GEA Bock HG12P/75-4 Bedienungsanleitung

09652-06.2015-DGbFEIRu

engineering for a better world

GEA Bock Compressor HG12P

Assembly instructions

HG12P/75-4 HG12P/60-4 S HGX12P/75-4 HGX12P/60-4 S

HG12P/90-4 HG12P/75-4 S HGX12P/90-4 HGX12P/75-4 S

HG12P/110-4 HG12P/90-4 S HGX12P/110-4 HGX12P/90-4 S

HG12P/110-4 S HGX12P/110-4 S

09652-06.2015-DGbFEIRu

1 Safety 4

 1.1 Identicationofsafetyinstructions

 1.2 Qualicationsrequiredofpersonnel

 1.3 Generalsafetyinstructions

 1.4 Intendeduse

2 Product description 6

 2.1 Shortdescription

 2.2 Nameplate

 2.3 Typekey

About these instructions

Readtheseinstructionsbeforeassemblyandbeforeusingthecompressor.Thiswillavoidmisunder-

standings andpreventdamage.Improperassemblyanduseof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

[email protected]

www.gea.com

Manufacturer

Contact

Contents Page

09652-06.2015-DGbFEIRu

Contents Page

3 Areas of application 8

 3.1 Refrigerants

 3.2 Oilcharge

 3.3 Limitsofapplication

4Compressor assembly 10

 4.1 Storageandtransport

 4.2 Settingup

 4.3 Pipeconnections

 4.4 Pipes

 4.5 Layingsuctionandpressurelines

 4.6 Operatingtheshut-offvalves

 4.7 Operatingmodeofthelockableserviceconnections

5 Electrical connection 13

 5.1 Information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-->with MP10

 5.4 ElectronictriggerunitMP10

 5.5 ConnectionoftheelectronictriggerunitMP10

 5.6 FunctionaltestoftheelectronictriggerunitMP10

 5.7 Circuitdiagramfordirectstart230VΔ/400VY-->with INT69 G

 5.8 ElectronictriggerunitINT69G

 5.9 ConnectionoftheelectronictriggerunitINT69G

 5.10 FunctionaltestoftheelectronictriggerunitINT69G

6 Commissioning 22

 6.1 Preparationsforstart-up

 6.2 Pressurestrengthtest

 6.3 Leaktest

 6.4 Evacuation

 6.5 Refrigerantcharge

 6.6 Start-up

 6.7 Avoidingslugging

 6.8 Connectionofoillevelregulator

7 Maintenance 24

 7.1 Preparation

 7.2 Worktobecarriedout

 7.3 Sparepartsrecommendation

 7.4 Accessories

 7.5 Extractfromthelubricantstable

 7.6 Decommissioning

8 Technical data 26

9 Dimensions and connections 27

10 Declaration of conformity and installation 28

11 Service 29

09652-06.2015-DGbFEIRu

1|Safety

1.2 Qualicationsrequiredofpersonnel

DANGER Indicates a dangerous situation which, if not avoided,

will cause immediate fatal or serious injury.

WARNING Indicates a dangerous situation which, if not avoided,

may cause fatal or serious injury.

CAUTION Indicates a dangerous situation which, if not avoided,

may cause fairly severe or minor injury.

ATTENTION Indicates a situation which, if not avoided,

may cause property damage.

INFO Important information or tips on simplifying work.

WARNING Inadequatelyqualied personnelposesthe riskof accidents,the

consequencebeingseriousorfatalinjury.Workoncompressors

isthereforereservedforpersonnelwhichisqualiedtoworkon

pressurized refrigerant systems:

•For example, a refrigeration technician, refrigeration mechatronic

engineer. As well as professions with comparable training, which

enables personnel to assemble, install, maintain and repair

refrigerationandair-conditioningsystems.Personnelmustbecapable

ofassessingtheworktobecarriedoutandrecognisinganypotential

dangers.

1.1 Identicationofsafetyinstructions:

09652-06.2015-DGbFEIRu

1|Safety

1.4 Intended use

1.3 General safety instructions

WARNING Risk of accidents.

