GEA HG88e series, Assembly Instruction Manual

Page 1: ...96260 08 2015 DGbFEIRu engineering for a better world GEA Bock Compressor HG88e Assembly instructions HG88e 2735 4 HG88e 2735 4 S HGX88e 2735 4 HGX88e 2735 4 S HG88e 3235 4 HG88e 3235 4 S HGX88e 3235 4 HGX88e 3235 4 S ...

Page 2: ...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 refrigeration gea com www gea com ...

Page 3: ...Standard 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 Circuit diagram for star delta start 230 V 400 V Y 5 6 Electronic trigger unit INT69 G 5 7 Connecting the trigger unit INT69 G 5 8 Functional test of the trigger unit INT69 G 5 9 Oil sump heater accessories 6 C...

Page 4: ...damage 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 com...

Page 5: ...used in potentially explosive environments These assembly instructions describe the standard version of the compressor named in the title manufactured by GEA Bock GEA Bock 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 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 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 Oil sight glass Drive section Motor section Suction shut off valve Name ...

Page 7: ...ine 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 over pressure Low pressure side HD HP max admissible over pressure High pressure side Fig 2 50 Hz 60 Hz SE 55 AW09529A047 GEA Bock GmbH 72636 Frickenhausen Germany 2 2 Name plate example 2 1 3 4 5 7 8 9 10 11 12 13 14 6 7 Voltage circuit frequency 8 N...

Page 8: ...d For operation with supplementary cooling Use only oils with high thermal stability Avoid continuous operation near the threshold Additional fans accessories can be used for additional cooling For operation with capacity regulator The suction gas superheat temperature may need to be reduced or set individually when operating near to the threshold The limits of application are reduced For operatio...

Page 9: ...c 61 5 12 5 25 tOh 20K t 20 C Oh R407C 0 t C o R407F t C o 20 30 40 50 60 70 t C c 59 toh 20K t 20 C oh 20 15 25 10 5 0 5 10 15 R407C 30 t C o 20 10 0 10 20 30 20 30 40 50 60 70 t C o t C c 61 5 12 5 25 tOh 20K t 20 C Oh R407C 20 t C o R407F t C o 20 30 40 50 60 70 t C c 59 toh 20K t 20 C oh 20 15 25 10 5 0 5 10 15 R407F Fig 5 Fig 6 30 40 60 80 90 20 10 10 0 20 30 t C o t C c 82 30 50 70 12 5 25 t...

Page 10: ...oh 20K 10 0 10 20 30 40 50 20 30 40 50 60 70 t C o t C c toh 20K t 20 C oh 58 5 7 5 45 R404A R507 20 30 40 50 60 70 t C c 59 toh 20K t 20 C oh 20 15 25 10 5 0 5 10 R404A R507 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 Evaporation temperature C Condensi...

Page 11: ...sers install only with rubber metal shock mountings Provide adequate clearance for maintenance work Ensure adequate compressor ventilation Do not use in a corrosive dusty damp atmosphere or a com bustible environment Fig 11 Fig 12 Fig 13 Fig 14 Installation of pipe vibration mufflers is recommended F E D C 1 2 3 4 1 Storage and transport Use transport eyelet Do not lift manually Use lifting gear S...

Page 12: ... 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 installed in...

Page 13: ...sor is integral to the system s smooth running and vibration behaviour 4 Compressor assembly Important Start unloader may only be employed during the starting phase Check the solenoid valve and the non return valve regulary 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 overloading Con...

Page 14: ...dle Turn 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 7 Operating the shut off valves Before opening or closing the shut off valve release the valve spindle seal by approx of a turn counter clockwise After activating the shut off valve re tighten the ...

Page 15: ...e 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 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 t...

Page 16: ...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 Designation on the name plate Sticker on the terminal box Y YY Y YY ...

Page 17: ...e Brücken Typschildangabe Y Gelber Aufkleber am Klemmenkasten hrung für Direkt oder Teilwicklungsstart hter mit dieser Kennzeichnung ist für Direkt Teilwicklungsstart PW Anlauf geeignet otor ist in zwei Teilwicklungen unterteilt Teil ng 1 60 und Teilwicklung 2 40 Dadurch eim Teilwicklungsstart derAnlaufstrom um ca egenüber dem Direktstart verringert Für den Teilwicklungsstart PW Anlauf ist die Ver...

Page 18: ...3 4 2 5 6 3 1U1 1V1 1W1 EC1 M YYY 2U1 2V1 2W1 FC1 2 I 33 I I I 1 2 QA3 4 3 4 5 5 6 6 7 FC1 1 FC1 2 8 BT2 FC2 4A SF1 BT2 9 BT2 10 BT2 11 OG OG 11 12 14 L N B1 B2 PE BP1 Oil differential pressure monitor BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT3 Release switch thermostat BT1 Cold conductor PTC sensor motor winding BT2 X Thermal protection thermostat EB1 Oil s...

