GEA HG5 Assembly Instructions Manual Download | Manualshive

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engineering for a better world

GEA Compressor HG5

Assembly instructions

HG5/725-4

HG5/725-4 S

HGX5/725-4

HGX5/725-4 S

HG5/830-4

HG5/830-4 S

HGX5/830-4

HGX5/830-4 S

HG5/945-4

HG5/945-4 S

HGX5/945-4

HGX5/945-4 S

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Summary of Contents for HG5

Page 1: ... engineering for a better world GEA Compressor HG5 Assembly instructions HG5 725 4 HG5 725 4 S HGX5 725 4 HGX5 725 4 S HG5 830 4 HG5 830 4 S HGX5 830 4 HGX5 830 4 S HG5 945 4 HG5 945 4 S HGX5 945 4 HGX5 945 4 S 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

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: ...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 Basic circuit diagram for star delta start with special motor 5 6 Electronic trigger unit MP 10 5 7 Connecting the trigger unit MP 10 5 8 Functional test of the trigger unit MP 10 5 9 Oil sump heater accessories ...

Page 4: ... potential dangers WARNING Refrigerating compressors are pressurised machines and therefore require particular caution and care in handling Risk of burns Depending on the operating conditions surface temperatures of over 60 C on the pressure side or below 0 C on the suction side can be reached The maximum permissible overpressure must not be exceeded even for testing purposes 1 1 Identification of...

Page 5: ...efrigerating compressor named in the title is intended for installing 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 only permissible if the compressor has been installed in accordance with these assembly instructions and the entire system into which it is integrate...

Page 6: ...tor Flange mounted drive motor on the compressor case Preferred application range normal refrigerating and air conditioning 2 1 Short description Dimension and connection values can be found in Chapter 9 Name plate Fig 1 Valve plate Cylinder cover Terminal box Transport eyelet Discharge shut off valve Oil pump Suction shut off valve Oil sight glass Drive section Motor section ...

Page 7: ...rotation speed 3 maximum operating current 8 Displacement 4 Starting current rotor blocked 9 Voltage circuit frequency Y Part winding 1 10 Nominal rotation speed YY Part windings 1 and 2 11 Displacement 5 ND LP max admissible operating 12 Oil type filled at the factory pressure g Low pressure side 13 Terminal box protection type HD HP max admissible operating Electrical accessories can change pres...

Page 8: ...an not under certain circumstances ensure that sufficient oil is transported back to the compressor For operation with frequency converter The maximum current and power consumption must not be exceeded In the case of operation above the mains frequency the application limit can therefore be limited When operating in the vacuum range there is a danger of air entering on the suction side This can ca...

Page 9: ...cation Design for other areas on request R134a R407C R404A R507 R22 Fig 4 Fig 5 Fig 6 Fig 7 Unlimited application range Supplementary cooling or reduced suction gas temperature Supplementary cooling and reduced suction gas temperature Motor version S more powerful motor Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure ...

Page 10: ...te compressor ventilation Do not use in a corrosive dusty damp atmosphere or a combustible environment Fig 10 Fig 11 Fig 12 ATTENTION Superheating can damage the valve Remove the pipe supports from the valve for soldering Only solder using inert gas to inhibit oxidation products scale 4 3 Pipe connections F E D C 1 2 3 4 2 Setting up 4 1 Storage and transport Use transport eyelet Do not lift manua...

Page 11: ...Pipes Pipes and system components must be clean and dry inside and free of scale 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 The pipe connections have graduated inside diameters...

Page 12: ...ve completely opened service connection closed The connection which cannot be shut off is intended for safety devices Fig 18 Opening the service connection Spindle Turn 1 turn clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service connec tion closed Connection blocked Spindle Connection cannot be shut off Connection ...

Page 13: ...artial winding 1 66 and part winding 2 33 This winding division reduces the start up current needed for a part winding start to approx 65 of that for a direct start INFO A mechanical unloaded start with bypass solenoid valve is not required 5 1 Information for contactor and motor contactor selection All protection devices and switching or monitoring units must be fitted in accordance with the loca...

