GEA Pluscom Bock EX-HG12P Manuel utilisateur

Assembly instructions

09691-08.2019-Gb

Translation of the original instructions

GEA Bock EX-HG12P

EX-HG12P75-4 EX-HGX12P/75-4 EX-HG12P/75-4 HC

EX-HG12P/90-4 EX-HGX12P/90-4 EX-HG12P/90-4 HC

EX-HG12P/110-4 EX-HGX12P/110-4 EX-HG12P/110-4 HC

EX-HG12P/60-4 S EX-HGX12P/60-4 S EX-HG12P/60-4 S HC

EX-HG12P/75-4 S EX-HGX12P/75-4 S EX-HG12P/75-4 S HC

EX-HG12P/90-4 S EX-HGX12P/90-4 S EX-HG12P/90-4 S HC

EX-HG12P/110-4 S EX-HGX12P/110-4 S EX-HG12P/110-4 S HC

Device category 2 G

acc. to directive 2014/34/EU

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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

compressor is installed.

GEA Bock GmbH

72636 Frickenhausen

Manufacturer

Contact

GEA Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Phone +49 7022 9454-0

Fax +49 7022 9454-137

[email protected]

www.gea.com

1 Safety 4

1.1 Identicationofsafetyinstructions

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

1.3 Safety instructions

1.4 Intended use

2 Product description 7

2.1 Short description

2.2 Ignition protection concept

2.3 Name plate

2.4 Type key

 2.5 ATEX-identication

Contents Page

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Contents Page

3 Areas of application 12

3.1 Approved refrigerant

3.2 Important information on the use of hydrocarbons

3.3 Oil charge

3.4 Limits of application

4Compressor assembly 15

4.1 Ignition source control of the compressor

4.2 Storage and transport

4.3 Setting up

4.4 Pipe connections

4.5 Pipes

4.6 Laying suction and pressure lines

4.7 Operating the shut-off valves

4.7 Operating mode of the lockable service connections

 4.9 Suctionpipelter

5 Electrical connection 19

 5.1 Potentialequalization

5.2 Information for contactor and motor contactor selection

5.3 Terminal cross section for leads

5.4 Connection of the drive motor

5.5 Circuit diagram direct start

5.6 Electronic trigger unit INT69 EX2

5.7 Connection of the electronic trigger unit INT69 EX2

5.8 Functional test of the electronic trigger unit INT69 EX2

5.9 To verify the intrinsic safety of the PTC hot gas sensor

6 Commissioning 27

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liquidsluggings

6.8 Preventing icing on the compressor

7 Maintenance 29

7.1 Preparation

7.2 Work to be carried out

7.3 Spare part recommendation

7.4 Screw connections

7.5 Decommissioning

8 Accessories 31

8.1 Oil sump heater

9 Technical data 32

10 Dimensions and connections 33

  ECTypeExaminationCerticate 36

  IECExCerticateofConformity 39

Service 42

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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

must therefore only be performed by personnel with hereinafter

qualicationsandappropriatetoadditionalqualicationaccording

to EN 60079-14.

• For example, a refrigeration technician, refrigeration mechatronic

engineer. As well as professions with comparable training, which ena-

bles 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:

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1.3 Safety instructions

1|Safety

The GEA refrigerating compressor named in the title is intended for installation in machines that were

set up in areas falling under the EU Explosion Protection Directive 1999/92/EC (operator directive). In

the European Union, electrical as well as mechanical devices operated in explosive atmospheres must

fulfil what are known as ATEX (ATmospheres EXplosibles) conditions.

The compressors are specially designed for the category shown on the name plate in accordance with

the ATEX directive and may only be used in conformity with the conditions specified and documented

in the set-up area (explosion protection document). User safety is taken into account as a particular

focus of design. But it is permissible to start up the compressor only if it was installed in accordance

with these instructions and the entire system into which it is integrated has been inspected in accor-

dance with legal regulations and approved.

The declarations and remarks by GEA can only refer to the product itself. We assume that the appli-

cable regulations, standards and technical rules are followed in installation and during operation. The

plant constructor/operator must evaluate the interactions with other devices and components of the

system and with the environment, especially regarding potential ignition sources.

WARNING • Refrigerating compressors are pressurised machines and there-

fore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.

• The compressor may be operated only if it is free of defects!

• No work may be performed when an explosive atmosphere is

present!

• Smoking,reandopenamearestrictlyprohibited!Mobiletele-

phones must be switched off!

• Strongly charge-generating processes must be excluded within

2 meters. The contact of rapidly moving particles with the sur-

face of the compressor must be avoided with certainty (e.g.

pneumaticallymoveddust,owinguids,directventilation,belt

drives, brushes, foils, etc.).

• Perform installation work only if no damage, leaks and/or

appearances of corrosion can be recognized.

