GEA Bock HG8 Series, Assembly Instructions Manual

Page 1: ...y instructions 09790 02 2018 Gb Translation of the original instructions HG8 2470 4 HG8 2470 4 S HGX8 2470 4 HGX8 2470 4 S HG8 2830 4 HG8 2830 4 S HGX8 2830 4 HGX8 2830 4 S HG8 3220 4 HG8 3220 4 S HGX8 3220 4 HGX8 3220 4 S ...

Page 2: ...e 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 in which the compres sor is installed GEA Bock GmbH 72636 Frickenhausen GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 info gea com www gea com Manu...

Page 3: ...t diagram for partial winding start with standard motor 5 4 Special motor design for direct or star delta start 5 5 Circuit diagram for star delta start 230 V 400 V Y 5 6 Electronic trigger unit MP10 5 7 Connecting the trigger unit MP10 5 8 Functional test of the trigger unit MP10 5 9 Oil sump heater accessories 6 Commissioning 25 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak t...

Page 4: ...age 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 compar...

Page 5: ...not 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 comp...

Page 6: ...r flows over the motor and cools it intensively In this way the motor can be kept at a relatively low temperature level particularly under high loads Name plate Fig 1 2 1 Short description Valve plate Cylinder cover Terminal box Dimension and connection values can be found in Chapter 10 Transport eyelet Discharge shut off valve Oil pump Suction shut off valve Drive section Motor section Oil sight ...

Page 7: ...ype designation 2 Machine number 3 Type code 4 Maximum operating current 5 Starting current rotor blocked Y Part winding 1 YY Part windings 1 and 2 6 ND LP max admissible operating pressure g Low pressure side HD HP max admissible operating pressure g High pressure side 7 Voltage circuit frequency 8 Nominal rotation speed 9 Displacement 10 Voltage circuit frequency 11 Nominal rotation speed 12 Dis...

Page 8: ...ng 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 Additional fans accessories or water cooled cylinder covers accessories can be used for additional cooling For operation with capacity regulator Continuous operation when the capacity regulator...

Page 9: ...imited condensing temperature up to tC 55 C HG8 3220 4 S max evaporating temperature t0 5 C Unlimited application range Supplementary cooling or reduced suction gas temperature Supplementary cooling and reduced suction gas temperature Motor version S more powerful motor Evaporation temperature C Condensing temperature C Suction gas superheat K Suction gas temperature C Design for other areas on re...

Page 10: ...osphere or a combustible environment Fig 10 Fig 11 Fig 12 F E D 1 2 3 INFO New compressors are factory filled with inert gas Leave this ser vice charge in the compressor for as long as possible and prevent the ingress of air Check the compressor for transport damage before starting any work 4 1 Storage and transportation Use transport eyelet Do not lift manually Use lifting gear Storage at 30 C 70...

Page 11: ...ge and suction line valves have graduated inside diameters so that pipes with standard millimetre and inch dimensions can be used The pipe will be immersed more or less deeply according to dimension The connection 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 4 4 P...

Page 12: ... 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 the result being a loss of refrigerant INFO Proper layout of the suction and discharge lines directly after the compressor is integral to the system s smooth running and vibration behaviour Fig 15 ...

Page 13: ...Turn 1 2 1 turn clockwise Service connection opened shut off valve opened Connection blocked Spindle Spindle Connection open Compressor Compressor Service connec tion closed Service connec tion opened 4 6 Operating the shut off valves Before opening or closing the shut off valve release the valve spindle seal by approx 1 4 of a turn counter clockwise After activating the shut off valve re tighten ...

Page 14: ...chine which must respond at 1 2 times the set current within 2 hours and must not have responded at 1 05 times the set current within 2 hours or another comparable device INFO Connect the compressor motor in accordance with the circuit diagram see inside of terminal box Use suitable cable entry point of the correct protection type see name plate for routing cables into the terminal box Insert the ...

Page 15: ...ber am Klemmenkasten für Direkt oder Teilwicklungsstart t dieser Kennzeichnung ist für Direkt klungsstart PW Anlauf geeignet in zwei Teilwicklungen unterteilt Teil 0 und Teilwicklung 2 40 Dadurch wicklungsstart derAnlaufstrom um ca ber dem Direktstart verringert en Teilwicklungsstart PW Anlauf ist die Verwendung einer mechanischen fentlastung mit Bypass Magnetventil nicht erforderlich darfsfall ka...

Page 16: ...rcuit fuse F3 High pressure safety monitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor P oil Οnderung 0 Datum Name Datum Bearb Gepr Norm 1 20 02 2009 Kelich 10 02 2012 Urspr 2 Ers f 3 Ers d 4 X SS Anschlußkasten Verdichter R1 MP10 Q1 L1 L2 L3 N PE F1 1 I 66 I I I 1 2 K1 1 3 4 2 5 6 3 1U1 1V1 1W1 PE M1 M YYY 2U1 2V1 2W1 F1 2 I 33 I I I 1 2 K2 4 3 4 5 5 6 6 X1 L...

Page 17: ... F4 P 20 K1 K1T K2 2 8 3 7 4 8 21 22 K1T 2 8 B1 P 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE B1 Release switch thermostat Q1 Main switch M1 Compressor motor K1 Mains contactor part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s E1 Oil sump heater S1 Control voltage switch XSS Terminal strip in the external switch cabinet ...

Page 18: ...otor 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 Stern Dreieck Start L3 L1 V1 W1 U1 V2 U2 W2 L1 L2 L3 L2 V1 W1 U1 V2 U2 W2 L3 L2 L1 40...

