GEA HG22e/125-4 User manual

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engineering for a better world
GEA Compressor HG22e
Assembly instructions
HG22e/125-4 HG22e/125-4 S HGX22e/125-4 HGX22e/125-4 S
HG22e/160-4 HG22e/160-4 S HGX22e/160-4 HGX22e/160-4 S
HG22e/190-4 HG22e/190-4 S HGX22e/190-4 HGX22e/190-4 S
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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
Telephone [phone]
Fax [phone]
[email protected]
www.gea.com
Manufacturer
Contact
Contents Page
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

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Contents Page
3 Areas of application 8
3.1 Refrigerants
3.2 Oil charge
3.3 Limits of application
4Compressor assembly 10
4.1 Storage and transport
4.2 Setting up
4.3 Pipe connections
4.4 Pipes
4.5 Laying suction and pressure lines
4.6 Operating the shut-off valves
4.7 Operating mode of the lockable service connections
5 Electrical connection 13
5.1 Information for contactor and motor contactor selection
5.2 Connection of the driving motor
5.3 Circuit diagram for direct start 230 V Δ/ 400 V Y --> with MP10
5.4 Electronic trigger unit MP10
5.5 Connection of the electronic trigger unit MP10
5.6 Functional test of the electronic trigger unit MP10
5.7 Circuit diagram for direct start 230 V Δ/ 400 V Y --> with INT69 G
5.8 Electronic trigger unit INT69 G
5.9 Connection of the electronic trigger unit INT69 G
5.10 Functional test of the electronic trigger unit INT69 G
5.11 Start unloader
6 Commissioning 22
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 slugging
6.8 Connection of oil level regulator
7 Maintenance 24
7.1 Preparation
7.2 Work to be carried out
7.3 Spare parts recommendation
7.4 Accessories
7.5 Extract from the lubricants table
7.6 Decommissioning
8 Technical data 26
9 Dimensions and connections 27
10 Declaration of installation 28
11 Service 29

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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,97/23/ECPressureEquipment
Directive and 2006/95/EC – Low Voltage 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 two-cylinder reciprocating compressor with oil pump lubrication.
• Suction gas cooled drive motor.
2.1 Short description
Name plate
Fig. 1
Fig. 2
Oil sight glass
Cylinder cover
Oil pump
Suction
shut-off valve
Drive section
Motor section
Dimension and connection values can be found in Chapter 9
Transport eyelet
Valve plate
Discharge
shut-off valve
Terminal box

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2|Product description
2.2 Name plate (example)
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
pressure (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
Observe the limits of application Electrical accessories can change
diagrams! the IP protection class!
50 Hz
}
60 Hz
}
/
HG 22 e 190-4 SX
2.3 Type key (example)
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)
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)
Typschild (Beispiel)
1
2
3
4
513
12
7
11
6
10
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9
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Stillstandsdruck
Saugseite
HD (HP): max. zulässiger Betriebsdruck
Hochdruckseite
Einsatzgrenzendiagramme beachten!
50 Hz
60 Hz
6 Spannung, Schaltung, Frequenz
7 Nenndrehzahl
8 Hubvolumen
9 Spannung, Schaltung, Frequenz
10 Nenndrehzahl
11 Hubvolumen
12 Werkseitig eingefüllte Ölsorte
13 Schutzart Klemmenkasten
HGX22e/190-4
SE 55
AS35830A001
13,8/8,0A
69A 40A
66
GEA Bock GmbH
72636 Frickenhausen, Germany
Fig. 3

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3|Areas of application
Thecompressorsarelledatthefactorywiththefollowingoiltype:
- for R134a, R404A/R507, R407C 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. HGX22e/190-4).
3.1 Refrigerants
• HFKW / HFC: R134a, R404A/R507, R407C
• (H)FCKW / (H)CFC: R22
3.2 Oil charge
INFO For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.5
INFO For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.5
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! Fig. 4
max.
min.
0,6Ltr.
oil level ~
~
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8x/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.
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.
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

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Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Suction gas temperature (°C)
3|Areas of application
Design for other
areasonrequest
R134a
R407C
R404A/R507
R22
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Unlimited application range
Supplementary cooling or
reduced suction gas temperature
Supplementary cooling and
reduced suction gas temperature
Motor version S
(more powerful motor)
1) LP = Low pressure
HP = High pressure
Max. permissible operating
pressure (LP/HP)1): 19/28 bar

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4|Compressor assembly
 Setuponanevensurfaceorframewithsufcientload-
bearing capacity.
Single compressor preferably on vibration damper.
Duplex and parallel circuits always rigid.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
Do not use in a corrosive, dusty, damp atmosphere or a
combustible environment.
Fig. 11
Fig. 12
Fig. 13
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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
4.2 Setting up
?
4.1 Storage and transport
Use transport eyelet.
Do not lift manually!
Use lifting gear!
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 com-
bustible environment.
Fig. 10
Fig. 9
4.3 Pipe connections
ATTENTION 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).
ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
INFO Newcompressorsarefactory-lled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.