GEA Bock HG88e User Manual
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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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 +49 7022 9454 0
Fax +49 7022 9454 137
refrigeration@gea.com
www.gea.com
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Contents Page
1 Safety 4
1.1
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
4.3 Pipe connections
4.4 Pipes
4.5 Laying suction ans pressure lines
4.6 Operating the shut-off valves
4.7 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 34
11 Declaration of conformity and installation 36
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12 Service 37
Identication of safety instructions
Setting up
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1| Safety
1.1 Identicationofsafetyinstructions:
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.
1.2 Qualicationsrequiredofpersonnel
WARNING Inadequately qualied personnel poses the risk of accidents,the
consequencebeing serious or fatalinjury. Work on compressors
istherefore reservedfor personnel which is qualiedtoworkon
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.
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1| Safety
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.
1.4 Intended use
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
2.1 Short 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.
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Terminal box
Transport eyelet
Valve plate
Discharge
shut-off valve
Oil pump
Fig. 1
Dimension and connection values can be found in Chapter 10
Suction
shut-off valve
Cylinder cover
Motor section
Drive section
Name plate
Oil sight glass
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2| Product description
2
3
4
5
8
9
2.2 Name plate (example)
GEA Bock GmbH
72636 Frickenhausen, Germany
1
6
1 Type designation
2 Machine number
3 Type code
4 Maximum operating current
5 Starting current (rotor blocked)
∆: Part winding 1
YYY: Part windings 1 and 2
Y: Part winding 1
YY: Part windings 1 and 2
6 ND (LP): max. admissible over pressure
HD (HP): max. admissible over pressure
HGX88e/3235-4
AW09529A044
135,0 A
475A
Fig. 2
Low pressure side
High pressure side
Observe the limits of
application diagrams!
551A
until A044
}
from A047
}
281
338
IP 65
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!
SE 55
50 Hz
}
60 Hz
}
10
11
12
13
14
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2.3 Type key (example)
HG 88 e
¹
²
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3235-
/
)
HG - Hermetic Gas-Cooled (suction gas-cooled) for the normal- / air conditioning applications
)
X - Ester oil charge (HFC refrigerant, e.g. R134a, R404A/R507, R407C, R407F)
S - More powerful motor, e.g. for air-conditioning applications
4 SX
Motor variant
Number of poles
Swept volume
e-series
Numbers of cylinders
Size
Oil charge ²
Series ¹
3)
)
)
7
3| Areas of application
3.1 Refrigerants
• HFKW / HFC: R134a, R404A/R507, R407C, R407F
• (H)FCKW / (H)CFC: R22
3.2 Oil charge
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).
INFO
For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.4.
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3.3 Limits of application
8
ATTENTION The oil level must be in the
visible part of the sight
glass; damage to the compressor is possible if overfilled or underfilled!
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!
max.
oil level
min.
~
~
Fig. 3
3,0 Ltr.
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3| Areas of application
-5 12,5
-25
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)
EGD HG88e
R134a
10
0
-10
-20
-30
20
30
40
50
60
70
t (°C)
c
61
-5 12,5
-25
?t
Oh
<20K
t +20°C
Oh
R407C
c
90
82
80
70
60
50
40
30
20
-30
Fig. 4
t (°C)
c
70
61
60
50
40
30
20
-30
Fig. 5
t (°C)
c
70
60
59
50
40
30
20
-25 -10 -5
Fig. 6
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<20K
Oh
?t
t +20°C
-20 -10 100 20
?t
<20K
Oh
t +20°C
Oh
-20
<20K
?t
oh
t +20°C
oh
-20
-15
R134a
Oh
R407C
-10
R407F
0
0
12,5
10
5 10 15
25
Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Suction gas temperature (°C)
30
t (°C)
o
Unlimited application range
Supplementary cooling or
reduced suction gas temperature
Supplementary cooling and
reduced suction gas temperature
Motor version S
(more powerful motor)
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20
t (°C)
o
Maximum admissible
operating pressure (g)
(LP/HP): 19/28 bar
1)
LP = Low pressure
HP = High pressure
Design for other
areasonrequest
9
t (°C)
o
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
10
0
-10
-20
-30
20
30
40
50
60
70
t (°C)
c
61
-5 12,5
-25
?t
Oh
<20K
t +20°C
Oh
R407C
R22
R407F
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
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
10
0
-10
-20
-30
20
30
40
50
60
70
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
R404A/R507
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
3| Areas of application
t (°C)
c
70
66
60
50
40
?toh<20K
30
20
-40
-35
-30
Fig. 7
t (°C)
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10
c
70
60
58
50
40
? toh<20K
30
Fig. 8
-40
20
-50
Unlimited application range
Supplementary cooling or
reduced suction gas temperature
Supplementary cooling and
reduced suction gas temperature
Motor version S
(more powerful motor)
R22
t +20°C
oh
-10
-20
0
-5 12,5
R404A/R507
t +20°C
oh
-20
-30
-10
t (°C)
o
20
10
0
10
7,5-45
-5
t (°C)
o
Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Suction gas temperature (°C)
Maximum admissible
operating pressure (g)
(LP/HP): 19/28 bar
1)
LP = Low pressure
HP = High pressure
Design for other
areasonrequest
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4| Compressor assembly
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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.
4.1 Storage and transport
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-
?
Fig. 9
Fig. 10
4.2 Setting up
ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,
Fig. 11
bustible environment.
Use transport eyelet.
Do not lift manually!
Use lifting gear!
etc.) directly to the compressor are not permissible!
Provide adequate clearance for maintenance work.
Ensure adequate compressor ventilation.
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Fig. 12
Fig. 13
Fig. 14
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Do not use in a corrosive, dusty, damp atmosphere or a com-
bustible environment.
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.
Installation of pipe vibration mufers is recommended!
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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.
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 maxi-
Fig. 15: graduated
internal diameter
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.
mum compressor output. Theactualrequiredpipecrosssection
must be matched to the output. The same applies for non-return
valves.
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