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1|Safety

These assembly instructions describe the standard version of the EX-HG12(P)(e) manufactured by

GEA. The compressor is intended for use in refrigeration systems inside explosion-endangered areas

underthedesignationspeciedonthenameplateinaccordancewiththeEuropeanATEX Directives.

Useofthespeciedrefrigerantsaswellasobservanceoftheoperatinglimitsandlistedstandards

must be ensured in any case. Likewise, all accessories available from, approved and specially marked

by GEA are exclusively approved, according to their intended use, for attachment to and operation with

GEA compressors of appliance category 2 in accordance with Directive 2014/34/EU.

1.4 Intended use

WARNING Any other use of the compressor and its approved accessories is

prohibited! The ATEX permit is voided if the compressor is used

outside the operating limits or undergoes inadmissible design

changes!

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Dimension and connection values can be found in Chapter 10.

Name plate

Fig. 1

Fig. 2

Oil sight glass

Valve plate

Discharge

shut-off valve

Oil pump

Terminal box

Potentialequalization

Suction

shut-off valve

Drive section

Motor section

Transport eyelet

Cylinder cover

2|Product description

• Semi-hemetic two-cylinder reciprocating compressor with oil pump lubrication

• Suction-gas-cooled drive motor

• For use in explosion-endangered areas

2.1 Short description

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2|Product description

2.2 Ignition protection concept

In accordance with Directive 2014/34/EU, GEA ATEX compressors are suitable for use in device

category 2 for explosive gas atmospheres up to temperature class T3 and explosion hazard subgroup

IIB/IIC.

The entire compressor, including motor, is perceived as technically tight and therefore does not need

an ignition protection.

To prevent ignition risk caused by working materials also during system malfunctions, all used work-

ingmaterialshavetomeettherequirementsforthetemperatureclassofthecompressor.Thesurface

temperature of the compressor may not exceed 80 % of the ignition temperature of the working

material. For this reason all working materials need to have an auto-ignition temperature of > 250 °C.

To protect against high temperatures that may occur during incorrect operation or faults at the com-

pressor, the areas with the highest heat potential are controlled with temperature sensors (Ex b).

The installation of the electronic control unit INT69 EX2 and the safety barrier,

both included in the scope of supply, is therefore absolutely necessary.

Theconnectionareasforloadcircuitsaredesignedaccordingtotherequirementsoftheappliance

category in Ex e. The circuits for the temperature sensors of the used ignition source control Ex b have

to be intrinsically safe to prevent inadmissibly high thermal or electric values. To ensure the intrinsic

safety, the included safety barrier has to additionally be integrated in the electric circuit according to

this assembly instruction. The terminal board is designed for the protection type Ex de. The whole

electricconnectionareaisprotectedbyahousingthatcomplieswiththerequirementsfortheprotec-

tion type increased safety (Ex e).

Thescopeofdeliveryofthestandardcompressorcomprisesaconductivepaintnish,thatissuitable

for the use in explosion group IIC. If the compressor is delivered with the accessory "Offshore Paint

Finish", the application is restricted to explosion group IIB.

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Accessories

Heating elements for the compressors to protect against explosion risks are designed in the protection

types increased safety (Ex d) and have to have to be mounted stationary at the designated areas in

the compressor housing. The heating elements can be operated without temperature- and oil level

controlsincethethermaltypetestingbythemanufacturerveriedthattheheatingelementsprevent

the exceeding of the temperature class of the compressor. The control has to be carried out in a way

that the heating element can only be operated during shutdown of the compressor.

Equipment Type of ignition protection

Terminal box Ex e

Terminal board Ex d

Through terminals in the terminal box Ex e

Cable/line entrances/plug Ex d/e

Oil sump heater Ex d

Hot gas PTC sensor Ex i

2|Product description

09691-08.2019-DGbFEIRu

EX-HG12P/110-4 S

IP66

AY15595A008

6,1 A

26 A 11,3

9,4

II 2G Ex d e ia IIC T3 Gb / EPS 16 ATEX 1095 X

2|Product description

2.2 Name plate (example)

2.3 Name plate (example)

50Hz

60Hz

}

2.4 Type key (example)

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

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

³) Additional declaration for Pluscom compressors

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

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

5 ND (LP):

max. admissible operating

10 Nominal rotation speed

pressur

e (g) Low pressure side 11 Displacement

HD (HP):

max. admissible operating

 12 Oiltypelledatthefactory

pressur

e(g) High pressure side 13 Terminal box protection type

14 Permissible ambient temperature

Electrical accessories can change

the IP protection class!

Observe the limits of

application diagrams!

EX 21 P 110-

-4 SX

for hydrocarbons

Motor variant 4)

Number of poles

Swept volume

³)

Number of cylinders

Size

Esteroillling²)

Series ¹)

Ex-design

Fig. 3

Ce manuel convient aux modèles suivants

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