Page 19: ...s wired for direct starting at high voltage The brides are to be removed for star delta starting at low voltage 230 V Δ Direct start Star delta start 400 V Y Direct start only 5 Electrical connection Star delta start up is only possible for 230 V power supply Example ...

Page 20: ...e safety monitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor B1 Enabling switch thermostat Οnderung 2 0 Datum Name Datum Bearb Gepr Norm 1 20 02 2009 Kelich 10 02 2012 Urspr 2 Ers f 3 Ers d 4 X SS Anschlußkasten Verdichter R2 MP10 Q1 L1 L2 L3 N PE F1 1 I 66 I I I 1 2 K1 1 3 4 2 5 6 3 U1 V1 W1 M1 M 3 1 2 K3 Y PE 3 4 5 6 W2 U2 V2 F1 2 I 33 I I I 1 2 K2 4 3 4 5 5...

Page 21: ... 19 F4 P K4T K3 K2 1 8 2 8 4 8 20 K4T K2 K3 4 8 21 22 K4T B1 P 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE Q1 Main switch M1 Compressor motor K1 Mains contactor K2 Δ contactor K3 Y contactor K1T Delay relay max 1s K4T Delay relay for contactor switch over E1 Oil sump heater S1 Control voltage switch XSS Terminal strip in the external switch cabinet ...

Page 22: ...rotection function The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause 5 7 Connection of the trigger unit MP10 PTC1 PTC2 Terminal box Fig 22 ATTENTION Terminals 1 6 on the trigger unit MP10 and terminals PTC 1 and PTC 2 on the compressor terminal board must not come into contact with mains voltage This would destroy the trigger unit and PTC sensors ...

Page 23: ...r 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 Interrupt power supply again L1 or S1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or S1 OFF OFF ON MP10 is operational agai...

Page 24: ...mpressor starts up the refrigerant contained in the oil evaporates out through 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 heate...

Page 25: ...ge 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 shorten this can result in winding and terminal board damage 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 o...

Page 26: ... starting the compressor ATTENTION If larger quantities of oil have to be topped up there is a risk of oil hammer effects If this is the case check the oil return 6 7 Avoiding slugging 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 ...

Page 27: ...hanical oil level regulator at the O connection Fig 24 ahr von Anschluss Ölspiegelregulator Bei Verbundschaltungen von mehreren Verdichtern haben sich Ölstandsregulierungssystemebewährt Für die Montage eines Ölspie gelregulators ist derAnschluss O vorgesehen siehe Maßzeichnung Alle gängigen Ölspiegelregulatoren von AC R ESK sowie das elek tronische ReglersystemTRAXOILS1A1 von SPORLAN können direkt...

Page 28: ...e 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 HG8 2470 4 S 2830 4 S 3220 4 S Designation Item No Item No Item No Set of gaskets kit 80235 Valve plate kit 80199 Oil pump kit 80290 Oil sump heater kit 220 240 V 80237 Only use genuine GEA spare parts 7 3 Reco...

Page 29: ... accordance with the applicable national regulations Refrigerants GEA standard oil types Recommended alternatives HFC e g R134a R404A R407C Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Arctic 46 Sunoco Suniso SL 46 Texaco Capella HFC 55 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 7 4 Extract from the lubrican...

Page 30: ... to remove the compressor from a refrigerating plant 8 3 Additional fan Item No 80270 When the HG8 compressor is used in the deep freeze range the application limits can be extended by additional cooling if the cylinder heads see limits of application diagramms The kit contains all necessary fastening parts for mounting on the cylinder covers Fig 25 Fig 26 Fig 27 Oil pump ATTENTION Thestartunloade...

Page 31: ...y controller with sealing ring Torque 60 Nm To fit a capacity controller remove bung N from the cover Special accessories are only premounted in the factory if ordered specially by customer Retrofitting is possible in full compliance with the safety instructions and repair instructions enclosed with the kits Information about the use operation maintenance and servicing of the components is availab...

Page 32: ...tion measuring area measuring distance 1m Compressor operation at 50 Hz 1450 rpm refrigerant R404A Values stated are average values tolerance 2 dB A 5 3 4 Type No of cylinders Displacement 50 60 Hz 1450 1740 rpm Electrical data Weight Connections Oil charge Sound pressure level Voltage Max operating current PW 1 2 Max power con sumption Starting current rotor locked PW 1 PW 1 2 Discharge line DV S...

Page 33: ...7 16 Connection oil pressure safety switch OIL inch D Anschluss Öldrucksicherheitsschalter LP Zoll 7 16 Connection oil pressure safety switch LP inch D1 Anschluss Ölrückführung vom Ölabscheider Zoll 1 4 N Connection oil return from oil separator inch E Anschluss Öldruckmanometer Zoll 7 16 Connection oil pressure gauge inch F Ölablass mm M22x Oil drain H Stopfen Ölfüllung mm M33 Oil charge plug J A...

Page 34: ...il pressure switch OIL 7 16 UNF D Connection oil pressure switch LP 7 16 UNF D1 Connection oil return from oil separator 1 4 NPTF E Connection oil pressure gauge 7 16 UNF F Oil drain M22x1 5 H Oil charge plug M33x2 J Connection oil sump heater M22x1 5 K Sight glass L Connection thermal protection thermostat 1 8 NPTF N Connection capacity controller M45x1 5 O Connection oil level regulator 3 x M6 Ö...

Page 35: ...eferenced 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 on request The spec...

Page 36: ...f you have any questions about installation operation and accessories please contact our technical service or specialist wholesaler and or our representative The GEA Bock service team can be con tacted 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 ...

Page 37: ...D GB F E I Ru 37 09790 02 2018 DGbFEIRu ...

Page 38: ...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 ...