GEA HG76e/1620-4 Manuel utilisateur

96263-01.2016-DGbFEIRu

engineering for a better world

GEA Compressor HG76e

Assembly instructions

HG76e/1620-4 HG76e/1620-4 S HGX76e/1620-4 HGX76e/1620-4 S

HG76e/1860-4 HG76e/1860-4 S HGX76e/1860-4 HGX76e/1860-4 S

HG76e/2110-4 HG76e/2110-4 S HGX76e/2110-4 HGX76e/2110-4 S

HG76e/2500-4 HG76e/2500-4 S HGX76e/2500-4 HGX76e/2500-4 S

96263-01.2016-DGbFEIRu

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

Telephone +49 7022 9454 0

Fax +49 7022 9454 137

[email protected]

www.gea.com

Manufacturer

Contact

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 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

4Compressor 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 and 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 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 Circuit diagram for star-delta start 230 V ∆/ 400 V Y

5.6 Electronic trigger unit INT69 G

5.7 Connection of the trigger unit INT69 G

5.8 Function 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 strength test

6.3 Leak test

6.4 Evacuation

6.5 Refrigerant charge

6.6 Start-up

6.7 Avoiding slugging

7 Maintenance 29

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 31

8.1 Capacity regulator

8.2 Oil separator

8.3 Oil level regulator

9 Technical data 33

10 Dimensions and connections 34

11 Declaration of installation 36

12 Service 37

96263-01.2016-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 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

4Compressor 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 and 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 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 Circuit diagram for star-delta start 230 V ∆/ 400 V Y

5.6 Electronic trigger unit INT69 G

5.7 Connection of the trigger unit INT69 G

5.8 Function 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 strength test

6.3 Leak test

6.4 Evacuation

6.5 Refrigerant charge

6.6 Start-up

6.7 Avoiding slugging

7 Maintenance 29

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 31

8.1 Capacity regulator

8.2

Oil separator

8.3 Oil level regulator

9 Technical data 33

10 Dimensions and connections 34

11 Declaration of installation 36

12 Service 37

96263-01.2016-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

96263-01.2016-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,97/23/EC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!

96263-01.2016-DGbFEIRu

2|Product description

• Semihermetic six-cylinder reciporating compressor with oil pump lubrication.

• Thestreamofcoolantsuckedoutoftheevaporatorows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 sight glass

Drive section

Name plate

Motor section

Suction

shut-off valve

Oil pump

96263-01.2016-DGbFEIRu

2|Product description

Fig. 2

2.2 Name plate (example)

2.3 Type key (example)

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 12 Oiltypelledatthefactory

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

HD (HP): max. admissible operating Electrical accessories can change

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

Observe the limits of application diagrams!

50 Hz

}

60 Hz

}

SE 55IP 65

AV12345-A001

HGX76e/2500-4

GEA Bock GmbH

72636 Frickenhausen, Germany

HG 67 e 2500 -4 SX

¹) HG - Hermetic-Gas-cooled (suction gas cooled) for the normal- / air conditioning applications

²) X - Ester oil filling (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)

107,0 A

YY: 412,0 AY: 268,0 A

217

260

380-420 Y/YY

440-480 Y/YY

96263-01.2016-DGbFEIRu

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. HGX76e/2500-4).

3.1 Refrigerants

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

• (H)FCKW / (H)CFC: R22

3.2 Oil charge

INFO For refilling, we recommend the above oil types.

Alternatives: see lubricants table, Chapter 7.4

Fig. 3

ATTENTION The correct oil level is shown

in figure 3.

Damage to the compressor

is possible if overfilled or

underfilled!

max.

min.

1,5 Ltr.

oil level ~

ATTENTION Compressor operation is possible within the operating limits

showninthediagrams.Pleasenotethesignicance

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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.

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!