Refrigerating compressors are pressurised machines and as such

call for heightened caution and care in handling.

The maximum permissible overpressure must not be exceeded,

even for testing purposes.

Risk of burns!

- Depending on the operating conditions, surface temperatures of

over 60°C on the discharge side or below 0°C on the suction side

can be reached.

- Avoid contact with refrigerant necessarily.

Contact with refrigerant can cause severe burns and skin

damage.

WARNING The compressor may not be used in potentially explosive

environments!

These assembly instructions describe the standard version of the compressor named in the title

manufacturedbyGEA Bock.GEABockrefrigerating compressorsareintended for installation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permissibleonlyifthecompressorhasbeeninstalledinaccordancewiththeseas-

semblyinstructionsandtheentiresystemintowhichitisintegratedhasbeeninspectedandapproved

inaccordancewithlegalregulations.

Thecompressorsareintendedforuseinrefrigerationsystemsincompliancewiththelimitsof

application.

Onlytherefrigerantspeciedintheseinstructionsmaybeused.

Any other use of the compressor is prohibited!

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2|Product description

• Semi-hermetictwo-cylinderreciprocatingcompressorwithoilpumplubrication.

• Suctiongascooleddrivemotor.

2.1 Short description

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

DimensionandconnectionvaluescanbefoundinChapter9

Transporteyelet

Nameplate

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2|Product description

2.2 Name plate (example)

1 Typedesignation 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lledatthefactory

pressur

e(g)Highpressureside 13 Terminalboxprotectiontype

Observe the limits of application Electrical accessories can change

diagrams! the IP protection class!

50 Hz

}

60 Hz

}

HG 21 P 110- 4 SX

2.3 Type key (example)

¹) HG-HermeticGas-cooled(suctiongas-cooled)forthenormal-/airconditioningapplications

²) X

-Esteroilcharge(HFCrefrigerant,e.g.R134a,R404A/R507,R407C)

³) AdditionaldeclarationforPluscomcompressors

4) S - Morepowerfulmotor,e.g.forair-conditioningapplications

Motorvariant4)

Numberofpoles

Sweptvolume

³)

Numbersofcylinders

Size

Oilcharge²)

Series¹)

Typschild (Beispiel)

513

1 Typbezeichnung

2 Maschinennummer

3 maximaler Betriebsstrom

4 Anlaufstrom (Rotor blockiert)

5 ND (LP): max. zulässiger Stillstandsdruck

Saugseite

HD (HP): max. zulässiger Betriebsdruck

Hochdruckseite

Einsatzgrenzendiagramme beachten!

50 Hz

60 Hz

6 Spannung, Schaltung, Frequenz

7 Nenndrehzahl

8 Hubvolumen

9 Spannung, Schaltung, Frequenz

10 Nenndrehzahl

11 Hubvolumen

12 Werkseitig eingefüllte Ölsorte

13 Schutzart Klemmenkasten

10,6/6,1A

45A 26A

9,4

11,3

HGX12P/110-4S

AS35830A001

SE 55

AS35830A001

GEA Bock GmbH

72636 Frickenhausen, Germany

Fig.3

09652-06.2015-DGbFEIRu

3|Areas of application

 Thecompressorsarelledatthefactorywiththefollowingoiltype:

-forR134a,R404A/R507,R407C FUCHSRenisoTritonSE55

 -forR22 FUCHSRenisoSP46

Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXinthetype

designation(e.g.HGX12P/110-4).

3.1 Refrigerants

• HFKW/HFC:  R134a,R404A/R507,R407C

• (H)FCKW/(H)CFC: R22

3.2 Oil charge

3.3 Limits of application

INFO For refilling, we recommend the above oil types.

Alternatives: see lubricants table, Chapter 7.5

ATTENTION The oil level must be in the

visible part of the sight glass;

damage to the compressor is

possible if overfilled or under-

filled! Fig.4

max.

min.

0,5Ltr.

oillevel ~

ATTENTION Compressor operation is possible within the operating limits

shown in the diagrams. Please note the signicance of the

shaded areas. Thresholds should not be selected as design or

continuous operation points.

