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GEA HG76e/1620-4, Assembly Instructions Manual, Page: 2 / 38

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2

96263-01.2016-DGbFEIRu

 D
 GB
 F
 E
 I
 Ru

About these instructions

Read these instructions before assembly and before using the compressor. This will avoid misunder-

standings

 

and prevent damage. Improper assembly and use of 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

Tel49 7022 9454 0
Fax  

+49 7022 9454 137

[email protected]
www.gea.com

Manufacturer

Contact

 

1 Safety 

4

 

1.1  Identification of safety instructions

 

1.2  Qualifications required of personnel

 

1.3  General safety instructions

 

1.4  Intended use

 

2 

Product description 

6

 

2.1  Short description

 

2.2  Name plate

 

2.3  Type key

 

3 

Areas of application 

8

 

3.1 Refrigerants

 

3.2  Oil charge

 

3.3  Limits of application

 

4

 

Compressor assembly 

11

 

4.1  Storage and transport

   

4.2  Setting up

 

4.3  Pipe connections

 

4.4 Pipes

 4.5 

Start unloader (external) 

 4.6 

Laying suction and pressure lines

 

4.7  Operating the shut-off valves

 

4.8  Operating mode of the lockable service connections

 

5 

Electrical connection 

15

 

5.1  Information for contactor and motor contactor selection

 

5.2  Standard motor, design for direct or part winding start

 

5.3  Basic circuit diagram for part 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  Connection of the trigger unit INT69 G

 

5.8  Function test of the trigger unit INT69 G

 

5.9  Oil sump heater (accessories)

 

6 Commissioning 

26

 

6.1  Preparations for start-up

 

6.2  Pressure strength test

 

6.3  Leak test

 

6.4 Evacuation

 

6.5  Refrigerant charge

 

6.6 Start-up

 

6.7  Avoiding slugging

 

7 Maintenance 

29

 

7.1 Preparation

 

7.2  Work to be carried out

 

7.3  Spare parts recommendation

 

7.4  Extract from the lubricants table

 

7.5 Decommissioning

 

8 Accessories 

31

 

8.1  Capacity regulator 

 8.2 

Oil separator 

 8.3 

Oil level regulator 

 

9 

Technical data 

33

 

10  Dimensions and connections 

34

 

11  Declaration of installation 

36

 

12 Service 

37

Summary of Contents for HG76e/1620-4

Page 1: ...EA Compressor HG76e Assembly instructions HG76e 1620 4 HG76e 1620 4 S HGX76e 1620 4 HGX76e 1620 4 S HG76e 1860 4 HG76e 1860 4 S HGX76e 1860 4 HGX76e 1860 4 S HG76e 2110 4 HG76e 2110 4 S HGX76e 2110 4 HGX76e 2110 4 S HG76e 2500 4 HG76e 2500 4 S HGX76e 2500 4 HGX76e 2500 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: ...n 5 2 Standard motor design for direct or part winding start 5 3 Basic circuit diagram for part 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 Connection of the trigger unit INT69 G 5 8 Function test of the trigger unit INT69 G 5 9 Oil sump heater accessories 6 ...

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: ... 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 Commissioning is permissible only if the compr...

Page 6: ...ver 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 sight glass Drive section Name plate Motor section Suction shut off valve Oil pump ...

Page 7: ...13 Terminal box protection type HD HP max admissible operating Electrical accessories can change pressure g High pressure side the IP protection class Observe the limits of application diagrams 50 Hz 60 Hz SE 55 IP 65 AV12345 A001 HGX76e 2500 4 GEA Bock GmbH 72636 Frickenhausen Germany HG 6 7 e 2500 4 S X HG Hermetic Gas cooled suction gas cooled for the normal air conditioning applications X Este...

Page 8: ...0 C Max permissible switching frequency 12x h A minimum running time of 3 min steady state condition continuous operation must be achieved For operation with supplementary cooling Use only oils with high thermal stability Avoid continuous operation near the threshold For operation with capacity regulator Continuous operation when the capacity regulator is activated is not permissible and can cause...