Page 19: ...t winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch XSS Terminal strip in the external switch cabinet PW MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 6HG76e Bl 2 1 BP1 P Öl QA2 12 T2 13 N 14 L 15 M 16 S BP2 P 17 18 19 QA2 BP3 P 20 QA2 KF1 QA3 2 8 3 7 4 8 5HG76e 8 5HGZ76e 7 6HG76e 7 21 22 KF1 2 8 5HG76e 8 5HGZ76e 7 23 24 QA2 25 EB1 26 L1 1 L2 1 L3 1 L1 2 N PE BT3 PE ...

Page 20: ...rminal 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...

Page 21: ...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 22: ... 1 2 QA3 4 3 4 5 5 6 6 7 FC1 1 FC1 2 8 FC2 4A SF1 9 10 11 OG OG 11 12 14 L N B1 B2 BT2 BT2 BT2 BT2 5 5 Circuit diagram for star delta start 230 V 400 V Y Fig 24 BP1 Oil differential pressure monitor BP2 High pressure safety monitor BT2 X Thermal protection thermostat BP3 Safety chain high low pressure monitoring BT3 Release switch thermostat EB1 Oil sump heater EC1 Compressor motor FC1 1 Motor pro...

Page 23: ... Y contactor SF1 Control voltage switch XSS Terminal strip in the external switch cabinet D S MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 6HG76e Bl 4 3 BP1 P Öl QA2 12 T2 13 N 14 L 15 M 16 S BP2 P 17 QA2 QA2 4 7 6HG76e 7 18 QA4 19 BP3 P KF4 QA4 QA3 1 8 2 8 4 8 5HG76e 8 5HGZ76e 7 6HG76e 7 20 KF4 QA3 QA4 4 8 6HG76e 8 21 22 KF4 23 24 QA2 25 EB1 26 L1 1 L2 1 L3 1 L1 2 N PE BT3 PE ...

Page 24: ...ating conditions occur Find and remedy the cause PTC1 PTC2 N L B1 B2 12 14 11 PTC Motor Protection INT69 G Terminal box Abb 25 supply Lock out 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 contactor even in case of a sen...

Page 25: ...e 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 throught the reduction in pressure The consequences can be foaming and migration of the oil causing oil shocks under c...

Page 26: ...dard 6 3 Leak test Carry out the leak test of the refrigerating system in accordance with EN 378 2 or a corresponding safety standard without including the compressor INFO Toprotectthecompressoragainstinadmissibleoperatingconditions 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 Nev...

Page 27: ... 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 28: ...sen werden s Abb Ein Schauglas am Ölspiegelregulator ist nicht erforderlich 124 o 1 2 4 o 1 2 4 o 1 2 4 o 47 6 M6 x 10 je 3 mal 3 Loch Anschlussbild für ESK AC R und CARLY 3 Loch Anschlussbild für TraxOil 3 hole connection diagramm for ESK AC R and CARLY 3 hole diagramm for TraxOil 3 times each Inordertoguaranteeoptimumoperationalreliabilityandservicelifeofthecompressor we recommend carrying out s...

Page 29: ...ard 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 R404A R407C R407F 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 ...

Page 30: ...ontrol unit pilot valve Cover Magnetic coil Fig 31 Screw in control unit pilot valve with seal ring and tight with 15 Nm Wet thread sides with ester oil Insert magnetic coil fasten it with knurled nut and connect it Fig 32 ATTENTION If the capacity regulator is installed at the factory the control com ponent pilot valve is subsequently installed and connected by the customer Ifthecontrolcomponenti...

Page 31: ... and dimensioningaccordingly donotsetthecontrolintervalstoocloseand do not let the system switch more than 12 times per hour refriger ating plant must have reached a state 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 r...

Page 32: ...1 442 HG88e 3235 4 S 281 3 337 6 160 91 0 520 605 462 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 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 curr...

Page 33: ...n H Stopfen Ölfüllung Oil charge plug J Anschluß Ölsumpfheizung Connection oil sump heater K Schauglas Sight glass L Anschluß Wärmeschutzthermostat Typ type Teile Nr part no Typ type Teile Nr part no HG88e 2400 4 14256 HGX88e 2400 4 14258 HG88e 2400 4 S 14257 HGX88e 2400 4 S 14259 HG88e 2735 4 14292 HGX88e 2735 4 14296 HG88e 2735 4 S 14293 HGX88e 2735 4 S 14297 HG88e 3235 4 14294 HGX88e 3235 4 142...

Page 34: ...nnectoin oil 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 M22 x 1 5 H Oil charge plug M22 x 1 5 J Connection oil sump heater M22 x 1 5 K Sight glass L Connection thermal protection thermostat 1 8 NPTF O Connection oil level regulator 3 x M6 ÖV Connection oil servic...

Page 35: ...mpressor HG88e 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 36: ...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 12 Service ...

Page 37: ...D GB F E I Ru 37 96260 08 2015 DGbFEIRu ...

Page 38: ... 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 ...