GEA HG44e/475-4 S, Translation Of The Original Instructions

Page 1: ...HGX44e 475 4 S HG44e 565 4 HG44e 565 4 S HGX44e 565 4 HGX44e 565 4 S HG44e 665 4 HG44e 665 4 S HGX44e 665 4 HGX44e 665 4 S HG44e 770 4 HG44e 770 4 S HGX44e 770 4 HGX44e 770 4 S HG56e 850 4 HG56e 850 4 S HGX56e 850 4 HGX56e 850 4 S HG56e 995 4 HG56e 995 4 S HGX56e 995 4 HGX56e 995 4 S HG56e 1155 4 HG56e 1155 4 S HGX56e 1155 4 HGX56e 1155 4 S ...

Page 2: ...mbly 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 in which the compres sor is installed GEA Bock GmbH 72636 Frickenhausen GEA Bock GmbH B...

Page 3: ...Special motor design for direct or star delta start 5 5 Basic circuit diagram for star delta start with special motor 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 accessories 6 Commissioning 25 6 1 Preparations for start up 6 2 Pressure integrity test 6 3 Leak test 6 4 Evacuation 6 5 Refrigerant c...

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: ...uction gas cooled drive motor Preferred application range normal refrigerating and air conditioning 2 Product description Name plate Fig 1 2 1 Short description Valve plate Cylinder cover Dimension and connection values can be found in Chapter 10 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 7: ...rating Electrical accessories can change pressure g High pressure side the IP protection class Observe the limits of application diagrams 50 Hz 60 Hz 2 Product description Fig 3 2 2 Name plate example 1 2 3 4 5 6 7 8 9 10 11 12 13 AV12345A001 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 8: ...sible ambient temperature 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 ope...

Page 9: ...ted compressed gas temperature Prevent the ingress of air at all costs 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 request Maximum admissi...

Page 10: ... 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 request Maximum admissible operating pressure g LP HP 19 28 bar 1 LP Low pressure HP High pressure ...

Page 11: ...ts 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 F E D 1 2 3 4 2 Set...

Page 12: ...inimum The pipe connections have graduated inside diameters so that pipes with standart millimetre and inch dimensions can be used 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 Fig 10 graduated internal diameter 4 3 Pipe connections ATTENTION Damage ...

Page 13: ...e 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 a For HG44e a intermediate flange height 27 mm is optional available Art Nr 81194 With this intermediate flange it is possible to lay the ...

Page 14: ...ockwise as far as it will go Shut off valve completely opened service connection closed The connection which cannot be shut off is intended for safety devices Fig 15 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service connection closed Connection bloc...

Page 15: ...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 16: ...A3 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 Compressor terminal box 5 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 pr...

Page 17: ...8 6 5 8 6 a 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT3 BT2 Θ Θ vio bn bu gr og pk Θ 1 2 PE EB1 6 a 5 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 ...

Page 18: ... 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 19: ... W1 U1 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 Direktstar...

Page 20: ...I 1 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 17 5 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 pres...

Page 21: ... Θ vio bn bu gr og pk Θ 1 2 PE EB1 6 4 6 QA2 QA2 2 7 2 1 5 2 1 7 2 2 5 2 2 7 13 14 2 5 QA4 KF1 QA4 QA3 2 8 2 1 8 2 2 8 KF1 QA3 QA4 2 8 2 1 8 2 2 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 ...

Page 22: ...t 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 contacto...

Page 23: ... G Before commissioning after troubleshooting or making changes to the control power circuit check the functionality of the trigger unit Perform this check using a continuity tester or gauge Gauge state Relay position Deactivated state 11 12 INT69 G switch on 11 14 Remove PTC connector 11 12 Insert PTC connector 11 12 Reset after mains on 11 14 ...

Page 24: ...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 25: ...inadmissibleoperatingconditions 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 refrigeran...

Page 26: ...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 6 6 Start up Check that the safety and protection devices pressure switch motor protection electrical contact protec...

Page 27: ...ate 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 at the O connection Fig...

Page 28: ...rrying out servicing and inspection work at regular intervals Oil 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 l...

Page 29: ...riate hoist Dispose of the oil inside in accordance with the applicable national regulations 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 e g R134a R4...

Page 30: ... Cylinder cover prepared for capacity regulator Fig 24 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 t...

Page 31: ...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 32: ...1 HG44e 665 4 S 57 7 69 2 30 18 3 101 174 168 HG44e 770 4 67 0 80 4 30 17 8 101 174 168 HG44e 770 4 S 67 0 80 4 35 21 4 101 174 168 1 2 3 2 4 380 420 V Y YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 50 50 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 op...

Page 33: ...G56e 1155 4 100 4 120 5 51 30 4 149 246 212 HG56e 1155 4 S 100 4 120 5 61 34 5 196 335 221 1 2 3 2 4 380 420 V Y YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 50 50 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 specificat...

Page 34: ...o 0 1 über above Der Lieferant muss sicherstellen dass die Ware in einwandfreiem Zustand angeliefert wird Korrosionsschutz Verpackung für sicheren Allgemeintoleranzen General tolerances Drawing No bis up to t s 0850 Part No in proper conditions corrosion prevention packaging for safe transportation DIN ISO 2768 mK Ra Rz The supplier has to ensure the delivery of parts Transport prohibited Offender...

Page 35: ...erances Gewicht Weight kg 0 1 Rz 160 25 6 3 Nein No 0850 1 s über above bis up to 360 4x 15 305 436 2 O K B L A2 X B1 DV B 25 30 M12 50 Schwingungsdämpfer Vibration absorbers essor HG 1 0850 14937 0 Maße in mm Dimensions in mm Änderungen vorbehalten Subject to change without notice Massenschwerpunkt Centre of gravity Anschlüsse Connections SV Saugabsperrventil Rohr L mm Zoll 54 2 1 8 Suction line ...

Page 36: ...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 Directive 2006 42 EC The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery on reque...

Page 37: ...y 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 ...