Page 9: ... K 20 t 20 C Oh R134a 0 10 20 30 20 30 40 50 60 70 t C c 61 5 25 tOh 20K t 20 C Oh R407C 20 10 0 10 20 30 40 20 30 40 50 60 70 t C o t C c 66 35 t 20 C oh 5 12 5 toh 20K R22 R407F 30 40 50 60 70 t C c toh 20K t 20 C oh 58 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 R134a Fig 4 Additional cooling and reduced suction gas temperature Unlimited application range Additiona...

Page 10: ...2 5 toh 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 R404A R507 Fig 7 Fig 8 Additional cooling and reduced suction gas temperature Unlimited application range Additional cooling or reduced suction gas temperature Motor variant S stronger motor Evaporation temperature C Condensing temper...

Page 11: ...ion Do not use in a corrosive dusty damp atmosphere or a combustible environment Fig 11 Fig 12 4 2 Setting up 4 1 Storage and transport Use transport eyelet Do not lift manually Use lifting gear 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 Fig 10 Fig 9 Fig 14 Installation of p...

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: ...ctly after the compressor is integral to the system s smooth running and vibration behaviour 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: ... 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 terminal box Insert the strain reliefs and prevent chafe marks on the cables C...

Page 16: ... 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 5 Electrical connection INFO A mechanical unloaded start with bypass solenoid valve is not required Y YY PW ...

Page 17: ...al winding 1 and partial winding 2 are wired internally in HG76e ATTENTION Failure to do this results in opposed rotary fields and results in damage to the motor After the motor starts up via partial winding 1 partial winding 2 must be switched on after a maximum delay of one second Failure to comply can adversely affect the service life of the motor 400 V Direktstart YY Teilwicklungsstart Y YY 1V...

Page 18: ... QA2 1 3 4 2 5 6 3 1U1 1V1 1W1 PE 2U1 2V1 2W1 FC1 2 I I I 1 2 QA3 4 3 4 5 5 6 6 7 FC1 1 FC1 2 8 BT2 FC2 SF1 BT2 9 10 BT2 11 OG OG 11 12 14 L N B1 B2 EC1 M Y YY BP1 Oil differential pressure monitor BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BP4 Release switch thermostat BT1 Cold conductor PTC sensor motor winding BT2 X Thermal protection thermostat EB1 Oil sump ...

Page 19: ...t winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch XSS Terminal strip in the external switch cabinet PW INT69 5 6 7 BOCK COMPRESSORS 8 9 Bl 6HG76e Bl 5HGZ76e 5HG76e 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 1 8 2 8 3 7 4 8 5HGZ76e 7 6HG76e 7 21 22 KF1 1 8 2 8 5HGZ76e 7 23 24 QA2 25 EB1 26 L1 1 L2 1 L3 1 L1 2 N PE BT3 PE ...

Page 20: ...20 96263 01 2016 DGbFEIRu D GB F E I Ru 5 Electrical connection 5 4 Special motor design for direct or star delta start Designation on the name plate Sticker on the terminal box Y ...

Page 21: ...l 230 V Direktstart Stern Dreieck Start L3 L1 V1 W1 U1 V2 U2 W2 L1 L2 L3 L2 V1 W1 U1 V2 U2 W2 L3 L2 L1 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 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 U1 V2 U2 W2 L3 L2 L1 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 Y Stern Dreieck Anla...

Page 22: ...2 I I I 1 2 QA3 4 3 4 5 5 6 6 7 FC1 1 FC1 2 8 FC2 SF1 9 10 11 OG OG 11 12 14 L N B1 B2 BT2 BT2 BT2 5 5 Circuit diagram for star delta start 230 V 400 V Y Fig 24 BT1 Oil differential pressure monitor BT2 High pressure safety monitor BT2 X Thermal protection thermostat BT3 Safety chain high low pressure monitoring BT4 Release switch thermostat EB1 Oil sump heater EC1 Compressor motor FC1 1 Motor pro...