- Permissible ambient temperature (-20°C) - (+60°C).

- Max. permissible discharge end temperature 140°C.

-Max.permissibleswitchingfrequency8x/h.

- A minimum running time of 3 min. steady-state condition

(continuous operation) must be achieved.

For operation with supplementary cooling:

- Use only oils with high thermal stability.

- Avoid continuous operation near 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,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!

09652-06.2015-DGbFEIRu

Evaporationtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

3|Areas of application

Design for other

areasonrequest

R134a

R407C

R404A/R507

R22

Fig.5

Fig.6

Fig.7

Fig.8

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

09652-06.2015-DGbFEIRu

4|Compressor assembly

 Setuponanevensurfaceorframewithsufcientload-

bearingcapacity.

 Singlecompressorpreferablyonvibrationdamper.

 Duplexandparallelcircuitsalwaysrigid.

 Provideadequateclearanceformaintenancework.

 Ensureadequatecompressorventilation.

 Donotuseinacorrosive,dusty,dampatmosphereora

combustibleenvironment.

Fig.11

Fig.12

Fig.13

Tol.-Ang. DIN ISO 2768-mK

Ra Rz

Maß

Passung

Freigabe

Alternativbezug:

Baumustergeprüft

Teil inaktiv

Lieferantenzeichnung

K.-Auftrag:

PL:

Zeichnung ungültig

Entwicklungsstand

Teil keine Serie

120

400

±0.5

über 0.5

bis 6

Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de

Unbemaßte Radien:

Diese Zeichnung ist unser Eigentum!

Sie darf ohne unsere Genehmigung weder nach-

gebildet, vervielfältigt, oder Dritten Personen zu-

gänglich gemacht werden. Der Nachbau nach

dieser Zeichnung, oder an Hand der nach dieser

Zeichnung hergestellten Gegenstände durch den

Abnehmer oder Dritte ist nicht gestattet.

Wir behalten uns alle Rechte, gemäß DIN ISO 16016

an dieser Zeichnung vor.

Bearb.

Datum

Änderungs-Nr.

Werkstoff:

Ausgangsteil, bzw. Rohteil:

Gepr.

Name

Datum

19.04.

Werkstückkanten

DIN ISO 13715

Ersatz für:

Ersetzt durch:

Erstellt

2010

Geprüft

Kurz

Zone

1/x

Oberflächenbehandlung / Härte:

Blatt:

Änderungsbeschreibung

400

Benennung:

±0.8

1000

±0.3

120

±0.2

Zeichn.-Nr. Teile-Nr.

Oberflächenangaben ISO 1302

x.xxxx-xxxxx.x

Zust.

Gußtoleranzen:

Gewicht: (kg)

±0.1

Maßstab:

1:1

Wasserwaage

für Indesign

Der Lieferant muß sicherstellen, dass die Ware in

einwandfreiem Zustand angeliefert wird (Korrosions-

schutz, Verpackung für sicheren Transport).

Rz 25

Rz 160

0,05

Rz 1,6

0,3

0,7

1,6

Rz 16

6,3

Rz 63

Rz 6,3

Rz 12,5

F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage

4.2 Setting up

4.1 Storage and transport

 Usetransporteyelet.

 Donotliftmanually!

 Useliftinggear!

 Storageat(-30°C)-(+70°C),maximumpermissiblerelativehumidity

10%-95%,nocondensation

 Donotstoreinacorrosive,dusty,vaporousatmosphereorinacom-

bustibleenvironment.

Fig.10

Fig.9

INFO Newcompressorsarefactory-lledwithinertgas(3barnitrogen).

Leave this service charge in the compressor for as long as possible

and prevent the ingress of air. Check the compressor for transport

damage before starting any work.

ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,

etc.) directly to the compressor are not permissible!

ATTENTION Damage possible.

Do not solder as long as the compressor is under pressure.

Superheating can damage the valve. Remove the pipe supports

therefore from the valve for soldering and accordingly cool the

valve body during and after soldering.

Only solder using inert gas to inhibit oxidation products (scale).

4.3 Pipe connections

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