D GB F E GEA Bock Compressor HG44e 96280-12.
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.
Contents Compressor assembly Storage and transport Setting up Pipe connections Pipes Laying suction ans pressure lines Operating the shut-off valves Operating mode of the lockable service connections Electrical connection Information for contactor and motor contactor selection Standard motor, design for direct or partial winding start Basic circuit diagram for partial winding start with standard motor Special motor: design for direct or star-delta start Basic circuit diagram for star-delta start with sp
1| Safety 1.1 Identification of safety instructions: 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| Safety 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. T he 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.
2 | Product description 2.1 Short description • Semi-hermetic four-cylinder reciprocating compressor with suction-gas cooled drive motor. • Preferred application range: normal refrigerating and air-conditioning. Transport eyelet Valve plate Cylinder cover Oil pump Name plate D GB Oil sight glass F Fig. 1 Discharge shut-off valve Terminal box Drive section Suction shut-off valve Motor section Fig. 2 Dimension and connection values can be found in Chapter 9 6 96280-12.
2 | Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany 1 2 3 4 5 HGX44e/770-4 S AV12345A001 39,7A 133 A 171 A 67,0 80,4 SE 55 6 7 8 9 10 11 12 13 Fig. 3 1 2 3 4 5 Type designation Machine number maximum operating current Starting current (rotor blocked) Y: Part winding 1 YY: Part windings 1 and 2 ND (LP): max. admissible operating pressure (g) Low pressure side HD (HP): max.
3 | Areas of application 3.1 Refrigerants • HFKW / HFC: • (H)FCKW / (H)CFC: R134a, R404A/R507, R407C, R407F R22 3.2 Oil charge The compressors are filled 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. HGX44e/665-4). INFO For refilling, we recommend the above oil types.
3 | Areas of application R134a Unlimited application range Supplementary cooling or reduced suction gas temperature Fig. 5 Supplementary cooling and reduced suction gas temperature Motor version S (more powerful motor) Evaporation temperature (°C) Condensing temperature (°C) D Suction gas superheat (K) R404A/R507 GB Suction gas temperature (°C) F E Fig. 6 Maximum admissible operating pressure (g) (LP/HP): 19/28 bar 1) 96280-12.
3 | Areas of application R407C Fig. 8 D GB R407F F E Fig. 9 Unlimited application range Supplementary cooling and reduced suction gas temperature Maximum admissible operating pressure (g) (LP/HP): 19/28 bar Motor version S (more powerful motor) Evaporation temperature (°C) Condensing temperature (°C) Suction gas superheat (K) Suction gas temperature (°C) 10 1) LP = Low pressure HP = High pressure Design for other areas on request 96280-12.
4 | Compressor assembly INFO New compressors are factory-filled with inert gas (3 bar nitrogen). 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 ? Fig. 10 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 combustible environment. Fig.
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). T he pipe connections have graduated inside diameters so that pipes with standart millimetre and inch dimensions can be used. The connection diameters of the shut-off valves are rated for maximum compressor output.
4 | Compressor assembly 4.5 Laying suction and pressure lines ATTENTION Improperly installed pipes can cause cracks and tears, the result being a loss of refrigerant. INFO Proper layout of the suction and discharge lines directly after the compressor is integral to the system’s smooth running and vibration behaviour. A rule of thumb: Always lay the first pipe section starting from the shut-off valve downwards and parallel to the drive shaft. D 67 89 10 11 12 13 1 2 3 4 GB 5 F Fig. 16 96280-12.
4 | Compressor assembly 4.6 Operating the shut-off valves Before opening or closing the shut-off valve, release the valve spindle seal by approx. ¼ of a turn counter-clockwise. After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise. Tighten Release Valve spindle seal Fig. 17 Fig. 18 4.
5| Electrical connection 5 Electrical connection DANGER INFO Risk of electric shock! High voltage! Only carry out work when the electrical system is disconnected from the power supply! Connect the compressor motor in accordance with the circuit diagram (see inside of terminal box). Use suitable cable entry point of the correct protection type (see name plate) for routing cables into the terminal box. Insert the strain reliefs and prevent chafe marks on the cables.
