GEA Bock HA6, Assembly Instructions Manual

Page 1: ... 09 2013 DGbFEI engineering for a better world GEA Refrigeration Technologies Bock Compressor HA6 Assembly instructions HA6 1080 4 HAX6 1080 4 HA6 1240 4 HAX6 1240 4 HA6 1410 4 HAX6 1410 4 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 2: ... 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 49 7022 9454 0 Fax 49 7022 9454 137 bock gea com www bock de Manufact...

Page 3: ...ect 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 MP 10 5 7 Connecting the trigger unit MP 10 5 8 Functional test of the trigger unit MP 10 5 9 Oil sump heater accessories 5 10 Fan motor 6 Commissioning...

Page 4: ...tential dangers WARNING Refrigerating compressors are pressurised machines and therefore 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 1 1 Identification of sa...

Page 5: ...igerating compressor named in the title is intended for installing 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 only permissible if the compressor has been installed in accordance with these assembly instructions and the entire system into which it is integrated h...

Page 6: ...rive motor on the compressor case Specially or deep cooling with air cooled motor and direct suction at the cylinder Name plate Fig 1 2 1 Brief description Oil sight glass Valve plate Cylinder cover Terminal box Suction shut off valve Dimension and connection values can be found in Chapter 9 Transport eyelet Discharge shut off valve Oil pump Air guide hood with fan Drive section ...

Page 7: ... 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 pressure 12 Oil type filled at the factory g Low pressure side 13 Terminal box protection type HD HP max admissible operating Electrical accessories can change pressure g High pressure side the IP p...

Page 8: ... 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 The compressors are filled at the factory with the fo...

Page 9: ...emperature Evaporation temperature C Condensing temperature C Suction gas superheat K Suction gas temperature C Fig 5 Fig 4 3 Areas of application Design for other areas on request R404A R507 R22 Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure ...

Page 10: ...ons The pipe connections have graduated inside diameters so that pipes with standart millimetre and inch 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 10 graduated internal diameter F E D C B 1 2 3 Alternativbezug Baumuster...

Page 11: ... of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft 4 Compressor assembly 4 3 Pipes Pipes and system components must be clean and dry inside and free of scale swarf and layers of rust and phosphate Only use air tight parts Lay pipes correctly Suitable vibration compensators must be provided to prevent pipes being cracked and broken...

Page 12: ...hut off valve Spindle turn to the left counter clockwise as far as it will go Shut off valve completely opened service connection closed The connection which cannot be shut off is intended for safety devices Fig 15 Opening the service connection Spindle Turn 1 turn clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Servi...

Page 13: ...ided into two parts Partial winding 1 66 and part winding 2 33 This winding division reduces the start up current needed for a part winding start to approx 65 of that for a direct start INFO A mechanical unloaded start with bypass solenoid valve is not required 5 1 Information for contactor and motor contactor selection All protection equipment switching and monitoring devices must comply with the...

Page 14: ...onitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor C1 Fan operating capacitor B1 Release switch thermostat Fig 16 nderung 0 Datum Name Datum Bearb Gepr Norm 1 02 Feb 2009 Kelich 10 Feb 2010 Urspr 2 Ers 3 Ers d 4 X SS Q1 L1 L2 L3 N PE Anschlu asten Verdichter I 66 F1 1 K1 1 2 1 3 4 2 5 6 3 1U1 1V1 1W1 M Y YY M1 R1 2U1 2V1 2W1 I 33 F1 2 K2 1 2 4 3 4 5 5 6 6 PE X...

Page 15: ...part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s S1 Control voltage switch E1 Oil sump heater PW MP10 5 6 7 B CK C MPRESS RS 8 9 Bl 1 Bl 1 M 1 M1 1 K1 9 X3 1 10 2 C1 3 F5 4 T2 N P l L P F3 M S 11 12 13 K1 P F4 14 K1 K1T K2 15 16 K1T P B1 17 18 K1 19 E1 20 L1 1 L2 1 L3 1 L1 2 N PE ...

Page 16: ... this results in opposed rotary fields and results in damage to the motor After the motor starts up via partial winding 1 partial winding 2 must be switched on after a maximum delay of one second Failure to comply can adversely affect the service life of the motor The motor is wired for direct start YY at the factory For part winding start Y YY the bridges must be removed and the motor feed line c...

Page 17: ...W1 U1 V2 U2 W2 L3 L2 L1 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 5 4 Sondermotor Ausführung für Direkt oder Stern Dreieck Anlauf Für den Stern Dreieck Anlauf ist eine mechanische Anlaufentlastung mit Bypass Magnetventil Zubehör erforderlich Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Y Stern Dreieck Anlauf ist nur im Spannungsbereich 230 V möglich Beispiel 230 V Direktstart...

