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GEA Plusbox, Assembly & Instruction Manual

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96284-09.2015-DGbF

Contents  

 

        

 

    

Page

 

1 

Safety 

  4

 

1.1  Identification of safety instructions

 

1.2  Qualifications required of personnel

 

1.3  Safety instructions

 

1.4  Intended use

 

2 

Product description 

  6

 

2.1  Short description

 

2.2  Name plate

 

2.3  Type key

 3

 

Assembly 

  8

   

3.1  Setting up

 

4 

Electrical connection 

  9

 

4.1  Circuit diagram for Plusbox with accessories

 

4.2  Circuit diagram for Plusbox with frequency converter

 

5 Commissioning 

16

 

5.1  Commissioning Plusbox without EFCe 

 

5.2  Commissioning Plusbox with EFCe

 

6 Running 

24

 

6.1  Status Messages

 

6.2  Application Example

 

7 Maintenance 

26

 

7.1 Preparation

 

7.2  Work to be carried out

 

8 

Technical data 

27

 9 

Dimensions and connections 28

 

10 Service 

29

Summary of Contents for Plusbox

Page 1: ...gineering for a better world GEA Plusbox Assembly instructions SHG X 34e 215 4 S PB SHG X 34e 215 4 S P P SHG X 34e 255 4 S PB SHG X 34e 255 4 S P P SHG X 34e 315 4 S PB SHG X 34e 315 4 S P P SHG X 34e 380 4 S PB SHG X 34e 380 4 S P P ...

Page 2: ...he safety instructions contained in these instructions and in the compressor instructions These instructions must be passed onto the end customer along with the unit in which the Plusbox is installed Observe also the other documentation included with the Plusbox GEA Bock GmbH 72636 Frickenhausen GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 re...

Page 3: ...Type key 3 Assembly 8 3 1 Setting up 4 Electrical connection 9 4 1 Circuit diagram for Plusbox with accessories 4 2 Circuit diagram for Plusbox with frequency converter 5 Commissioning 16 5 1 Commissioning Plusbox without EFCe 5 2 Commissioning Plusbox with EFCe 6 Running 24 6 1 Status Messages 6 2 Application Example 7 Maintenance 26 7 1 Preparation 7 2 Work to be carried out 8 Technical data 27 ...

Page 4: ...comparable training which enablespersonneltoassemble install maintainandrepairrefrigeration and air conditioning systems Personnel must be capable of assessing the work to be carried out and recognising any potential dangers 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...

Page 5: ...cause severe burns and skin damage WARNING The Plusbox may not be used in potentially explosive environments These assembly instructions describe the standard version of the Plusbox named in the title manufac tured by GEA The Plusbox is 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 Commission...

Page 6: ...rther connections see dimensio Weitere Anschlüsse siehe Maßzeichn Cotes en mm Dimensions in mm Maße in mm Luftgekühlter Verflüssigungssatz Air cooled condensing unit Groupe de condensation à air Coordination de montage optimal sur fiche technique réf XXXX Zuordnung für optionale Anbauten auf Datenblatt Teile Nr XXXX Coordination of optimum mounting on data sheet ref no XXXX Darstellungen ohne Zuga...

Page 7: ...HGX34e 315 4 P P AV38125A001 SHG 4 3 e 380 PB 4 S X 2 3 Type key example HG Hermetic Gas Cooled suction gas cooled X Ester oil charge 3 S Stronger motor 4 PB Plusbox P P Plug and Play Plusbox 4 Motor variant 3 Number of poles Swept volume e Series Number of cylinders Size Oil charge Series GEA Bock GmbH 72636 Frickenhausen Germany 19 28 2 Product description 2 2 Name plate example Fig 3 ...

Page 8: ...ty damp atmosphere or a combustible environment F E D C 1 2 3 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 On the Plusbox backside there is a sheet metal in the area of the connection lines The sheet metal can be moved after releasing the four screws so the lines can be easie...

Page 9: ...erminal strip terminal box Legend circuit diagram for Plusbox with accessories DANGER Risk of electric shock High voltage Only carry out work when the electrical system is discon nected from the power supply 4 Electrical connection to 4 2 Circuit diagram for Plusbox with frequency converter see Fig 10 ATTENTION For frequency converter operation Max permissible ambient temperature 10 C to 40 C Perm...

Page 10: ...T1 INT69 G KF1 T1 lL1 T2 L2 T3 L3 QA1 L1 T1 L2 T2 L3 T3 FC1 I I I 1 2 QA2 3 4 5 6 21 22 FC1 13 14 EB1 21 22 QA2 PE EC1 3 M Θ BT2 Θ X3 1 400V 4x4mm W1 1 2 3 4 230V 5x1 0mm W2 1 2 230V 3x1 0 mm W8 1 2 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 PE 2 1 2 FC2 4 5 PE OG OG 11 12 14 L N B1 B2 L1 L2 L3 N PE Compressor terminal box ...

