GEA GEA Bock HG66e Series, Assembly Instructions Manual

Page 1: ...70 4 HGX66e 1340 4 HGX66e 1540 4 HGX66e 1750 4 HGX66e 2070 4 HG66e 1340 4 S HG66e 1540 4 S HG66e 1750 4 S HG66e 2070 4 S HGX66e 1340 4 S HGX66e 1540 4 S HGX66e 1750 4 S HGX66e 2070 4 S Assembly instructions 96446 04 2019 Gb Translation of the original instructions ...

Page 2: ...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 in which the compres sor 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 Manufa...

Page 3: ...ndard motor design for direct or partial winding start 5 3 Basic circuit diagram for partial winding start with standard motor 5 4 Special motor design for direct or star delta start 5 5 Basic circuit diagram for star delta start 230 V 400 V Y 5 6 Electronic trigger unit INT69 G 5 7 Connecting of the trigger unit INT69 G 5 8 Functional test of the trigger unit INT69 G 5 9 Oil sump heater accessori...

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: ... 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 Fig 1 2 1 Short description Dimension and connection values can be found in Chapter 10 Cylinder cover Terminal box Suction shut off valve Transport eyelet Name plate Motor section Drive section Valve plate Discharge shut off valve Oil pump Oil sight g...

Page 7: ...of cylinders Size Oil charge Series 107 0 A YY 335 0 A Y 196 0 A 180 0 217 2 380 420 Y YY 440 480 Y YY 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 1 and 2 11 Displacement 5 ND LP Max admissib...

Page 8: ...ity in the system can not under certain circumstances ensure that suffi cient oil is transported back to the compressor For operation with frequency converter The maximum current and power consumption must not be exceeded In the case of operation above the mains frequency the application limit can therefore be limited Max 60 Hz When operating in the vacuum range there is a danger of air entering o...

Page 9: ... 60 40 tOh 20K t 20 C Oh 20 tOh 20 K 20 10 0 10 20 30 40 10 20 30 50 60 70 t C o t C c 66 35 t 20 C oh 5 12 5 toh 20 K R22 10 0 10 20 30 40 50 20 30 40 50 60 70 t C o t C c t o h 2 0 K t 20 C oh 58 5 7 5 45 R404A R507 40 10 R513A R448A R449A 0 10 20 30 40 10 20 30 50 60 70 t C c t 20 C oh 5 t o h 2 0 K 40 30 40 60 80 90 20 10 10 0 t C c 82 30 50 70 12 20 t 20 C Oh 10 tOh 20 K 30 20 10 10 0 20 30 t...

Page 10: ...o t C c 82 30 50 70 12 5 25 20 t 20 C Oh 10 tOh 20 K tOh 20 K C 20 10 0 10 20 30 t C o 5 12 5 25 C C 10 R513A R448A R449A 20 10 0 10 20 30 40 10 20 30 50 60 70 t C o t C c t 20 C oh 5 12 5 t o h 2 0 K 40 30 40 60 80 90 20 10 10 0 20 30 t C o t C c 82 30 50 70 12 5 25 20 t 20 C Oh 10 tOh 20 K tOh 20 K C 20 10 0 10 20 30 50 70 t C o t C c 5 12 5 25 R407C C 10 30 60 40 tOh 20K t 20 C Oh 20 R513A 30 4...

Page 11: ...ening parts etc 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 4 2 Settin...

Page 12: ...f 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 Ensure a proper oil return Keep pressure losses to an absolute minimum 4 5 Start unloader external A internal start unloader ex factory is not available Alternatively a start unloader can be insta...

Page 13: ...s directly after the compressor is integral to the system s smooth running and vibration behaviour Important Start unloader may only be employed during the starting phase Check the solenoid valve and the non return valve regularly for tightness In addition we recommend to use a heat protection thermostat on the discharge side of the com pressor This protects the compressor against thermal overload...

Page 14: ... Turn 1 2 1 turn clockwise Service connection opened shut off valve opened Connection blocked Spindle Spindle Connection open Compressor Compressor Service connection closed Service connection opened 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 4 7 Operating the shut off valves Before ...

Page 15: ...orking current 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 strain relieves and prevent chafe marks on the cables Compare the voltage and frequency values with the data for the mains power supply Only connect the mot...

Page 16: ...echanical unloaded start with bypass solenoid valve is not required 5 Electrical connection Compressors with this marking are suitable for direct or partial winding start The motor winding is subdivided into two parts Part winding 1 50 and part winding 2 50 This winding division reduces the start up current needed for a part winding start to approx 50 of that for a direct start ...

Page 17: ...TENTION 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 adversely affect the service life of the motor 400 V Direktstart YY Teilwicklungsstart Y YY 1V1 1W1 1U1 2W1 2V1 2U1 L3 L2 L1 L3 L2 L1 L3 L2 L1 1V1 1W1 1U1 2W1 2V...

Page 18: ...FC1 1 I I I QA2 1U1 1V1 1W1 PE EC1 M Y YY 2U1 2V1 2W1 FC1 2 I I I QA3 FC1 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 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 pressure sensor DELTA P II a...

