GEA Bock HA12P, Assembly Instructions Manual

Page 1: ...651 08 2018 DGbFEIRu GEA Bock HA12P Assembly instructions 09651 08 2018 Gb Translation of the original instructions HA12P 60 4 HAX12P 60 4 S HA12P 75 4 HAX12P 75 4 S HA12P 90 4 HAX12P 90 4 S HA12P 110 4 S HAX12P 110 4 S ...

Page 2: ...mbly 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 B...

Page 3: ... 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 Fan motor 6 Commissioning 22 6 1 Preparations for start up 6 2 Pressure...

Page 4: ...age INFO Important information or tips on simplifying work WARNING Inadequately qualified personnel poses the risk of accidents the consequence being serious or fatal injury Work on compressors is therefore reserved for personnel which is qualified to work on pressurized refrigerant systems For example a refrigeration technician refrigeration mechatronic engineer As well as professions with compar...

Page 5: ...t 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 and 2014 68 EU Pressure Equipment Directive Commissioning is permissible only if the co...

Page 6: ...rocating compressor with oil pump lubrication Air cooled drive motor Fig 1 Fig 2 Oil sight glass Valve plate Cylinder cover Discharge shut off valve Oil pump Terminal box Suction shut off valve Drive section Dimension and connection values can be found in Chapter 9 Transport eyelet Air guide hood with fan Name plate ...

Page 7: ...cuit 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 filled at the factory pressure g High pressure side 13 Terminal box protection type Observe ...

Page 8: ...vel ATTENTION Compressor operation is possible within the operating limits shown in the diagrams Please note the significance of the shaded areas Thresholds should not be selected as design or continuous operation points Max permissible ambient temperature 45 C Max permissible discharge end temperature 140 C Max permissible switching frequency 8x h A minimum running time of 3 min steady state cond...

Page 9: ...re C Suction gas superheat K Suction gas temperature C Design for other areas on request Unlimited application range Reduced suction gas temperature R404A R507 R22 Fig 5 Fig 6 3 Areas of application Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure ...

Page 10: ...adequate compressor ventilation The compressor must not be in the air stream to another component of the refrigeration system e g condenser The cooling of the drive motor must be reliable guaranteed 4 3 Pipe connections INFO New compressors are factory filled with inert gas Leave this ser vice charge in the compressor for as long as possible and prevent the ingress of air Check the compressor for ...

Page 11: ...dimensions can be used The connection diameters of the shut off valves are rated for maximum compressor output The actual required pipe cross section must be matched to the output The same applies for non return valves Fig 12 graduated internal diameter Fig 13 As short as possible Rigid fixed point 4 5 Laying suction and pressure lines A rule of thumb Always lay the first pipe section starting fro...

Page 12: ...Spindle Connection open Compressor Compressor Before opening or closing the shut off valve release the valve spindle seal by approx 1 4 of a turn counter clockwise After activating the shut off valve re tighten the adjustable valve spindle seal clockwise Fig 14 Fig 15 4 6 Operating the shut off valves Valve spindle seal Release Tighten After activating the spindle generally fit the spindle protect...

Page 13: ...Star delta start 400 V Y Direct start only Elektrischer Anschluss Electrical connection Raccordement électrique Y Niedere Spannung Low voltage Bas voltage Hoh Hi Ha L3 L1 L2 Electrical connection Raccordement électrique Y 96027 11 06 DGbF Niedere Spannung Low voltage Bas voltage Y Hohe Spannung High voltage Haut voltage L3 L1 L2 L3 L1 L2 L1 L2 L3 L1 L2 L3 INFO Connect the compressor motor in accor...

Page 14: ...E EC1 3 M Θ L1 L2 L3 N PE Compressor terminal box BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor FC1 Load circuit safety switches FC2 Control power circuit fuse BP1 Safety chain high low pressure monitoring BP2 Release switch thermostat pressostat QA1 Main switch Fig 18 5 3 Circuit diagramm for direct start 230 V 400 V Y compressor with MP10 ...

Page 15: ...3 Alarm Hochdruck A3 BP2 P PE QA2 1 2 EB1 QA2 3 4 L1 1 L2 1 L3 1 L1 2 N PE GQ1 M 1 QA2 SF1 Control voltage switch EC1 Compressor motor GQ1 Fan motor QA2 Compressor contactor MP10 Electronic trigger unit MP10 EB1 Oil sump heater A1 Alarm motor protection A2 Overheating BT1 BT2 A3 Alarm high pressure ...

Page 16: ...he cause 5 5 Connection of the trigger unit MP10 Temperature monitoring connections Motor winding Terminals 1 2 Thermal protection thermostat Terminals 3 4 Restart prevention Terminals 5 6 INFO The unit has a restart prevention device After you have rectified the fault interrupt the mains voltage This unlocks the restart prevention device and the LEDs H1 and H2 go out INFO Connect the trigger unit...

