GEA HG88e series, HG88e/2735-4, HG88e/2735-4 s, HG88e/3235-4, HG88e/3235-4 s Assembly Instruction Manual
...
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engineering for a better world
GEA Bock Compressor HG88e
Assembly instructions
HG88e/2735-4 HG88e/2735-4 S HGX88e/2735-4 HGX88e/2735-4 S
HG88e/3235-4 HG88e/3235-4 S HGX88e/3235-4 HGX88e/3235-4 S
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About these instructions
Read these instructions before assembly and before using the compressor. This will avoid misunderstandings 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 compressor 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
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Contents Page
1 Safety 4
1.1
Identication of safety instructions
1.2
Qualications 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 ans 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 partial winding start
5.3
Basic circuit diagram for partial 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
Connecting the trigger unit INT69 G
5.8
Functional 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 strengh test
6.3
Leak test
6.4
Evacuation
6.5
Refrigerant charge
6.6
Start-up
6.7
Avoid slugging
6.8
Connection of oil level regulator
7
Maintenance 28
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 30
8.1
Capacity regulator
9
Technical data 32
10
Dimensions and connections 33
11
Declaration of conformity and installation 35
12 Service 36
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1| Safety
1.2 Qualicationsrequiredofpersonnel
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.
ATTENTION Indicates a situation which, if not avoided,
may cause property damage.
INFO Important information or tips on simplifying work.
WARNING Inadequatelyqualiedpersonnelposes theriskofaccidents,the
consequencebeing seriousor fatalinjury.Workon compressors
isthereforereservedfor personnelwhichisqualiedtoworkon
pressurized refrigerant systems:
• For example, a refrigeration technician, refrigeration mechatronic
engineer. As well as professions with comparable training, which
enables personnel to assemble, install, maintain and repair refrigeration
and air-conditioning systems. Personnel must be capable of assessing
the work to be carried out and recognising any potential dangers.
1.1 Identicationofsafetyinstructions:
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1| Safety
1.4 Intended use
1.3 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.
- Avoid contact with refrigerant necessarily.
Contact with refrigerant can cause severe burns and skin
damage.
WARNING The compressor may not be used in potentially explosive
environments!
These assembly instructions describe the standard version of the compressor named in the title
manufactured by GEA Bock. GEA Bock 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 compressor has been installed in accordance with these assembly instructions and the entire system into which it is integrated has been inspected and approved
in accordance with legal regulations.
The compressors are intended for use in refrigeration systems in compliance with the limits of
application.
Only the refrigerant specied in these instructions may be used.
Any other use of the compressor is prohibited!
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2| Product description
• Semi-hermetic eight-cylinder reciprocating compressor with suction-gas cooled drive motor.
• The stream of refrigerant sucked out of the evaporator flows over 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 pump
Oil sight glass
Drive section
Motor section
Suction
shut-off valve
Name plate
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2| Product description
2.3 Type key (example)
/
HG 88 e
3235-
4 SX
¹
)
HG - Hermetic Gas-Cooled (suction gas-cooled) for the normal- / air conditioning applications
²
)
X - Ester oil charge (HFC refrigerant, e.g. R134a, R404A/R507, R407C, R407F)
3)
S - More powerful motor, e.g. for air-conditioning applications
Motor variant
3)
Number of poles
Swept volume
e-series
Numbers of cylinders
Size
Oil charge ²
)
Series ¹
)
Observe the limits of
application diagrams!
1 Type designation
2 Machine number
3 Type code
4 Maximum operating current
5 Starting current (rotor blocked)
Y: Part winding 1
YY: Part windings 1 and 2
6 ND (LP): max. admissible over pressure
Low pressure side
HD (HP): max. admissible over pressure
High pressure side
Fig. 2
50 Hz
}
60 Hz
}
SE 55
AW09529A047
GEA Bock GmbH
72636 Frickenhausen, Germany
2.2 Name plate (example)
2
1
3
4
5
8
9
10
11
12
13
14
6
7 Voltage, circuit, frequency
8 Nominal rotation speed
9 Displacement
10 Voltage, circuit, frequency
11 Nominal rotation speed
12 Displacement
13 Oil type lled at the factory
14 Terminal box protection type
Electrical accessories can
changethe IP protection class!
HGX88e/3235-4
135,0 A
475A
551A
281
338
IP 65
Y/YY
Y/YY
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3| Areas of application
The compressors are lled at the factory with the following oil type:
- for R134a, R404A/R507, R407C, R407F 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. HGX88e/3235-4).
