GEA HG44e Manuel utilisateur

GEA Bock HG44e/HG56e (HC/LG)

Assembly instructions

96416-08.2020-Gb

Translation of the original instructions

HG(X)44e/475-4 (S) HG(X)56e/850-4 (S)

HG(X)44e/565-4 (S) HG(X)56e/995-4 (S)

HG(X)44e/665-4 (S) HG(X)56e/1155-4 (S)

HG(X)44e/770-4 (S)

HG44e/475-4 (S) HC ..................... HG44e/770-4 (S) HC

HG56e/850-4 (S) HC ..................... HG56e/1155-4 (S) HC

HGX44e/475 (S/ML) 9 LG .............. HGX44e/770 (S/ML) 22 LG

HGX56e/850 (S/ML) 18 LG ............ HGX56e/1155 (S/ML) 35 LG

96416-08.2020-DGbFEIRu

Contents Page

1 Safety 4

 1.1 Identicationofsafetyinstructions

 1.2 Qualicationsrequiredofpersonnel

 1.3 Generalsafetyinstructions

 1.4 Intendeduse

 2 Safetyinstructionsforuseofammablerefrigerants 6

 2.1 Safetyinstructions

2.2 Qualicationsrequiredofpersonnel

3 Product description 7

 3.1 Shortdescription

 3.2 Nameplate

 3.3 Typekey

 3.4 TypekeyHCcompressors

 3.5 TypekeyLGcompressors

About these instructions

Readtheseinstructionsbeforeassemblyandbeforeusingthecompressor.Thiswillavoidmisunder-

standings 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compres-

sorisinstalled.

GEABockGmbH

72636Frickenhausen

GEABockGmbH

Benzstraße7

72636Frickenhausen

Germany

Phone+49702294540

Fax+4970229454137

gea.com/contact

www.gea.com

Manufacturer

Contact

96416-08.2020-DGbFEIRu

Contents Page

 4 Areasofapplication 10

 4.1 Refrigerants

 4.2 Oilcharge

 4.3 Limitsofapplication

5AreasofapplicationonHCandLGcompressors 12

5.1 Refrigerants

 5.2 Oilcharge

 5.3 Limitsofapplication

6Compressorassembly 13

 6.1 Storageandtransport

 6.2 Settingup

 6.3 Pipeconnections

 6.4 Pipes

 6.5 Layingsuctionanspressurelines

 6.6 Operatingtheshut-offvalves

 6.7 Operatingmodeofthelockableserviceconnections

 6.8 Suctionpipelterandlterdrier

 7 Electricalconnection 17

 7.1 Informationforcontactorandmotorcontactorselection

 7.2 Standardmotor,designfordirectorpartialwindingstart

 7.3 Basiccircuitdiagramforpartialwindingstartwithstandardmotor

 7.4 Specialmotor:designfordirectorstar-deltastart

7.5 Basiccircuitdiagramfor star-delta startwithspecialmotor

7.6 ElectronictriggerunitINT69G

7.7 ConnectingofthetriggerunitINT69G

7.8 FunctionaltestofthetriggerunitINT69G

 7.9 ElectronictriggerunitINT69GonHCandLGcompressors

 7.10 Oilsumpheater(accessories)

 7.11 OilsumpheateronHCandLGcompressors

 7.12 Capacityregulator(accessories)

 8 Commissioning 28

 8.1 Preparationsforstart-up

8.2 Pressureintegritytest

 8.3 Leaktest

 8.4 Evacuation

 8.5 Refrigerantcharge

 8.6 Start-up

 8.7 Avoidslugging

 8.8 Connectionofoillevelregulator

9 Maintenance 31

 9.1 Preparation

 9.2 Worktobecarriedout

 9.3 Sparepartsrecommendation/Accessories

 9.4 Extractfromthelubricantstable

 9.5 Decommissioning

 9.6 Additionalinformationwhenusingammablerefrigerants

 10 Accessories 33

 10.1Capacityregulator

 11 Technicaldata 35

 12 Dimensionsandconnections 37

 13 Declarationofincorporation 39

 14 Service 40

96416-08.2020-DGbFEIRu

1|Safety

1.2 Qualicationsrequiredofpersonnel

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 Inadequatelyqualiedpersonnelposestherisk ofaccidents,the

consequencebeingseriousor fatalinjury.Workoncompressors

isthereforereservedforpersonnelwhichisqualiedtoworkon

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 Identicationofsafetyinstructions:

96416-08.2020-DGbFEIRu

1|Safety

1.4 Intended use

1.3 General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man-

ufacturedbyGEA. GEArefrigeratingcompressorsareintendedforinstallationinamachine(withinthe

EUaccordingtotheEUDirectives2006/42/ECMachineryDirective,2014/68/EUPressureEquipment

Directive).

