GEA Bock EX-HG44e Series User manual

GEA Bock EX-HG44e/EX-HG56e
Assembly instructions
96389-08.2019-Gb
Translation of the original instructions
Device category 2 G
acc. to directive 2014/34/EU
EX-HG(X)44e/475-4 EX-HG(X)56e/850-4 EX-HG44e/475-4 HC EX-HG56e/850-4 HC
EX-HG(X)44e/565-4 EX-HG(X)56e/995-4 EX-HG44e/565-4 HC EX-HG56e/995-4 HC
EX-HG(X)44e/665-4 EX-HG(X)56e/1155-4 EX-HG44e/665-4 HC EX-HG56e/1155-4 HC
EX-HG(X)44e/770-4 EX-HG44e/770-4 HC
EX-HG(X)44e/475-4 S EX-HG(X)56e/850-4 S EX-HG44e/475-4 S HC EX-HG56e/850-4 S HC
EX-HG(X)44e/565-4 S EX-HG(X)56e/995-4 S EX-HG44e/565-4 S HC EX-HG56e/995-4 S HC
EX-HG(X)44e/665-4 S EX-HG(X)56e/1155-4 S EX-HG44e/665-4 S HC EX-HG56e/1155-4 S HC
EX-HG(X)44e/770-4 S EX-HG44e/770-4 S HC

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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/IECExidentication
3 Areas of application 13
 3.1 Approvedrefrigerant
 3.2 Importantinformationontheuseofhydrocarbons
 3.3 Oilcharge
 3.4 Limitsofapplication
Contents Page
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

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Contents Page
4Compressor assembly 16
 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
 4.8 Operatingmodeofthelockableserviceconnections
 4.9 Suctionpipelter
5
Electrical connection 20
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-5.7Circuitdiagrams
5.8
ElectronictriggerunitINT69GEx
 5.9 ConnectionoftheelectronictriggerunitINT69GEx
 5.10FunctionaltestoftheelectronictriggerunitINT69GEx
5.11 ToverifytheintrinsicsafetyofthePTChotgassensor
6 Commissioning 33
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 36
7.1 Preparation
7.2 Worktobecarriedout
7.3 Sparepartrecommendation
7.4 Screwconnections
7.5 Decommissioning
8 Accessories 38
8.1 Capacityregulation
8.2 Oilsumpheater
 8.3 OildifferentialpressuresensorINT250Ex
9
Technical data 41
10 Dimensions and connections 43
EU Type Examination Certicate 47
IECEx Certicate of Conformity 50
Service 54

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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compressorsnamedinthetitleareintendedforinstallationinmachinesthat
weresetupinareasfallingundertheEUExplosionProtectionDirective1999/92/EC(operatordirec-
tive).IntheEuropeanUnion,electricalaswellasmechanicaldevicesoperatedinexplosiveatmos-
pheres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compressorsnamedinthetitle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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2|Product description
Fig. 1
2.1 Short description
Fig. 2
Oilsightglass
Valveplate
Cylindercover
Discharge
shut-offvalve
Oilpump
Terminalbox
Suction
shut-offvalve
Drivesection
Motorsection
DimensionandconnectionvaluescanbefoundinChapter10
Transporteyelet
Potential
equalization
• EX-HG44e:Semi-hemeticfour-cylinderreciprocatingcompressorwithoilpumplubrication.
• EX-HG56e:Semi-hemeticsix-cylinderreciprocatingcompressorwithoilpumplubrication.
• Foruseinexplosion-endangeredareas.
EX-HG44e
EX-HG56e
Nameplate