3.1 Refrigerants
• HFKW / HFC: R134a, R404A/R507, R407C, R407F
• (H)FCKW / (H)CFC: R22
3.2 Oil charge
3.3 Limits of application
ATTENTION Compressor operation is possible within the operating limits
showninthediagrams.Pleasenotethesignicance
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.permissibleswitchingfrequency12x/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.
- Additional fans (accessories) can be used for additional cooling.
For operation with capacity regulator:
- The suction gas superheat temperature may need to be reduced
or set individually when operating near to the threshold.
- The limits of application are reduced.
Foroperationwithfrequencyconverter:
- The maximum current and power consumption must not be
exceeded.Inthecaseofoperationabovethemainsfrequency,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 cause chemical reactions,
a pressure rise in the condenser and an elevated compressed-gas
temperature. Prevent the ingress of air at all costs!
INFO
For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.4.
ATTENTION The oil level must be in the
visible part of the sight
glass; damage to the compressor is possible if overfilled or underfilled!
max.
min.
3,0 Ltr.
oil level
Fig. 3
~
~
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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)
Suction gas temperature (°C)
Design for other
areasonrequest
Maximum admissible
operating pressure (g)
(LP/HP): 19/28 bar
1)
LP = Low pressure
HP = High pressure
20
10
0
-10
-20
-30
20
30
40
50
60
70
t (°C)
o
t (°C)
c
61
-5 12,5
-25
?t
Oh
<20K
t +20°C
Oh
R407C
R407C
20
10
0
-10
-20
-30
20
30
40
50
60
70
t (°C)
o
t (°C)
c
61
-5 12,5
-25
?t
Oh
<20K
t +20°C
Oh
R407C
R407F
t (°C)
o
20
30
40
50
60
70
t (°C)
c
59
?t
oh
<20K
t +20°C
oh
-20
-15
-25 -10 -5
0
5 10 15
R407F
Fig. 5
Fig. 6
30
40
60
80
90
-20 -10 100 20
30
t (°C)
o
t (°C)
c
82
-30
50
70
12,5
25
?t
Oh
<20K
20
t +20°C
Oh
EGD HG88e
R134a
20
10
0
-10
-20
-30
20
30
40
50
60
70
t (°C)
o
t (°C)
c
61
-5 12,5
-25
?t
Oh
<20K
t +20°C
Oh
R407C
R134a
Fig. 4
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3| Areas of application
30
40
60
80
90
-20 -10 100 20
30
t (°C)
o
t (°C)
c
82
-30
50
70
12,5
25
?t
Oh
<20K
20
t +20°C
Oh
EGD HG88e
R134a
20
10
0
-10
-20
-30
20
30
40
50
60
70
t (°C)
o
t (°C)
c
61
-5 12,5
-25
?t
Oh
<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
t (°C)
o
20
30
40
50
60
70
t (°C)
c
59
?t
oh
<20K
t +20°C
oh
-20
-15
-25 -10 -5
0
5 10 15
R22
30
40
60
80
90
-20 -10 100 20
30
t (°C)
o
t (°C)
c
82
-30
50
70
12,5
25
?t
Oh
<20K
20
t +20°C
Oh
R134a
20
10
0
-10
-20
-30
20
30
40
50
60
70
t (°C)
o
t (°C)
c
61
-5 12,5
-25
?t
Oh
<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
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
t (°C)
o
20
30
40
50
60
70
t (°C)
c
59
?t
oh
<20K
t +20°C
oh
-20
-15
-25 -10 -5
0
5 10 15
R404A/R507
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)
Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Suction gas temperature (°C)
Design for other
areasonrequest
Maximum admissible
operating pressure (g)
(LP/HP): 19/28 bar
1)
LP = Low pressure
HP = High pressure
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4| Compressor assembly
INFO Newcompressorsarefactory-lledwithinertgas(3barnitrogen).
Leave this service 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.
4.2 Setting up
Setup on an even surface or frame with sufcient load-bearing capacity.
Single compressor preferably on vibration damper.
Duplex and parallel circuits always rigid.
On shell and tube condensers, install only with rubber-metal shock
mountings.
Provide adequate clearance for maintenance work.
Ensure adequate compressor ventilation.
Do not use in a corrosive, dusty, damp atmosphere or a com-
bustible environment.
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Installation of pipe vibration mufers is recommended!
F
E
1
2
?
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
ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
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4| Compressor assembly
4.3 Pipe connections
ATTENTION Damage possible.
