GEA Bock HG44e/475-4, Assembly Instructions Manual

Page 1: ...al instructions HG X 44e 475 4 S HG X 56e 850 4 S HG X 44e 565 4 S HG X 56e 995 4 S HG X 44e 665 4 S HG X 56e 1155 4 S HG X 44e 770 4 S HG44e 475 4 S HC HG44e 770 4 S HC HG56e 850 4 S HC HG56e 1155 4 S HC HGX44e 475 S ML 9 LG HGX44e 770 S ML 22 LG HGX56e 850 S ML 18 LG HGX56e 1155 S ML 35 LG ...

Page 2: ...3 5 Type key LG compressors 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 along with the unit...

Page 3: ...rect or star delta start 7 5 Basic circuit diagram for star delta start with special motor 7 6 Electronic trigger unit INT69 G 7 7 Connecting of the trigger unit INT69 G 7 8 Functional test of the trigger unit INT69 G 7 9 Electronic trigger unit INT69 G on HC and LG compressors 7 10 Oil sump heater accessories 7 11 Oil sump heater on HC and LG compressors 7 12 Capacity regulator accessories 8 Comm...

Page 4: ...e INFO Important information or tips on simplifying work WARNING Inadequately qualified personnel poses the risk of accidents the consequence being serious or fatal injury Work on compressors is therefore reserved for personnel which is qualified to work on pressurized refrigerant systems For example a refrigeration technician refrigeration mechatronic engineer As well as professions with comparab...

Page 5: ...t be used in potentially explosive environments These assembly instructions describe the standard version of the compressor named in the title man ufactured by GEA GEA refrigerating compressors are intended for installation in a machine within the EU according to the EU Directives 2006 42 EC Machinery Directive 2014 68 EU Pressure Equipment Directive Commissioning is permissible only if the compre...

Page 6: ...fied in order to achieve sufficient risk reduction If necessary a classification of the hazardous areas according to EN60079 10 1 should be carried out If the refriger ant concentration exceeds the value of 25 of the lower flamma bility limit LEL all equipment in the hazardous area which is not permitted for operation in hazardous areas must be immediately switched off without any voltage Use only...

Page 7: ...uction gas cooled drive motor Preferred application range normal refrigerating and air conditioning 3 Product description Name plate Fig 1 3 1 Short description Valve plate Cylinder cover Dimension and connection values can be found in Chapter 12 Transport eyelet Discharge shut off valve Oil pump Suction shut off valve Oil sight glass Drive section Motor section Fig 2 HG44e HG56e Terminal box ...

Page 8: ...rating Electrical accessories can change pressure g High pressure side the IP protection class Observe the limits of application diagrams 50 Hz 60 Hz 3 Product description Fig 3 3 2 Name plate example 1 2 3 4 5 6 7 8 9 10 11 12 13 BB12345A001 HGX44e 770 4 S 35 0 A 101 A 174 A 67 0 80 4 SE 55 GEA Bock GmbH 72636 Frickenhausen Germany HG 4 4 e 770 4 S X HG Hermetic Gas Cooled suction gas cooled X Es...

Page 9: ...suction gas cooled S More powerful motor HG Hermetic Gas Cooled suction gas cooled X Ester oil charge 3 S More powerful motor ML Motor for normal cooling and deep freezing Hydrocarbons Motor variant Number of poles Swept volume e series Numbers of cylinders Size Series HFO refrigerant Engine performance in HP Motor variant 3 Swept volume e series Numbers of cylinders Size Oil filling Series ...

Page 10: ...ature 20 C 60 C Max permissible discharge end temperature 140 C Max permissible switching frequency 12x h A minimum running time of 3 min steady state condition continuous operation must be achieved For operation with supplementary cooling Use only oils with high thermal stability Avoid continuous operation near the threshold For operation with capacity regulator Continuous operation when the capa...

Page 11: ...nge there is a danger of air entering on the suction side This can cause chemical reactions a pressure rise in the condenser and an elevated compressed gas temperature Prevent the ingress of air at all costs Maximum admissible operating pressure g LP HP 1 19 28 bar 1 LP Low pressure HP High pressure ...

Page 12: ...mperature 30 C Operation in the vacuum range is not permitted During operation in the vacuum range there is a danger of air entering on the suction side This can cause chemical reactions pressure rise in the condenser and an excessive pressure gas tem perature as well as shifting of the refrigerant ignition limit into the critical range Avoid absolutely any entry of air Use a low pressure switch S...

Page 13: ...directly to the compressor are not permissible Setup on an even surface or frame with sufficient load bearing capacity Single compressor preferably on vibration damper Duplex and parallel circuits always rigid Provide adequate clearance for maintenance work Ensure adequate compressor ventilation Do not use in a corrosive dusty damp atmosphere or a combustible environment F E D 1 2 3 6 2 Setting up...

