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
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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
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14
2.3 Name plate (example)
4 e