GEA HGX7 R134a, Assembly Instructions Manual

Page 1: ...D GB F E 1 96182 09 2013 DGbFEI engineering for a better world GEA Refrigeration Technologies Bock Compressor HGX7 R134a Assembly instructions HGX7 1620 4 R134a HGX7 1860 4 R134a HGX7 2110 4 R134a ...

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: ...m for part winding start with standard motor 5 3 Standard motor design for direct or part winding start 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 6 Commissioning 23 6 1 P...

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: ...refrigerating 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 integrat...

Page 6: ...it intensively In this way the motor can be kept at a relatively low temperature level particularly under high loads Cylinder arrangement in pairs in W design Name plate Fig 1 2 1 Short description Valve plate Cylinder cover Terminal box Dimension and connection values can be found in Chapter 9 Transport eyelet Discharge shut off valve Oil pump Suction shut off valve Oil sight glass Motor section ...

Page 7: ...Part windings 1 and 2 11 Displacement 5 ND LP max admissible operating 12 Oil type filled at the factory pressure 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 Observe the limits of application diagrams 50 Hz 60 Hz 2 Product description HG 7 2110 4 X 2 3 Type key example 1 H...

Page 8: ...se only oils that are highly thermally stable Avoid continuous operation near the limits For operation with capacity regulator The suction gas superheat temperature may need to be reduced or set individually when operating near to the threshold For operation with frequency converter The maximum current and power consumption must not be exceeded In the case of operation above the mains frequency th...

Page 9: ...est Unlimited application range Additional cooling or reduced suction gas temperature Abb 4 Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure R134a Evaporation temperature C Condensing temperature C Suction gas superheat K Suction gas temperature C ...

Page 10: ... 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 20 00 5 Bearb Datum Änderungs Nr Werkstoff Ausgangsteil bzw Rohteil Gepr Zone 1 x...

Page 11: ... the smooth running and vibration behaviour of the system ATTENTION Improperly installed pipes can cause cracks and tears which can result in a loss of refrigerant A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft 4 3 Pipes Pipes and system components must be clean and dry inside and free of scale swarf and layers of rust a...

Page 12: ...g 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 shut off is intended for safety devices Service connec tion closed Connection blocked Spindle Connection cannot be shut off Connection cannot be shut off Service connec tion opened Spindle Connection open Compressor Compressor Before opening ...

Page 13: ...es are the same 5 1 Information for contactor and motor contactor selection All protection equipment switching and monitoring devices must comply with the local safety regula tions and established specifications e g VDE and regulations as well as the manufacturer s specifica tions Motor protection switch is required Motor contactors feed lines fuses and motor protection switches must be rated acco...

Page 14: ...M YYY M1 R1 2U1 2V1 2W1 I 33 F1 2 K2 1 2 4 3 4 5 5 6 6 X1 L1 L1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 7 F1 1 F1 2 8 R2 4A F2 S1 R2 9 R2 10 MP10 11 60 40 Fig 15 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 1 2 2 motor safety switches 60 40 of I A total F2 Control power circuit fuse F3 High pressure safety monitor F4 Safety chain high low pressure mon...

Page 15: ...T2 13 N P l 14 L 15 M 16 S P F3 17 18 19 K1 P F4 20 K1 K1T K2 21 22 K1T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE Q1 Main switch M1 Compressor motor K1 Mains contactor part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s S1 Control voltage switch E1 Oil sump heater ...

Page 16: ...g start Δ YYY the bridges must be removed and the motor feed line connected according to the circuit diagram INFO When testing coils with resistance tester please note that partial winding 1 and partial winding 2 are wired internally in HGX7 5 3 Standard motor design for direct or part winding start Designation on the name plate Sticker on the terminal box YYY Compressors with this marking are sui...

Page 17: ...3 L2 V1 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 Dir...

Page 18: ... 6 X1 L1 L1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 7 F1 1 F1 2 8 R2 4A F2 S1 R2 9 R2 10 MP10 11 60 40 5 5 Basic circuit diagram for star delta start with special motor Fig 16 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 1 2 2 motor safety switches F2 Control power circuit fuse F3 High pressure safety monitor F4 Safety chain high low pressure monitori...

Page 19: ... P l 14 L 15 M 16 S P F3 17 K1 K1 18 K3 19 P F4 K4T K3 K2 20 K4T K2 K3 21 22 K4T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE Q1 Main switch M1 Compressor motor K1 Mains contactor K2 contactor K3 Y contactor K4T Delay relay for contactor changeover S1 Control voltage switch E1 Oil sump heater ...

Page 20: ...lled by the H3 LED green after the power supply is applied In the case of excess temperature in the motor winding the unit switches off the 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 inad...

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: ...nding on pressure and ambient temperature This reduces the lubricating capacity of the oil When the compressor 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 c...

Page 23: ...n and discharge pressure sides using the vacuum pump At the end of the evacuation process the vacuum should be 1 5 mbar when the pump is switched off Repeat this process as often as is required 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: ... 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 effects If this is the case check the oil return 6 7 Avoid slugging ATTENTION Slu...

Page 25: ...n limit for the first time after 100 to 200 operating hours 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 Switc...

Page 26: ...r set 230 V 08426 Available accessories can be found on the Internet at www bock de 7 4 Accessories 7 6 Decommissioning Close the shut off valves on the compressor Drain the refrigerant it must not be discharged into the environment and dispose of it according to the regulations When the compressor is depressurised undo the fastening screws of the shut off valves Remove the compressor using an app...

Page 27: ...ng Winding ratio 60 40 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 1 2 The max working current remains unchanged Take account of the max operating current max power consumption for des...

Page 28: ... 25 50 M10 30 P J1 F B1 A1 D ÖV ca 500 ca 505 340 189 ca 315 ca 215 150 90 612 472 331 290 4x 11 B DV SV A2 A Q ca 830 439 Schwingun dämpfer 25 50 M10 30 P J1 F B1 A1 D ÖV ca 500 ca 505 340 189 9 Dimensions and connections Dimensions in mm Centre of gravity Fig 20 ca 315 ca 215 150 90 612 472 331 290 4x 11 B DV SV A2 A Q ca 830 439 Schwingungs dämpfer 25 50 M10 30 E P H D1 J1 F K O B B1 A1 X C L D...

Page 29: ...toin oil 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 J1 Oil sump heater accessories M22 x 1 5 K Sight glass L Connection thermal protection thermostat 1 8 NPTF O Connection oil level regulator 3 x M6 ÖV Connection oil service ...

Page 30: ...ssor HGX7 R134a complies with the basic require ments 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 Machine...

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: ...54 0 Fax 49 7022 9454 137 bock gea com www bock de We live our values Excellence Passion Integrity Responsibility GEA versity 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 ...