GEA Bock HGZ7 Series, Assembly Instructions Manual

Page 1: ...slation of the original instructions HGZX7 1620 4 R404A R507 HGZX7 1620 4 R410A HGZX7 1860 4 R404A R507 HGZX7 1860 4 R410A HGZX7 2110 4 R404A R507 HGZX7 2110 4 R410A HGZX7 1620 4 R448A R449A HGZ7 1620 4 R22 HGZX7 1860 4 R448A R449A HGZ7 1860 4 R22 HGZX7 2110 4 R448A R449A HGZ7 2110 4 R22 ...

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 info gea com www gea com Manufactu...

Page 3: ...system optional design 5 6 Pipe connections 5 7 Pipes 5 8 Laying suction ans pressure lines 5 9 Operating the shut off valves 5 10 Operating mode of the lockable service connections 6 Electrical connection 23 6 1 Information for contactor and motor contactor selection 6 2 Circuit diagram for part winding start 6 3 Standard motor design for direct or partial winding start 6 4 Electronic trigger uni...

Page 4: ...rtant 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 comparable training...

Page 5: ...n potentially explosive environments These assembly instructions describe the standard version of the compressor named in the title manufactured 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 2014 68 EU Pressure Equipment Directive Commissioning is permissible only if the compressor has bee...

Page 6: ...ompressor with intermediate pressure shut off mounted and insulated 2 1 Short description standard version Dimension and connection values can be found in Chapter 10 Oil pump Suction shut off valve Name plate Notice CE certification for piping only for HGZ7 2110 4 Oil sight glasses Charge plug Valve plate Discharge shut off valve Intermediate pressure line Fig 1 Fig 2 Terminal box Intermediate pre...

Page 7: ... Fig 3 Liquid subcooler expansion valve solenoid valve filter drier and a sight glass mounted directly to the compressor piped and insulated Fig 4 2 3 Short description optional version mounted Dimension and connection values can be found in Chapter 10 Sight glass 2 2 Short description optional version enclosed Fig 3 Liquid subcooler Filter drier Solenoid valve Fig 4 Expansion valve ...

Page 8: ...0 Voltage circuit frequency 11 Nominal rotation speed 12 Displacement VND low pressure stage VHD high pressure stage 13 Oil type filled at the factory 14 Terminal box protection type Electrical accessories can change the IP protection class 2 Product description HGZ 7 2110 4 X Fig 5 2 4 Name plate example 2 5 Type key example 1 HGZ Hermetic gas cooled suction gas cooled two stage 2 X Ester oil fil...

Page 9: ... 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 When op...

Page 10: ...ressure HP high pressure tO Evaporation temperature C tC Condensing temperature C tOh suction gas superheat K Unlimited application range Fig 7 Fig 8 R404A R507 Anwendungsbe tc t0 Dtoh Verdampfungstemper Verflüssigungstemper Sauggasüberhitzung 20 30 40 50 60 20 30 40 50 60 t C o t C c 66 Dtoh 10K 10 30 50 60 60 50 30 40 20 10 t C o t C c 70 20 40 70 R448A R449A toh 10K R448A R449A ...

Page 11: ...P HP 1 19 19 28 bar Design for other areas on request 3 Areas of application 1 LP low pressure MP intermediate pressure HP high pressure tO Evaporation temperature C tC Condensing temperature C tOh suction gas superheat K Unlimited application range Fig 9 Fig 10 R410A R22 ...

Page 12: ...p of the diagram by approximately calculating the subcooling temperature arising in the relevant operating conditions t0 tc Diagrams for determining the subcooling temperature at the output of the liquid subcooler 3 4 Subcooling temperature tU Subcooling temperature at the subcooler outlet FUA tO Evaporating temperature Fig 11 Fig 12 ...

Page 13: ...D GB F E 13 09726 06 2018 DGbF 3 Areas of application tU Subcooling temperature at the subcooler outlet FUA tO Evaporating temperature Fig 13 Fig 14 ...

Page 14: ...ers 5 and compressed to the final pressure Liquid subcooler system The liquid subcooler system consists of the components liquid subcooler plate heat exchanger 6 expansion valve 7 sight glass 8 solenoid valve 9 filter drier 10 After the refrigerant reciever 15 the liquid line will be splitted into two lines Line A leads through the liquid subcooler 6 and the subcooled refrigerant flows to the evap...