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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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2|Product description
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.
Themagneticcoilofthecapacityregulatorisdesignedintheprotectiontypeencapsulation(Exm)to
protectagainstexplosionrisks.Inaddition,theconnectingareasofthecoilareplacedinahousing
thatcomplieswiththerequirementsoftheprotectiontypeincreasedsafety(Exe).
TheoildifferentialpressuresensorINT250ExfromKriwanisexecutedasasimpleelectricaloperating
devicewithoutarecognisedignitionprotectiontype.Toensurereliableoperation,however,itmustbe
equippedasanintrinsicallysafeelectricalcircuitwithswitchingrepeater.Pleasenotethattheplastic
housingoftheINT250Excanbeelectricallychargedbymeansofcharge-generatingprocesses(e.g.
cleaningwithadrycloth,directadditionalventilationviafanetc.).Accordingly,theoperatorisrequired
totakemeasuressothatignitionhazardscanbereliablyruledout.
Equipment Typeofignitionprotection
Terminalbox Exe
Terminalboard Exd+e
Throughterminalsintheterminalbox Exe
Cable/lineentrances/plug Exd/e
Magneticcoil Exemb
Oilsumpheater Exd
OildifferentialpressuresensorINT250Ex Exi
HotgasPTCsensor Exi

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GGEA Bock GmbH
I 72636 Fricken hausen, Germany
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2|Product description
/
HG
EX 4770-
-4 SX
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)S- Morepowerfulmotor,e.g.air-conditioningapplications
Fig. 3
HC
forhydrocarbons
Motorvariant3)
Numberofpoles
Sweptvolume
e-series
Numberofcylinders
Size
Esteroillling²)
Series ¹)
Ex-design
}
}
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
pressur e(g)Lowpressureside 13 Terminalboxprotectiontype
 HD(HP):max.admissibleoperating 14 Permissibleambienttemperature
 pressure(g)Highpressureside
Electrical accessories can change
the IP protection class!
Observe the limits of
application diagrams!
50 Hz
60 Hz
1
2
3
4
5
6
7
8
9
10
12
13
11
14
2.3 Name plate (example)
4 e

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2.5 ATEX identication / IECEx identication
2G T3 Gb
II ia IIB/IIC
Ex
demb
ExplosiongroupIIforEx-endangered
areas(notundergroundbuildings)
Suitabilityforgas-explosivearea
Devicecategory2(=zone1)
TemperatureclassT3(max.200°C)
Equipmentprotectionlevel
Explosionsubgroups,
IIB=Offshorepaintnish
IIC=ESDpaintnish
Intrinsicallysafeequipment
Increasedsafety
Flameproofenclosure,heater(option)
Europ.explosionprotectionacc.to
Direc.2014/34/EU
Encapsulation,magneticcoil(option)

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EPS 17 ATEX 1002 X / IECEx EPS 17.0001 X
BureauVeritas
ConsumerProductsServices
GermanyGmbH
Internationalexplosionprotection
Yearoftest/Testreportnumber
Yearoftest
BureauVeritas
ConsumerProductsServices
GermanyGmbH
Specialconditions:
see"ConditionsofCertication"
Specialconditions:
seepoint17oftheECtype
examinationcerticate
Testreportnumber
ATmospheresEXplosibleseuropean
explosionprotection
ATEX approval type IECEx approval type

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3.2 Important information on the use of hydrocarbons
Hydrocarbons(combustiblerefrigerants)maybeusedinthecompressorsnamedinthetitleonlyifall
relevantandapplicableregulations,standardsandtechnicalrulesarefollowed.Nationalsafetyregu-
lationsmustbeobserved.Inaddition,werefertothefollowingapplicablestandardsandregulations:
EN378,BGR500,TRBS2152,ECDirectives1999/92/ECand2014/34/EU.
The compressor and the refrigeration system must be permanently equipped with clear, identical
labels/plates(ISO3864)thatstatethatcombustiblerefrigerantsareused.Thiswarningplatemustbe
unremovablyattachedtothecompressor.
AhazardanalysisinaccordancewiththeOperationalSafetyOrdinancemustbeperformedforthe
set-uplocation.Useandhandlingoftherefrigerationsystemandcompressoraretobegovernedin
theexplosionprotectiondocument.
Installation,placementintooperation,serviceandrepair(aspermittedbythemanufacturer)mayonly
beperformedbypersonnelwhohavebeenspeciallytrainedoncombustiblerefrigerants.
Ifthecompressorhastoberemovedfromthesystemforinspection/maintenance/repair,theremaining
refrigerantmustbesuctionedoutandthecompressorevacuated,lledwithnitrogen(<0.5bar)and
closedgas-tight.Thecompressormustbeequippedwithatagthatclearlystatesthatthecompressor
wasoperatedwithcombustiblerefrigerant(nametherefrigerant).
Ifthesystemcontainscombustiblerefrigerantsorresidues,extremecautionmustbeexercisedwhen
workingonthecompressorduetothedangerofexplosion.Thisappliesespeciallyfortheuseofre,open
ameorotherignitionsources(e.g.electronicdevices,mobiletelephones,staticcharges,sparks,...).
Duringmaintenanceandrepair,itmustbenotedthathydrocarbonresiduesmayremaindissolvedin
theoil.Inadditionuseddryerscontainbottomsoftheinammablerefrigerants.Flushthedryerwith
nitrogenandsupplyittotherecycling.
Itshouldbenotedthatthesolubilityofhydrocarbonsinoilcanbeveryhigh,especiallyathighsuction
pressures.Ahigh-viscositylubricantmayberequired,dependingontheapplicationandexperience.
ThelubricantmustbereleasedforusebyGEA.Dependingontheapplication,apump-downswitch
shouldalsobeadded(e.g.whentherefrigerationsystemissetupoutside).
3.1 Approved refrigerant
INFO Used refrigerants have to have a self-ignition temperature of
> 250 °C.
•  HFKW/HFC:  R134a,R404A,R507,R407C
•  (H)FCKW/(H)CFC: R22
• Hydrocarbons:  R290,R1270