Superheating can damage the valve.
Remove the pipe supports from the valve for soldering.
Only solder using inert gas to inhibit oxidation products (scale).
The discharge gas connection can be moved upwards with an
adapter (accessory). This makes it easier to remove the compressor from a refrigerating system.
Fig. 15: graduated
internal diameter
Pipe connections on the compressor are available for soldering or
welding (accessories). The discharge and suction line valves have
graduated inside diameters so that pipes with standart millimetre and
inch dimensions can be used. The pipe will be immersed more or less
deeply according to dimension.
The connection diameters of the shut-off valves are rated for maximum
compressor output. Theactualrequiredpipecrosssectionmustbe
matched to the output. The same applies for non-return valves.
4.4 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.
4.5 Start unloader (external)
A internal start unloader ex factory is not available. Alternatively a start unloader can be installed in
the plant.
Operation:
When the compressor is started, a solenoid valve receives power via a time switch and opens a bypass between the discharge- and suction line. At the same time, a non-return valve in the discharge
line closes and prevents a backow of refrigerant from the condenser (Fig. 16).
The compressor is now short-circuited and delivers from the outow directly into the intake. The
pressure differential consequently decreases substantially. As a result, the torque on the drive shaft
of the compressor is considerably diminished. The drive motor can now start with a low level of
starting torque. As soon as the motor and the compressor reach their rated speed, the solenoid valve
closes and the non-return valve opens (Fig. 17). The compressor now works under normal load.
Solenoid valve actuated
Non-return valve closed
Fig. 16
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Rigid
fixed point
Fig. 18
As short as
possible
4.6 Laying suction and pressure lines
A rule of thumb: Always lay the rst pipe section starting from the shut-off valve downwards
and parallel to the drive shaft.
ATTENTION Improperly installed pipes can cause cracks and tears, the result
being a loss of refrigerant.
INFO Proper layout of the suction and discharge lines directly after
the compressor is integral to the system’s smooth running and
vibration behaviour.
4| Compressor assembly
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 compressor. This protects the compressor against thermal overloading. Connect the heat protection
thermostat in series on the safety chain of the control circuit, to switch off the compressor if
necessary.
- Follow these instructions to avoid thermal overloading.
Fig. 17
Solenoid valve dead
Non-return valve open
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4| Compressor assembly
Fig. 19
Fig. 20
Valve spindle seal
Release
Tighten
Pipe connection
Pipe connection
4.8 Operating mode of the lockable service connections
Fig. 21
Opening the shut-off valve:
Spindle: turn to the left (counter-clockwise) as far as it will go.
—> Shut-off valve completely opened / service connection closed.
Fig. 22
Opening the service connection
Spindle: Turn ½ - 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. ¼ of a turn
counter-clockwise.
After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise.
After activating the spindle, generally t the spindle protection cap again and tighten with 14-16 Nm.
This serves as a second sealing feature during operation.
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5| Electrical connection
5.1 Information for contactor and motor contactor selection
All protection devices and switching or monitoring units must be tted in accordance with the local
safety regulations and established specications (e.g. VDE) as well as with the manufacturer’s infor-
mation. Motor protection switches are required! Motor contactors, feed lines, fuses and motor
protection switches must be rated on the basis of the maximum working current (see name plate).
For motor protection use a current-dependent and time-delayed overload protection device for monitoring all three phases. Set the 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.
Compare the voltage and frequency values with the data for the
mains power supply.
Only connect the motor if these values are the same.
DANGER Risk of electric shock! High voltage!
Only carry out work when the electrical system is disconnected
from the power supply!
5 Electrical connection
16
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5.2 Standard motor, design for direct or partial winding start
INFO
A mechanical unloaded start with bypass solenoid valve is
notrequired.
5| Electrical connection
Compressors with 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.
Designation on the name plate Sticker on the terminal box
Y/YY
Y/ YY
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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 line connected according to the circuit diagram:
400 V
Direct start Part winding start
Gelber Aufkleber
am Klemmenkasten
∆/YYY
Typschildangabe
Gelber Aufkleber
am Klemmenkasten
ATTENTION Failureto dothis results inopposed rotary elds 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.
INFO When testing coils with resistance tester, please note that partial
winding 1 and partial winding 2 are wired internally in HG88e.