Page 11: ...15 DGbF HP LP ex factory not connected P Oil BP2 BP1 Duopress P A1 A2 QA2 13 14 QA2 13 14 BT3 T2 N L M S 230V 5x1 0mm W3 1 230V 5x1 0mm W4 2 3 1 4 14 15 16 17 18 19 20 3 2 PE 4 21 22 PE 23 24 PE 1 2 3 4 PE PE StSP1 N PE StSP2 ...

Page 12: ...0V 3x1 0mm W6 230V 3x1 0mm W7 13 14 Freigabe Leistungsregler X1 PE 25 26 27 28 PE 29 30 1 X4 1 2 3 X5 1 2 3 1 2 PE PE 2 PE StSP1 N PE StSP2 4 1 Circuit diagram for Plusbox with accessories continuation Release Capacity regulator Capacity regulator rotation speed control fan ex factory not connected Fig 9 ...

Page 13: ...D GB F E 13 96284 09 2015 DGbF N PE 1 2 PE MA1 Kondensator lüfter 1 M 0 230V 3x1 0mm W5 PE 1 2 31 32 PE 1 PE1 Gehäuseboden 1 PE2 Gehäusedeckel PE PE housing cover housing base fan ...

Page 14: ...3 L3 QA1 EB1 PE EC1 3 M Θ 91 96 92 97 93 98 95 99 12 18 19 54 BP3 1 2 Duopress P 11 14 QA2 21 22 FC1 13 14 L1 T1 L2 T2 L3 T3 FC1 I I I X1 1 2 4 5 6 7 10 11 12 13 14 15 8 3 400V 4x4 0mm W9 PE 1 2 3 0 400V 4x4 0mm W10 1 2 3 PE 230V 3x1 0mm W11 1 2 230V 5x1 0mm W12 4 3 2 1 X3 12 11 13 PE PE 24V DC 3x1 0mm W17 1 9 PE PE 10 PE 24V DC 5x1 0mm W16 1 2 3 2 1 2 3 4 L1 2 0 L2 2 0 L3 2 0 N 2 1 PE 2 1 Compres...

Page 15: ...01 Relais1 03 02 T2 N L M S A1 A2 QA2 15 18 17 19 20 21 16 4 230V PE1 0mm W13 1 2 3 4 230V 3x1 0mm W14 2 1 230V 3x1 0mm W16 PE 1 2 22 23 24 25 26 PE PE 27 28 29 PE 230V 5x1 0mm W18 PE 04 Relais2 06 05 A1 A2 QA3 PE 1 2 3 PE 1 2 FC2 X4 1 2 3 12 11 14 QA3 4 N PE Drehzahl steuerung Lüfter Konden sator lüfter ...

Page 16: ...ing Set the fan speed controller according to the operating conditions of the plant Commissioning EFCe 5 1 Commissioning Plusbox without EFCe 5 2 Commissioning Plusbox with EFCe Note the enclosed Danfoss product manual The function and operation of the user interface are described there Here take a look what you need to set values and parameters specifically for the GEA Plusbox Due to software upd...

Page 17: ... compressor 5 Set the maximum continuous current and the nominal speed You can find the values on the nameplate of the compressor Please select language English AKD Wizard Select Application Compressor AKD Assistent Which motor type is connected to the drive Asynchron VLT Assistent Select Motor Voltage 400 V Compressor Select Motor Frequency 50 Hz Max Cont Current MCC 9 000 A Compressor Enter Nomi...

Page 18: ...nd 70 Hz 10 This setting depends on the application 9 Set the desired recycle time We recommend 3 minutes Does the application include a sine wave filter No Compressor Would you like to run AMA Recommended AS takes a few min PM takes a few sec Yes Compressor Min Frequency 30 0 Hz Compressor Max Frequency 60 0 Hz Recycle Time Start to Start 3 1 min Compressor Does the application include a bypass v...

Page 19: ... Sensor signal 4 20 mA 14 This connection is already pre wired by GEA 15 Check switch position below the user interface Compressor Attention Connect your 4 20 mA Signal as shown 13 54 Compressor Attention Please switch A54 to position I under LCP U I Select Sensor Range 1 12 bar Compressor Select Sensor Signal 4 20 mA Sensor Type Pressure Transmitter bar Compressor Select internal or external cont...

