GEA Bock EX-HG88e Series User manual

EX-HG88e/2400-4 3G EX-HGX88e/2400-4 3G EX-HG88e/2400-4 3G HC
EX-HG88e/2735-4 3G EX-HGX88e/2735-4 3G EX-HG88e/2735-4 3G HC
EX-HG88e/3235-4 3G EX-HGX88e/3235-4 3G EX-HG88e/3235-4 3G HC
EX-HG88e/2400-4 S 3G EX-HGX88e/2400-4 S 3G EX-HG88e/2400-4 S 3G HC
EX-HG88e/2735-4 S 3G EX-HGX88e/2735-4 S 3G EX-HG88e/2735-4 S 3G HC
EX-HG88e/3235-4 S 3G EX-HGX88e/3235-4 S 3G EX-HG88e/3235-4 S 3G HC
GEA Bock EX-HG88e
Assembly instructions
96403-08.2019-Gb
Translation of the original instructions
Device category 3 G
acc. to directive 2014/34/EU

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Contents Page
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
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 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 21
 5.1 Informationforcontactorandmotorcontactorselection
 5.2 Terminalcrosssectionforleads
 5.3 Connectionofthedrivemotor
 5.4-5.6Circuitdiagram
 5.7 ElectronictriggerunitINT69GEx
 5.8 ConnectionoftheelectronictriggerINT69GEx
 5.9 FunctionaltestoftheelectronictriggerunitINT69GEx
6 Commissioning 32
 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 35
 7.1 Preparation
 7.2 Worktobecarriedout
 7.3 Sparepartrecommendation
 7.4 Screwconnections
 7.5 Decommissioning
8 Accessories 37
 8.1 Capacityregulation
 8.2 Oilsumpheater
 8.3 OildifferentialpressuresensorINT250Ex
 8.4 Oilseparator
9 Technical data 41
10 Dimensions and connections 42
  CerticateofConformity 44
  IECExCerticateofConformity 47
Service 50

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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engi-
neer.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
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.
1.3 Safety instructions
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 surface
of the compressor must be avoided with certainty (e.g. pneumati-
cally moved dust, owing uids, direct ventilation, belt drives,
brushes, foils, etc.).
• Perform installation work only if no damage, leaks and/or appear-
ances 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
Terminalbox
DimensionandconnectionvaluescanbefoundinChapter10.
Drivesection
• Semi-hermeticeight-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.
Motorsection
Valveplate
Transporteyelet
Discharge
shut-offvalve
Oilpump
Suction
shut-offvalve
Nameplate
Oilsightglass
Cylindercover

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2|Product description
2.2 Ignition protection concept
Thecompressordescribedintheseinstructionsforassemblyissuitableforuseindevicecategory3
forexplosivegasatmospheresuptotemperatureclassT3andexplosionhazardsubgroupIIB/IICin
accordancewithDirective2014/34/EU.
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working
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.
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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Equipment Typeofignitionprotection
Terminalbox(Offshore) Exe
Terminalbox(Onshore) ExnA
Terminalboard ExnA
Throughterminalsintheterminalbox Exe
Cable/lineentrancesintheterminalbox(accessories) Exe
MagneticcoilLR Exemb
Oilsumpheater Exd
OildifferentialpressuresensorINT250Ex ExnC
HotgasPTCsensor ExnA
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. 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.

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337,0
281,0
551A
EX-HGX88e/3235-4 3G
Tamb: / Tamb with capacity regulator:
475A
[-20°C]-[60°C] / [-20°C]-[50°C]
AY09529A040
131,0 A
Ex d e mb nA nC IIC T3 Gc / IECEx EPS 16.0018 X
II 3G Ex d e mb nA nC IIC T3 Gc / EPS 16 ATEX 1042 X
2.4 Type key (example)
1)HG-HermeticGas-Cooled(suctiongas-cooled)
2)X- Esteroilfilling(HFKWrefrigerant,e.g.R134a,R404A,R507,R407C)
3)e - Additionaldeclarationfore-Seriecompressors
4)S- Morepowerfulmotor,e.g.airconditioningapplications
5)forexplosion-endangeredatmospherescausedbygases,vapoursormists
/
HG
EX 88 e 3235-
-4 SX 3G
Devicecategory3 5)
Motorvariant4)
Numberofpoles
Sweptvolume
e-series3)
Numberofcylinders
Size
Esteroillling2)
Series1)
Ex-design
Fig. 2
1
2
4
3
5
6
7
8
9
10
11
13
14
12
15
2.3 Name plate (example)
Observe the limits of application diagrams!
1 Typedesignation
2 Machinenumber
3 Typecode
4 Maximumoperatingcurrent
5 Startingcurrent(rotorblocked)
Y: Partwinding1
 YY: Partwinding1and2
6 ND(LP):max.admissibleoverpressure
 Lowpressureside
 HD(HP):max.admissibleoverpressure
 Highpressureside
50 Hz
}
60 Hz
}
7 Voltage,circuit,frequency
8 Nominalrotationspeed
9 Displacement
10 Voltage,circuit,frequency
11 Nominalrotationspeed
12 Displacement
13 Oiltypelledatthefactory
14 Terminalboxprotectiontype
15 Permissibleambienttemperature
Electrical accessories can change
the IP protection class!
2|Product description