5| Electrical connection
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5.3 Basic circuit diagram for part winding start with standart motor
Fig. 23
0
1
2
3
4
5 6 7
X SS
Anschlußkasten Verdichter
BT1
BP1
P-Öl
INT69
QA1
L1 L2 L3 N PE
FC1.1
I=66%
I>
I>
I>
1
2
QA2
1
3
4
2
5
6
3
1U1
1V1
1W1
EC1
M
/YYY
2U1
2V1
2W1
FC1.2
I=33%
I>
I>
I>
1
2
QA3
4
3
4
5
5
6
6 7
FC1.1
FC1.2
8
BT2
FC2
4A
SF1
BT29BT2
10
BT2
11
QA2
12
T2
OG OG
1112 14
L N B1 B2
PE
PE
BP1 Oil differential pressure monitor
BP2 High pressure safety monitor
BP3
Safety chain (high/low pressure monitoring)
BT3 Release switch (thermostat)
BT1 Cold conductor (PTC sensor) motor winding
BT2.X Thermal protection thermostat
EB1 Oil sump heater
EC1 Compressor motor
FC1.1 Motor protection switch (part winding 1)
60%
40%
Compressor terminal box
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FC1.2 Motor protection switch (part winding 2)
FC2 Control power circuit fuse
KF1 Delay relay max. 1s
QA1 Main switch
QA2 Mains contactor (part winding 1)
QA3 Mains contactor (part winding 2)
SF1 Control voltage switch
XSS Terminal strip in the external switch cabinet
5 6 7
8
9
BP1
P-Öl
QA2
12T213N14L15M16
S
BP2
P>
17 18 19
QA2
BP3
P
20
QA2
KF1
QA3
21 22
KF1
23 24
QA2
25
EB1
26
L1.1
L2.1
L3.1
L1.2
N
PE
BT3
PE
20
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5| Electrical connection
5.4 Special motor: design for direct or star-delta start
Amechanicalunloadedstartwithbypasssolenoidvalve(accessories)isrequiredforthe
star-delta start.
Designation on the name plate Sticker on the terminal box
∆ / Y
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In the factory the motor is wired for direct starting at high voltage.
The brides are to be removed for star delta starting at low voltage.
230 V Δ
Direct start Star-delta-start
400 V Y
Direct start only
5| Electrical connection
Star-delta start-up is only possible for ∆ (230 V) power supply. Example:
22
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0
1
2
3
4
5 6 7
X SS
Anschlußkasten Verdichter
BT1
BP1
P-Öl
INT69
QA1
L1 L2 L3 N PE
FC1.1
I>
I>
I>
1
2
QA2
1
3
4
2
5
6
3
U1
V1
W1
EC1
M
3
˜
1
2
QA4
Y
PE
345
6
W2
U2
V2
FC1.2
I>
I>
I>
1
2
QA3
4
3
4
5
5
6
6 7
FC1.1
FC1.2
8
FC2
4A
SF1
9 10 11
QA2
12T213
N
OG OG
1112 14
L N B1 B2
BT2
BT2 BT2BT2
PE
5.5 Circuit diagram for star-delta start 230 V ∆ / 400 V Y
Fig. 24
BP1 Oil differential pressure monitor
BP2 High pressure safety monitor
BT2.X Thermal protection thermostat
BP3
Safety chain (high/low pressure monitoring)
BT3 Release switch (thermostat)
EB1 Oil sump heater
EC1
Compressor motor
FC1.1
Motor protection switch (mains contactor)
FC1.2
Motor protection switch ( Δ-contactor)
Compressor terminal box
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FC2 Control power circuit fuse
KF4 Delay relay for contactor switch over
QA1 Main switch
QA2 Mains contactor
QA3 Δ-contactor
QA4 Y-contactor
SF1 Control voltage switch
XSS Terminal strip in the external switch cabinet
5 6 7
8
9
BP1
P-Öl
QA2
12T213N14L15M16
S
BP2
P>
17
QA2
QA2
18
QA4
19
BP3
P
KF4
QA4
QA3
20
KF4
QA3
QA4
21 22
KF4
23 24
QA2
25
EB1
26
L1.1
L2.1
L3.1
L1.2
N
PE
BT3
PE
24
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5| Electrical connection
5.6 Electronic trigger unit INT69 G
5.7 Connection of the trigger unit INT69 G
The compressor motor is tted 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 INT 69 G deactivates the motor contactor. Once cooled, it can be restarted only if the
electronic lock of the output relay (terminals B1+B2) is released by interrupting the supply voltage.
The hot gas side of the compressor can also be protected against overtemperature using thermal
protection thermostats (accessory).
The unit trips when an overload or inadmissible operating conditions occur. Find and remedy
the cause.