Page 20: ...6 Set setpoint unit depends on the application 16 1 Select type of refrigerant 17 Set setpoint type Recommended setting Constant 18 Enter setpoint depends on the application Select Setpoint Unit C Compressor Select Refrigerant Type R404a Select Setpoint Type Constant Compressor Setpoint 10 000 C Compressor Max Setpoint Limit 40 000 C Compressor Min Setpoint Limit 60 000 C Cut off Value 25 000 C Co...

Page 21: ...n Setting ex factory No 22 Compressor setup completed 23 Go to main menu Compressor Compressor Setup Completed Do you wish to configure Pack Control No Compressor You now have the following options Go to Main Menu Compressor 6 24 Terminal 54 Skal Low Ref Feedb Value 1 000 0 000 C Analog input 54 0 000 C 6 2 6 25 Terminal 54 Skal High Ref Feedb Value 19 000 0 000 C Analogeing 54 0 000 C 6 2 12 000 ...

Page 22: ...ime has elapsed 3 minutes Suction pressure is high enough No other parameters were change If other parameters were changed we recom mend to reset the EFCe to factory settings Afterwards have a look at the Danfoss product manual Follow again the instructions of the startup wizard 1 90 Motor Thermal Protection Thermistor shutdown 54 2 Motor Temperatur 12 6 A 1 9 2 1 93 Thermistor connection 4 Digita...

Page 23: ...certain frequencies you have the option to skip them From the main menu Parameter 4 61 Bypass speed from Parameter 4 63 Bypass speed to 5 Commissioning 4 61 Bypass Speed from O Hz 0 0 Hz Speed Bypass 4 6 0 000 C 0 000 C 4 63 Bypass Speed to O Hz 0 0 Hz Speed Bypass 4 6 0 000 C 0 000 C ...

Page 24: ...njunction with current limit W59 Imax reached Rotation speed of the compressor is not increased e g if suction pressure too high when compressor first installed 4 Auto Remote standby Release by the inverter safety chain is not open Status 5 000 C 0 00 A 10 6 C Auto Remote Cut out 0 0Hz 3940kWh Status 5 000 C 9 25 A 6 554 C Auto Remote Run on ref 25 0Hz 3939kWh Status 5 000 C 9 33 A 6 387 C Auto Re...

Page 25: ...ages Display 0 2 1 0 1 2 2 6 3 3 22 28 Temp C 30 15 10 0 P P C P P Cut out ND switch Cut in ND switch Room temperatur Cut in HD switch Cut out HD switch Cut out VLT Cut in VLT and Low Setpoint Limit VLT Auto Remote Standby Setpoint High Setpoint Limit VLT Auto Remote Ist Sollwert Auto Remote Standby Auto Remote Standby Auto Remote Istwert niedr ...

Page 26: ...ser fan and machine room and then remove again before subsequent start up Neither dirt nor moisture are allowed to penetrate the machine room We recommend using compressed air and a soft brush for cleaning Further maintenance work in accordance with the instructions for assembly on the compressor WARNING Before starting any work on the compressor Switch off the compressor and secure it to prevent ...

Page 27: ... 80 18 3 10 5 2 60 600 7895 8 0 1 2 1 1 8 47 201 SHG34e 255 4 P P 22 10 17 0 9 8 2 60 600 7895 8 0 1 2 1 1 8 47 195 SHG34e 255 4 S P P 22 10 21 1 12 2 2 60 600 7895 8 0 1 2 1 1 8 47 200 SHG34e 315 4 P P 27 30 21 1 12 2 2 60 600 7895 8 0 1 2 1 1 8 47 198 SHG34e 315 4 S P P 27 30 25 5 14 7 2 60 600 7020 10 0 5 8 1 3 8 47 207 SHG34e 380 4 P P 33 10 26 1 15 1 2 60 600 7020 10 0 5 8 1 3 8 47 203 SHG34e...

Page 28: ...Raccords HG34 215 HG34 255 HG34 315 HG34 380 Suction line valve tube L Vanne d arrêt d aspiration de tuyau L mm Zoll 28 1 1 8 35 1 3 8 Liquid outlet tube L Sortie du liquide de tuyau L mm Zoll 16 5 8 Connection safety valve Raccord soupape de sûreté Zoll 1 2 NPTF Connection liquid side lockable Raccord côté liquide obturable Zoll 7 16 UNF ar Connection liquid side not lockable Raccord côté liquide...

Page 29: ... SHG34e 380 4 S PB 35 13 8 16 5 8 1 2 NPTF 7 16 UNF 7 16 UNF 7 16 UNF SV Suction line shut off valve FLA Liquid outlet SI Connection safety valve Y1 Connection liquid side lockable Y2 Connection liquid side not lockable Y3 Schrader connection speed controller fan 1 Further compressor connections can be found in the assembly instructions of the compressor Dear customer GEA compressors are top quali...

Page 30: ...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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