GEA InTouch HA12P/110-4, Assembly Instructions Manual

Page 1: ...D GB F E 1 09651 03 2011 DGbFEI GEA Refrigeration Technologies GEA Bock HA12P 60 4 HAX12P 60 4 HA12P 75 4 HAX12P 75 4 HA12P 90 4 HAX12P 90 4 HA12P 110 4 HAX12P 110 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: ...ormation 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 Electronic trigger unit MP 10 5 5 Connection of the electronic trigger unit MP 10 5 6 Functional test of the electronic trigger unit MP 10 5 7 Fan motor 6 Commissioning 18 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak test 6 4 Evacuat...

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: ...ting compressor with oil pump lubrication Air cooled drive motor 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 Dimension and connection values can be found in Chapter 9 Transport eyelet Air guide hood with fan ...

Page 7: ...t 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 type Observe the...

Page 8: ...eded 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 at the factory with the followi...

Page 9: ...perature C Suction gas superheat K Suction gas temperature C Design for other areas on request Maximum admissible operating pressure g High pressure side HD 28 bar Unlimited application range Reduced suction gas temperature R404A R507 R22 Fig 4 Fig 5 3 Areas of application ...

Page 10: ...required pipe cross section must be matched to the output The same applies for non return valves Fig 10 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 IN...

Page 11: ...e 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 broke...

Page 12: ...rvice connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened Service connec tion closed Connection blocked Spindle Service connec tion opened Spindle Connection open Compressor Compressor Before opening or closing the shut off valve release the valve spindle seal by approx of a turn counter clockwise After activating the shut off valve re tighten the ...

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: ...mpressor 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 S1 Control voltage switch ...

Page 15: ...mpressor 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: ... 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 inadmissible operating conditions occur Find and remedy the cause 5 5 Connection of the trigger unit MP10 INFO Connect the trigger unit MP1...

Page 17: ...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 Before start up troubleshooting or making changes to the control power circuit check the functionality of the trigger unit 5 7 Fan motor The fan motor for cooling the compre...

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: ...ng 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 on lock 6 8 ...

Page 21: ... regulations 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 R404A Fuchs Reniso Triton SE 55 Fuchs SEZ 32 ICI Emkarate RL 46 S Mobil Ar...

Page 22: ...ea measuring distance 1m Compressor operation at 50 Hz 1450 rpm refrigerant R404A Values stated are average values tolerance 2 dB A 5 Type No of cylin ders Displace ment 50 60 Hz 1450 1740 rpm Electrical data Weight Connections Oil charge Sound pres sure level Voltage Max Operating current Y Max power consump tion Starting current rotor locked Y Dis charge line DV Suction line SV m 3 h A kW A kg m...

Page 23: ...P 90 4 HA12P 90 4 14561 14562 HAX12P 75 4 14557 HA12P 75 4 14560 HAX12P 60 4 HA12P 110 4 14556 HA12P 60 4 14559 Teile Nr Typ HAX12P 110 4 Teile Nr Typ 14563 Anschlüsse Connections Raccords SV Saugabsperrventil Rohr L Suction line valve tube L Vanne d arrêt d aspiration de tu DV Druckabsperrventil Rohr L Discharge line valve tube L Vanne d arrêt de refoulement de A Anschluß Saugseite nicht absperrb...

Page 24: ...r HA12P 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 Ma...

Page 25: ...ör wenden 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 deu 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 Ve...

Page 26: ...26 D GB F E 09651 03 2011 DGbFEI www gearefrigeration com www bock de Corporate Design Manual _ In touch with our corporate design GEA Refrigeration Technologies www gearefrigeration com ...