PTC1
PTC2
NL B1 B2 12 14 11
PTC
Motor Protection INT69 G
Terminal box
Abb. 25
supply
Lock out
INFO The relay switching output is executedas a oating changeover
contact.Thiselectricalcircuitoperatesaccordingtothequiescent
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-action fuse (F) of max.
4 A. In order to guarantee the protection function, install the trigger
unitastherstelementinthecontrolpowercircuit.
ATTENTION
PTC cable on the trigger unit
INT69 G and terminals PTC 1 and
PTC 2 on the compressor terminal board must not come into
contact with mains voltage.
This would destroy the trigger
unit INT69 G and PTC sensors.
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5| Electrical connection
5.8 Function test of the trigger unit INT69 G
Before commissioning, after troubleshooting or making changes to the control power circuit, check
the functionality of the trigger unit. Perform this check using a continuity tester or gauge.
Gauge state Relay position
Deactivated state 11-12
INT69 G switch-on 11-14
Remove PTC connector 11-12
Insert PTC connector 11-12
Reset after mains on 11-14
Relay position INT69 G
B2 12 14 11
5.9 Oil sump heater (accessories)
Anschlussschema für Ölsumpfheizung
Connection diagramm for oil sump heater
Plan de raccordement pour résistance de carter d‘huile
When the compressor is at a standstill, refrigerant diffuses into the lubricating oil of the compressors
housing, depending on pressure and ambient temperature. This reduces the lubricating capacity of
the oil. When the compressor starts up, the refrigerant contained in the oil evaporates out throught the
reduction in pressure. The consequences can be foaming and migration of the oil, causing oil shocks
under certain circumstances.
Operation: The oil sump heater operates when the compressor is at a standstill. When the compressor 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 auxiliary contact) of the compressor contactor to a seperate electric circuit.
El. data: 230 V - 1 - 50/60 Hz, 200 W.
Fig. 27
Fig. 26
ATTENTION Connection to the current path of the safety control chain is not
permitted.
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6| Commissioning
6.1 Preparations for start-up
6.4 Evacuation
First evacuate the system and then include the compressor in the evacuation process.
Relieve the compressor pressure.
Open the suction and pressure line shut-off valves.
Evacuate the suction and discharge pressure sides using the vacuum pump.
At the end of the evacuation process, the vacuum should be < 1.5 mbar when the pump is switched off.
Repeat this process as often as is required.
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!
6.2 Pressure strength test
The compressor has been factory-tested for pressure resistance. The following must be observed if
the entire plant is subjected to an additional pressure strength test:
Test the refrigeration circuit according to EN 378-2 or a corresponding safety standard.
6.3 Leak test
Carry out the leak test of the refrigerating system in accordance with EN 378-2 or a corresponding
safety standard without including the compressor.
INFO
To protect the compressor against inadmissible operating conditions,
high pressure and low pressure pressostats are mandatory on the
installation side.
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 the ignition limit to shift into the critical range.
DANGER Risk of bursting!
Do not mix any refrigerant with the nitrogen (N2) as this could cause the ignition limit to shift into the critical range.
ATTENTION Do not start the compressor if it is under vacuum. Do not apply
any voltage - even 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.
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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.
6.5 Refrigerantlling
CAUTION Wear personal protective clothing such as goggles and protective
gloves!
ATTENTION Avoidoverllingthesystemwithrefrigerant!
To avoid shifts in concentration, zeotropic refrigerant blends must
alwaysonlybelledintotherefrigeratingplantinliquidform.
Donotpourliquidcoolantthroughthesuctionlinevalveon
the compressor.
It is not permissible to mix additives with the oil and
refrigerant.
6.7 Avoiding slugging
To prevent slugging:
The complete refrigeration 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 recommended such
as replacement 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 the compressor and allow to run for a minimum of 10 min.
Check the oil level by: The oil must be visible in the sightglass.
WARNING Ensure that both shut-off valves are open before starting the
compressor!
ATTENTION Iflargerquantitiesofoilhavetobetoppedup,thereisariskof
oil hammer effects.
If this is the case check the oil return!
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7.2 Work to be carried out
7.1 Preparation
7| Maintenance
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 (see Fig. 25). A sight glass on the oil
level regulator is not required.
