GEA Bock EX-HG(X)44e/475-4, Assembly Instructions Manual

Page 1: ... EX HG X 56e 995 4 EX HG44e 565 4 HC EX HG56e 995 4 HC EX HG X 44e 665 4 EX HG X 56e 1155 4 EX HG44e 665 4 HC EX HG56e 1155 4 HC EX HG X 44e 770 4 EX HG44e 770 4 HC EX HG X 44e 475 4 S EX HG X 56e 850 4 S EX HG44e 475 4 S HC EX HG56e 850 4 S HC EX HG X 44e 565 4 S EX HG X 56e 995 4 S EX HG44e 565 4 S HC EX HG56e 995 4 S HC EX HG X 44e 665 4 S EX HG X 56e 1155 4 S EX HG44e 665 4 S HC EX HG56e 1155 ...

Page 2: ... charge 3 4 Limits of application Contents Page About these instructions Read these instructions before assembly and before using the compressor This will avoid misunder standings and prevent damage Improper assembly and use of the compressor can result in serious or fatal injury Observe the safety instructions contained in these instructions These instructions must be passed onto the end customer...

Page 3: ...nit INT69 G Ex 5 9 Connection of the electronic trigger unit INT69 G Ex 5 10 Functional test of the electronic trigger unit INT69 G Ex 5 11 To verify the intrinsic safety of the PTC hot gas sensor 6 Commissioning 33 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak test 6 4 Evacuation 6 5 Refrigerant charge 6 6 Start up 6 7 Avoiding liquid sluggings 6 8 Preventing icing on the comp...

Page 4: ...tion or tips on simplifying work WARNING Inadequately qualified personnel poses the risk of accidents the consequence being serious or fatal injury Work on compressors must therefore only be performed by personnel with hereinafter qualifications and appropriate to additional qualification according to EN 60079 14 For example a refrigeration technician refrigeration mechatronic engineer As well as ...

Page 5: ...lf We assume that the appli cable regulations standards and technical rules are followed in installation and during operation The plant constructor operator must evaluate the interactions with other devices and components of the system and with the environment especially regarding potential ignition sources WARNING Refrigerating compressors are pressurised machines and there fore require particula...

Page 6: ...s well as observance of the operating limits and listed standards must be ensured in any case Likewise all accessories available from approved and specially marked by GEA are exclusively approved according to their intended use for attachment to and operation with GEA compressors of appliance category 2 in accordance with Directive 2014 34 EU 1 4 Intended use WARNING Any other use of the compresso...

Page 7: ...tion shut off valve Drive section Motor section Dimension and connection values can be found in Chapter 10 Transport eyelet Potential equalization EX HG44e Semi hemetic four cylinder reciprocating compressor with oil pump lubrication EX HG56e Semi hemetic six cylinder reciprocating compressor with oil pump lubrication For use in explosion endangered areas EX HG44e EX HG56e Name plate ...

Page 8: ... highest heat potential are controlled with temperature sensors Ex b The installation of the electronic control unit INT69 EX2 and the safety barrier both included in the scope of supply is therefore absolutely necessary The connection areas for load circuits are designed according to the requirements of the appliance category in Ex e The circuits for the temperature sensors of the used ignition s...

Page 9: ...on the connecting areas of the coil are placed in a housing that complies with the requirements of the protection type increased safety Ex e The oil differential pressure sensor INT250 Ex from Kriwan is executed as a simple electrical operating device without a recognised ignition protection type To ensure reliable operation however it must be equipped as an intrinsically safe electrical circuit w...

Page 10: ...cations Fig 3 HC for hydrocarbons Motor variant 3 Number of poles Swept volume e series Number of cylinders Size Ester oil filling Series Ex design 1 Type designation 6 Voltage circuit frequency 2 Machine number 7 Nominal rotation speed 3 maximum operating current 8 Displacement 4 Starting current rotor blocked 9 Voltage circuit frequency Y Part winding 1 10 Nominal rotation speed YY Part windings...