Commissioningispermissibleonlyifthecompressorhasbeeninstalledinaccordancewiththeseas-

sembly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speciedintheseinstructionsmaybeused.

Anyotheruseofthecompressorisprohibited!

96416-08.2020-DGbFEIRu

2 |Safety instructions for use of

flammable refrigerants

DANGER • Explosion and fire risk! Hydrocarbons and synthetic HFO

refrigerants are colourless, combustible gases which

occur naturally and which are explosive in a certain blend!

• Hydrocarbons are classied into the safety group A3 (highly-

inammablerefrigerant)accordingtoEN378.

•HFOrefrigerantsareclassiedintothesafetygroupA2L(hardly-

inammablerefrigerant)accordingtoEN378.

Astheyareheavierthanair,theoperatinglocationmustbeabove

groundleveltoallowunrestricteddischargeofthegas.

• By means of a risk and hazard analysis, appropriate technical

measuresaretobeidentifiedinordertoachievesufficientrisk

reduction. If necessary, a classification of the hazardous areas

accordingtoEN60079-10-1shouldbecarriedout.Iftherefriger-

antconcentrationexceedsthevalueof25%ofthelowerflamma-

bilitylimit(LEL),allequipmentinthehazardousareawhichisnot

permittedforoperationinhazardousareasmustbeimmediately

switchedoffwithoutanyvoltage.

•Useonlysuitableequipmentapprovedforflammablerefrigerants.

•Observethenationalregulations.

INFO Semi-hermeticcompressorsaretobeclassifiedas"technically

tight"(seee.g.TRBS2152part2/TRGS722).

2.1 Safety instructions

2.2 Qualicationsrequiredofpersonnel

WARNING Inadequatelyqualiedpersonnelposestheriskof accidents,the

consequence being serious or fatal injury. Work on compressors

isthereforereservedforpersonnelwhichisqualiedinhandling

ammablerefrigerants.

96416-08.2020-DGbFEIRu

• HG44e:Semi-hermeticfour-cylinderreciprocatingcompressorwithsuction-gascooleddrivemotor.

• HG56e:Semi-hermeticsix-cylinderreciprocatingcompressorwithsuction-gascooleddrivemotor.

• Preferredapplicationrange:normalrefrigeratingandair-conditioning.

3|Product description

Nameplate

Fig.1

3.1 Short description

Valveplate Cylinder

cover

DimensionandconnectionvaluescanbefoundinChapter 12

Transporteyelet

Discharge

shut-offvalve

Oilpump

Suction

shut-offvalve

Oilsightglass

Drivesection

Motorsection

Fig.2

HG44e

HG56e

Terminalbox

96416-08.2020-DGbFEIRu

1 Typedesignation 6 Voltage,circuit,frequency

2 Machinenumber 7 Nominal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pressur

e12 Oiltypelledatthefactory

(g)Lowpressureside 13 Terminalboxprotectiontype

 HD(HP):

max.admissibleoperating

Electricalaccessoriescanchange

pressur

e(g)Highpressureside theIPprotectionclass!

Observethelimitsofapplication

diagrams!

50 Hz

}

60 Hz

}

3|Product description

Fig.3

3.2 Nameplate (example)

BB12345A001

HGX44e/770-4S

35,0A

101A 174 A

67,0

80,4

SE 55

GEA Bock GmbH

72636 Frickenhausen, Germany

HG 44 e 770-4 SX

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

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(optimizedefciency)

Numbersofcylinders

Size

Oilcharge²)

Series¹)

3.3 Typekey (example)

96416-08.2020-DGbFEIRu

3|Product description

770-

770

3.4 Typekey HCcompressor (example)

3.5 Typkey LGcompressor (example)

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

²)S - Morepowerfulmotor

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

²)X

- Esteroilcharge

3)S - Morepowerfulmotor

ML-Motorfornormalcoolinganddeepfreezing

Hydrocarbons

Motorvariant²)

Numberofpoles

Sweptvolume

e-series

Numbersofcylinders

Size

Series¹)

HFOrefrigerant

EngineperformanceinHP

Motorvariant3)

Sweptvolume

e-series

Numbersofcylinders

Size

Oillling²)

Series¹)

96416-08.2020-DGbFEIRu

ATTENTION The oil level must be in the

visiblepartofthesightglass;

damage to the compressor

is possible if overfilled or

underfilled!