Mechanical oil level regulator
at the "O" connection
6| Commissioning
Fig. 28
124
o
124
o
124
o
124
o
47,6
M6 x 10
je 3 mal
3-Loch-Anschlussbild für ESK,
AC&R und CARLY
3-Loch-Anschlussbild für TraxOil
3 hole connection diagramm for
ESK, AC&R and CARLY
3 hole diagramm for TraxOil
3 times each
In order to guarantee optimum operational reliability and service life of the compressor, we recommend
carrying out servicing and inspection work at regular intervals:
Oil change:
- not mandatory for factory-produced series systems.
- for eld installations or when operating near the application limit: for the rst 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
auxiliary devices such as oil sump heater, pressure switch.
WARNING Before starting any work on the compressor:
Switch off the compressor and secure it to prevent a restart.
Relieve compressor of system pressure.
Preventairfrominltratingthesystem!
After maintenance has been performed:
Connect safety switch.
Evacuate compressor.
Release switch lock.
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7.5 Decommissioning
Close the shut-off valves on the compressor. Drain the refrigerant (it must not be discharged into the
environment) and dispose of it according to the regulations. When the compressor is depressurised,
undo the fastening screws of the shut-off valves. Remove the compressor using an appropriate hoist.
Dispose of the oil inside in accordance with the applicable national regulations.
7| Maintenance
7.4 Extract from the lubricants table
The oil type lled 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 Bock standard oil types
Recommended alternatives
HFC
(e.g. R134a, R404A,
R407C, R407F)
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 LPT 46
Sunoco Suniso 3,5 GS
Texaco Capella WF 46
HG88e / ...
2735-4 (S) 3235-4 (S)
Designation
Item No. Item No.
Set of gaskets kit 81007
Valve plate kit 81040 81041
Oil pump kit 80116
Oil sump heater kit (220-240 V) 80237
Only use genuine GEA Bock spare parts!
7.3 Recommended spare parts
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8| Accessories
8.1 Capacity regulator
Fig. 29
LR 3
LR 1 LR 2
Delivery condition (from the factory):
Capacity regulator installed with cover
(transport protection).
Fig. 30
WARNING Several capacity regulators cannot switch at the same time during
compressor operation! Otherwise the sudden change in load can
damage the compressor! Comply with the switching interval of 60 s.
• Comply with the switching sequence:
Swiching on LR1 60s LR2 60s LR3
Swiching off LR3 60s LR2 60s LR1
Control unit
(pilot valve)
Cover
Magnetic coil
Fig. 31
Screw in control unit (pilot 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. 32
ATTENTION If the capacity regulator is installed at the factory, the control com-
ponent(pilotvalve)issubsequentlyinstalledandconnectedbythe
customer. If the control component is not connected, the cylinder bank
is switched off permanently. Damage to the compressor is possible!
Before start-up, remove the cover at the capacity
regulator and replace it with the enclosed control
unit (pilot valve).
Attention! Compressor is under pressure!
Depressurize the compressor first.
Knurled nut
Seal ring
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Special accessories are only premounted in the factory if ordered specially by customer. Retrotting is
possible in full compliance with the safety instructions and repair instructions enclosed with the kits.
Information about the use, operation, maintenance and servicing of the components is available in the
printed literature or on the internet under www.gea.com
ATTENTION Capacity-regulated operation alters the gas speeds and pressure
ratios of the refrigerating plant: Adjust the suction line routing and
dimensioning accordingly, do not set the control intervals too close and
do not let the system switch more than 12 times per hour (refriger-
atingplantmusthavereachedastateofequilibrium).Continuous
operation in the control stage is not recommended as the gas
velocity in the plant system under certain circumstances does not
guaranteesufcientoilreturntothecompressorwithactivated
capacity regulator.
We recommend switching to unregulated operation (100% capac-
ity) for at least 5 minutes per capacity-regulated operating hour.
An assured oil return can also be realised by a 100% capacity
requirementaftereachcompressorrestart.
Electrical actuation of the solenoid valve: Normally open, (cor-
responds to 100 % compressor capacity).
8| Accessories
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9| Technical data
Type
No. of cylinders
Displacement
50 / 60 Hz
(1450 / 1740
rpm)
Electrical data Weight Connections
Oil charge
Voltage Max.
Operating
current
PW 1 + 2
Max.
power con-
sumption
Starting
current
(rotor locked)
PW 1 / PW 1 + 2
Discharge
line
DV
Suction
line
SV
m
3
/h A kW A kg mm (inch) mm (inch) Ltr.