Page 11: ...s not underground buildings Suitability for gas explosive area Device category 2 zone 1 Temperature class T3 max 200 C Equipment protection level Explosion subgroups IIB Offshore paint finish IIC ESD paint finish Intrinsically safe equipment Increased safety Flameproof enclosure heater option Europ explosion protection acc to Direc 2014 34 EU Encapsulation magnetic coil option ...

Page 12: ...ational explosion protection Year of test Test report number Year of test Bureau Veritas Consumer Products Services Germany GmbH Special conditions see Conditions of Certification Special conditions see point 17 of the EC type examination certificate Test report number ATmospheres EXplosibles european explosion protection ATEX approval type IECEx approval type ...

Page 13: ...nspection maintenance repair the remaining refrigerant must be suctioned out and the compressor evacuated filled with nitrogen 0 5 bar and closed gas tight The compressor must be equipped with a tag that clearly states that the compressor was operated with combustible refrigerant name the refrigerant If the system contains combustible refrigerants or residues extreme caution must be exercised when...

Page 14: ...d Operate compressors only with the approved refrigerants and the corresponding assigned and approved oils Other combinations e g R22 with ester oils are not permitted Conversion to another refrigerant oil is not permitted ATTENTION The oil level must be in the visible part of the sight glass damage to the compressor is possible if overfilled or under filled max min oil level The following oil gra...

Page 15: ...operation near the limits For operation with capacity regulator Continuous operation when the capacity regulator is activated is not permissible and can cause damage to the compressor The suction gas superheat temperature may need to be reduced or set individually when operating near to the threshold When the capacity regulator is activated the gas velocity in the system can not under certain circ...

Page 16: ...embly instruction For a safe function of the ignition source control the INT69 EX2 has to be installed according to the wiring diagram fig 21 Check the function of the ignition protection system according to section 5 10 Defective sensors or ignition protection systems have to be replaced before reconnection of the compressor Operation of the compressor without igintion source control is not permi...

Page 17: ...Blatt g Benennung Zeichn Nr Teile Nr x xxxx xxxxx x Maßstab 1 1 4 Compressor assembly Lightening protection If the compressor is set up outdoors a lightening protection concept has to be integrated Sun protection If the compressor is set up outdoors it has to be protected from direct sunlight Fig 10 Fig 11 4 3 Setting up 4 2 Storage and transport Use transport eyelet Do not lift manually Use lifti...

Page 18: ...nal diameter 4 4 Pipe connections ATTENTION An explosive atmosphere must not be present Do not solder as long as the compressor is under pressure Superheating can damage the valve Remove the pipe supports therefore from the valve for soldering and accordingly cool the valve body during and after soldering Only solder using inert gas to inhibit oxidation products scale Pipes and system components m...

Page 19: ...d pressure lines Fig 13 A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft ATTENTION Improperly installed pipes can cause cracks and tears which can result in a loss of refrigerant INFO Proper layout of the suction and pressure lines directly after the com pressor is integral to the smooth running and vibration behaviour of ...

Page 20: ...e shut off is intended for safety devices Fig 17 Opening the service connection Spindle Turn 1 2 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service connection closed Connection blocked Spindle Connection cannot be shut off Connection cannot be shut off Service connection opened Spindle Connect...

Page 21: ... free protection against loosening can be achieved through check nuts or appropriate adhesive Avoid abrasion points on cables For cable lead through at the terminal box use suitable Ex cable screw connections in the correct protective version see name plate Use strain relief Avoid abrasion points on cables Install all switching devices outside the explosion endangered area Motor contactors feed li...

Page 22: ... followed At ambient temperatures 40 C supply lines and cable line bushings with a temperature resistance of at least 90 C must be used The interpretation of the minimum terminal cross sections refer to the voltage range of 400 V 50 Hz at 30 C ambient temperature 5 2 Information for contactor and motor contactor selection All protection devices and switching or monitoring units must be fitted in a...