4 |Areas of application

Thecompressorsarelledatthefactorywiththefollowingoiltype:

-fürR134a,R404A/R507,R407C,R407F FUCHSRenisoTritonSE55

 -für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.HGX44e/770-4).

4.1 Refrigerants

• HFKW/HFC:  R134a,R404A/R507,R407C,R407F

• (H)FCKW/(H)CFC: R22

4.2 Oilcharge

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

Alternatives:seelubricantstable,Chapter 7.5

ATTENTION Compressoroperationispossiblewithintheoperatinglimits.

ThesecanbefoundinBockcompressorselectiontool(VAP)

undervap.bock.de.Observetheinformationgiventhere.

-Permissibleambienttemperature(-20°C)-(+60°C)

-Max.permissibledischargeendtemperature140°C.

-Max.permissibleswitchingfrequency12x/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.

Foroperationwithcapacityregulator:

- Continuousoperation,whenthecapacityregulatorisactivated,

isnotpermissibleandcancausedamagetothecompressor.

-Thesuctiongassuperheattemperaturemayneedtobereduced

orsetindividuallywhenoperatingneartothethreshold.

- Whenthecapacityregulatorisactivated,thegasvelocityinthe

systemcannotundercertaincircumstancesensurethatsuf-

cient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.

4.3 Limitsofapplication

max.

min.

oillevel

Fig.4Fig.4Fig.4

HG44e

1,6Ltr.

HG56e

1,4Ltr.

Ce manuel convient aux modèles suivants

Table des matières

Autres manuels GEA Compresseur d'air

GEA

GEA Bock HGX46 CO2 T Series Manuel utilisateur

GEA

GEA Bock HG8 Series Manuel utilisateur

GEA

GEA FK50/460 N Manuel utilisateur

GEA

GEA HGX46/280-4 ML CO2T Manuel utilisateur

GEA

GEA HG22e/125-4 Manuel utilisateur

GEA

GEA Bock F76 Series Manuel utilisateur

GEA

GEA HGX22P CO2 Series Manuel utilisateur

GEA

GEA HGX34/130-4 ML CO2 T Manuel utilisateur

GEA

GEA FK20 Manuel utilisateur

GEA

GEA HG76e/1620-4 Manuel utilisateur

GEA

GEA HG88e series Manuel utilisateur

GEA

GEA Grasso RC9 Series Manuel utilisateur

GEA

GEA Grasso 5 Manuel utilisateur

GEA

GEA GEA Bock HG66e Series Manuel utilisateur

GEA

GEA HGX34/110-4 ML CO2 T Manuel utilisateur

GEA

GEA HGX6 R134a series Manuel utilisateur

GEA

GEA Grasso M-Series Manuel utilisateur

GEA

GEA HG22e/160-4 Manuel utilisateur

GEA

GEA HG12P Manuel utilisateur

GEA

GEA HG34P/215-4 Manuel utilisateur

GEA

GEA HGX12e S CO2 Manuel utilisateur

GEA

GEA Bock HGZ Series Manuel utilisateur

GEA

GEA Bock HG8 Series Manuel utilisateur

GEA

GEA HGX5/725-4 R134a Manuel utilisateur

Manuels Compresseur d'air populaires d'autres marques

Sparmax

Sparmax DC-25XR Manuel utilisateur

KAESER

KAESER M122 Manuel utilisateur

GMC

GMC GAC1500 Manuel utilisateur

Briggs & Stratton

Briggs & Stratton Air Compressor Manuel utilisateur

Fini

Fini F3GST2TK Manuel utilisateur

Industrial Air

Industrial Air CP1580325 Manuel de programmation

Campbell Hausfeld

Campbell Hausfeld RP3300 Guide de démarrage rapide

Ingersoll-Rand

Ingersoll-Rand UP6 20 HP Manuel utilisateur

Hitachi

Hitachi EC99S Manuel de l'opérateur

Parkside

Parkside PKO 270 A1 Manuel utilisateur

Sullair

Sullair 185 Manuel utilisateur

Clas Ohlson

Clas Ohlson QIE-ZTH-15 Manuel utilisateur

Ferm

Ferm CRM1046 Manuel utilisateur

BE AC153 Manuel utilisateur

RIDGID

RIDGID OF25150A Manuel utilisateur

Johnson Controls

Johnson Controls QUANTUM LX Manuel

Sears

Sears Craftsman 919.167463 Manuel utilisateur

Ring Automotive

Ring Automotive RAC700 Manuel utilisateur