GEA Bock EX-HG44e Series, 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...

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 Im...

Page 3: ...it 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 Co...

Page 4: ...ion 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...

Page 5: ...f 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 de...

Page 6: ...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 accor...

Page 7: ...ion 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 comp...

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 a...

Page 9: ...n 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 i...

Page 10: ...tions 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 Machi...

Page 11: ...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 p...

Page 12: ...tional 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 se...

Page 13: ...spection 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 th...

Page 14: ...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...

Page 15: ...peration 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 s...

Page 16: ...mbly 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 accord...

Page 17: ...att g Benennung Zeichn Nr Teile Nr x xxxx xxxxx x Ma stab 1 1 4 Compressor assembly Lightening protection If the compressor is set up outdoors a lightening protection concept has to be integrated Sun...

Page 18: ...al 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 suppo...

Page 19: ...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 crack...

Page 20: ...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 canno...

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 conn...

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 t...

Page 23: ...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 moto...

Page 24: ...tside 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 prot...

Page 25: ...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...

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 dela...

Page 27: ...tte L1 L2 L3 N PE FC2 1 SF1 FC1 1 XSS 1 1 3 2 4 PA A1 A2 KF3 P l 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...

Page 28: ...inet 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...

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 ma...

Page 30: ...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 e...

Page 31: ...69 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 s...

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...

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 wh...

Page 34: ...opped 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 unde...

Page 35: ...sible 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 e...

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 accor...

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 dr...

Page 38: ...nying 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 ope...

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 ea...

Page 40: ...y 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...

Page 41: ...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...

Page 42: ...8 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 3...

Page 43: ...07 03 17 07 03 17 Werkst ckkanten Workpiece edges DIN ISO 13715 Erstellt Drawn Gepr ft Verified M Gneiting J Fa bender 1 4 Oberfl chenbehandlung H rte Treatment of surface Hardness Blatt Page 400 Ben...

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 Conn...

Page 45: ...z Freigabe Approved ber 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...

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 Conn...

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Page 54: ...y 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 t...

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

Page 56: ...ne 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 com...