Page 23: ...g to the circuit diagram INFO The compressor is equipped with a motor in Part Winding design ATTENTION Failure to comply results in reversed fields of rotation and can cause motor damage After the motor has started up with part winding 1 part winding 2 must be switched on after max 1 second delay Failure to comply can be detrimental to the service life of the motor ATTENTION Terminal boxes and cab...

Page 24: ...utside of the explosion endangered area Power section QA1 Main switch QA2 Performance contactor direct start FC1 1 Motor safety switch EC1 Compressor motor BT1 PTC sensor motor winding BT2 Thermal protection thermostat UC1 Terminal box compressor X KK Terminal strip in terminal box compressor X SS Terminal strip in external switch cabinet 5 5 Circuit diagrams for power section ATTENTION Ensure tha...

Page 25: ...1 L1 L2 L3 N PE FC1 1 I I I 1 2 QA2 1 L1 L1 L2 L2 L3 L3 U1 U2 V1 V2 W1 W2 2 3 4 3 4 5 6 5 6 M 3 Y YY PE PE 7 9 4 BT2 1 2 BT2 5 L1 L2 L3 N PE QA1 L1 L2 L3 N PE FC1 1 I I I 1 2 QA2 1 L1 L1 L2 L2 L3 L3 U1 U2 V1 V2 W1 W2 2 3 4 3 4 5 6 5 6 M 3 Y YY PE PE FC1 2 I I I 1 2 QA3 3 4 7 5 6 9 4 BT2 1 2 BT2 5 L1 L2 L3 N PE BT2 BT2 PA PA XKK D 1 1 b 4 XKK D 2 1 b 4 XKK D 3 1 b 4 XKK D 4 1 b 4 XKK PW 1 1 b 9 XKK...

Page 26: ... in the external switch cabinet X KK Terminal strip in the supplemental terminal box with recognised protection type Optional KF1 Time delay relay on delay max 90 sec bypass time at start KF2 Time delay relay drop off delay max 90 sec function begins when the oil pressure monitoring is reached during operation BP5 Oil differential pressure sensor Kriwan EB1 Oil sump heater ATEX design FA2 Switchin...

Page 27: ...te L1 L2 L3 N PE FC2 1 SF1 FC1 1 XSS 1 1 3 2 4 PA A1 A2 KF3 P öl Kriwan 1 3 or 2 4 br rot 13 14 QA2 PE PE 8 BT3 A2 A1 KF1 Max 90sec 16 15 KF2 18 16 15 KF1 A1 A2 QA2 18 PE PE PE FC2 2 23 24 QA2 9 8 EB1 10 10 19 20 11 LR P 12 L1 L2 L3 N PE PE PE 12 11 KF3 14 PE 12 11 14 BP2 P PE PE PE 2 4 5 3 6 1 2 3 4 FB1 Δ I 7 1 2 11 12 14 L N XKK 3 6 7 9 24V A1 A2 X1 KF2 12 11 14 BP1 P XKK D 1 XKK D 2 XKK D 3 XKK...

Page 28: ...binet X KK Terminal strip in the supplemental terminal box with recognised protection type Optional KF1 Time delay relay on delay max 90 sec bypass time at start KF2 Time delay relay drop off delay max 90 sec function begins when the oil pressure monitoring is reached during operation BP5 Oil differential pressure sensor Kriwan EB1 Oil sump heater ATEX design FA2 Switching repeater oil pressure co...

Page 29: ...2 L3 N PE 12 FC2 1 SF1 FC1 1 FC1 2 11 KF3 14 1 3 2 4 PA A1 A2 KF3 1 10 Y1 Y2 KF2 max 90s 2 11 33 34 QA2 A2 A1 KF1 max 90s 16 15 KF2 18 16 15 KF1 A1 A2 QA2 18 13 14 KF5 43 44 QA2 A1 A2 QA3 A2 A1 KF5 max 1s L1 L2 L3 N PE XSS 1 P öl Kriwan or br rot PE PE 8 BT3 PE PE PE 9 8 EB1 10 10 11 LR 12 PE PE PE 12 11 14 12 11 14 BP2 P PE PE PE 2 4 5 3 6 7 FC2 2 23 24 QA2 19 20 P 1 2 3 4 FB1 Δ I 11 12 14 L N 1 ...