Page 15: ...r drier 11 Damper pressure line 12 Oil separator 13 Non return valve 14 Condenser 15 Refrigerant receiver 16 Filter drier 17 Solenoid valve 18 Sight glass 19 Expansion valve evaporator 20 Evaporator 21 Liquid separator 22 Damper suction line 23 Filter suction line LP Low pressure MP Intermediate pressure HP High pressure FUE Liquid subcooler inlet FUA Liquid subcooler outlet 4 1 Two stage refriger...

Page 16: ...ctory 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 transport damage before starting any work 5 1 Storage and transportation 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 ...

Page 17: ...serve manufacturer s instructions INFO The points listed here represent general guidelines and information on how to pipe and connect the subcooler unit To perform this work technical knowledge and skill as well as proof of a hard soldering test certificate in accordance with DIN EN 13133 is required INFO Use only suitable hard solder and flux Solder under an inert gas atmosphere when copper compo...

Page 18: ...sation line for expansion valve 7 16 UNF W Refrigerant injection connection M22 x 1 5 X Schrader connection for intermedie pressure gauge 7 16 UNF Y Position of temperature sensor unpainted Fig 22 Intermediate pressure line Shown without insulation Y R X W Intermediate pressure chamber ...

Page 19: ... FUE Fig 23 5 4 Installation example liquid subcooler with accessories GB INFO General notes Sensor lines wires etc should not be attached with cable binders directly to pipes or frames otherwise the thin pipes may be worn through It is better to run them through spiral protective tubes If the compressor will be set up outside UV resistant materials should be used X Y Line A to the evaporator Dia ...

Page 20: ...ly ATTENTION Damage possible Superheating can damage the valve Remove the pipe supports therefore from the valve for soldering Only solder using inert gas to inhibit oxidation products scale INFO A soldering suppot for tube diameter 54 mm is mounted to the suction shut off valve of the compressor A soldering support for tube diameter 2 1 8 accompanies the compressor Liquid subcooler expansion valv...

Page 21: ...racked and broken by severe vibrations Ensure a proper oil return Keep pressure losses to an absolute minimum A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft ATTENTION Improperly installed pipes can cause cracks and tears the result being a loss of refrigerant INFO Proper layout of the suction and discharge lines directly...

Page 22: ...ckwise 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 30 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service connection closed Connection block...

Page 23: ...ected from the power supply 6 Electrical connection All protection devices and switching or monitoring units must be fitted in accordance with the local safety regulations and established specifications e g VDE as well as with the manufacturer s infor mation Motor protection switches are required Motor contactors feed lines fuses and motor protection switches must be rated on the basis of the maxi...

Page 24: ...re monitor SF1 Control voltage switch BT3 Release switch thermostat QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 Οnderung 5HGZ76e 0 Datum Name Datum Bearb Gepr Norm 1 20 02 2009 bauknecht 08 03 2017 Urspr 2 Ers f 3 Ers d 4 X SS Anschlußkasten Verdichter BT1 MP10 QA1 L1 L2 L3 N PE FC1 1 I I I 1 2 QA2 1 3 4 2 5 6 3 1U1 1V1 1W1 PE 2U1 2V1 2W1 FC1 2 I I I 1 2 QA3 4 3 4 5 5 6 6...

Page 25: ...ooler QM1 Solenoid valve intermediate cooler EC1 Compressor motor BT1 Cold conductor PTC sensor BT2 Thermal protection thermostat PTC sensor K1 Auxiliary contactor safety chain HGZ7 HGZ76e 5 6 7 BOCK COMPRESSORS 8 9 Bl 6HGZ76e Bl 6HGZ76e BP1 P Öl QA2 12 T2 13 N 14 L 15 M 16 S BP2 P 17 18 19 QA2 BP3 P 20 QA2 KF1 QA3 5HGZ76e 7 21 22 KF1 5HGZ76e 7 23 24 QA2 25 EB1 26 L1 1 L2 1 L3 1 L1 2 N PE BT3 QM1 ...

Page 26: ...h bypass solenoid valve is not required ATTENTION Failure to do 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 Compressors with this marking are suitable for direct or partial winding...

Page 27: ...H1 and H2 go out INFO Connect the trigger unit MP10 in accordance with the circuit diagram Protect the trigger unit with a delayed action fuse F of max 4 A In order to guarantee the protection function install the trigger unit as the first element in the control power circuit 6 4 Electronic trigger unit MP10 The compressor motor is fitted with cold conductor temperature sensors PTC connected to th...

Page 28: ...nnection 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 MP10 is operational again Be...

