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Summary of Contents for GEA HG88e series
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Page 1: Assembly Instructions
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 engineering for a better world... - Page 2 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. Manufacturer GEA Bock GmbH 72636 Frickenhausen Contact GEA Bock GmbH Benzstraße 7...
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Page 3: Table Of Contents
Contents Page Safety Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use Product description 2.1 Short description 2.2 Name plate 2.3 Type key Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application Compressor assembly 4.1 Storage and transport 4.2 Setting up... -
Page 4: Safety
1| Safety 1.1 Identification of safety instructions: DANGER Indicates a dangerous situation which, if not avoided, will cause immediate fatal or serious injury. WARNING Indicates a dangerous situation which, if not avoided, may cause fatal or serious injury. CAUTION Indicates a dangerous situation which, if not avoided, may cause fairly severe or minor injury. -
Page 5: Intended Use
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). -
Page 6: Product Description
2| Product description 2.1 Short description • Semi-hermetic eight-cylinder reciprocating compressor with suction-gas cooled drive motor. • The stream of refrigerant sucked out of the evaporator 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. -
Page 7: Type Key
2| Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany Y/YY HGX88e/3235-4 AW09529A047 Y/YY 135,0 A 551A 475A IP 65 SE 55 Fig. 2 Type designation Voltage, circuit, frequency Machine number Nominal rotation speed 50 Hz Type code... -
Page 8: Areas Of Application
3| Areas of application 3.1 Refrigerants • HFKW / HFC: R134a, R404A/R507, R407C, R407F • (H)FCKW / (H)CFC: 3.2 Oil charge The compressors are filled at the factory with the following oil type: - for R134a, R404A/R507, R407C, R407F FUCHS Reniso Triton SE 55 - for R22 FUCHS Reniso SP 46 Compressors with ester oil charge (FUCHS Reniso Triton SE 55) are marked with an X in the type... - Page 9 R134a R407C 3| Areas of application t (°C) t (°C) Evaporation temperature (°C) R134a <20K Condensing temperature (°C) Suction gas superheat (K) t +20°C Suction gas temperature (°C) t +20°C R407C t (°C) 12,5 Fig. 4 R407C t (°C) R407F t (°C) Unlimited application range t (°C)
- Page 10 t (°C) t (°C) R407F 3| Areas of application <20K t (°C) t (°C) <20K <20K t +20°C t +20°C t (°C) 12,5 <20K t +20°C t +20°C t (°C) 12,5 R404A/R507 Fig. 7 t (°C) R404A/R507 t (°C) R404A/R507 <20K t +20°C t (°C)
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Page 11: Compressor Assembly
4| Compressor assembly 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 damage before starting any work. 4.1 Storage and transport 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. -
Page 12: Pipe Connections
4| Compressor assembly 4.3 Pipe connections ATTENTION Damage possible. Superheating can damage the valve. Remove the pipe supports from the valve for soldering. Only solder using inert gas to inhibit oxidation products (scale). The discharge gas connection can be moved upwards with an adapter (accessory). -
Page 13: Laying Suction Ans Pressure Lines
4| Compressor assembly Solenoid valve dead Non-return valve open Fig. 17 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. -
Page 14: Operating The Shut-Off Valves
4| Compressor assembly 4.7 Operating the shut-off valves Before opening or closing the shut-off valve, release the valve spindle seal by approx. ¼ of a turn counter-clockwise. After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise. Release Tighten Valve spindle seal Fig. -
Page 15: Electrical Connection 15 Gb
5| Electrical connection Electrical connection DANGER Risk of electric shock! High voltage! Only carry out work when the electrical system is disconnected from the power supply! 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. -
Page 16: Standard Motor, Design For Direct Or Partial Winding Start
5| Electrical connection 5.2 Standard motor, design for direct or partial winding start Designation on the name plate Sticker on the terminal box Y/YY Y/YY 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%. - Page 17 nmotor für Direkt- oder Teilwicklungsstart Typschildangabe Gelber Aufkleber ührung für Direkt- oder Teilwicklungsstart t dieser Kennzeichnung ist für Direkt- Typschildangabe Gelber Aufkleber am Klemmenkasten chter mit dieser Kennzeichnung ist für Direkt- klungsstart (PW-Anlauf) geeignet. am Klemmenkasten 5| Electrical connection ∆/YYY Teilwicklungsstart (PW-Anlauf) geeignet.
- Page 18 5.3 Basic circuit diagram for part winding start with standart motor FC1.2 FC1.1 I=33% I=66% I> I> I> I> I> I> FC1.1 FC1.2 X SS B1 B2 /YYY OG OG INT69 Compressor terminal box Anschlußkasten Verdichter Fig. 23 Oil differential pressure monitor High pressure safety monitor Safety chain (high/low pressure monitoring) Release switch (thermostat)
- Page 19 L1.1 L2.1 L3.1 L1.2 P> P-Öl FC1.2 Motor protection switch (part winding 2) Control power circuit fuse Delay relay max. 1s 5HG76e.8 Main switch 5HGZ76e.7 5HG76e.8 Mains contactor (part winding 1) 5HGZ76e.7 Mains contactor (part winding 2) 6HG76e.7 Control voltage switch Terminal strip in the external switch cabinet PW MP10 BOCK COMPRESSORS...
