GEA HG22P Series, Assembly Instructions Manual

Page 1: ... a better world GEA Bock Compressor HG22P Assembly instructions HG22P 125 4 HG22P 125 4 S HGX22P 125 4 HGX22P 125 4 S HG22P 160 4 HG22P 160 4 S HGX22P 160 4 HGX22P 160 4 S HG22P 190 4 HG22P 190 4 S HGX22P 190 4 HGX22P 190 4 S 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 2: ...s 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 refrigeration gea com www gea com Manufacturer Contact Contents Page 1 Safety 4 1 1 Identification of safety instructions 1 2 Qualifications required...

Page 3: ... electronic trigger unit MP10 5 6 Functional test of the electronic trigger unit MP10 5 7 Circuit diagram for direct start 230 V Δ 400 V Y with INT69 G 5 8 Electronic trigger unit INT69 G 5 9 Connection of the electronic trigger unit INT69 G 5 10 Functional test of the electronic trigger unit INT69 G 5 11 Start unloader 6 Commissioning 22 6 1 Preparations for start up 6 2 Pressure strength test 6 ...

Page 4: ... potential 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...

Page 5: ...Bock 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 97 23 EC Pressure Equipment Directive and 2006 95 EC Low Voltage 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 int...

Page 6: ...ng compressor with oil pump lubrication Suction gas cooled drive motor 2 1 Short description Name plate Fig 1 Fig 2 Oil sight glass Cylinder cover Oil pump Terminal box Suction shut off valve Drive section Motor section Dimension and connection values can be found in Chapter 9 Transport eyelet Valve plate Discharge shut off valve ...

Page 7: ...ine 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 10 Nominal rotation speed pressure g Low pressure side 11 Displacement HD HP max admissible operating 12 Oil type filled at the factory pressure g High pressure side 13 Terminal box protection type Observe the limits of applica...

Page 8: ...above the mains frequency the application limit can therefore be limited When operating in the vacuum range 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 The compressors are filled at the factory with the following oil type for R134a R404A R5...

Page 9: ...n for other areas on request R134a R407C R404A R507 R22 Fig 5 Fig 6 Fig 7 Fig 8 Unlimited application range Supplementary cooling or reduced suction gas temperature Supplementary cooling and reduced suction gas temperature Motor version S more powerful motor Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure ...

Page 10: ...t 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 atmosphere or in a com bustible environment Fig 10 Fig 9 ATTENTION Attachments e g pipe holders additional units fastening parts etc directly to the compressor are not permissible 4 2 Setting up Setup on an even sur...

Page 11: ...nents 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 Ensure a proper oil return Keep pressure losses to an absolute minimum Fig 15 As short as possible Rigid fixed point The pipe connections have graduate...

Page 12: ... 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 opened Spindle Connection open Compressor Compressor Valve spindle seal Release Tighten Before opening or closing the shut off valve release the valve spindle seal by approx of a turn counter clockwise After activat...

Page 13: ...ssible on 230 V voltage supply Example 230 V Direct start Star delta start 400 V Y Direct start only Elektrischer Anschluss Electrical connection Raccordement électrique Y Niedere Spannung Low voltage Bas voltage Y Hohe S High v Haut v 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 L...

Page 14: ...tion thermostat PTC sensor FC1 Load circuit safety switches FC2 Control power circuit fuse BP1 Safety chain high low pressure monitoring BP2 Release switch thermostat pressostat 0 1 2 3 4 Klemmenkasten Verdichter MP10 BT1 QA1 FC1 I I I QA2 PE FC1 A1 X1 L1 L1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 FC2 SF1 BT2 A2 BP1 P PE EC1 3 M Θ L1 L2 L3 N PE Compressor terminal box Fig 20 ...

Page 15: ...ssor motor QA2 Compressor contactor MP10 Electronic trigger unit MP10 EB1 Oil sump heater 5 6 7 8 9 A1 Alarm Motorschutz A2 Übertemperatur BT1 BT2 A3 Alarm Hochdruck A3 BP2 P PE QA2 1 2 EB1 QA2 3 4 L1 1 L2 1 L3 1 L1 2 N PE A1 Alarm motor protection A2 Overheating BT1 BT2 A3 Alarm high pressure ...