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Compressorswithesteroillling(FUCHSRenisoTritonSE55)aremarkedwithanXinthetype
designation(e.g.EX-HGX44e/770-4).CompressorswithoilllingFUCHSRenisoSnyth68are
markedwithHC(e.g.EX-HG44e/770-4HC).
Oillevel:Theoillevelfromthefactoryreachestheupperedgeofthesightglass.Theoillevelmust
beregulatedinoperation;ifnecessarytoachieveacorrectoillevel(seeFig.4),oilmayhavetobe
drainedofforadded.
Operate compressors only with the approved refrigerants and the corresponding assigned and
approvedoils.Othercombinations(e.g.R22withesteroils)arenotpermitted!
 Conversiontoanotherrefrigerant/oilisnotpermitted!
ATTENTION The oil level must be in the
visible part of the sight glass;
damage to the compressor is
possible if overfilled or under-
filled!
max.
min.
oillevel
 Thefollowingoilgradesareapprovedforthecompressor:
3.3 Oil charge
Refrigerant Oilgrade
R22 FUCHSRenisoSP46
R134a,R404A,R507,R407C FUCHSRenisoTritonSE55
R290,R1270 FUCHSRenisoSynth68
INFO Used refrigerant oils have to have a self-ignition temperature of
> 250 °C.
Fig. 4Fig. 4
E X - H G 4 4 e 
1.6Ltr.
EX-HG56e
1.4Ltr.
~
~
~
~

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3.4 Limits of application
ATTENTION Compressor operation is possible within the operating limits.
These can be found in GEA Bock compressor selection tool (VAP)
under vap.gea.com. Observe the information given there.
- Max. permissible discharge end temperature 140 °C.
- Max. permissible switching frequency 12 x / h.
- A minimum running time of 3 min. steady-state condition
(continuous operation) must be achieved.
Suction gas overheating ∆toh:
The correct setting of the suction gas overheating temperature
∆toh at the compressor entrance is of decisive importance:
Too low ∆toh => danger of liquid operation
Too high ∆toh => danger of compressor overheating
∆toh min = 7 - 10 K, individual adjustment required.
Permissible ambient temperature range −20 °C to +60 °C.
Avoid continuous operation near the limits.
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 may not
be exceeded. During operation above the mains frequency
the application limit can be restricted.
Variable frequency range : 25 - 70 Hz.
During operation in the vacuum range, there is a danger of air
entering on the suction side. This can cause chemical reactions,
pressure rise in the condenser and an excessive pressure gas tem-
perature as well as shifting of the refrigerant ignition limit into the
critical range. Avoid absolutely any entry of air!

