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GEA HG22e/125-4, Assembly Instructions Manual

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96188-11.2015-DGbFEIRu

engineering for a better world

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

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Summary of Contents for HG22e/125-4

Page 1: ...for a better world 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 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 2: ...s 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 Manufacturer Contact Contents Page 1 Safety 4 1 1 Identification of safety instructions 1 2 Qualifications required...

Page 3: ... of the electronic trigger unit MP10 5 6 Functional test of the electronic trigger unit MP10 5 7 Circuit diagram for direct start 230 V Δ 400 V Y with INT69 G 5 8 Electronic trigger unit INT69 G 5 9 Connection of the electronic trigger unit INT69 G 5 10 Functional test of the electronic trigger unit INT69 G 5 11 Start unloader 6 Commissioning 22 6 1 Preparations for start up 6 2 Pressure strength ...

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: ...tentially 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 Commissioning is permissibl...

Page 6: ...ng compressor with oil pump lubrication Suction gas cooled drive motor 2 1 Short description Name plate Fig 1 Fig 2 Oil sight glass Cylinder cover Oil pump Suction shut off valve Drive section Motor section Dimension and connection values can be found in Chapter 9 Transport eyelet Valve plate Discharge shut off valve Terminal box ...

Page 7: ...Hermetic Gas cooled suction gas cooled for the normal air conditioning applications X Ester oil charge HFC refrigerant e g R134a R404A R507 R407C S More powerful motor e g for air conditioning applications Motor variant Number of poles Swept volume e series Numbers of cylinders Size Oil charge Series Typschild Beispiel 1 2 3 4 5 13 12 7 11 6 10 8 9 1 Typbezeichnung 2 Maschinennummer 3 maximaler Be...

Page 8: ...tion 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 permissible discharge end temperature 140 C Max permissible switching frequency 8x h A minimum running time of 3 min steady state condition continuous operation mu...

Page 9: ...cation Design for other areas on request R134a R407C R404A R507 R22 Fig 5 Fig 6 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 1 LP Low pressure HP High pressure Max permissible operating pressure LP HP 1 19 28 bar ...

Page 10: ... no condensation Do not store in a corrosive dusty vaporous atmosphere or in a com bustible environment Fig 10 Fig 9 4 3 Pipe connections ATTENTION Do not solder as long as the compressor is under pressure Superheating can damage the valve Remove the pipe supports therefore from the valve for soldering and accordingly cool the valve body during and after soldering Only solder using inert gas to in...

Page 11: ...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 4 5 Laying suction and pressure lines A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to...

Page 12: ...on opened shut off valve opened Service connec tion closed Connection blocked Spindle Service connec tion opened Spindle Connection open Compressor Compressor Valve spindle seal Release Tighten 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 adjustable valve spindle seal clockwise F...

Page 13: ...ressor 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 Insert the strain reliefs and prevent chafe marks on the cables Compare the voltage and frequency values with the data for the mains power supply Only connect the motor if these values are the same DANGE...

Page 14: ...tion thermostat PTC sensor FC1 Load circuit safety switches FC2 Control power circuit fuse BP1 Safety chain high low pressure monitoring BP2 Release switch thermostat pressostat 0 1 2 3 4 Klemmenkasten Verdichter MP10 BT1 QA1 FC1 I I I QA2 PE FC1 A1 X1 L1 L1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 FC2 SF1 BT2 A2 BP1 P PE EC1 3 M Θ L1 L2 L3 N PE Compressor terminal box Fig 20 ...

Page 15: ...ssor motor QA2 Compressor contactor MP10 Electronic trigger unit MP10 EB1 Oil sump heater 5 6 7 8 9 A1 Alarm Motorschutz A2 Übertemperatur BT1 BT2 A3 Alarm Hochdruck A3 BP2 P PE QA2 1 2 EB1 QA2 3 4 L1 1 L2 1 L3 1 L1 2 N PE A1 Alarm motor protection A2 Overheating BT1 BT2 A3 Alarm high pressure ...

Page 16: ...he cause 5 5 Connection of the trigger unit MP10 Temperature monitoring connections Motor winding Terminals 1 2 Thermal protection thermostat Terminals 3 4 Restart prevention Terminals 5 6 INFO The unit has a restart prevention device After you have rectified the fault interrupt the mains voltage This unlocks the restart prevention device and the LEDs H1 and H2 go out INFO Connect the trigger unit...

Page 17: ... connection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or SF1 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 SF1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or SF1 OFF OFF ON MP10 is operational ag...

Page 18: ... BT2 L1 L2 L3 N PE 5 7 Circuit diagramm for direct start 230 V 400 V Y compressor with INT69 G Fig 22 BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor FC1 Load circuit safety switches FC2 Control power circuit fuse BP1 Safety chain high low pressure monitoring BP2 Release switch thermostat pressostat Compressor terminal box ...

Page 19: ...BT2 A3 Alarm Hochdruck A3 BP2 P PE QA2 1 2 EB1 QA2 3 4 L1 L2 L3 L1 1 N PE QA1 Main switch SF1 Control voltage switch EC1 Compressor motor QA2 Compressor contactor INT69 G Electronic trigger unit INT69 G EB1 Oil sump heater A1 Alarm motor protection A2 Overheating BT1 BT2 A3 Alarm high pressure ...

Page 20: ... 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 sensor break or open circuit INFO Connect the trigger unit INT69 G in accordance with the circuit dia gram Protect the trigger unit with a delayed act...

Page 21: ...the trigger unit Perform this check using a continuity tester or gauge 5 Electrical connection Gauge state Relay position 1 Deactivated state 11 12 2 INT69 G switch on 11 14 3 Remove PTC connector 11 12 4 Insert PTC connector 11 12 5 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 St...

Page 22: ...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 23: ...ation 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 recom...

Page 24: ...ness running noises pressures temperatures function of auxiliary devices such as oil sump heater pressure switch 6 8 Connection of oil level regulator The connection O is provided for installing an oil level regulator A corresponding adapter must be obtained from the trade 6 Commissioning Only use genuine GEA spare parts 7 3 Spare parts recommendation HG22e 125 4 S 160 4 S 190 4 S Designation Ref ...

Page 25: ...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 HFC e g R134a R407C R404A Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Arct...

Page 26: ...0 240 V 380 420 V Y 3 50 Hz 265 290 V 440 480 V Y 3 60 Hz 5 L M H 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 cu...

Page 27: ...tion oil level regulator Raccord régula L Lötanschluß L Brazing connection L Raccord Maße Zubehör D Halbhermetischer Verdichter HG Semi hermetic compressor HG Compresseur semi herméti Massenschwerpunkt Centre of gravity Centre de gravité ca 5 4 5 6 7 4 5 über 0 5 Tol Ang DIN ISO 2768 mK 1 Revisionsdurchlauf Transportwinkel geändert Betrifft Blatt 2 Betrifft Blatt 3 BS Befestigungsteile Maß Passung...

Page 28: ...ndards 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 ...

Page 29: ...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 72636 Frickenhausen Germany 11 Service ...

Page 30: ... 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 ...

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