) pressure sensor -7.25 ÷ 87 psi 20 mA @ 6 bar / 87 psi respected

Piezoelectric 0 ÷ 0.3 bar 4 mA @ 0 bar / 0 psi Polarity to be


Lt 4…20 mA
pressure sensor 0 ÷ 4.35 psi 20 mA @ 0.3 bar / 4.35 psi respected.

10 EQUIPMENT DISPOSAL

Please refer to local regulations. Once the unit is out of service, the lubricant inside the pump and all the
electrical parts IN THE CIRCUIT MUST BE PROPERLY DISPOSED according to local regulations.

11 CE DECLARATION ANNEX

CE declaration is attached to this manual.

12 REVISION
00_00: First release.
01_00: Update pictures GPP 4800, update probe table, probe technical data, GPA technical characteristic.
02_00: GPV added.
03_00: GPI added. Updated sensor nomenclature according to “3PR Communication Network”.

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