GEA HG34P Series, Assembly Instructions Manual

Page 1: ...es Bock Compressor HG34P Assembly instructions HG34P 125 4 HG34P 125 4 S HGX34P 125 4 HGX34P 125 4 S HG34P 255 4 HG34P 255 4 S HGX34P 255 4 HGX34P 255 4 S HG34P 315 4 HG34P 315 4 S HGX34P 315 4 HGX34P 315 4 S HG34P 380 4 HG34P 380 4 S HGX34P 380 4 HGX34P 380 4 S 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: ...mation for contactor and motor contactor selection 5 2 Connection of the driving motor 5 3 Circuit diagram for direct start 230 V Δ 400 V Y 5 4 Start unloader 5 5 Electronic trigger unit MP 10 5 6 Connection of the electronic trigger unit MP 10 5 7 Functional test of the electronic trigger unit MP 10 6 Commissioning 18 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak test 6 4 Evac...

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: ...rigerating 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 ...

Page 6: ...compressor with oil pump lubrication Suction gas cooled drive motor 2 1 Short description Dimension and connection values can be found in Chapter 9 Name plate 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 Motor section Transport eyelet ...

Page 7: ...6 Voltage circuit 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 ...

Page 8: ...er 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 of air at all costs The compressors are filled ...

Page 9: ...on Design for other areas on request R134a R407C R404A R507 R22 Fig 4 Fig 5 Fig 6 Fig 7 Unlimited application range Supplementary cooling or reduced suction gas temperature Supplementary cooling and reduced suction gas temperature Motor version S more powerful motor Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure ...

Page 10: ... required pipe cross section must be matched to the output The same applies for non return valves Fig 12 graduated internal diameter F E D C B 1 2 3 Alternativbezug Baumustergeprüft Lieferantenzeichnung Entwicklungsstand Bearb Datum Änderungs Nr Werkstoff Ausgangsteil bzw Rohteil Gepr Zone 1 x Blatt ung 400 Benennung 0 8 1000 Zeichn Nr Teile Nr x xxxx xxxxx x Maßstab 1 1 Wasserwaage für Indesign I...

Page 11: ...rigerant A rule 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 cra...

Page 12: ...ction 4 6 Operating mode of the lockable service connections Fig 16 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 Fig 17 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened Service connec tion closed Connection blocked Spindle...

Page 13: ...ifica tions Motor protection switch is required Motor contactors feed lines fuses and motor protection switches must be rated according to the maximum operating current see name plate Set the short circuit trigger current at max 7 times the permissible operating current according to the compressor name plate 5 2 Connection of the driving motor The compressor is designed with a motor for star delta...

Page 14: ...V Y Fig 18 Compressor terminal box R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 Load circuit safety switches F2 Control power circuit fuse F3 Safety chain high low pressure monitoring B1 Release switch thermostat pressostat Q1 Main switch ...

Page 15: ...K1 Compressor contactor MP10 Electronic trigger unit MP 10 E Oil sump heater X3 Terminal strip in terminal box XSS Terminal strip in the external switch cabinet A1 Alarm Motor protection A2 Overheating R1 R2 A3 Alarm high pressure XSS Terminal strip in the external switch cabinet ...

Page 16: ...cted 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 6 Connection of the trigger unit MP10 INFO Connect the trigger unit MP10 in accordance with the circuit dia gram Protect the trigger unit with a delayed action fuse ...

Page 17: ...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 18: ...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 19: ...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 20: ...ghtness 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 Relieve compressor of system pressure Prevent air from infiltrating the system After maintenance has been performed Connect safety switch Evacuate compressor Release switch...

Page 21: ...ations 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 Bock standard oil types Recommended alternatives HFC e g R134a R407C R404A Fuchs Reniso Triton SE 55 Fuchs SEZ 32 ICI Emkarate RL 46 S Mo...

Page 22: ...7 64 5 64 HG34P 380 4 S 33 1 39 7 32 4 18 7 11 1 134 77 96 67 64 5 64 1 2 3 2 4 220 240 V 380 420 V Y 3 50 Hz 265 290 V 440 480 V Y 3 60 Hz L M H 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 ...

Page 23: ...nschluß Saugseite nicht absperrbar Connection suction side not lockable Raccord côté aspiration non obturable Zoll 1 8 NPTF A1 Anschluß Saugseite absperrbar Connection suction side lockable Raccord côté aspiration obturable Zoll 7 16 UNF B Anschluß Druckseite nicht absperrbar Connection discharge side not lockable Raccord côté refoulement non obturable Zoll 1 8 NPTF B1 Anschluß Druckseite absperrb...

Page 24: ...omplies 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 Machinery D...

Page 25: ...enden Sie sich bitte an unsere Anwendungstechnik oder a Kältefachgroßhandel bzw unsere Vertretung Das Bock Serviceteam erreichen Sie direkt u 49 7022 9454 0 via e mail mail bock de oder im Internet www bock de Für den deut chigen Raum steht darüber hinaus die kostenlose Bock Hotline 00 800 800 000 88 von mo bis samstags zwischen 8 und 21 Uhr zur Verfügung Für Anregungen zur Weiterentwicklung Verdi...

Page 26: ...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 09618 05 2012 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 ...