HG88e/2735-4
8
237,9 / 285,5 114 63,7 475 / 551 448
54 (2
1
/
8
) 76 (3
1
/
8
) 9,0
HG88e/2735-4 S
237,9 / 285,5 135 7 7,5 520 / 605 468
HG88e/3235-4
281,3 / 337,6 131 74,6 475 / 551 442
HG88e/3235-4 S
281,3 / 337,6 160 91,0 520 / 605 462
1
2
3
2
4
Tolerance (± 10%) relative to the mean value of the voltage range.
Other voltages and types of current on request.
- The specications for max. power consumption apply for 50Hz operation.
For 60Hz operation, the specications have to be multiplied by the factor
1.2. The max. working current remains unchanged.
- Take account of the max. operating current / max. power consumption for
design of fuses, supply lines and safety devices. Fuse: Consumption
category AC3
1
2
All specications are based on the average of the voltage range
For solder connections
3
4
380-420 V Y/Y Y - 3 - 50 Hz PW
440-480 V Y/YY - 3 - 60 Hz PW
PW = Part Winding
Winding ratio : 50% / 50%
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10| Dimensions and connections
Suction connection on the side left or right 90°
Fig. 33
Fig. 34
1)
Suction cover 90° rotatable
Dimensions in mm
360
(L)* = Brazing connection
(L)* = Lötanschluß
Maße in mm
Änderungen vorbehalten
Massenschwerpunkt
inchConnection oil temperature sensor
Anschluß Ölspiegelregulator
O
inch
Connection thermal protection thermostat
1/8" NPTF
ZollAnschluß Öltemperatursensor
mm
Q
inchConnection oil service valve
7/16" UNF
3xM6
ZollAnschluß Ölserviceventil
ÖV
Connection oil level regulator
mmConnection oil pressure differential sensor
M20x1,5
mmAnschluß Öl-Differenzdrucksensor
P
mm
Anschlüsse / Connections
SV
Saugabsperrventil, Rohr (L)* mm - Zoll
76 - 3 1/8“
Suction line valve, tube (L)* mm - inch
DV
Druckabsperrventil, Rohr
(L)* mm - Zoll
54 - 2 1/8“
Discharge line valve, tube (L)* mm - inch
A
Anschluß Saugseite, nicht absperrbar Zoll
1/8" NPTF
Connection suction side, not lockable inch
A1
Anschluß Saugseite, absperrbar Zoll
7/16" UNF
Connection suction side, lockable inch
A2
Anschluß Saugseite, nicht absperrbar Zoll
1/4" NPTF
Connection suction side, not lockable inch
B
Anschluß Druckseite, nicht absperrbar Zoll
1/8" NPTF
Connection discharge side, not lockable inch
B1
Anschluß Druckseite, absperrbar Zoll
7/16" UNF
Connection discharge side, lockable inch
C
Anschluß Öldrucksicherheitsschalter OIL
Zoll
7/16" UNF
Connection oil pressure safety switch OIL inch
D
Anschluß Öldrucksicherheitsschalter LP Zoll
7/16" UNF
Connection oil pressure safety switch LP inch
D1
Anschluß Ölrückführung vom Ölabscheider Zoll
1/4" NPTF
Connection oil return from oil separator inch
E
Anschluß Öldruckmanometer Zoll
7/16" UNF
Connection oil pressure gauge inch
F
Ölablaß mm
M22x1,5
Oil drain mm
H
Stopfen Ölfüllung mm
M22x1,5
Oil charge plug mm
J
Anschluß Ölsumpfheizung mm
M22x1,5
Connection oil sump heater mm
K
Schauglas -
-
Sight glass -
L
Anschluß Wärmeschutzthermostat Zoll
1/8" NPTF
D1
D
B
B1 A1
L
C
E
H
K,O
Q
ÖV
J
F
P
412
ca.655
430
252
4x 13,5
ca.610
Schwingungsdämpfer
Vibration absorbers
45
M12
70
37
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1
2
34
5
Vibration damper
360
101 569
680 164
ca.345
ca.290
X
Anschluß Ölspiegelregulator
O
inch
Connection thermal protection thermostat
mm
inchConnection oil service valve
7/16" UNF
3xM6
ZollAnschluß Ölserviceventil
ÖV
Connection oil level regulator
mmConnection oil pressure differential sensor
M20x1,5
mmAnschluß Öl-Differenzdrucksensor
P
mm
Anschlüsse / Connections
SV
Saugabsperrventil, Rohr (L)* mm - Zoll
76 - 3 1/8“
Suction line valve, tube (L)* mm - inch
DV
Druckabsperrventil, Rohr
(L)* mm - Zoll
54 - 2 1/8“
Discharge line valve, tube (L)* mm - inch
A
Anschluß Saugseite, nicht absperrbar Zoll
1/8" NPTF
Connection suction side, not lockable inch
A1
Anschluß Saugseite, absperrbar Zoll
7/16" UNF
Connection suction side, lockable inch