Page 17: ... connection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or SF1 ON Function check of motor temperature sensor operational ON Function check of hot gas temperature sensor operational ON 3 Interrupt power supply again L1 or SF1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or SF1 OFF OFF ON MP10 is operational ag...

Page 18: ...ol power circuit fuse BP1 Safety chain high low pressure monitoring BP2 Release switch thermostat pressostat QA1 Main switch 0 1 2 3 4 Klemmenkasten Verdichter INT69 G BT1 QA1 FC1 I I I QA2 PE FC1 A1 FC2 SF1 A2 BP1 P PE 11 12 14 L N B1 B2 EC1 3 M Θ BT2 L1 L2 L3 N PE 5 7 Circuit diagramm for direct start 230 V 400 V Y compressor with INT69 G Fig 20 Compressor terminal box ...

Page 19: ...tor QA2 Compressor contactor INT69 G Electronic trigger unit INT69 G EB1 Oil sump heater 5 6 7 8 9 A1 Alarm Motorschutz A2 Übertemperatur BT1 BT2 A3 Alarm Hochdruck A3 BP2 P PE QA2 1 2 EB1 QA2 3 4 L1 L2 L3 L1 1 N PE GQ1 M 1 QA2 A1 Alarm motor protection A2 Overheating BT1 BT2 A3 Alarm high pressure ...

Page 20: ... The relay switching output is executed as a floating changeover contact This electrical circuit operates according to the quiescent current principle i e the relay drops into a the idle position and deactivates the motor contactor even in case of a sensor break or open circuit INFO Connect the trigger unit INT69 G in accordance with the circuit dia gram Protect the trigger unit with a delayed act...

Page 21: ...ical connection Gauge state Relay position 1 Deactivated state 11 12 2 INT69 G switch on 11 14 3 Remove PTC connector 11 12 4 Insert PTC connector 11 12 5 Reset after mains on 11 14 5 11 Fan motor The fan motor for cooling the compressor is already wired in the terminal box The power supply as well as triggering of the compressor contactor should be made in accordance with the basic circuit diagra...

Page 22: ...for test purposes must only be operated with refrigerant Under vacuum the spark over and creepage current distances of the terminal board connection bolts shorten this can result in winding and terminal board damage 6 3 Leak test Carry out the leak test on the refrigerating plant in accordance with EN 378 2 or a corresponding safety standard while always observing the maximum permissible overpress...

Page 23: ...ation system must be properly designed All components must be compatibly rated with each other with regard to output particularly the evaporator and expansion valves Suction gas superheat at the compressor input should be min 7 10 K check the setting of the expansion valve The system must reach a state of equilibrium Particularly in critical systems e g several evaporator points measures are recom...

Page 24: ...ses pressures temperatures function of auxiliary devices such as oil sump heater pressure switch 6 8 Connection of oil level regulator The connection O is provided for installing an oil level regulator A corresponding adapter must be obtained from the trade 6 Commissioning Only use genuine GEA spare parts 7 3 Spare parts recommendation HA12P 60 4 75 4 90 4 110 4 Designation Ref No Ref No Ref No Re...

Page 25: ...ons 7 Maintenance 7 5 Extract from the lubricants table The oil type filled as standard in the factory is marked on the name plate This oil type should be used as a preference Alternatives are stated in the extract from our lubricants table below Refrigerants GEA standard oil types Recommended alternatives HFC e g R404A Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Arctic 46 ...

Page 26: ...2 2 43 25 53 61 60 8 Technical data 1 2 3 2 4 5 Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request The specifications for max power consumption apply for 50 Hz operation For 60 Hz operation the specifications have to be multiplied by the factor 1 2 The max working current remains unchanged Take account of the max operating current max power ...

Page 27: ...6 16 17 Grill_Sa Grass Gneiting Gneiting Buck_Ta Egeler_Ch M Gneiting Layh Keuerleber Layh Layh Layh Layh A Layh MK HA12P 110 4 0850 1 Kunde Customer s t u w x y z Freigabe Approved über above bis up to Teile Nr Part No 208 438 2 66 150 145 J SV A1 162 128 4x 10 192 211 274 310 2 226 2 75 81 F H D1 E K O A DV B1 B L Schwingungsdämpfer Vibration absorbers Änderungen vorbehalten Subject to change wi...

Page 28: ...referenced A partly completed machine may only be put into operation when it has been established that the machine into which the partly completed machine is to be installed conforms to the regulations of the Machinery Directive 2006 42 EC The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery on request The spe...

Page 29: ...any questions about installation operation and accessories please contact our technical service or specialist wholesaler and or our representative The GEA service team can be contacted by phone with a toll free hotline 00 800 800 000 88 or via e mail info gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 11 Service ...

Page 30: ...s a global engineering company with multi billion euro sales and operations in more than 50 countries Founded in 1881 the company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index We live our values Excellence Passion Integrity Responsibility GEA versity ...