Page 18: ...hain high low pressure monitoring F5 Oil differential pressure monitor C1 Fan operating capacitor B1 Enabling switch thermostat Q1 Main switch nderung 0 Datum Name Datum Bearb Gepr Norm 1 20 Feb 2009 Kelich 10 Feb 2010 Urspr 2 Ers 3 Ers d 4 X SS Q1 L1 L2 L3 Net 400V 50 N PE F1 1 K1 1 2 F1 2 1 Anschlu asten Verdichter 3 4 2 5 6 3 U1 V1 W1 M 3 M1 Y K3 1 2 R1 3 4 5 6 W2 U2 V2 D K2 1 2 4 3 4 5 5 6 6 P...

Page 19: ...lay S D changeover K5T Delay relay start unloader S1 Control voltage switch AL Start unloader E1 Oil sump heater D S MP10 5 6 7 B CK C MPRESS RS 8 9 Bl 1 Bl 1 9 X3 1 M 1 M1 1 10 2 K1 11 3 C1 4 F5 K1 K1 T2 K3 P F3 N P l K4T K3 K2 L 12 M K4T K2 K3 13 S 14 K4T P F4 15 K5T AL 16 17 K5T P B1 18 19 K1 20 E1 21 L1 1 L2 1 L3 1 L1 2 N PE ...

Page 20: ... LED lights red The hot gas side of the compressor can also be protected against overtemperature using a thermal protection thermostat accessory The H2 LED red is provided for the protection function The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause 5 7 Connection of the trigger unit MP10 INFO The unit has a restart prevention device After you hav...

Page 21: ...onnection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or S1 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 S1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or S1 OFF OFF ON MP 10 is operational again ...

Page 22: ...and depending on the pressure and ambient temperature refrigerant diffuses into the compressor s lubricating oil This reduces the oil s lubricating ability When the compressor is started the refrigerant contained in the oil evaporates due to the decline in pressure This can result in oil foaming and oil exodus which can result in oil hammer in certain circumstances Operation mode The oil sump heat...

Page 23: ...ation side The compressor has undergone trials in the factory and all functions have been tested There are therefore no special running in instructions Check the compressor for transport damage 6 2 Pressure strength test DANGER Bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximum permissible overpressure of the compressor must n...

Page 24: ...pen before starting the compressor Check that the safety and protection devices pressure switch motor protection electrical con tact protection measures etc are functioning properly Switch on the compressor and let it run for at least 10 minutes Check the oil level The oil must be visible in the sight glass ATTENTION If larger quantities of oil have to be topped up there is a risk of oil impact ef...

Page 25: ... then approx every 3 years or 10 000 12 000 operating hours Dispose of used oil according to the regulations observe national regulations Annual checks Oil level leak tightness running noises pressures temperatures function of auxiliary devices such as oil sump heater pressure switch WARNING Before starting any work on the compressor Switch off the compressor and secure it to prevent a restart Rel...

Page 26: ...n the name plate This oil type should be used as a preference Alternatives are stated in the extract from our lubricants table below Refrigerants Bock standard oil types Recommended alternatives HFC e g R404A R507 Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Arctic 46 Sunoco Suniso SL 46 Texaco Capella HFC 55 HCFC e g R22 Fuchs Reniso SP 46 Fuchs Reniso SP 32 BP Energol LPT ...

Page 27: ...ding ratio 66 33 L M 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 50Hz operation For 60Hz 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 consumption for design of f...

Page 28: ...n damper Ansicht X Anschlußmöglichkeit für Ölspiegelregulator View X Possibility of connection of oil level regulator Vue X Raccord pour régulateur de niveau d huile Dreilochanschluß für TRAXOIL 3xM6x10 Three hole connection for TRAXOIL 3xM6x10 Raccord à trois rainures pour TRAXOIL 3xM6x10 z Dreilochanschluß für ESK AC R CARLY 3xM6x10 Three hole connection for ESK AC R CARLY 3xM6x10 Raccord à troi...

Page 29: ...e switch OIL 7 16 UNF D Connection oil pressure switch LP 7 16 UNF D1 Connection oil return from oil separator 1 4 NPTF E Connection oil pressure gauge 7 16 UNF F Oil drain M22 x 1 5 H Oil charge plug M22 x 1 5 J Oil sump heater accessories M22 x 1 5 K Sight glass L Connection thermal protection thermostat 1 8 NPTF N Connection capacity controller M45 x 1 5 O Connection oil level regulator 3 x M6 ...

Page 30: ...ssor HA6 complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006 42 EC Applied harmonised standard EN 12693 2008 and the corresponding standards 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 Direc...

Page 31: ...r specialist wholesaler and or our representative The Bock service team can be contacted by phone with a toll free hotline 00 800 800 000 88 or via e mail bock gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany We also provide information on the Internet at www bock de For example under the Documentation link you will find Technical information Product information Prod...

Page 32: ...st providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index 09912 09 2013 DGbFEI GEA Group AG All rights reserved GEA Refrigeration Technologies GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 bock gea com www bock de We live our values Excellence Passion Integrity Responsibility GEA versity ...