3.3 Limits of application

96263-01.2016-DGbFEIRu

3|Areas of application

-20 -10 100 20 30 t (°C)

t (°C)

-30

12,5 25

<20K

t +20°C

EGD HG88e

R134a

-10

-20

-30

t (°C)

-5 12,5

-25

?tOh<20K

t +20°C

R407C

-10

-20

-30

-40

t (°C)

-35

t +20°C

-5 12,5

?toh<20K

R22 R407F

-10

-20

-30

-40

-50

t (°C)

? toh<20K

t +20°C

-5 7,5-45

R404A/R507

t (°C)

?toh<20K

t +20°C

-20 -15

-25 -10 -5 05 10 15

R407C

-20 -10 100 20 30 t (°C)

t (°C)

-30

12,5 25

<20K

t +20°C

EGD HG88e

R134a

-10

-20

-30

t (°C)

-5 12,5

-25

?tOh<20K

t +20°C

R407C

-10

-20

-30

-40

t (°C)

-35

t +20°C

-5 12,5

?toh<20K

R22 R407F

-10

-20

-30

-40

-50

t (°C)

? toh<20K

t +20°C

-5 7,5-45

R404A/R507

t (°C)

?toh<20K

t +20°C

-20 -15

-25 -10 -5 05 10 15

R407F

Fig. 5

Fig. 6

-20 -10 100 20 30 t (°C)

t (°C)

-30

12,5 25

<20K

t +20°C

EGD HG88e

R134a

-10

-20

-30

t (°C)

-5 12,5

-25

?tOh<20K

t +20°C

R407C

-10

-20

-30

-40

t (°C)

-35

t +20°C

-5 12,5

?toh<20K

R22 R407F

-10

-20

-30

-40

-50

t (°C)

? toh<20K

t +20°C

-5 7,5-45

R404A/R507

t (°C)

?toh<20K

t +20°C

-20 -15

-25 -10 -5 05 10 15

R134a

Fig. 4

Additional cooling and reduced

suction gas temperature

Unlimited application

range

Additional cooling or reduced

suction gas temperature

Motor variant - S

(stronger motor)

Evaporation temperature (°C)

Condensing temperature (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

Design for other

areasonrequest

Maximum admissible

operating pressure (g)

(LP/HP): 19/28 bar

1) LP = Low pressure

HP = High pressure

96263-01.2016-DGbFEIRu

3|Areas of application

-20 -10 100 20 30 t (°C)

t (°C)

-30

12,5 25

<20K

t +20°C

EGD HG88e

R134a

-10

-20

-30

t (°C)

-5 12,5

-25

?tOh<20K

t +20°C

R407C

-10

-20

-30

-40

t (°C)

-35

t +20°C

-5 12,5

?toh<20K

R22 R407F

-10

-20

-30

-40

-50

t (°C)

? toh<20K

t +20°C

-5 7,5-45

R404A/R507

t (°C)

?toh<20K

t +20°C

-20 -15

-25 -10 -5 05 10 15

R22

-20 -10 100 20 30 t (°C)

t (°C)

-30

12,5 25

<20K

t +20°C

EGD HG88e

R134a

-10

-20

-30

t (°C)

-5 12,5

-25

?tOh<20K

t +20°C

R407C

-10

-20

-30

-40

t (°C)

-35

t +20°C

-5 12,5

?toh<20K

R22 R407F

-10

-20

-30

-40

-50

t (°C)

? toh<20K

t +20°C

-5 7,5-45

R404A/R507

t (°C)

?toh<20K

t +20°C

-20 -15

-25 -10 -5 05 10 15

R404A/R507

Fig. 7

Fig. 8

Additional cooling and reduced

suction gas temperature

Unlimited application

range

Additional cooling or reduced

suction gas temperature

Motor variant - S

(stronger motor)

Evaporation temperature (°C)

Condensing temperature (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

Design for other

areasonrequest

Maximum admissible

operating pressure (g)

(LP/HP): 19/28 bar

1) LP = Low pressure

HP = High pressure

Ce manuel convient aux modèles suivants

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