GEA Bock In Touch HAX4/465-4, Assembly Instructions Manual

Page 1: ...D GB F E 1 09791 08 2011 DGbFEI GEA Refrigeration Technologies GEA Bock HA4 310 4 HAX4 310 4 HA4 385 4 HAX4 385 4 HA4 465 4 HAX4 465 4 HA4 555 4 HAX4 555 4 HA4 650 4 HAX4 650 4 Assembly instructions ...

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 mail bock de www bock de Manufact...

Page 3: ...sign for direct or partial winding start 5 3 Basic circuit diagram for partial winding start with standard motor 5 4 Special motor design for direct or star delta start 5 5 Circuit diagram for direct start 230 V 400 V Y 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 5 10 Fan motor 6 Commissioning 23 6 1 Prep...

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: ...he 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: ...lacement 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 protection class...

Page 8: ... 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...

Page 9: ...ion gas temperature Evaporation temperature C Condensing temperature C Suction gas superheat K Suction gas temperature C Fig 4 Fig 3 3 Areas of application R404A R507 R22 Design for other areas on request Maximum admissible operating pressure g High pressure side HD 28 bar ...

Page 10: ... inch dimansions 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 9 graduated internal diameter F E D C B 1 2 3 K Alternativbezug Baumustergeprüft Lieferantenzeichnung K Auftrag PL Entwicklungsstand 120 400 0 5 Bearb Datum Änderungs Nr W...

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: ...nections Fig 13 Opening the shut 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 14 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cannot be shu...

Page 13: ... box Y YY Compressors with this marking are suitable for direct or partial winding start The motor winding is subdivided 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 co...

Page 14: ...onitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor C1 Fan operating capacitor B1 Release switch thermostat Fig 15 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: ...h 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 PE X1 L1 ...

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: ...compressor and the H1 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...

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: ...ressor 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 In order to prevent damage to the compressor the compressor is equipped with an oil sump heater as standard The oil sump...

Page 23: ...igerant with the testing medium as this could cause the ignition limit to shift into the critical range 6 4 Evacuation First evacuate the system and then include the compressor in the evacuation process Relieve the compressor pressure Open the suction and pressure line shut off valves Evacuate the suction and discharge pressure sides using the vacuum pump At the end of the evacuation process the v...

Page 24: ...e open 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...

Page 25: ...s 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 Re...

Page 26: ...e 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 SEZ 32 ICI Emkarate RL 46 S Mobil Arctic AL 46 Shell Clavus R 46 HCFC e g R22 Fuchs Reniso SP 46 Mobil SHC 425 Shell Clavus SD 22 12 Sunoil Suniso 4GS Texaco Capel...

Page 27: ... 140 157 HA4 650 4 56 6 67 9 26 15 6 107 140 156 1 2 3 2 4 Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request Take account of the max operating current max power consumption for design of fuses supply lines and safety devices Fuse Consumption category AC3 All specifications are based on the average of the voltage range For solder connections...

Page 28: ...on obturable B1 Anschluß Druckseite absperrbar Connection discharge side lockable Raccord côté refoulement obturable C Anschluß Öldrucksicherheitsschalter OIL Connection oil pressure safety switch OIL Raccord pressostat de sécurité d huile OIL D Anschluß Öldrucksicherheitsschalter LP Connection oil pressure safety switch LP Raccord pressostat de sécurité d huile LP D1 Anschluß Ölrückführung vom Öl...

Page 29: ...pressure 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 M22 x 1 5 K Sight glas L Connection thermal protection thermostat 1 8 NPTF N Connection capacity controller M48 x 1 5 O Connection oil level regulator 3 x M6 ÖV Con...

Page 30: ...r HA4 complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006 42 EC The following harmonised standards have been applied EN ISO 12100 1 EN ISO 12100 2 EN 12693 EN 349 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 Mach...

Page 31: ...achgroßhandel bzw unsere Vertretung Das Bock Serviceteam erreichen Sie direkt unter 49 7022 9454 0 via e mail mail bock de oder im Internet www bock de Für den deutsch chigen Raum steht darüber hinaus die kostenlose Bock Hotline 00 800 800 000 88 von monta bis samstags zwischen 8 und 21 Uhr zur Verfügung Für Anregungen zur Weiterentwicklung un Verdichter Ausrüstungs und Ersatzteilprogramms sind wi...

Page 32: ...32 D GB F E 09791 08 2011 DGbFEI www gearefrigeration com www bock de Corporate Design Manual _ In touch with our corporate design GEA Refrigeration Technologies www gearefrigeration com ...