Page 29: ...sor starts up the refrigerant contained in the oil evaporates out throught the reduction in pressure The consequences can be foaming and migration of the oil causing oil shocks under certain circumstances Operation The oil sump heater operates when the compressor is at a standstill When the compres sor starts up the oil sump heater switches off again automatically Connection The oil sump heater mu...

Page 30: ...da tory on the installation side ATTENTION Do not start the compressor if it is under vacuum Do not apply any voltage even 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 7 3 Leak test Carry out the leak test on the refrigerating pl...

Page 31: ...such as goggles and protective gloves ATTENTION Avoid overfilling the system with refrigerant To avoid shifts in concentration zeotropic refrigerant blends must always only be filled into the refrigerating plant in liquid form Do not pour liquid coolant through the suction line valve on the compressor It is not permissible to mix additives with the oil and refrigerant 7 6 Start up WARNING Ensure t...

Page 32: ...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 When selecting the evaporator expansion valve pay attention to correction factors for liquid subcoolin...

Page 33: ...ent air from infiltrating the system After maintenance has been performed Connect safety switch Evacuate compressor Release switch lock 8 2 Work to be carried out In order to guarantee optimum operational reliability and service life of the compressor we recommend carrying out servicing and inspection work at regular intervals Oil change not mandatory for factory produced series systems for field ...

Page 34: ... compressors are divided into an LP and an HP compressor stage Different valve plate designs are required because of the different ducts in the individual compressor stages Fig 34 WARNING Thevalveplateshavebeenfittedwithsafetyboltstopreventanyconfusion The safety bolts engage in the corresponding bores on the cylinder heads the safety bolts must not be removed Ventilplatte LP Stufe Ventilplatte HP...

Page 35: ...ulations 8 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 Available accessories can be found on the Internet at www gea com 8 7 Accessories Refrigerants GEA standard oil types Recommended alternatives HFKW e g R404A R407...

Page 36: ...ces A ll specifications are based on the average of the voltage range 380 420 V Y YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW Winding ratios 50 50 HGZ7 1620 4 6 93 7 46 9 112 5 56 2 50 27 0 175 269 294 35 1 3 8 54 2 1 8 4 5 HGZ7 1860 4 107 6 53 8 129 1 64 6 55 30 0 175 269 290 HGZ7 2110 4 122 4 61 2 146 9 73 5 65 36 0 232 357 288 Type No of cylinders 50 Hz 1450 rpm LP HP 60 Hz 1740 rpm LP HP Voltage M...

Page 37: ... has to ensure the delivery of parts Transport 13 01 15 Wurster 0g Ölsumpfheizung aus Verdichter entfernt Auf Bl 3 Zubehör Öldr Sich Schalter entfernt 9155 Layh Weitergabe sowie Vervielfältigung dieses Dokuments Verwertung und Mitteilung seines Inhalts sind ver boten soweit nicht ausdrücklich gestattet Zuwider handlungen verpflichten zu Schadenersatz Alle Rechte für den Fall der Patent Gebrauchsmu...

Page 38: ...A 2 A n s c h l u ß M i t t e l d r u c k n i C o n n e c t i o n m e d i u m p r e A 3 A n s c h l u ß M i t t e l d r u c k n i C o n n e c t i o n m e d i u m p r e B A n s c h l u ß D r u c k s e i t e n i C o n n e c t i o n d i s c h a r g e s i B 1 A n s c h l u ß D r u c k s e i t e a C o n n e c t i o n d i s c h a r g e s i C A n s c h l u ß Ö l d r u c k s i c h e r C o n n e c t i o n ...

Page 39: ...tor 1 4 NPTF E Connection oil pressure gauge 7 16 UNF F Oil drain M22 x 1 5 FS Sight glass liquid line Ø 12 mm 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 L1 Thermal protection thermostat 1 8 NPTF N Filter drier Ø 12 mm O Connection oil level regulator see view X ÖV Connection oil service valve 1 4 NPTF ÖV1 O...

Page 40: ...enced 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 special ...

Page 41: ...frigerant compressors HGZX7 2110 4 R404A HGZX7 2110 4 R448A R449A HGZX7 2110 4 R410A HGZ7 2110 4 R22 agrees with the Pressure Equipment Directive 2014 68 EU dated 15 May 2014 Valid for Category I piping Evaluation procedure module A The other parts of the piping fall under article 3 3 of the Guideline and correspond to good engineering practice Frickenhausen 2017 09 04 i A Alexander Layh Head of C...

Page 42: ...u have 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 ...

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Page 44: ...usen Germany Phone 49 0 7022 9454 0 Fax 49 0 7022 9454 137 info gea com gea com GEA Group is 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 ...