5.3 Basic circuit diagram for part winding start with standard motor 0 1 2 3 4 FC1.2 FC1.1 70% I> I> FC2 30% I> I> I> I> QA2 SF1 1 QA1 3 5 QA2 1 3 5 2 4 6 QA3 2 4 6 FC1.1 FC1.2 X SS L1 L2 L3 N PE 1 2 3 PE 4 5 6 7 8 9 10 11 11 12 14 12 13 D GB EC1 F 1U1 E 1W1 1V1 M Y/YY 2U1 L N EB1 2V1 2W1 BT1 INT69 Θ Θ BT2 BT2 Compressor terminal box Anschlußkasten Verdichter BP1 BP2 BP3 BT1 BT2 BT3 2EB1 EC1 FC1.
5 6 7 8 9 L1.1 L2.1 L3.1 L1.2 QA2 QA2 KF1 QA2 14 15 16 17 18 14 15 16 QA3 17 18 KF1 19 N PE 20 21 D BP1 T2 N L M GB S P> BP2 F P BP3 BT3 E P-Öl 96280-12.2014-DGbFEIRu FC1.2 FC2 KF1 QA1 QA2 QA3 SF1 PW INT69 HG44/56 XSS Motor protection switch (part winding 2) Control power circuit fuse Delay relay max.
5| Electrical connection The motor is wired for direct start (YY) at the factory. For part winding start Y / YY, the bridges must be removed and the motor feed line connected according to the circuit diagram: 400 V Direct start YY YY Direktstart Part winding start Y/YY Teilwicklungsstart L1 L2 L3 2U1 2V1 2W1 2U1 2V1 2W1 1U1 1V1 1W1 1U1 1V1 1W1 L1 L2 L3 L1 L2 L3 ATTENTION Failure to do this results in opposed rotary fields and results in damage to the motor.
5| Electrical connection 5.4Sondermotor: Sondermotor:Ausführung Ausführungfür fürDirektDirekt-oder oderStern-Dreieck-Anlauf Stern-Dreieck-Anlauf 5.4 5.4 Special motor: design forist direct star-delta start Fürden den Stern-Dreieck-Anlauf ist eineor mechanische Anlaufentlastungmit mitBypass-Magnetventil Bypass-Magnetventil Für Stern-Dreieck-Anlauf eine mechanische Anlaufentlastung (Zubehör) erforderlich.
5.5 Basic circuit diagram for star-delta start with special motor 0 1 2 3 4 FC2 FC1.1 4A I> I> I> QA2 SF1 FC1.1 QA1 1 3 5 1 QA2 3 5 QA4 2 4 6 I> I> I> Y 1 3 5 2 4 6 QA3 2 4 6 D FC1.2 FC1.
5 6 7 8 9 L1.1 L2.1 L3.1 L1.2 13 QA2 QA2 QA4 14 KF1 QA4 QA2 14 15 16 17 18 T2 N L M S 19 20 KF1 QA3 QA3 21 QA4 22 23 KF1 24 N PE 25 D 26 GB BP1 P> F P BP2 BP3 E BT3 P-Öl D/S 96280-12.2014-DGbFEIRu 13 INT69 HG44/56 FC2 KF1 QA1 QA2 QA3 QA4 SF1 XSS 14 .
5| Electrical connection 5.6 Electronic trigger unit INT69 G The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the electronic trigger unit INT69 G in the terminal box. In case of excess temperature in the motor winding, the INT 69 G deactivates the motor contactor. Once cooled, it can be restarted only if the electronic lock of the output relay (terminals B1+B2) is released by interrupting the supply voltage.
5| Electrical connection 5.8 Function test of the trigger unit INT69 G Before commissioning, after troubleshooting or making changes to the control power circuit, check the functionality of the trigger unit. Perform this check using a continuity tester or gauge. Gauge state Relay position Deactivated state 11-12 INT69 G switch-on 11-14 Remove PTC connector 11-12 Insert PTC connector 11-12 Reset after mains on 11-14 Relay position INT69 G B2 12 14 11 Fig. 24 D GB F 96280-12.