Page 30: ...3 SELV or PELV safety transformer must be installed in series The safety transformer must conform to EN 60950 1 5 8 Electronic trigger unit INT69 EX2 ATTENTION Install INT69 EX2 outside the explosion endangered area The INT69 EX2 trigger unit must be installed according to the wiring diagram INFO The relay switching output is executed as a floating changeover contact This electrical circuit operat...

Page 31: ... EX2 must be designed as intrinsically safe sensor circuits and clearly marked in accordance with EN 60079 14 Appropriate measures e g barrier must be taken Make the connecting lines intrinsically safe Do not exceed the maximum resistance of 50 Ω Take into account the resistance values of the thermal protection thermostats Motor sensor as triple PTC resistor 50 450 Ω Rcold at 25 C not intrinsicall...

Page 32: ... V Uo Ui2 15 8 30 V Io Ii1 200 300 mA Io Ii2 200 300 mA Po Pi1 395 9000 mW Po Pi2 395 9000 mW Lo Li1 Li2 Lc 0 5 0 25 mH Co Ci1 Ci2 Cc 478 50 nF To verify the intrinsic safety of the hot gas sensor the following values must be rated Values for Lc Cc represent example values for the total output length of 250 m and they must be updated by the system builder in accordance with your design Li1 Li2 O m...

Page 33: ... corresponding safety standard without the inclusion of the compressor 6 3 Leak test Carry out the leak test on the refrigerating plant in accordance with EN 378 2 or a corresponding safety standard while always observing the maximum permissible overpressure for the compressor DANGER Risk of bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other ga...

Page 34: ...topped up in vapour form on the suction side or taking suitable precautions also in liquid form at the inlet to the evaporator 6 5 Refrigerant charge ATTENTION Do not start the compressor if it is under vacuum Do not apply any voltage even for test purposes must only be operated with refrigerant Under vacuum the spark over and creepage current distances of the terminal board connection bolts short...

Page 35: ...isible in the sight glass To prevent slugging The complete refrigeration plant must be properly designed All components must be compatibly rated with each other with regard to output particularly the evaporator and expansion valves Suction gas superheating at the compressor input should be min 7 10 K check the setting of the expansion valve The system must reach a state of equilibrium Particularly...

Page 36: ... field installations or when operating near the application limit for the first time after 100 to 200 operating hours then approx every 3 years or 10 000 12 000 operating hours Dispose of old oil according to the regulations observe national regulations WARNING All work must be performed only by qualified personnel see page 4 with exclusion of any danger of explosion Before starting any work on th...

Page 37: ... parts list Further repair work can only be carried out at the factory The following torques must be used when re assembling the compressor Cylinder cover bearing cover M10 75 Nm Oil filler plug oil drain plug oil sump heater M22x1 5 100 Nm Flange connection soldering supports for shut off valves 7 16 M10 M12 13 Nm 60 Nm 90 Nm Plug 1 8 NPTF 25 Nm Rotor M12 65 Nm Valve body LR 14 M10 75 Nm Screw in...

Page 38: ...anying kit documentation Terminal cross section of magnetic coil 3 x 1 5 2 5 mm2 Mountable cable diameter 7 9 mm INFO The gas velocities and pressure conditions of the refrigerating plant change in operation with capacity regulation Adapt the suction line run and dimensioning correspondingly do not set control intervals too closely steady state condition of the ref rigeration plant must be reached...

Page 39: ...peration The oil sump heater operates when the compressor is at a standstill When the compressor starts up the oil sump heater switches off again ATTENTION To limit the heat resulting from abnormal earth connection and earth conducting current the following protective equipment must be installed in addition to excess current protection In a TT or TN system a residual current protection device RCD ...

Page 40: ...ly protected During assembly and installation of the oil differential pressure sensor INT250 Ex the requirements of EN 60079 14 and the BetrSichV operational safety regulations must be met In addition nationally valid laws regulations in Germany VDE 0100 or provisions must be observed Additional installation instructions and installation deinstallation instructions can be obtained from the accompa...

