GEA HGX4 R134a, Assembly Instructions Manual

Page 1: ...179 01 2015 DGbFEI engineering for a better world GEA Refrigeration Technologies GEA Bock Compressor HGX4 R134a Assembly instructions HGX4 465 4 R134a HGX4 555 4 R134a HGX4 650 4 R134a 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 2: ... 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 refrigeration gea com www gea com Man...

Page 3: ... motor design for direct 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 6 Commiss...

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: ...ock 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 inte...

Page 6: ...e mounted drive motor on the compressor case Preferred application range normal refrigerating and air conditioning with R134a 2 1 Short description Dimension and connection values can be found in Chapter 9 Name plate Fig 1 Valve plate Cylinder cover Terminal box Transport eyelet Discharge shut off valve Oil pump Suction shut off valve Oil sight glass Drive section Motor section ...

Page 7: ...speed 3 maximum operating 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 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 Hi...

Page 8: ...mentary cooling Use only oils with high thermal stability Avoid continuous operation near the threshold 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 mai...

Page 9: ...tion gas superheat K Suction gas temperature C Unlimited application range Supplementary cooling or reduced suction gas temperature 3 Areas of application Design for other areas on request R134a Fig 4 Max permissible operating pressure LP HP 1 19 28 bar 1 LP low pressure HP high pressure ...

Page 10: ... compressor ventilation Do not use in a corrosive dusty damp atmosphere or a combustible environment Fig 7 Fig 8 Fig 9 ATTENTION Superheating can damage the valve Remove the pipe supports from the valve for soldering Only solder using inert gas to inhibit oxidation products scale 4 3 Pipe connections F E D C 1 2 3 4 2 Setting up 4 1 Storage and transport Use transport eyelet Do not lift manually U...

Page 11: ...s 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 by severe vibrations Ensure a proper oil return Keep pressure losses to an absolute minimum The pipe connections have graduated inside diameters so ...

Page 12: ...e 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 to the right clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service conn...

Page 13: ...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 contactor and motor contactor selection All protection devices and...

Page 14: ...safety monitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor B1 Release switch thermostat Fig 16 nderung 0 Datum Name Datum Bearb Gepr Norm 1 20 Feb 2009 Kelich 09 M r 2010 Urspr 2 Ers f 3 Ers d 4 X SS Q1 L1 L2 L3 N PE Anschluákasten Verdichter I 66 F1 1 K1 1 2 1 3 4 2 5 6 3 1U1 1V1 1W1 PE M Y YY 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 4...

Page 15: ...art 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 BOCK COMPRESSORS 8 9 Bl 1 Bl 1 F5 K1 12 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 ...

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: ...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 9 10 MP10 11 5 5 Basic circuit diagram for star delta start with special motor Fig 17 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 1 2 2 motor protection switches F2 Control power circuit fuse F3 High pressure safety monitor F4 Safety chain high low pressure monitoring F5 Oil differe...

Page 19: ...1 K3 P F3 K4T K3 K2 17 K4T K2 K3 18 19 K4T P F4 20 K5T AL 21 22 K5T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE M1 Compressor motor K1 Mains contactor K2 contactor K3 Y contactor K4T Delay relay for contactor changeover K5T Delay relay for start unloader S1 Control voltage switch AL Start unloader E1 Oil sump heater ...

Page 20: ... 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 Connect the trigger unit MP10 in accordance with the circu...

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: ...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 heater operates when the compressor is shut down The oil sump heater is switched off when the compressor starts Connection Connect the oil sump heater via an auxilia...

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: ... 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 effec...

Page 25: ...lock 6 8 Connection of oil level regulator Oil level regulation systems have proven themselves with parallel circuits of several compressors The connection 0 is provided for installing an oil level regulator see dimensions drawing All common oil level regulators from AC R ESK and Carly as well as the OM3 TraxOil oil level regulation system from Alco can be connected directly without adapters see F...

Page 26: ...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 GEA Bock standard oil types Recommended alternatives HFC R134a Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Arctic 46 Sunoco Suniso SL 46 Texaco Capella HFC 55 Available accesso...

Page 27: ... 45 C H air conditioning 5 50 C sound pressure level measured in low reflection measuring area measuring distance 1m Compressor operation at 50 Hz 1450 rpm refrigerant R404A Values stated are average values tolerance 2 dB A 5 3 4 Type No of cylinders Displace ment 50 60 Hz 1450 1740 rpm Electrical data Weight Connections Oil charge Sound pressure level Voltage Max Operating current PW 1 2 Max powe...

Page 28: ...mostat Connecti L Bra L Lötanschluß N Anschluß Leistungsregler Connecti O Anschluß Ölspiegelregulator Connecti P Anschluß Öl Differenzdrucksensor Connecti ÖV Anschluß Ölserviceventil Connecti Q Anschluß Öltemperatursensor Connecti Anschlüsse Connec SV Saugabsperrventil Rohr L Suction li DV Druckabsperrventil Rohr L Discharg A Anschluß Saugseite nicht absperrbar Connecti A1 Anschluß Saugseite abspe...

Page 29: ...witch 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 M 22 x 1 5 H Oil charge plug M 22 x 1 5 J Oil sump heater accessories M 22 x 1 5 K Sight glass L Connection thermal protection thermostat 1 8 NPTF N Connection capacity controller M 48 x 1 5 O Connection oil level regulator 3 x M ...

Page 30: ...ssor HGX4 R134a 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 Machiner...

Page 31: ...tions about installation operation and accessories please contact our techni cal service or specialist wholesaler and or our representative The GEA Bock service team can be contacted by phone with a toll free hotline 00 800 800 000 88 or via e mail refrigeration gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 11 Service ...

Page 32: ...Fax 49 7022 9454 137 refrigeration gea com www gea com 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 ...