GEA Bock HG34e User Manual

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GEA Bock Compressor HG34e

Assembly instructions

HG34e/215-4	HGX34e/215-4	HGX34e/215-4 S R407C
HG34e/255-4	HGX34e/255-4	HGX34e/255-4 S R407C
HG34e/315-4	HGX34e/315-4	HGX34e/315-4 S R407C
HG34e/380-4	HGX34e/380-4	HGX34e/380-4 S R407C
HG34e/215-4 S	HGX34e/215-4 S
HG34e/255-4 S	HGX34e/255-4 S
HG34e/315-4 S	HGX34e/315-4 S
HG34e/380-4 S	HGX34e/380-4 S
engineering for a better world		GEA Refrigeration Technologies

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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.

Manufacturer

GEA Bock GmbH

72636 Frickenhausen

Contact

GEA Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Telephone [phone]

Fax

[phone]

[e-mail]

www.gea.com

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Contents		Page
	1 Safety	4

1.1Identification of safety instructions

1.2Qualifications required of personnel

1.3General safety instructions

1.4Intended use

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Product description

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2.1Short description

2.2Name plate

2.3Type key

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Areas of application

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3.1Refrigerants

3.2Oil charge

3.3Limits of application

3.4Refrigerants - design for R407C, 35 bar

3.5Oil charge for R407C, 35 bar

3.6Limits of application, R407C, 35 bar

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Compressor assembly

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4.1Storage and transport

4.2Setting up

4.3Pipe connections

4.4Pipes

4.5Laying suction and pressure lines

4.6Operating the shut-off valves

4.7Operating mode of the lockable service connections

5	Electrical connection	15
5.1	Information for contactor and motor contactor selection
5.2	Connection of the driving motor	/ 400 V Y
5.3	Circuit diagram for direct start 230 V

5.4Start unloader

5.5Electronic trigger unit MP 10

5.6Connection of the electronic trigger unit MP 10

5.7Functional test of the electronic trigger unit MP 10

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Commissioning

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6.1Preparations for start-up

6.2Pressure strength test

6.3Leak test

6.4Evacuation

6.5Refrigerant charge

6.6Start-up

6.7Avoiding slugging

6.8Connection of oil level regulator

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Maintenance

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7.1Preparation

7.2Work to be carried out

7.3Spare parts recommendation

7.4Accessories

7.5Extract from the lubricants table

7.6Decommissioning

8	Technical data	24
9	Dimensions and connections	26
10	Declaration of conformity and installation	27
11	Service	28

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1| Safety

1.1 Identification of safety instructions:

	DANGER!	Indicates a dangerous situation which, if not
		avoided, will cause immediate fatal or serious injury.
		Indicates a dangerous situation which, if not
	WARNING!	avoided, may cause fatal or serious injury.
		Indicates a dangerous situation which, if not
	CAUTION!	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.

1.2 Qualifications required of personnel

WARNING! Inadequately qualified personnel poses the risk of accidents, the consequence being serious or fatal injury. Work on compressors must therefore only be performed by personnel with the qualifications listed below:

• For example, a refrigeration technician, refrigeration mechatronics engineer. As well as professions with comparable training, which enable personnel to assemble, install, maintain and repair refrigeration and air-conditioning systems. Personnel must be capable of assessing thework to be carried out and recognising any potential dangers.

1.3 General safety instructions

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.

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1| Safety

1.4 Intended use

These assembly instructions describe the standard version of the HG34e manufactured by GEA Bock. The compressor is intended for use in refrigeration systems in compliance with the limits of application. Only the refrigerant specified in these instructions may be used.

Any other use of the compressor is prohibited!

WARNING! The compressor may not be used in potentially explosive environments!

The GEA Bock refrigerating 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 integrated has been inspected and ­approved in accordance with legal regulations.

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2| Product description

2.1 Short description

•Semi-hermetic four-cylinder reciprocating compressor with oil pump lubrication.

•Suction gas cooled drive motor.

Transport eyelet

Valve plate

Discharge shut-off valve

					Name plate
D			Oil pump
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					Oil sight glass
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Terminal box

Cylinder cover

Drive section

Motor section

Suction shutoff valve

Fig. 2

Dimension and connection values can be found in Chapter 9

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2| Product description

2.2 Name plate (example)

												GEA Bock GmbH
												72636 Frickenhausen, Germany
1																																					6
									HGX34e/315-4
2																																								7
							AS38125A001																						27,3
																																8
3
																																							9
								21,1/12,2A
4																																						10
										111A			64A																32,8
																																11
5
																19/28																									12
																													SE 55
																								IP66
					Fig. 3																																					13
1						Type designation																6				Voltage, circuit, frequency						} 50 Hz
		2				Machine number																7				Nominal rotation speed
	3					maximum operating current																8				Displacement
		4 Starting current (rotor blocked)																					9			Voltage, circuit, frequency						} 60 Hz
		5 ND LP: max. admissible operating pressure																				10				Nominal rotation speed
							(g) Low pressure side																11			Displacement
						HD (HP): max. admissible operating																12				Oil type filled at the factory																			D
									pressure (g) High pressure side															13 Terminal box protection type
																																													GB
						Observe the limits of application																				Electrical accessories can change
						diagrams!																				the IP protection class!
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2.3					Type key (example)
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HG X 3 4 e / 380-4 S R407C	Ru

Refrigerant Motor variant 3) Number of poles Swept volume e-series

Numbers of cylinders Size

Oil charge ²) Series ¹)

¹) HG - Hermetic Gas-cooled (suction gas-cooled)

²) X - Ester oil charge (HFC refrigerant, e.g. R134a, R404A/R507, R407C)

3) S - More powerful motor, e.g. for air-conditioning applications

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3| Areas of application

3.1 Refrigerants
•	HFKW / HFC:	R134a, R404A/R507, R407C
•	(H)FCKW / (H)CFC:	R22
3.2 Oil charge
	The compressors are filled at the factory with the following oil type:
	- for R134a, R404A/R507, R407C		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. HGX34e/380-4).

INFO! For refilling, we recommend the above oil types.

Alternatives: see lubricants table, Chapter 7.5.

ATTENTION! The oil level must be in the	max.
visible part of the sight
	oil level
glass; damage to the com-			~ 0,8 Ltr.
pressor is possible if over-	min.
filled or underfilled!				Fig. 4

3.3 Limits of application

ATTENTION! Compressor operation 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) must be achieved.

For operation with additional cooling:

-Use only oils that are highly thermally stable.

-Avoid continuous operation near the limits.

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 cause chemical reactions, a pressure rise in the condenser and an elevated compressed-gas temperature. Prevent the ingress of air at all costs!

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R134a

Fig. 5

R407C

Fig. 6

R404A/R507

Fig. 7

R22

Fig. 8

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Unlimited application range

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Supplementary cooling or

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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)

Max. permissible operating pressure (LP/HP)1): 19/28 bar

1)LP = Low pressure HP = High pressure

Design for other areas on request

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