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GEA Bock HG22e/HG34e
Assembly instructions
96415-01.2018-Gb
Translation of the original instructions
HG22e/125-4
HG22e/160-4
HG22e/190-4
HG34e/215-4
HG34e/255-4
HG34e/315-4
HG34e/380-4
HGX34e/215-4 S R407C
HGX34e/255-4 S R407C
HG22e/125-4 S
HGX22e/125-4
HG22e/160-4 S
HGX22e/160-4
HG22e/190-4 S
HGX22e/190-4
HG34e/215-4 S
HG34e/215-4
HG34e/255-4 S
HG34e/255-4
HG34e/315-4 S
HG34e/315-4
HG34e/380-4 S
HG34e/380-4
HGX34e/315-4 S R407C
HGX34e/380-4 S R407C
HGX22e/125-4 S
HGX22e/160-4 S
HGX22e/190-4 S
HGX34e/215-4 S
HGX34e/255-4 S
HGX34e/315-4 S
HGX34e/380-4 S
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Table of Contents
Related Manuals for GEA Bock HG22e Series
Summary of Contents for GEA Bock HG22e Series
- Page 1 GEA Bock HG22e/HG34e Assembly instructions 96415-01.2018-Gb Translation of the original 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 HG34e/215-4 HG34e/215-4 S HG34e/215-4 HGX34e/215-4 S HG34e/255-4 HG34e/255-4 S HG34e/255-4 HGX34e/255-4 S...
- 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 1.1 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 3.4 Refrigerants - design for R407C, 35 bar 3.5 Oil charge for R407C, 35 bar 3.6 Limits of application for R407C, 35 bar Compressor assembly... -
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
1| Safety 1.3 General safety instructions WARNING Risk of accidents. Refrigerating compressors are pressurised machines and as such call for heightened caution and care in handling. The maximum permissible overpressure must not be exceeded, even for testing purposes. Risk of burns! - Depending on the operating conditions, surface temperatures of over 60°C on the discharge side or below 0°C on the suction side can be reached. -
Page 6: Product Description
2| Product description 2.1 Short description • HG22e: Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication. • HG34e: Semi-hermetic four-cylinder reciprocating compressor with oil pump lubrication. • Suction gas cooled drive motor. Transport eyelet Discharge shut-off valve Valve plate Name plate Oil pump Oil sight glass Fig. -
Page 7: Type Key
2| Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany HGX34e/315-4 AS38125A001 27,3 27,3 21,1/12,2A 111A 32,8 32,8 19/28 IP66 SE 55 SE 55 Fig. 3 Type designation Voltage, circuit, frequency 50 Hz Machine number Nominal rotation speed maximum operating current... -
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. HGX34e/380-4). INFO For refilling, we recommend the above oil types. - Page 9 3| Areas of application ATTENTION When operating in the vacuum range, there is a danger of air entering on the suction side. This can cause chemical reactions, a pressure rise in the condenser and an elevated compressed-gas temperature. Prevent the ingress of air at all costs! t (°C) <20K HGX34e/...
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Page 10: Refrigerants - Design For R407C, 35 Bar
3| Areas of application 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) Fig. 8 Suction gas temperature (°C) Max. permissible operating Design for other pressure (LP/HP) : 19/28 bar areas on request LP = Low pressure HP = High pressure... -
Page 11: Limits Of Application For R407C, 35 Bar
3| Areas of application 3.6 Limits of application for R407C, 35 bar ATTENTION Compressor operation is possible within the operating limits shown in the diagrams. Please note the significance of the shaded areas. Thresholds should not be selected as design or continuous operation points. - Permissible ambient temperature (-20°C) - (+60°C) - Max. -
Page 12: Compressor Assembly
4| Compressor assembly INFO New compressors are factory-filled with inert gas. Leave this ser- vice 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 humidi- ty 10 % - 95 %, no condensation Do not store in a corrosive, dusty, vaporous atmosphere or in a com- bustible environment. -
Page 13: 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 14: 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. Release Tighten Valve spindle seal Fig. -
Page 15: Electrical Connection 15 E
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 16 5.3 Circuit diagramm for direct start 230 V ∆ / 400 V Y FC1.1 I> I> I> FC1.1 L3 N PE -EC1 Θ B1 B2 INT69G Compressor terminal box Anschlußkasten Verdichter Fig. 17 Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Load circuit safety switches Control power circuit fuse High pressure safety monitor Safety chain (high/low pressure monitoring ) Release switch (thermostat)
- Page 17 L1.1 L2.1 L3.1 L1.2 P> Θ Θ Main switch Control voltage switch Compressor motor Compressor contactor INT69 G Electronic trigger unit INT69 G Oil sump heater...
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Page 18: I Ru
5| Electrical connection 5.4 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 19: Start Unloader
INT69 G switch-on 11-14 B2 12 14 11 Remove PTC connector 11-12 Fig. 19 Insert PTC connector 11-12 Reset after mains on 11-14 5.7 Start unloader To avoid current peaks during the starting phase we recommend using the GEA Bock-ESS soft starting device (Electronic Soft Start). Refer to "Accessories" for further information. -
Page 20: 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 21: Start-Up
6| Commissioning 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. ATTENTION Avoid overfilling the system with refrigerant! To avoid shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always only be filled into the refrigerating plant in liquid form. -
Page 22: Maintenance
7| Maintenance 7.1 Preparation WARNING Before starting any work on the compressor: Switch off the compressor and secure it to prevent a restart. Relieve compressor of system pressure. Prevent air from infiltrating the system! After maintenance has been performed: Connect safety switch. Evacuate compressor. Release switch lock. 7.2 Work to be carried out In order to guarantee optimum operational reliability and service life of the compressor, we recommend carrying out servicing and inspection work at regular intervals:... -
Page 23: Extract From The Lubricants Table
7| Maintenance 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 Fuchs Reniso Triton SEZ 32 Esso/Mobil EAL Arctic 46 Fuchs Reniso Triton SE 55 (e.g. R404A) -
Page 24: Technical Data
8| Technical data Oil charge Weight 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz No. of cylinders... - Page 25 8| Technical data Oil charge Weight 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz No. of cylinders...
- Page 26 8| Technical data Oil charge Weight 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz No. of cylinders...
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Page 27: Dimensions And Connections
9| Dimensions and connections HG22e Centre of gravity Vibration damper Dimensions in mm SV 90° rotatable Fig. 20 Suction line see technical data, Chapter 8 Discharge line Connection suction side, not lockable 8 “ NPTF Connection suction side, lockable 16 “ UNF Connection discharge side, not lockable 8 “... - Page 28 9| Dimensions and connections HG34e Centre of gravity Vibration damper Dimensions in mm Fig. 21 SV 90° rotatable Suction line see technical data, Chapter 8 Discharge line Connection suction side, not lockable 8 “ NPTF Connection suction side, lockable 16 “ UNF Connection discharge side, not lockable 8 “...
- Page 29 9| Dimensions and connections HG34e R407C Centre of gravity Vibration damper Dimensions in mm Fig. 22 SV 90° rotatable Suction line see technical data, Chapter 8 Discharge line Connection suction side, not lockable 8 “ NPTF Connection suction side, lockable 16 “...
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Page 30: Declaration Of Installation
DECLARATION OF INSTALLATION for using the compressors within the 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 and HG34e complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. Applied harmonised standard:... -
Page 31: Service
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... - Page 32 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. GEA Bock GmbH Benzstraße 7 Phone +49 (0)7022 9454-0 info@gea.com...