GEA HG6/1080-4, Assembly Instructions Manual

Page 1: ...1080 4 HG6 1080 4 S HG6 1240 4 HG6 1240 4 S HG6 1410 4 HG6 1410 4 S HGX6 1080 4 HGX6 1080 4 S HGX6 1240 4 HGX6 1240 4 S HGX6 1410 4 HGX6 1410 4 S Assembly instructions 09971 06 2016 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: ...5 2 Standard motor design for direct or partial winding start 5 3 Basic circuit diagram for part 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 with special motor 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 ...

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 97 23 EC Pressure Equipment Directive Commissioning is permissible only if the compr...

Page 6: ...t off valve Drive section Motor section Fig 2 2 Product description Semi hermetic four cylinder reciprocating compressor with suction gas cooled drive motor Flange mounted drive motor on the compressor case Preferred application range normal refrigerating and air conditioning 2 1 Short description Transport eyelet Oil pump Cylinder cover Name plate Oil sight glass ...

Page 7: ...tage 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 admissible operating pressure 12 Oil type filled at the factory g Low pressure side 13 Terminal box protection type HD HP max admissibl...

Page 8: ... When the capacity regulator is activated the gas velocity 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 When operating in the vac...

Page 9: ... R22 Fig 5 Fig 6 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 R404A R507 1 2 Fig 7 HGX6 1410 4 S max evaporating temperature t0 2 C HGX6 1410 4 max evaporating temperature t0 7 C 1 2 Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP Hig...

Page 10: ...e 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 INFO New compressors are factory filled with inert gas 3 bar nitrogen Leave this service charge in the compressor for as long as possible and prevent the ingress of air Check the compressor for transport ...

Page 11: ...pes 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 14 graduated internal diameter A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to...

Page 12: ...ve completely opened service connection closed The connection which cannot be shut off is intended for safety devices Fig 19 Opening the service connection Spindle Turn 1 turn clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service connec tion closed Connection blocked Spindle Connection cannot be shut off Connection ...

Page 13: ...he maximum working current see name plate For motor protection use a current dependent and time delayed overload protection device for moni toring all three phases Set the overload protection device so that it must be actuated within 2 hours if there is 1 2 times the max working current INFO A mechanical unloaded start with bypass solenoid valve is not required INFO Connect the compressor motor in...

Page 14: ...re safety monitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor B1 Release switch thermostat nderung 0 Datum Name Datum Bearb Gepr Norm 1 20 Feb 2009 Kelich 09 M r 2010 Urspr 2 Ers f 3 Ers d 4 X SS Q1 L1 L2 L3 N PE Anschluákasten Verdichter I 66 F1 1 K1 1 2 1 3 4 2 5 6 3 1U1 1V1 1W1 PE M Y YY M1 R1 2U1 2V1 2W1 I 33 F1 2 K2 1 2 4 3 4 5 5 6 6 X1 L1 L1 N N 43 43 11...

Page 15: ...or part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s S1 Control voltage switch E1 Oil sump heater PW MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 1 Bl 1 F5 K1 12 T2 13 N P l 14 L 15 M 16 S P F3 17 18 19 K1 P F4 20 K1 K1T K2 21 22 K1T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE ...

Page 16: ...for 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 a...

Page 17: ...V1 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 Direktst...

Page 18: ...L1 L1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 7 F1 1 F1 2 8 R2 4A F2 S1 9 10 MP10 11 5 5 Basic circuit diagram for star delta start with special motor Fig 21 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 1 2 2 motor protection switches F2 Control power circuit fuse F3 High pressure safety monitor F4 Safety chain high low pressure monitoring F5 Oil diff...

Page 19: ...16 S K1 K1 K3 P F3 K4T K3 K2 17 K4T K2 K3 18 19 K4T P F4 20 K5T AL 21 22 K5T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE M1 Compressor motor K1 Mains contactor K2 Δ contactor K3 Y contactor K4T Delay relay S D changeover K5T Delay relay start unloader S1 Control voltage switch AL Start unloader E1 Oil sump heater ...

Page 20: ...he trigger unit MP10 Temperature monitoring connections Motor winding Terminals 1 2 Thermal protection thermostat Terminals 3 4 Restart prevention Terminals 5 6 Fig 22 Terminal board INFO Connect the trigger unit MP10 in accordance with the circuit dia gram Protect the trigger unit with a delayed action fuse F of max 4 A In order to guarantee the protection function install the trigger unit as the...

Page 21: ...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 22: ...en the compressor is started the refrigerant contained in the oil evaporates due to the decline in pressure This can result in oil foaming and oil exodus which can result in oil hammer in certain circumstances Operation mode The oil sump heater operates when the compressor is shut down The oil sump heater is switched off when the compressor starts Connection Connect the oil sump heater via an auxi...

Page 23: ...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 overpress...

Page 24: ... 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 gas superheat at the compressor input should be min 7 10 K check the setting of the expansion valve The system must reach a state of equilibrium Particularly in critical systems e g several evaporator points measures are recommende...

Page 25: ... well as the OM3 TraxOil oil level regulation system from Alco can be connected directly without adapters see Fig 19 A sight glass on the oil level regulator is not required Mechanical oil level regulator at the O connection 6 Commissioning Fig 24 ahr von Anschluss Ölspiegelregulator Bei Verbundschaltungen von mehreren Verdichtern haben sich Ölstandsregulierungssystemebewährt Für die Montage eines...

Page 26: ...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 HFC e g R134a 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...

Page 27: ... YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 66 33 L M H 5 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 t...

Page 28: ...n suction side not lockable inch A1 Anschluss Saugseite absperrbar Zoll 7 16 UNF Connection suction side lockable inch B Anschluss Druckseite nicht absperrbar Zoll 1 8 NPTF Connection discharge side not lockable inch B1 Anschluss Druckseite absperrbar Zoll 7 16 UNF Connection discharge side lockable inch C Anschluss Öldrucksicherheitsschalter OIL Zoll 7 16 UNF Connection oil pressure safety switch...

Page 29: ...sure 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 M22 x 1 5 H Oil charge plug M22 x 1 5 J Oil sump heater accessories M22 x 1 5 K Sight glass L Connection thermal protection thermostat 1 8 NPTF N Connection capacity controller M45 x 1 5 O Connection oil level regulator 3 x ...

Page 30: ...dards 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 request T...

Page 31: ...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 11 Service ...

Page 32: ...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 ...