GEA Bock HG34e A Series, Assembly Instructions Manual

Page 1: ...A HG34e 255 4 S A HGX34e 255 4 A HGX34e 255 4 S A HG34e 315 4 A HG34e 315 4 S A HGX34e 315 4 A HGX34e 315 4 S A HG34e 380 4 A HG34e 380 4 S A HGX34e 380 4 A HGX34e 380 4 S A GEA Compressor HG34e A Assembly instructions 96191 07 2016 Gb Translation of the original instructions ...

Page 2: ...of the compressor can lead to serious or fatal injury Observe the safety instructions contained in these instructions These instructions must be passed onto the end customer along with the unit in which the compressor is installed GEA Bock GmbH 72636 Frickenhausen GEA Bock GmbH Benzstrasse 7 72636 Frickenhausen Germany Phone 49 7022 9454 0 Fax 49 7022 9454 137 info gea com www gea com Manufacturer...

Page 3: ...ns 5 Electrical connection 14 5 1 Information for contactor and motor contactor selection 5 2 Connecting the drive motor 5 3 Circuit diagram for direct start 230 V 400 V Y 5 4 Electronic trigger unit MP 10 5 5 Connecting the trigger unit MP 10 5 6 External connection of the MP 10 for terminal boxes at reduced height 5 7 Functional test of the trigger unit MP 10 6 Commissioning 20 6 1 Preparations ...

Page 4: ...ential dangers WARNING Refrigerating compressors are pressurised machines and therefore require particular caution and care in handling Risk of burns Depending on the operating conditions surface temperatures of over 60 C on the pressure side or below 0 C on the suction side can be reached The maximum permissible overpressure must not be exceeded even for testing purposes 1 1 Identification of saf...

Page 5: ...ited The GEA refrigerating compressor named in the title is intended for installing in a machine within the EU according to the EU Directives 2006 42 EC Machinery Directive and 2014 68 EU Pressure Equipment Directive Commissioning is only permissible if the compressor has been installed in accordance with these assembly instructions and the entire system into which it is integrated has been inspec...

Page 6: ...ith oil pump lubrication Lightweight aluminum design Suction gas cooled drive motor Fig 1 2 1 Short description Fig 2 Oil sightglass Valve plate Cylinder cover Discharge shut off valve Oil pump Terminal box Suction shut off valve Drive motor Motor part Dimension and connection values can be found in Chapter 9 Transport eyelet Name plate ...

Page 7: ...quency 2 Machine number 7 Nominal rotation speed 3 maximum operating current 8 Displacement 4 Starting current rotor blocked 9 Voltage circuit frequency 5 ND LP max admissible operating pressure 10 Nominal rotation speed Low pressure side 11 Displacement HD HP max admissible operating 12 Oil type filled at the factory pressure High pressure side 13 Protection system terminal box Observe the limits...

Page 8: ... At max rotation speed therefore the application limit can be reduced Use a thermal protection thermostat Do not operate an additional capacity controller Oil return at low frequency must be guaranteed Consultation with GEA 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 su...

Page 9: ...ge Supplementary cooling or reduced suction gas temperature Supplementary cooling and reduced suction gas temperature Motor version S more powerful motor Evaporating temperature C Condensing temperature C Suction gas superheat K Suction gas temperature C Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure ...

Page 10: ...te clearance for maintenance work Ensure adequate compressor ventilation Do not use in a dusty damp atmosphere or a combustible environment Fig 11 Fig 12 Fig 13 F E D C 1 2 3 4 2 Setting up 4 1 Storage and transport Use transport eyelet Do not lift manually Use lifting gear Storage at 30 C 70 C maximum permissible relative humidity 10 95 no condensation Do not store in a corrosive dusty vaporous a...

Page 11: ... valves are rated for maximumcompressoroutput Therequiredpipecross sectionmustbe matched to the output The same applies for non return valves Fig 15 Stepped internal diameters 4 4 Pipe connections 4 3 Maximum permissible inclination A a A a ATTENTION Poor lubrication can damage the compressor Respect the stated values Fig 14 A max 30 max 2 minutes a max 15 continuous operation ATTENTION Overheatin...

Page 12: ... thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft 4 5 Pipes Pipes and system components must be clean and dry inside and free of scale swarf and layers of rust and phosphate Only use air tight parts Lay pipes correctly Suitable vibration compensators must be provided to prevent pipes being cracked and broken by severe vibrations Ens...

Page 13: ...f the lockable service connections Fig 19 Opening the shut off valve Spindle turn to the left counter clockwise as far as it will go Shut off valve completely opened service connection closed Fig 20 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened Service connec tion closed Connection blocked Spindle Service connec tion opene...