Page 41: ...9 0 22 13 2 64 109 165 EX HG44e 565 4 S 49 2 59 0 26 15 6 101 171 170 42 1 5 8 EX HG44e 665 4 57 7 69 2 26 15 4 87 150 171 EX HG44e 665 4 S 57 7 69 2 30 18 3 101 171 168 EX HG44e 770 4 67 0 80 4 30 17 8 101 171 168 EX HG44e 770 4 S 67 0 80 4 35 21 4 101 171 168 9 Technical data 1 2 3 2 4 Tolerance 10 relative to the mean value of the voltage range The specifications for max power consumption apply...

Page 42: ...88 6 39 23 5 125 209 211 EX HG56e 995 4 86 6 103 9 39 23 2 125 209 208 EX HG56e 995 4 S 86 6 103 9 46 27 7 149 246 211 EX HG56e 1155 4 100 4 120 5 47 28 0 149 246 212 EX HG56e 1155 4 S 100 4 120 5 58 33 3 196 335 221 9 Technical data 1 2 3 2 4 Tolerance 10 relative to the mean value of the voltage range The specifications for max power consumption apply for 50 Hz operation For 60 Hz operation the ...

Page 43: ...e 07 03 17 07 03 17 Werkstückkanten Workpiece edges DIN ISO 13715 Erstellt Drawn Geprüft Verified M Gneiting J Faßbender 1 4 Oberflächenbehandlung Härte Treatment of surface Hardness Blatt Page 400 Benennung Description 0 8 1000 30 6 0 3 120 30 0 2 Zeichnungs Nr Drawing No Oberflächenangaben Indication of surface texture DIN EN ISO 1302 Gußtoleranzen General casting tolerances Gewicht Weight kg 0 ...

Page 44: ... pressure gauge 1 8 NPTF F Oil drain M12x1 5 H Oil charge plug 1 4 NPTF J Connection oil sump heater M22x1 5 K Sight glass 3 x M6 L1 Thermal protection thermostat 1 8 NPTF M Oil strainer M12x1 5 O Connection oil level regulator 3 x M6 PA Potential equalisation connection M8 Operate these components with the appropriate type of protection only 10 Dimensions and connections Dimensions INT69 EX2 for ...

Page 45: ...z Freigabe Approved über above bis up to Teile Nr Part No A Layh 4x 15 305 350 440 2 142 429 2 J F M E D O K L1 A B B1 DV L1 L1 X M16x1 5 4x 381 67 153 530 740 2 335 366 245 160 A1 SV B H D1 A PA M32x1 5 2x M40x1 5 2x M16x1 5 2x 25 M 30 Halbhermetischer Verdichter EX HG Semi hermetic compressor EX HG 1 Klemmbereich 4 8mm clamping area 4 8mm Änderungen vorbehalten Subject to change without notice M...

Page 46: ... pressure gauge 1 8 NPTF F Oil drain M12x1 5 H Oil charge plug 1 4 NPTF J Connection oil sump heater M22x1 5 K Sight glass 3 x M6 L1 Thermal protection thermostat 1 8 NPTF M Oil strainer M12x1 5 O Connection oil level regulator 3 x M6 PA Potential equalisation connection M8 Operate these components with the appropriate type of protection only 10 Dimensions and connections Fig 26 Oil sump heater Ca...

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Page 54: ...ny questions about installation operation and accessories please contact our technical service or specialist wholesaler and or our representative The GEA service team can be contacted by phone with a toll free hotline 00 800 800 000 88 or via e mail info gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 12 Service ...

Page 55: ...D GB F E I 55 96389 08 2019 DGbFEIRu ...

Page 56: ...one 49 0 7022 9454 0 Fax 49 0 7022 9454 137 info gea com gea com GEA Group is a global engineering company with multi billion euro sales and operations in more than 50 countries Founded in 1881 the company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index ...