Page 23: ...r QA4 Y contactor SF1 Control voltage switch XSS Terminal strip in the external switch cabinet D S INT69 5 6 7 BOCK COMPRESSORS 8 9 Bl 6HG76e Bl 6HG76e BP1 P Öl QA2 12 T2 13 N 14 L 15 M 16 S BP2 P 17 QA2 QA2 3 7 4 7 18 QA4 19 BP3 P KF4 QA4 QA3 1 8 2 8 3 7 4 8 5HG76e 8 5HGZ76e 7 20 KF4 QA3 QA4 3 8 4 8 21 22 KF4 23 24 QA2 25 EB1 26 L1 1 L2 1 L3 1 L1 2 N PE BT3 PE ...

Page 24: ...mal protection thermostats accessory The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause 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 sensor b...

Page 25: ...ation The oil sump heater operates when the compressor is at a standstill When the compres sor starts up the oil sump heater switches off again automatically Connection The oil sump heater must be connected via an auxiliary contact or parallel wired auxili ary contact of the compressor contactor to a seperate electric circuit El data 230 V 1 50 60 Hz 140 W Fig 27 ATTENTION Connection to the curren...

Page 26: ...lways observing the maximum permissible overpressure for the compressor DANGER Risk of bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximum permissible overpressure of the compressor must not be exceeded at any time during the testing process see name plate data Do not mix any refrigerant with the nitrogen as this could cause th...

Page 27: ...olts shorten this can result in winding and terminal board damage 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 precau...

Page 28: ...acement of liquid traps solenoid valve in the liquid line etc There should be no movement of coolant whatsoever while the compressor is at a standstill ATTENTION Slugging can damage the compressor and cause refrigerant to leak 6 6 Start up Check that the safety and protection devices pressure switch motor protection electrical contact protection measures etc are all functioning properly Switch on ...

Page 29: ...ge not mandatory for factory produced series systems for field installations or when operating near the application limit for the first time after 100 to 200 operating hours then approx every 3 years or 10 000 12 000 operating hours Dispose of used oil according to the regulations observe national regulations Annual checks Oil level leak tightness running noises pressures temperatures function of ...

Page 30: ...he applicable national regulations 7 Maintenance 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 Alternatives are stated in the extract from our lubricants table below Refrigerants GEA standard oil types Recommended alternatives HFKW e g R134a R404A R407C R407F Fuchs Reniso Triton SE 55 Fu...

Page 31: ...ot 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 31 ATTENTION If the capacity regulator is mounted at the factory the control com ponent pilot valve is mounted and connected subsequently by the customer Ifthecontrolcomponentisnotconnected thecylinderbank is switched off permanently Damage to the compress...

Page 32: ...cuits 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 30 A sight glass on the oil level regulator is not required Mechanical oil level regulator at the O connectio...

Page 33: ...9 64 2 5 8 HG76e 2110 4 S 183 6 220 3 115 61 6 326 501 297 HG76e 2500 4 217 2 260 6 107 59 9 268 412 HG76e 2500 4 S 217 2 260 6 133 72 6 326 501 1 2 3 2 4 380 420 V Y YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 50 50 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 appl...

Page 34: ...ch A Anschluss Saugseite nicht absperrbar Zoll 1 8 Connection suction side not lockable inch A1 Anschluss Saugseite absperrbar Zoll 7 1 Connection suction side lockable inch A2 Anschluss Saugseite nicht absperrbar Zoll 1 4 Anschluss Saugseite nicht absperrbar inch B Anschluss Druckseite nicht absperrbar Zoll 1 8 Connection discharge side not lockable inch B1 Anschluss Druckseite absperrbar Zoll 7 ...

Page 35: ...ge side lockable 7 16 UNF C Connectoin 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 Oil sump heater accessories M22 x 1 5 K Sight glass L Connection thermal protection thermostat 1 8 NPTF O Connection oil level regulator ...

Page 36: ...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 37: ...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 12 Service ...

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 ...

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