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Page 20: Special Motor: Design For Direct Or Star-Delta Start
5| Electrical connection 5.4 Sondermotor: Ausführung für Direkt- oder Stern-Dreieck-Anlauf 5.4 Special motor: design for direct or star-delta start Für den Stern-Dreieck-Anlauf ist eine mechanische Anlaufentlastung mit Bypass-Magnetventil A mechanical unloaded start with bypass solenoid valve (accessories) is required for the (Zubehör) erforderlich. star-delta start. Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Designation on the name plate Sticker on the terminal box ∆... - Page 21 5| Electrical connection Star-delta start-up is only possible for ∆ (230 V) power supply. Example: 230 V Δ 400 V Y Direct start only Direct start Star-delta-start In the factory the motor is wired for direct starting at high voltage. The brides are to be removed for star delta starting at low voltage.
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Page 22: Circuit Diagram For Star-Delta Start 230 V ∆ / 400 V Y
5.5 Circuit diagram for star-delta start 230 V ∆ / 400 V Y FC1.2 FC1.1 I> I> I> I> I> I> FC1.1 FC1.2 X SS B1 B2 ˜ OG OG INT69 Anschlußkasten Verdichter Compressor terminal box BT2 BT2 Fig. 24 Oil differential pressure monitor High pressure safety monitor BT2.X... - Page 23 L1.1 L2.1 L3.1 L1.2 P> P-Öl Control power circuit fuse Delay relay for contactor switch over Main switch 6HG76e.7 6HG76e.8 Mains contactor Δ-contactor 5HG76e.8 5HGZ76e.7 Y-contactor 6HG76e.7 Control voltage switch Terminal strip in the external switch cabinet D/S MP10 BOCK COMPRESSORS 6HG76e...
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Page 24: Electronic Trigger Unit Int69 G
5| Electrical connection 5.6 Electronic trigger unit INT69 G The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the electronic trigger unit INT69 G in the terminal box. In case of excess temperature in the motor winding, the INT 69 G deactivates the motor contactor. -
Page 25: Functional Test Of The Trigger Unit Int69 G
5| Electrical connection 5.8 Function test of the trigger unit INT69 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. Relay position INT69 G Gauge state Relay position... -
Page 26: Commissioning
6| Commissioning 6.1 Preparations for start-up INFO To protect the compressor against inadmissible operating conditions, high pressure and low pressure pressostats are mandatory on the installation side. The compressor has undergone trials in the factory and all functions have been tested. There are therefore no special running-in instructions. -
Page 27: Start-Up
6| Commissioning 6.5 Refrigerant filling CAUTION Wear personal protective clothing such as goggles and protective gloves! Make sure that the suction and pressure line shut-off valves are open. With the compressor switched off, add the liquid refrigerant directly to the condenser or receiver, breaking the vacuum. -
Page 28: Connection Of Oil Level Regulator
6| Commissioning 6.8 Connection of oil level regulator Oil level regulation systems have proven themselves with parallel circuits of several compressors. The connection "0" is provided for installing an oil level regulator (see dimensions drawing). All common oil level regulators from AC&R, ESK and Carly as well as the OM3 TraxOil oil level regulation system from Alco can be connected directly without adapters (see Fig. -
Page 29: Extract From The Lubricants Table
Oil sump heater kit (220-240 V) 80237 Only use genuine GEA Bock spare parts! 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. -
Page 30: Accessories
8| Accessories 8.1 Capacity regulator ATTENTION If the capacity regulator is installed at the factory, the control com- ponent (pilot valve) is subsequently installed and connected by the customer. If the control component is not connected, the cylinder bank is switched off permanently. Damage to the compressor is possible! LR 1 LR 2 LR 3... - Page 31 Special accessories are only premounted in the factory if ordered specially by customer. Retrofitting is possible in full compliance with the safety instructions and repair instructions enclosed with the kits. Information about the use, operation, maintenance and servicing of the components is available in the printed literature or on the internet under www.gea.com...
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Page 32: Technical Data
9| Technical data Oil charge 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% No. of cylinders... -
Page 33: Dimensions And Connections
The reproduction, distribution and utilization of this be held liable for the document as well as the communication of its rights reserved in the event GEA Bock GmbH - Benzstraße 7 - 72636 F Zust. / Rev. Maß Dimension Passung / Clearance contents to others without express authorization is Änd.-Nr. - Page 34 10| Dimensions and connections Suction line see technicla data, Chapter 9 Discharge line Connection suction side, , not lockable 8 “ NPTF Connection suction side, , lockable 16 “ UNF Connection suction side, , not lockable 4 “ NPTF Connection discharge side , not lockable 8 “...
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Page 35: Declaration Of Conformity And Installation
European Union (in accordance with Machinery Directive 2006/42/EC) The manufacturer: GEA Bock GmbH, Benzstraße 7 72636 Frickenhausen, Tel.: 07022/9454-0 hereby declares that the refrigerating compressor HG88e complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. -
Page 36: Service
If you have any questions 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... - Page 38 • • 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.
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