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4.1 Ignition source control of the compressor
To protectagainstanexceeding oftemperaturetheprotectiontypeignitionsourcecontrol"b"is
used at the compressor.Viasensors,theareas with the highest heat potential at every cylinder
coverarecontrolled.Additionally,thetemperatureofthemotorwindingiscontrolledbythesafety
deviceINT69EX2.
Thepermissiblelimittemperaturesfornormaloperationofthecompressorweresetwith130°Cfor
themotorandwith140°Cforthehotgassideofthecylindercover.Ifoneofthosevaluesisexceeded,
thecompressorisshutdownbythecontroldeviceINT69EX2.Besidestheinstallationaccordingto
wiringdiagram,theoperator/installerdoesnothavetoregardotherparametersforthecorrectfunc-
tioningoftheignitionprotectionsystem.Afunctioncheckhoweverhastobecarriedoutbeforeevery
startupofthecompressoraccordingtosection5.10ofthisassemblyinstruction.
ForasafefunctionoftheignitionsourcecontroltheINT69EX2hastobeinstalledaccordingtothe
wiring diagram g. 21. Check the function of the ignition protection system according to section
5.10.Defectivesensorsorignitionprotectionsystemshavetobereplacedbeforereconnectionofthe
compressor.
Operation of the compressor without igintion source control is not permitted!
After shutdown by the INT69 EX2, precise error diagnostics and error correction is necessary.
The INT69 EX2 has a restart interlock that can only be interrupted by means of voltage inter-
ruption.
INFO • New compressors are factory-lled with inert gas. Leave this ser-
vice 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.
•Before starting work, obtain written work release.
•Observe national regulations when setting up explosion-protected
systems (within the EU: ATEX Directive 1999/92/EG, EN 60079-14,
EN 60079-17 a.o.).
• Use only tools permitted for explosion-protected systems (within
the EU, in accordance with EN 1127-1).
• Observe work safety rules (TRGS 727, e.g. protective shoes,
clothing etc.)!

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 Setuponanevensurfaceorframewithsufcientload-
bearingcapacity.Onlysetuponaslantafterconsulting
withthemanufacturer.
 Singlecompressorpreferablyonvibrationdamper.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
Donotoperateinanaggressiveand/orcorrosiveatmosphere.
Fig. 7
Fig. 8
Fig.9
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B
A
1 2
3
4
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4
3
2
1
A
B
Tol.-Ang. DIN ISO 2768-mK
Ra Rz
Maß Passung
Freigabe
Alternativbezug:
Baumustergeprüft
Teil inaktiv
Lieferantenzeichnung
-
-
K.-Auftrag:
PL:
Zeichnung ungültig
Entwicklungsstand
Teil keine Serie
120
400
±0.5
über 0.5
bis 6
Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
Unbemaßte Radien:
-
Diese Zeichnung ist unser Eigentum!
Sie darf ohne unsere Genehmigung weder nach-
gebildet, vervielfältigt, oder Dritten Personen zu-
gänglich gemacht werden. Der Nachbau nach
dieser Zeichnung, oder an Hand der nach dieser
Zeichnung hergestellten Gegenstände durch den
Abnehmer oder Dritte ist nicht gestattet.
Wir behalten uns alle Rechte, gemäß DIN ISO 16016
an dieser Zeichnung vor.
Bearb.
Datum
Änderungs-Nr.
Werkstoff:
Ausgangsteil, bzw. Rohteil:
--
Gepr.
Name Datum
19.04.
Werkstückkanten
DIN ISO 13715
Ersatz für:
Ersetzt durch:
Erstellt
2010
Geprüft
-
Kurz
Zone
1/x
Oberflächenbehandlung / Härte:
-
Blatt:
Änderungsbeschreibung
400
Benennung:
±0.8
1000
30 6
-
±0.3
120
30
±0.2
Zeichn.-Nr. Teile-Nr.
Oberflächenangaben ISO 1302
x.xxxx-xxxxx.x
Zust.
Gußtoleranzen:
Gewicht: (kg)
±0.1
Maßstab:
1:1
Wasserwaage
für Indesign
Der Lieferant muß sicherstellen, dass die Ware in
einwandfreiem Zustand angeliefert wird (Korrosions-
schutz, Verpackung für sicheren Transport).
Rz 25
Rz 160
s
25
z y x w u t
0,05
Rz 1,6
0,3
0,7
1,6
2
Rz 16
6,3
Rz 63
Rz 6,3
Rz 12,5
F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage
4|Compressor assembly
 Lighteningprotection:Ifthecompressorissetupoutdoors,
alighteningprotectionconcepthastobeintegrated.
 Sunprotection:Ifthecompressorissetupoutdoors,ithas
tobeprotectedfromdirectsunlight.
Fig.10
Fig. 11
4.3 Setting up
?
4.2 Storage and transport
 Usetransporteyelet.
 Donotliftmanually!
 Useliftinggear!
 Storageat(−30°C)-(+70°C),maximumpermissiblerelativehumi-
dity10%-95%,nocondensation
 Donotstoreinacorrosive,dusty,vaporousatmosphereorinacom-
bustibleenvironment.
Fig. 6
Fig. 5
ATTENTION Fittings (e.g. pipe holders, additional units, mounting parts etc.)
on the compressor are not permissible!