A2
Anschluß Saugseite, nicht absperrbar Zoll
1/4" NPTF
Connection suction side, not lockable inch
B
Anschluß Druckseite, nicht absperrbar Zoll
1/8" NPTF
Connection discharge side, not lockable inch
B1
Anschluß Druckseite, absperrbar Zoll
7/16" UNF
Connection discharge side, lockable inch
C
Anschluß Öldrucksicherheitsschalter OIL
Zoll
7/16" UNF
Connection oil pressure safety switch OIL inch
D
Anschluß Öldrucksicherheitsschalter LP Zoll
7/16" UNF
Connection oil pressure safety switch LP inch
D1
Anschluß Ölrückführung vom Ölabscheider Zoll
1/4" NPTF
Connection oil return from oil separator inch
E
Anschluß Öldruckmanometer Zoll
7/16" UNF
Connection oil pressure gauge inch
F
Ölablaß mm
M22x1,5
Oil drain mm
H
Stopfen Ölfüllung mm
M22x1,5
Oil charge plug mm
J
Anschluß Ölsumpfheizung mm
M22x1,5
Connection oil sump heater mm
K
Schauglas -
-
Sight glass -
L
Anschluß Wärmeschutzthermostat Zoll
1/8" NPTF
D1
D
B B1 A1
L
C
E
H
K,O
Q
ÖV
J
F
P
412
ca.655
430
252
4x 13,5
ca.610
A2DV B A SV
ca.940
569
2
34
5
6
7
Centre of gravity
A2
ca.610
B
B1 A1
Anschlüsse / Connections
SV
Saugabsperrventil, Rohr
(L)*
mm - Zoll
76 - 3 1/8“
Suction line valve, tube
(L)*
mm - inch
DV
Druckabsperrventil, Rohr
(L)*
mm - Zoll
54 - 2 1/8“
Discharge line valve, tube
(L)*
mm - inch
A
Anschluß Saugseite, nicht absperrbar
Zoll
1/8" NPTF
1
2
3
4
5
6
1)
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SV
DV
Suction line
Discharge line
see technicla data, Chapter 9
A
Connection suction side,, not lockable
1
/8“ NPTF
A1
Connection suction side,, lockable
7
/16“ UNF
A2
Connection suction side,, not lockable
1
/4“ NPTF
B
Connection discharge side, not lockable
1
/8“ NPTF
B1
Connection discharge 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
Connection oil sump heater M22 x 1,5
K
Sight glass -
L
Connection thermal protection thermostat
1
/8“ NPTF
O
Connection oil level regulator 3 x M6
ÖV
Connection oil service valve
1
/4“ NPTF
P
Connection oil differential pressure sensor M20 x 1,5
Q
Connection oil temperature sensor
1
/8“ NPTF
10| Dimensions and connections
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11| Declaration of conformity and installation
DECLARATION OF CONFORMITY CE 13
for using the compressors within the European Union
(in accordance with Low Voltage Directive 2006/95/EC)
We hereby declare that the following refrigerating compressors
Product designation: HG88e
comply with the Low Voltage Directive 2006/95/EC.
Applied harmonised standard:
EN 60034-1:2010
EN 60204-1:2006
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 HG88e complies with the basic requirements
of Appendix II 1B of the Machinery Directive 2006/42/EC.
Applied harmonised standard:
EN 12693:2008 and the corresponding standards 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.
The special technical documentation required for partly completed machinery has been created
in accordance with Appendix VII Part B.
Person responsible for documentation is: Wolfgang Sandkötter, Benzstraße 7, 72636 Frickenhausen.
Frickenhausen, 21.08.2013 ppa. Wolfgang Sandkötter,
Chief Development Ofcer
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Dear customer,
GEA Bock compressors are top-quality, reliable and service-friendly quality products.
If you have any questions about installation, operation and accessories, please contact our techni-
cal service or specialist wholesaler and/or our representative. The GEA Bock 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
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96260-08.2015-DGbFEIRu © GEA Group AG. All rights reserved.
GEA Bock GmbH
Benzstraße 7, 72636 Frickenhausen, Germany
Telephone: +49 7022 9454-0, Fax: +49 7022 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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