GEA HG6/1080-4 User manual

GEA Compressor HG6
HG6/1080-4 HG6/1080-4 S
HG6/1240-4 HG6/1240-4 S
HG6/1410-4 HG6/1410-4 S
HGX6/1080-4 HGX6/1080-4 S
HGX6/1240-4 HGX6/1240-4 S
HGX6/1410-4 HGX6/1410-4 S
Assembly instructions
09971-06.2016-Gb
Translation of the original instructions

2
D
GB
F
E
I
Ru
09971-06.2016-DGbFEIRu
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

D
GB
F
E
I
Ru
3
09971-06.2016-DGbFEIRu
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
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 Standard motor, design for direct or partial winding start
5.3 Basic circuit diagram for part 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 with special motor
5.6 Electronic trigger unit MP10
5.7 Connecting the trigger unit MP10
5.8 Functional test of the trigger unit MP10
5.9 Oil sump heater (accessories)
6 Commissioning 23
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 25
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 27
9 Dimensions and connections 28
10 Declaration of installation 30
11 Service 31

4
D
GB
F
E
I
Ru
09971-06.2016-DGbFEIRu
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:

D
GB
F
E
I
Ru
5
09971-06.2016-DGbFEIRu
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).
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!

6
D
GB
F
E
I
Ru
09971-06.2016-DGbFEIRu
Fig. 1
Valve plate
Terminal box
Dimension and connection values can be found in Chapter 9
Discharge
shut-off valve
Suction
shut-off valve
Drive section
Motor
section
Fig. 2
2|Product description
• Semi-hermetic four-cylinder reciprocating compressor with suction-gas cooled drive motor.
• Flange-mounted drive motor on the compressor case.
• Preferred application range: normal refrigerating and air-conditioning.
2.1 Short description
Transport eyelet
Oil pump
Cylinder cover
Name plate
Oil sight glass

D
GB
F
E
I
Ru
7
09971-06.2016-DGbFEIRu
2|Product description
Fig. 3
2.2 Name plate (example)
2.3 Type key (example)
¹) HG - Hermetic Gas-cooled (suction gas-cooled)
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
Size
Oil charge ²)
Series ¹)
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 e 12 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
}
/
HG 61410-4 XS

8
D
GB
F
E
I
Ru
09971-06.2016-DGbFEIRu
INFO For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.5
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.
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.
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
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. HGX6/1410-4).
3.1 Refrigerants
• HFKW / HFC: R134a, R404A/R507, R407C
• (H)FCKW / (H)CFC: R22
3.2 Oil charge
Fig. 4
max.
min.
2,0 Ltr.
oil level ~
~
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!

D
GB
F
E
I
Ru
9
09971-06.2016-DGbFEIRu
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
R22
Fig. 5
Fig. 6
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)
R404A/R507
1
2
Fig. 7
HGX6/1410-4 S
max. evaporating temperature
t0 = 2 °C
HGX6/1410-4
max. evaporating temperature
t0 = -7 °C
1
2
Max. permissible operating
pressure (LP/HP)1): 19/28 bar
1) LP = Low pressure
HP = High pressure

10
D
GB
F
E
I
Ru
09971-06.2016-DGbFEIRu
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
4.3 Pipe connections
F
E
D
C
B
A
1 2
3
4
F
E
D
C
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
4.2 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
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.
ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
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).