Page 14: ...diameters of the shut off valves are rated for maximum compressor output The actual required pipe cross section must be matched to the output The same applies for non return valves Fig 5 graduated internal diameter 6 3 Pipe connections ATTENTION Damage possible Superheating can damage the valve Remove the pipe supports from the valve for soldering Only solder using inert gas to inhibit oxidation p...

Page 15: ...lange height 27 mm is optional available Art Nr 81194 With this intermediate flange it is possible to lay the pressure line directly from the valve to the left or right a 6 6 Operating the shut off valves Before opening or closing the shut off valve release the valve spindle seal by approx of a turn counter clockwise After activating the shut off valve re tighten the adjustable valve spindle seal ...

Page 16: ...vices Service connection closed Connection blocked Spindle Connection cannot be shut off Connection cannot be shut off Service connection opened Spindle Connection open Compressor Compressor After activating the spindle generally fit the spindle protection cap again and tighten with 14 16 Nm This serves as a second sealing feature during operation For systems with long pipes and higher degree of c...

Page 17: ...rding to the maximum operating current see name plate For motor protection use a current independent time delayed overload protection device for monitor ing all three phases Adjust the overload protection device so that it must be actuated within 2 hours at 1 2 times the maximum working current INFO Connect the compressor motor in accordance with the circuit diagram see inside of terminal box Use ...

Page 18: ...1 1 FC1 2 FC2 SF1 QA2 11 12 14 L N B1 B2 12 11 10 9 8 7 6 5 4 3 2 1 50 50 Compressor terminal box 7 3 Basic circuit diagram for part winding start with standard motor BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor BT3 Release switch thermostat DELTA P II Oil differential pressur...

Page 19: ...k og FC1 1 1 2 Motor protection switch FC2 Control power circuit fuse INT69 G Electronic trigger unit INT69 G KF1 Delay relay for contactor switchover QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch DANGER Explosion risk Electronic trigger INT69 G at HC and LG compressors has to be installed outside any danger area See also chapter 7...

Page 20: ... direct start YY at the factory For part winding start Y YY the bridges must be removed and the motor feed line connected according to the circuit diagram ATTENTION Failure to do this results in opposed rotary fields and results in damage to the motor After the motor starts up via partial winding 1 partial winding 2 must be switched on after a maximum delay of one second Failure to comply can adve...

Page 21: ... V2 U2 W2 L3 L2 L1 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 5 4 Sondermotor Ausführung für Direkt oder Stern Dreieck Anlauf Für den Stern Dreieck Anlauf ist eine mechanische Anlaufentlastung mit Bypass Magnetventil Zubehör erforderlich Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Y Stern Dreieck Anlauf ist nur im Spannungsbereich 230 V möglich Beispiel 230 V Direktstart Ster...

Page 22: ... 2 QA2 FC1 2 I I I 3 4 5 6 1 2 QA4 Y 3 4 5 6 1 2 QA3 D 3 4 5 6 EC1 M 3 Fig 12 7 5 Basic circuit diagram for star delta start with special motor Compressor terminal box BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor BT3 Release switch thermostat DELTA PII Oil differential pressur...

Page 23: ...QA2 6 b 7 QA4 KF1 QA4 QA3 6 b 8 KF1 QA3 QA4 6 b 8 KF1 FC2 Control power circuit fuse INT69 G Electronic trigger unit INT69 G KF1 Delay relay for contactor switchover QA1 Main switch QA2 Mains contactor QA3 Δ contactor QA4 Y contactor SF1 Control voltage switch DANGER Explosion risk Electronic trigger INT69 G at HC and LG compressors has to be installed outside any danger area See also chapter 7 9 ...

Page 24: ...gainst overtemperature using thermal protection thermostats accessory The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause INFO The relay switching output is executed as a floating changeover contact This electrical circuit operates according to the quiescent current principle i e the relay drops into a the idle position and deactivates the motor con...

Page 25: ... 14 7 9 Electronic trigger unit INT69 G at HC and LG compressors The supplied INT69 G must be connected according to the wiring diagram shown here in a separate control cabinet which must be installed outside each danger zone BT1 Cold conductor PTC sensor motor winding BT2 Heat protection thermo stat PTC sensor EB1 Oil sump heater ATTENTION Install heat protection thermostats and cold conductor mo...

Page 26: ...mpressor starts up the refrigerant contained in the oil evaporates out throught the reduction in pressure The consequences can be foaming and migration of the oil causing oil shocks under certain circumstances Operation The oil sump heater operates when the compressor is at a standstill When the compres sor starts up the oil sump heater switches off again automatically Connection The oil sump heat...

Page 27: ...n insulation monitoring device must be used National standards and regulations must be observed Compressor Electrical data HG44e HC HG44e LG HG56e HC HG56e LG 230 V 1 50 60 Hz 160 W 7 10 Capacity regulator Accessories ATTENTION A fuse max 3xlB in accordance with IEC 60127 2 1 corresponding to the rated current must be placed in front of every magnetic coil of the capacity regulator as short circui...