Page 19: ...it INT69 G KF1 Delay relay for contactor switch over QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch PW INT69 HG44 66 5 6 7 BOCK COMPRESSORS 8 9 Bl 6 c Bl 6 a 2 DELTA P II BP2 P QA2 BP3 P QA2 KF1 KF1 6 c 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT3 BT2 Θ Θ vio bn bu gr Θ EB1 pk og ...

Page 20: ... box Y 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 Stern Dreieck Start L3 L1 V1 W1 U1 V2 U2 W2 L1 L2 L3 L2 V1 W1 U1 V2...

Page 21: ...l 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 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 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 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 Y Stern Dreieck Anla...

Page 22: ...ostat DELTA PII Oil differential pressure sensor DELTA P II accessory EB1 Oil sump heater EC1 Compressor motor FC1 1 1 2 Motor protection switch Οnderung 4 0 Datum Name Datum Bearb Gepr Norm 1 20 02 2009 bauknecht 07 02 2018 Urspr 2 Ers f 3 Ers d 4 Anschlußkasten Verdichter BT1 INT69G QA1 L1 L2 L3 N PE U1 V1 W1 PE U2 V2 W2 FC1 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 FC1 1...

Page 23: ...tor switch over QA1 Main switch QA2 Mains contactor QA3 Δ contactor QA4 Y contactor SF1 Control voltage switch D S INT69 HG44 66 neu 5 6 7 BOCK COMPRESSORS 8 9 Bl 6 c Bl 6 b 6 a DELTA P II BP2 P BP3 P L1 1 L2 1 L3 1 L1 2 N PE BT3 BT2 Θ Θ vio bn bu gr pk og Θ 1 2 PE EB1 QA2 QA2 4 7 6 b 7 QA4 KF1 QA4 QA3 4 8 6 b 8 KF1 QA3 QA4 4 8 6 b 8 KF1 ...

Page 24: ... Once cooled it can be restarted only if the electronic lock of the output relay terminals B1 B2 is released by interrupting the supply voltage The hot gas side of the compressor can also be protected against 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 ou...

Page 25: ...he compressor is at a standstill refrigerant diffuses into the lubricating oil of the compressors housing depending on pressure and ambient temperature This reduces the lubricating capacity of the oil When the compressor 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 c...

Page 26: ...nstinadmissibleoperatingconditions 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 process see name plate data Do not mix any refrige...

Page 27: ...itch motor protection electrical contact protection measures etc are all functioning properly Switch on the compressor and allow to run for a minimum of 10 min Check the oil level by The oil must be visible in the sight glass WARNING Ensure that both shut off valves are open before starting the compressor ATTENTION If larger quantities of oil have to be topped up there is a risk of oil hammer effe...

Page 28: ...l change not mandatory for factory produced series systems for 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 used oil according to the regulations observe national regulations Annual checks Oil level leak tightness running noises pressures temperatures functi...

Page 29: ...in accordance with the applicable national regulations 7 4 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 e g R134a R407C Fuchs Reniso Triton SE 55 Fuchs Re...

Page 30: ...ut and connect it Fig 32 ATTENTION If the capacity regulator is installed at the factory the control component pilot valve is subsequently installed and connected by the customer Before start up remove the cover at the capacity regulator and replace it with the enclosed control unit pilot valve Attention Compressor is under pressure Depressurize the compressor first Delivery condition 2 from the f...

Page 31: ...ircumstances 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 realised by a 100 capacity requirement after each compressor restart Electrical actuation of the solenoid valve Normally open corre spond...

Page 32: ...position of the standard sight glass see fig 35 Mechanical oil level regulator at the O connection Fig 34 8 Accessories on 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...

Page 33: ... 280 HG66e 1540 4 S 133 8 160 5 75 44 196 335 285 HG66e 1750 4 152 2 182 6 72 42 196 335 280 HG66e 1750 4 S 152 2 182 6 87 51 222 361 282 HG66e 2070 4 180 0 216 0 85 51 196 335 276 64 2 5 8 HG66e 2070 4 S 180 0 216 0 103 61 222 361 278 9 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 po...

Page 34: ... Connection therma M Ölsieb Oil filter O Anschluss Ölspieg Connection oil leve ÖV Anschluss Ölservic Connection oil ser Q Anschluss Öltemp Connection oil tem W Anschluss Kältemi Connection for refr L Lötanschlus L Brazing con Q W 1 A Y 810 2 404 30 A1 Y SV W Ansicht X Anschlussmöglichkeit für Ölspiegelregulator View X Possibility of connection of oil level regulator Dreilochanschluss für TRAXOIL 3...

Page 35: ...6 UNF C Connection oil pressure safety switch OIL 1 8 NPTF D Connection oil pressure safetyswitch LP 7 16 UNF D1 Connection oil return from oil separator 1 4 NPTF F Oil drain M12x1 5 H Oil charge plug 1 4 NPTF J Connection oil sump heater 3 8 NPTF K Sight glass 3 x M6 L Connection thermal protection thermostat 1 8 NPTF M Oil filter M12x1 5 O Connection oil level regulator 3 x M6 ÖV Connection oil ...

Page 36: ... 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 compressors Remarks We also dec...

Page 37: ...any 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 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 ...