Page 16: ... the cause 5 5 Connection of the trigger unit MP10 INFO Connect the trigger unit MP10 in accordance with the circuit dia gram Protect the trigger unit with a delayed action fuse FC2 of max 4 A In order to guarantee the protection function install the trigger unit as the first element in the control power circuit Temperature monitoring connections Motor winding Terminals 1 2 Thermal protection ther...

Page 17: ... connection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or SF1 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 SF1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or SF1 OFF OFF ON MP 10 is operational a...

Page 18: ... BT2 L1 L2 L3 N PE 5 7 Circuit diagramm for direct start 230 V 400 V Y compressor with INT69 G Fig 22 BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor FC1 Load circuit safety switches FC2 Control power circuit fuse BP1 Safety chain high low pressure monitoring BP2 Release switch thermostat pressostat Compressor terminal box ...

Page 19: ...BT2 A3 Alarm Hochdruck A3 BP2 P PE QA2 1 2 EB1 QA2 3 4 L1 L2 L3 L1 1 N PE QA1 Main switch SF1 Control voltage switch EC1 Compressor motor QA2 Compressor contactor INT69 G Electronic trigger unit INT69 G EB1 Oil sump heater A1 Alarm motor protection A2 Overheating BT1 BT2 A3 Alarm high pressure ...

Page 20: ... 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 contactor even in case of a sensor break or open circuit INFO Connect the trigger unit INT69 G in accordance with the circuit dia gram Protect the trigger unit with a delayed act...

Page 21: ... trigger unit Perform this check using a continuity tester or gauge 5 Electrical connection Gauge state Relay position 1 Deactivated state 11 12 2 INT69 G switch on 11 14 3 Remove PTC connector 11 12 4 Insert PTC connector 11 12 5 Reset after mains on 11 14 5 11 Start unloader To avoid current peaks during the starting phase we recommend using the GEA Bock ESS soft starting device Electronic Soft ...

Page 22: ...tallation 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 6 2 Pressure strength test DANGER Bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximum permissible overpressure of the compressor mu...

Page 23: ...pen before starting the compressor Check that the safety and protection devices pressure switch motor protection electrical con tact protection measures etc are functioning properly Switch on the compressor and let it run for at least 10 minutes Check the oil level The oil must be visible in the sight glass ATTENTION If larger quantities of oil have to be topped up there is a risk of oil impact ef...

Page 24: ...l 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 infiltrating the system After maintenance has been performed Connect safety switch Evacuate compressor Relea...

Page 25: ...ntenance 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 Bock standard oil types Recommended alternatives HFC e g R134a R407C R404A Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Ar...

Page 26: ...0 240 V 380 420 V Y 3 50 Hz 265 290 V 440 480 V Y 3 60 Hz 5 L M H 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 current remains unchanged Take account of the max operating cu...

Page 27: ...P 190 4 S HGX22P 160 4 Typ 14435 Teile N HG22P 125 4 Anschlüsse Connections SV Saugabsperrventil Rohr L Suction line va DV Druckabsperrventil Rohr L Discharge line A Anschluß Saugseite nicht absperrbar Connection su A1 Anschluß Saugseite absperrbar Connection su B Anschluß Druckseite nicht absperrbar Connection dis B1 Anschluß Druckseite absperrbar Connection dis D1 Anschluß Ölrückführung vom Ölab...

Page 28: ...mpressor HG22P complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006 42 EC Applied harmonised standard EN 12693 2008 and the corresponding standards 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...

Page 29: ...uestions about installation operation and accessories please contact our techni cal service or specialist wholesaler and or our representative The GEA Bock service team can be contacted by phone with a toll free hotline 00 800 800 000 88 or via e mail refrigeration gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 11 Service ...

Page 30: ... 9454 137 refrigeration gea com www gea com We live our values Excellence Passion Integrity Responsibility GEA versity 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 ...