GEA GEA Bock HG66e Series User manual

GEA Bock HG66e
HG66e/1340-4
HG66e/1540-4
HG66e/1750-4
HG66e/2070-4
HGX66e/1340-4
HGX66e/1540-4
HGX66e/1750-4
HGX66e/2070-4
HG66e/1340-4 S
HG66e/1540-4 S
HG66e/1750-4 S
HG66e/2070-4 S
HGX66e/1340-4 S
HGX66e/1540-4 S
HGX66e/1750-4 S
HGX66e/2070-4 S
Assembly instructions
96446-04.2019-Gb
Translation of the original instructions

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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 compres-
sor is installed.
GEA Bock GmbH
72636 Frickenhausen
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Phone [phone]
Fax [phone]
[email protected]
www.gea.com
Manufacturer
Contact

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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
 4.9 Suctionpipelter
5 Electrical connection 15
5.1 Information for contactor and motor contactor selection
5.2 Standard motor, design for direct or partial winding start
5.3 Basic circuit diagram for partial winding start with standard motor
5.4 Special motor: design for direct or star-delta start
5.5 Basic circuit diagram for star-delta start 230 V ∆/ 400 V Y
5.6 Electronic trigger unit INT69 G
5.7 Connecting of the trigger unit INT69 G
5.8 Functional 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 integrity test
6.3 Leak test
6.4 Evacuation
6.5 Refrigerant charge
6.6 Start-up
6.7 Avoid slugging
7 Maintenance 28
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 30
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 incorporation 36
12 Service 37
Contents Page

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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
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:

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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,2014/68/EU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!

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2|Product description
• Semi-hermetic six-cylinder reciprocating compressor with suction-gas cooled drive motor.
• The stream of refrigerant sucked out of the evaporator flows 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
Dimension and connection values can be found in Chapter 10
Cylinder
cover
Terminal box Suction
shut-off valve
Transport
eyelet
Name plate
Motor section
Drive section
Valve plate
Discharge
shut-off valve
Oil pump
Oil sight glass

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2|Product description
2.2 Name plate (example)
2.3 Type key (example)
SE 55IP 65
BB12345-A001
HGX66e/2070-4
GEA Bock GmbH
72636 Frickenhausen, Germany
/
HG 66 e 2070 -4 SX
¹) HG - Hermetic Gas-Cooled (suction gas-cooled) for the normal- / air conditioning applications
²) X - Ester oil charge (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: 335,0 AY: 196,0 A
180,0
217,2
380-420 Y/YY
440-480 Y/YY
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 pressur e12 Oiltypelledatthefactory
(g) Low pressure side 13 Terminal box protection type
HD (HP): Max. admissible operating Electrical accessories can change
pressur e(g) High pressure side the IP protection class!
Observe the limits of application
diagrams!
50 Hz
}
60 Hz
}
Fig. 2

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3|Areas of application
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.
- Additional fans (accessories) can be used for additional cooling.
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. Max. 60 Hz.
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
 Thecompressorsarelledatthefactorywiththefollowingoiltype:
- für R134a, R404A/R507, R407C, R407F FUCHS Reniso Triton SE 55
- für 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. HGX66e/2070-4).
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
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.
1,9 Ltr.
Oil level
Fig. 3
~
~