Page 14: ...re safety monitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor B1 Release switch thermostat Fig 19 nderung 0 Datum Name Datum Bearb Gepr Norm 1 20 Feb 2009 Kelich 09 M r 2010 Urspr 2 Ers f 3 Ers d 4 X SS Q1 L1 L2 L3 N PE Anschluákasten Verdichter I 66 F1 1 K1 1 2 1 3 4 2 5 6 3 1U1 1V1 1W1 PE M Y YY M1 R1 2U1 2V1 2W1 I 33 F1 2 K2 1 2 4 3 4 5 5 6 6 X1 L1 L1 N N 4...

Page 15: ...or part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s S1 Control voltage switch E1 Oil sump heater PW MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 1 Bl 1 F5 K1 12 T2 13 N P l 14 L 15 M 16 S P F3 17 18 19 K1 P F4 20 K1 K1T K2 21 22 K1T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE ...

Page 16: ...o 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 The motor is wired for direct start YY at the factory For part winding start Y YY the bridges must be removed and the motor feed li...

Page 17: ...il Zubehör erforderlich Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten 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 5 4 Sondermotor Ausführung für Direkt oder Stern Dreieck Anlauf Für den Stern Dreieck Anlauf...

Page 18: ...4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor B1 Enabling switch thermostat Q1 Main switch nderung 0 Datum Name Datum Bearb Gepr Norm 1 20 Feb 2009 Kelich 09 M r 2010 Urspr 2 Ers f 3 Ers d 4 X SS Q1 L1 L2 L3 N PE F1 1 K1 1 2 F1 2 1 Anschluákasten Verdichter 3 4 2 5 6 3 PE U1 V1 W1 M 3 M1 Y K3 1 2 3 4 R1 5 6 W2 U2 V2 D K2 1 2 4 3 4 5 5 6 6 X1 L1 L1 N N 43 43 11 12...

Page 19: ... relay S D changeover K5T Delay relay start unloader S1 Control voltage switch AL Start unloader E1 Oil sump heater D S MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 1 Bl 1 F5 K1 12 T2 13 N P l 14 L 15 M 16 S K1 K1 K3 P F3 K4T K3 K2 17 K4T K2 K3 18 19 K4T P F4 20 K5T AL 21 22 K5T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE ...

Page 20: ...ressor can also be protected against overtemperature using a thermal protection thermostat accessory The H2 LED red is provided for the protection function The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause 5 7 Connection of the tripping unit MP10 INFO Connect the trigger unit MP10 in accordance with the circuit dia gram Protect the trigger unit wi...

Page 21: ...r connection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or S1 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 S1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or S1 OFF OFF ON MP 10 is operational aga...

Page 22: ...en the compressor is started the refrigerant contained in the oil evaporates due to the decline in pressure This can result in oil foaming and oil exodus which can result in oil hammer in certain circumstances Operation mode The oil sump heater operates when the compressor is shut down The oil sump heater is switched off when the compressor starts Connection Connect the oil sump heater via an auxi...

Page 23: ...ntrols 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 Check the compressor for transport damage 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 c...

Page 24: ...e open before starting the compressor Check that the safety and protection devices pressure switch motor protection electrical con tact protection measures etc are functioning properly Switch on the compressor and let it run for at least 10 minutes Check the oil level The oil must be visible in the sight glass ATTENTION If larger quantities of oil have to be topped up there is a risk of oil impact...

Page 25: ...on lock 6 8 Connection of oil level regulator Oil level regulation systems have proven themselves with parallel circuits 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 se...

Page 26: ...d 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 Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Arctic 46 Sunoco Suniso SL 46 Texaco Capella HFC 55 HCFC e g R22 Fuchs Reniso SP 46 Fuchs Reniso SP 32 BP Energol L...

Page 27: ... YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 66 33 L M H 5 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 t...

Page 28: ...kseite absperrbar Connection discharge C Anschluß Öldrucksicherheitsschalter OIL Connection oil pressu D Anschluß Öldrucksicherheitsschalter LP Connection oil pressu D1 Anschluß Ölrückführung vom Ölabscheider Connection oil return f E Anschluß Öldruckmanometer Connection oil pressu F Ölablaß Oil drain H Stopfen Ölfüllung Oil charge plug J Anschluß Ölsumpfheizung Connection oil sump h K Schauglas S...

Page 29: ...sure 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 N Connection capacity controller M45 x 1 5 O Connection oil level regulator 3 x ...

Page 30: ...dards 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 T...

Page 31: ...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 32: ... 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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