Page 14: ...d motor contactor selection All protection devices and switching or monitoring units must be fitted in accordance with the local safety regulations and established specifications e g VDE as well as with the manufacturer s infor mation Motor protection switches are required Motor contactors feed lines fuses and motor protection switches must be rated on the basis of the maximum working current see ...

Page 15: ...r Anschluss Electrical connection Raccordement électrique Y 96027 11 06 DGbF Niedere Spannung Low voltage Bas voltage Y Hohe Spannung High voltage Haut voltage L3 L1 L2 L3 L1 L2 Electrical connection Raccordement électrique Y 96027 11 06 DGbF Niedere Spannung Low voltage Bas voltage Y Hohe Spannung High voltage Haut voltage L3 L1 L2 L3 L1 L2 L1 L2 L3 L1 L2 L3 INFO The connection examples shown ref...

Page 16: ...ermal protection thermostat PTC sensor F1 Load circuit safety switches F2 Control power circuit fuse F3 Safety chain high low pressure monitoring B1 Release switch thermostat pressostat Q1 Main switch 5 3 Circuit diagram for direct start 230 V 400 V Y Fig 21 Compressor terminal box ...

Page 17: ...ssor contactor MP10 Electronic trigger unit MP 10 AC 230 V E Oil sump heater AC 230 V X3 Terminal strip in terminal box XSS Terminal strip in the external switch cabinet A1 Alarm Motor protection A2 Overheating R1 R2 A3 Alarm high pressure XSS Terminal strip in the external switch cabinet ...

Page 18: ...f the compressor can also be protected against overtemperature using a thermal protection thermostat accessory The H2 LED red is provided for the protection function The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause INFO The unit has a restart prevention device After the fault has been remedied either interrupt the mains voltage or acknowledge wit...

Page 19: ...ly interrupted L1 or S1 OFF OFF OFF Release the motor temperature sensor connection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or S1 ON Function check of motor temperature sensor operational ON Function check of hot gas temperature sensor operational ON 3 Power supply interrupted again L1 or S1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or ...

Page 20: ...nstallation side The compressor has undergone trials in the factory and all functions have been tested There are therefore no special running in instructions Check the compressor for transport damage DANGER Risk of bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximum permissible overpressure of the compressor must not be exceede...

Page 21: ...cause coolant to leak To prevent slugging The complete refrigeration system 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 superheat 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 in cr...

Page 22: ...ing the first maintenance system Then after every 10 000 12 000 operating hours though no more than 3 years cleaning oil and suction filter at the same time Annual checks Oil level tightness running noise pressures temperatures function of auxiliary devices such as a oil sump heater pressure switch Accessories available can be found on the Internet at www gea com 7 4 Accessories Only use original ...

Page 23: ...ith the valid national regulations 7 Maintenance 7 5 Extract from the lubricants table The oil type filled as standard in the factory is marked on the name plate This oil type should be used as a preference Alternatives are stated in the extract from our lubricants table below Refrigerants GEA standard oil types Recommended alternatives HFKW z B R134a R407 R 404A Fuchs Reniso Triton SE 55 Fuchs Re...

Page 24: ...7 HG34e 315 4 S A 27 3 32 8 25 5 14 7 8 9 132 76 60 HG34e 380 4 A 33 1 39 7 26 1 15 1 9 3 111 64 56 HG34e 380 4 S A 33 1 39 7 31 2 18 0 11 1 132 76 59 Type 1 2 3 2 4 220 240 V 380 420 V Y 3 50 Hz 265 290 V 440 480 V Y 3 60 Hz Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request The specifications for max power consumption apply for 50Hz operat...

Page 25: ... Connection oil pressure gauge 1 8 NPTF F Oil drain M10 H Oil charge plug 1 4 NPTF J Connection oil sump heater Ø 15 mm K Sight glass 1 1 8 18 UNEF L Connection thermal protection thermostat 1 8 NPTF O Connection oil level regulator 1 1 8 18 UNEF Fig 24 273 ca 135 ca 190 B1 F B L A E H D1 DV K O ca 272 ca 315 285 230 4x 12 115 J 310 79 419 46 ca 540 A1 1 SV A 30 10 M 20 40 273 ca 135 ca 190 B1 F B...

Page 26: ...ards referenced A partly completed machine may only be put into operation when it has been established that the machine into which the partly completed machine is to be installed conforms to the regulations of the Machinery Directive 2006 42 EC The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery upon request ...

Page 27: ...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 11 Service ...

Page 28: ...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 ...