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3|Areas of application
Maximum admissible operating
pressure (LP/HP)1): 19/28 bar
Maximum admissible
frequency:60Hz
1) LP = Low pressure
HP = High pressure
Fig. 5
Fig. 6
Fig. 4
Unlimited application range
Supplementary cooling or
reduced suction gas temperature
Supplementary cooling and
reduced suction gas temperature
Motor version S
(more powerful motor)
Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Suction gas temperature (°C)
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
EGD HG66e+88e
R134a
20
10
0
-10
-20
-30
50
70
t (°C)
o
t (°C)
c
-5 12,5
-25
R407C
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
66
-35
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
R22
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
? t
oh
< 20 K
t = 20 °C
oh
58
-5 7,5-45
R404A/R507
40
10
10
10
30
60
40
?t
Oh
<20K
t = 20 °C
Oh
20
?t
Oh
< 20 K
R513A
R448A/R449A
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
40
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
10
?t
Oh
< 20 K
?tOh = 20 K
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
EGD HG66e+88e
R134a
20
10
0
-10
-20
-30
50
70
t (°C)
o
t (°C)
c
-5 12,5
-25
R407C
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
66
-35
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
R22
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
? t
oh
< 20 K
t = 20 °C
oh
58
-5 7,5-45
R404A/R507
40
10
10
10
30
60
40
?t
Oh
<20K
t = 20 °C
Oh
20
?t
Oh
< 20 K
R513A
R448A/R449A
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
40
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
10
?t
Oh
< 20 K
?tOh = 20 K
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
EGD HG66e+88e
R134a
20
10
0
-10
-20
-30
50
70
t (°C)
o
t (°C)
c
-5 12,5
-25
R407C
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
66
-35
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
R22
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
? t
oh
< 20 K
t = 20 °C
oh
58
-5 7,5-45
R404A/R507
40
10
10
10
30
60
40
?t
Oh
<20K
t = 20 °C
Oh
20
?t
Oh
< 20 K
R513A
R448A/R449A
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
40
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
10
?t
Oh
< 20 K
?tOh = 20 K
R404A/R507
R134a
R22

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3|Areas of application
Maximum admissible operating
pressure (LP/HP)1): 19/28 bar
Maximum admissible
frequency:60Hz
1) LP = Low pressure
HP = High pressure
Unlimited application range
Supplementary cooling or
reduced suction gas temperature
Supplementary cooling and
reduced suction gas temperature
Motor version S
(more powerful motor)
Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Suction gas temperature (°C)
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
EGD HG66e+88e
R134a
20
10
0
-10
-20
-30
50
70
t (°C)
o
t (°C)
c
-5 12,5
-25
R407C
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
66
-35
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
R22
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
? t
oh
< 20 K
t = 20 °C
oh
58
-5 7,5-45
R404A/R507
40
10
10
10
30
60
40
?t
Oh
<20K
t = 20 °C
Oh
20
?t
Oh
< 20 K
R513A
R448A/R449A
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
40
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
10
?t
Oh
< 20 K
?tOh = 20 K
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
EGD HG66e+88e
R134a
20
10
0
-10
-20
-30
50
70
t (°C)
o
t (°C)
c
-5 12,5
-25
R407C
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
66
-35
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
R22
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
? t
oh
< 20 K
t = 20 °C
oh
58
-5 7,5-45
R404A/R507
40
10
10
10
30
60
40
?t
Oh
<20K
t = 20 °C
Oh
20
?t
Oh
< 20 K
R513A
R448A/R449A
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
40
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
10
?t
Oh
< 20 K
?tOh = 20 K
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
EGD HG66e+88e
R134a
20
10
0
-10
-20
-30
50
70
t (°C)
o
t (°C)
c
-5 12,5
-25
R407C
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
66
-35
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
R22
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
? t
oh
< 20 K
t = 20 °C
oh
58
-5 7,5-45
R404A/R507
40
10
10
10
30
60
40
?t
Oh
<20K
t = 20 °C
Oh
20
?t
Oh
< 20 K
R513A
R448A/R449A
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
40
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
10
?t
Oh
< 20 K
?tOh = 20 K
R407C
R448A/R449A
Fig. 8
Fig. 9
R513A
Fig. 7
Designforotherareasonrequest
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
EGD HG66e+88e
R134a
20
10
0
-10
-20
-30
50
70
t (°C)
o
t (°C)
c
-5 12,5
-25
R407C
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
66
-35
t = 20 °C
oh
-5 12,5
?t
oh
< 20 K
R22
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
? t
oh
< 20 K
t = 20 °C
oh
58
-5 7,5-45
R404A/R507
40
10
10
10
30
60
40
?t
Oh
<20K
t = 20 °C
Oh
20
?tOh < 20 K
R513A
R448A/R449A
20
10
0
-10
-20
-30
-40
10
20
30
50
60
70
t (°C)
o
t (°C)
c
t = 20 °C
oh
-5 12,5
?toh < 20 K
40
30
40
60
80
90
-20 -10 100 20 30 t (°C)
o
t (°C)
c
82
-30
50
70
12,5 25
20 t = 20 °C
Oh
10
?tOh < 20 K
?tOh = 20 K
Requiredminimumsuperheating
∆tOh = 20 K