Page 28: ...e compressor INFO Toprotectthecompressoragainstinadmissibleoperatingconditions high pressure and low pressure pressostats are mandatory on the installation side 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 exceeded at any time during the testing proces...

Page 29: ...gerant To avoid shifts in concentration zeotropic refrigerant blends must always only be filled into the refrigerating plant in liquid form Do not pour liquid coolant through the suction line valve on the compressor It is not permissible to mix additives with the oil and refrigerant 8 6 Start up Check that the safety and protection devices pressure switch motor protection electrical contact protec...

Page 30: ...e system must reach a state of equilibrium Particularly in critical systems e g several evaporator points measures are recommended such as replacement of liquid traps solenoid valve in the liquid line etc There should be no movement of coolant whatsoever while the compressor is at a standstill ATTENTION Slugging can damage the compressor and cause refrigerant to leak Mechanical oil level regulator...

Page 31: ...urs Dispose of used oil according to the regulations observe national regulations Annual checks Oil level leak tightness running noises pressures temperatures function of auxiliary devices such as oil sump heater pressure switch WARNING Before starting any work on the compressor Switch off the compressor and secure it to prevent a restart Relieve compressor of system pressure Prevent air from infi...

Page 32: ...standard oil types Recommended alternatives HFC e g R134a R407C R404A Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Arctic 46 Sunoco Suniso SL 46 Texaco Capella HFC 55 HFO e g R1234yf R1234ze R455A R454C Fuchs Reniso Triton SE 55 Fuchs Reniso C85E from tO 15 C HCFC e g R22 Fuchs Reniso SP 46 Fuchs Reniso SP 32 BP Energol LPT 46 Sunoco Suniso 3 5 GS Texaco Capella WF 46 HC e g...

Page 33: ...y Cylinder cover prepared for capacity regulator Fig 20 Before commissioning the blind flange with screws must be removed and replaced by the new set capacity regulator with O ring joints and screws Observe position and construction of the capacity regulator Attention Compressor is under pressure Depressurize the compressor first Delivery condition 2 from the factory Connect capacity regulator in ...

Page 34: ...e of equilibrium Continuous operation in the control stage is not recommended as the gas velocity in the plant system under certain circumstances does not guarantee sufficient oil return to the compressor with activated capacity regulator We recommend switching to unregulated operation 100 capac ity for at least 5 minutes per capacity regulated operating hour An assured oil return can also be real...

Page 35: ...7 149 174 HG44e 665 4 S 57 7 69 2 30 18 3 101 174 171 HG44e 770 4 67 0 80 4 30 17 8 101 174 171 HG44e 770 4 S 67 0 80 4 35 21 4 101 174 171 11 Technical data 1 2 3 2 4 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 operation For 60Hz operation the specifications have to be multi...

Page 36: ...6 211 HG56e 1155 4 100 4 120 5 47 28 0 149 246 212 HG56e 1155 4 S 100 4 120 5 58 33 3 196 335 221 11 Technical data 1 2 3 2 4 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 operation For 60Hz operation the specifications have to be multiplied by the factor 1 2 The max working cu...

Page 37: ... HC 16172 HG44e 665 4 S HC 16176 HG44e 770 4 HC 16173 HG44e 770 4 S HC 16177 Q W B B1 DV A1 SV H D1 A B L 695 649 2 25 30 A1 SV A Ansicht HG X 44e 475 4 S 565 4 View HG X 44e 475 4 S 565 4 X A D F M C O K B L J 300 256 2 5 361 142 383 2 4x 15 Ansicht X Anschlussmöglichkeit für Ölspiegelregulator View X Possibility of connection of oil level regulator Dreilochanschluss für TRAXOIL 3xM6x10 Three hol...

Page 38: ... change without notice Anschlüsse Connections SV Saugabsperrventil Rohr Suction line valve tube DV Druckabsperrventil Rohr Discharge line valve tube A Anschluss Saugseite nich Connection suction side n A1 Anschluss Saugseite absp Connection suction side lo B Anschluss Druckseite nich Connection discharge side B1 Anschluss Druckseite abs Connection discharge side C Anschluss Öldrucksicherhe Connect...

Page 39: ...ng to Annex I points 1 1 2 1 1 3 1 1 5 1 3 2 1 3 3 1 3 7 1 5 1 1 5 2 1 5 13 and 1 7 1 to 1 7 4 excepted 1 7 4 f are fulfilled Applied harmonised standards in particular EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction EN 12693 2008 Refrigerating systems and heat pumps Safety and environmental requirements Positive displacement refrigerant compr...

Page 40: ... If you have any questions about installation operation and accessories please contact our technical service or specialist wholesaler and or our representative The Bock service team can be contacted by phone 49 0 7022 9454 0 or via gea com contact Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 14 Service ...

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Page 42: ...e 49 0 7022 9454 0 Fax 49 0 7022 9454 137 gea com contact 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 ...