GEA HG22e/125-4 Assembly Instructions Manual
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Summary of Contents for GEA HG22e/125-4
- Page 1 GEA Compressor HG22e Assembly instructions HG22e/125-4 HG22e/125-4 S HGX22e/125-4 HGX22e/125-4 S HG22e/160-4 HG22e/160-4 S HGX22e/160-4 HGX22e/160-4 S HG22e/190-4 HG22e/190-4 S HGX22e/190-4 HGX22e/190-4 S engineering for a better world...
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Page 2: Table Of Contents
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... - Page 3 Contents Page 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 4.3 Pipe connections 4.4 Pipes 4.5 Laying suction and pressure lines 4.6 Operating the shut-off valves 4.7 Operating mode of the lockable service connections Electrical connection 5.1 Information for contactor and motor contactor selection 5.2 Connection of the driving motor...
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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: General Safety Instructions
The compressor may 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 and 2006/95/EC – Low Voltage Directive). -
Page 6: Product Description
2| Product description 2.1 Short description • Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication. • Suction gas cooled drive motor. Transport eyelet Valve plate Name plate Oil pump Oil sight glass Fig. 1 Cylinder cover Terminal box Discharge shut-off valve Drive section Suction Motor section... -
Page 7: Type Key
2| Product description Typschild (Beispiel) 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany HGX22e/190-4 AS35830A001 13,8/8,0A SE 55 Fig. 3 Typbezeichnung Spannung, Schaltung, Frequenz Type designation Voltage, circuit, frequency 50 Hz Maschinennummer Nenndrehzahl 50 Hz Machine number Nominal rotation speed maximaler Betriebsstrom... -
Page 8: Areas Of Application
3| Areas of application 3.1 Refrigerants • HFKW / HFC: R134a, R404A/R507, R407C • (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 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 designation (e.g. - Page 9 3| Areas of application R134a Fig. 5 R407C Fig. 6 Unlimited application range Supplementary cooling or reduced suction gas temperature Supplementary cooling and reduced suction gas temperature Motor version S R404A/R507 (more powerful motor) Evaporation temperature (°C) Condensing temperature (°C) Suction gas superheat (K) Fig.
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Page 10: 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 11: Pipes
4| Compressor assembly 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. -
Page 12: Operating The Shut-Off Valves
4| Compressor assembly 4.6 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. Tighten Release Valve spindle seal Fig. -
Page 13: Electrical Connection
5| Electrical connection DANGER Risk of electric shock! High voltage! Only carry out work when the electrical system is disconnected from the power supply! ATTENTION When attaching accessories with an electrical cable, a minimum bending radius of 3 x the cable diameter must be maintained for laying the cable. - Page 14 5.3 Circuit diagramm for direct start 230 V ∆ / 400 V Y --> compressor with MP10 I> I> I> X1 L1 L1 N N 43 43 11 -EC1 Θ MP10 X2 1 Compressor terminal box Klemmenkasten Verdichter Fig. 20 Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Load circuit safety switches...
- Page 15 L1.1 L2.1 L3.1 L1.2 A1 Alarm Motorschutz Alarm motor protection Overheating BT1, BT2 A2 Übertemperatur BT1, BT2 P< Alarm high pressure A3 Alarm Hochdruck Main switch Control voltage switch Compressor motor Compressor contactor MP10 Electronic trigger unit MP10 Oil sump heater...
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Page 16: Electronic Trigger Unit Mp10
5| Electrical connection 5.4 Electronic trigger unit MP10 The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the elec- tronic trigger unit MP10 in the terminal box. Readiness to operate is signalled by the H3 LED (green) after the power supply is applied. In the case of excess temperature in the motor winding, the unit switches off the compressor and the H1 LED lights red. - Page 17 5| Electrical connection 5.6 Function test of the trigger unit MP10 Before start-up, troubleshooting or making changes to the control power circuit, check the functionality of the trigger unit: LED H1 LED H2 LED H3 Procedure green • Interrupt power supply (L1 or SF1) •...
- Page 18 5.7 Circuit diagramm for direct start 230 V ∆ / 400 V Y --> compressor with INT69 G I> I> I> B1 B2 -EC1 INT69 G Θ Compressor terminal box Klemmenkasten Verdichter Fig. 22 Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Load circuit safety switches Control power circuit fuse...
- Page 19 L1.1 Alarm motor protection A1 Alarm Motorschutz Overheating BT1, BT2 A2 Übertemperatur BT1, BT2 P< Alarm high pressure A3 Alarm Hochdruck Main switch Control voltage switch Compressor motor Compressor contactor INT69 G Electronic trigger unit INT69 G Oil sump heater...
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Page 20: Electronic Trigger Unit Int69 G
5| Electrical connection 5.8 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 INT69 G deactivates the motor contactor. -
Page 21: Start Unloader
Fig. 24 Insert PTC connector 11-12 Reset after mains on 11-14 5.11 Start unloader To avoid current peaks during the starting phase we recommend using the GEA ESS soft starting device (Electronic Soft Start). Refer to "Accessories" for further information. -
Page 22: Preparations For Start-Up
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 23: Refrigerant Charge
6| Commissioning 6.5 Refrigerant charge 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. If the refrigerant needs topping up after starting the compressor, it can be topped up in vapour form on the suction side, or, taking suitable precautions, also in liquid form at the inlet to the evaporator. -
Page 24: Connection Of Oil Level Regulator
7.3 Spare parts recommendation HG22e / ... 125-4 (S) 160-4 (S) 190-4 (S) Designation Ref. No. Ref. No. Ref. No. Set of gaskets 80313 Valve plate kit 80305 80306 Oil pump kit 08324 Only use genuine GEA spare parts! -
Page 25: Accessories
7| Maintenance 7.4 Accessories Available accessories can be found on the Internet at www.gea.com 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. -
Page 26: Technical Data
8| Technical data 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz... -
Page 27: Dimensions And Connections
Connection suction side, not lockable 8 “ NPTF HG22P/125-4 14430 HGX22P/125-4 14433 HG22P/125-4 S 14436 HGX22P/125-4 S 14439 HG22e/125-4 14784 HGX22e/125-4 14787 HG22e/125-4 S F Ölablaß 14790 HGX22e/125-4 S Oil drain 14793 HG22P/160-4 14431 HGX22P/160-4 14434 HG22P/160-4 S 14437 HGX22P/160-4 S 14440 H Stopfen Ölfüllung... -
Page 28: Declaration Of 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 HG22e complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. -
Page 29: Service
11| Service Dear customer, GEA compressors are top-quality, reliable and service-friendly quality products. If you have 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: refrigeration@gea.com Yours faithfully GEA Bock GmbH Benzstraße 7... - Page 30 • • 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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