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4.5 Pipes
The pressure and suction shut-off valves have graduated inside
diameterssothatpipesinthecommonmillimeterandinchdimensions
canbeused.Thepipewillbeinsertedmoreorlessdeep,dependingon
thedimension.
The connection diameters of the shut-off valves are designed for
maximumcompressorperformance.The actual required pipe cross
section must be matched to the output. The same applies for
non-return valves.
Fig.12:graduated
internaldiameter
4.4 Pipe connections
ATTENTION An explosive atmosphere must not be present!
Do not solder as long as the compressor is under pressure.
Superheating can damage the valve. Remove the pipe supports
therefore from the valve for soldering and accordingly cool the
valve body during and after soldering.
Only solder using inert gas to inhibit oxidation products (scale).
 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.

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Rigid
fixed point
As short
as possible
4|Compressor assembly
4.7 Operating the shut-off valves
 Beforeopeningorclosingtheshut-offvalve,releasethevalvespindlesealbyapprox.1/4ofaturn
counter-clockwise.
 Afteractivatingtheshut-offvalve,re-tightentheadjustablevalvespindlesealclockwise.
Fig. 14 Fig. 15
Valve spindle seal
Release Tighten
4.6 Laying suction and pressure lines
Fig. 13
A rule of thumb: Alwayslaytherstpipesectionstartingfromtheshut-offvalvedownwards and
parallel to the drive shaft.
ATTENTION Improperly installed pipes can cause cracks and tears which can
result in a loss of refrigerant
INFO Proper layout of the suction and pressure lines directly after the com-
pressor is integral to the smooth running and vibration behaviour of
the system.
a)
a)ForEX-HG44eaintermediateange(height27mm)isoptionalavailable,
 Art-Nr.81194.
 Withthisintermediateangeitispossibletolaythepressurelinedirectlyfrom
thevalvetotheleftorright.

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4|Compressor assembly
DANGER Risk of electric shock! High voltage!
Only carry out work when the electrical system is disconnected
from the power supply!
5 Electrical connection
ATTENTION When attaching accessories with an electrical cable, a minimum
bending radius of 3 x the cable diameter must be maintained for
laying the cable.
Pipeconnection
Pipeconnection
4.8 Operating mode of the lockable service connections
Fig. 16
Opening the shut-off valve:
Spindle:turntotheleft(counter-clockwise)asfarasitwillgo.
—>Shut-offvalvecompletelyopened/serviceconnectionclosed.
Theconnectionwhichcannotbeshutoffisintendedforsafetydevices.
Fig. 17
Opening the service connection
Spindle:Turn1/2-1turntotherightclockwise.
—>Serviceconnectionopened/shut-offvalveopened.
Theconnectionwhichcannotbeshutoffisintendedforsafetydevices.
Serviceconnection
closed
Connection
blocked
Spindle
Connectioncannot
beshutoff
Connectioncannot
beshutoff
Serviceconnection
opened
Spindle Connection
open
Compressor
Compressor
Afteractivatingthespindle,generallytthespindleprotectioncapagainandtightenwith14-16Nm.
Thisservesasasecondsealingfeatureduringoperation.
5| Electrical connection
For systems with long pipes and higher degree of contamination, a lter on the suction-side is
recommended.Thelterhastobebereneweddependingonthedegreeofcontamination(reduced
pressureloss).
4.9 Suction pipe lter