5| Electrical connection 5.9 Oil sump heater (accessories) When the compressor is at a standstill, refrigerant diffuses into the lubricating oil of the compressors housing, depending on pressure and ambient temperature. This reduces the lubricating capacity of the oil. When the compressor starts up, the refrigerant contained in the oil evaporates out throught the reduction in pressure. The consequences can be foaming and migration of the oil, causing oil shocks under certain circumstances.
6 | Commissioning 6.1 Preparations for start-up INFO To protect the compressor against inadmissible operating conditions, high pressure and low pressure pressostats are mandatory on the installation side. The compressor has undergone trials in the factory and all functions have been tested. There are therefore no special running-in instructions. Check the compressor for transport damage! 6.2 Pressure strength test DANGER Risk of bursting! The compressor must only be pressurised using nitrogen (N2).
6| Commissioning 6.5 Refrigerant charge CAUTION Wear personal protective clothing such as goggles and protective gloves! Make sure that the suction and pressure line shut-off valves are open. With the compressor switched off, add the liquid refrigerant directly to the condenser or receiver, breaking the vacuum.
6| Commissioning 6.8 Connection of oil level regulator 12 4o 124 o o 4 12 Oil level regulation systems have proven themselves with parallel circuits of several compressors. The connection "0" is provided for installing an oil level regulator (see dimensions drawing). All common oil level regulators from AC&R, ESK and Carly as well as the OM3 TraxOil oil level regulation system from Alco can be connected directly without adapters (see Fig. 26). A sight glass on the oil level regulator is not required.
7 | Maintenance 7.3 Spare part recommendation HG44e / ... 475-4 (S) 565-4 (S) 665-4 (S) 770-4 (S) Designation Item No. Item No. Item No. Item No. Set of gaskets kit 80953 Valve plate kit 80965 80966 Oil pump kit 80950 Oil sump heater kit 230 V ~ 80854 Only use genuine GEA Bock spare parts! 7.4 Accessories Available accessories can be found on the Internet at www.gea.com 7.5 Extract from the lubricants table D The oil type filled as standard in the factory is marked on the name plate.
67,0 / 80,4 67,0 / 80,4 HG44e/770-4 HG44e/770-4 S 1 Voltage 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW PW = Part Winding Winding ratio : 70% / 30% 35 30 30 26 26 22 23 19 A PW 1 + 2 Max. Operating current 2 21,4 17,8 18,3 15,4 15,6 13,2 13,1 11,0 kW 2 Max.
1/8" NPTF Zoll / inch 7/16" UNF B B1 DV Connection discharge side, lockable Anschluss Öldrucksicherheitsschalter LP Connection oil pressure safety switch LP Anschluss Ölrückführung vom Ölabscheider Zoll / inch 7/16" UNF 1/4" NPTF B,L Connection oil return from oil separator Anschluss Öldruckmanometer D1 Connection oil pressure gauge Ölablass Oil drain Zoll / inch 1/8" NPTF Zoll / inch 1/4" NPTF mm M22x1,5 Stopfen Ölfüllung Oil charge plug Anschluss Ölsumpfheizung mm Connection oil sump h
9 | Dimensions and connections SV DV Suction line Discharge line A Connection suction side, not lockable A1 Connection suction side, lockable B Connection suction side, not lockable B1 Connection suction side, lockable D Connection oil pressure switch LP D1 Connection oil return from oil separator E Connection oil pressure gauge F Oil drain 1/ “ NPTF 8 7/ “ UNF 16 1/ “ NPTF 8 7/ “ UNF 16 7/ “ UNF 16 1/ “ NPTF 4 1/ “ NPTF 8 1/ “ NPTF 4 H Oil charge plug M22 x 1,5 J Connection oil sump
10 | Declaration of conformity and installation DECLARATION OF CONFORMITY CE 13 for using the compressors within the European Union (in accordance with Low Voltage Directive 2006/95/EC) We hereby declare that the following refrigerating compressors Product designation: HG44e comply with the Low Voltage Directive 2006/95/EC.
11 | Service Dear customer, GEA Bock compressors are top-quality, reliable and service-friendly quality products. If you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The GEA Bock service team can be contacted by phone with a toll-free hotline 00 800 / 800 000 88 or via e-mail: refrigeration@gea.com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany D GB F 96280-12.
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