GEA HA22P/125-4 Bedienungsanleitung

09636-12.2014-DGbFEIRu

engineering for a better world GEA Refrigeration Technologies

GEA Bock Compressor HA22P

Assembly instructions

HA22P/125-4 HAX22P/125-4

HA22P/160-4 HAX22P/160-4

HA22P/190-4 HAX22P/190-4

09636-12.2014-DGbFEIRu

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

09636-12.2014-DGbFEIRu

Contents Page

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

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

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

5.8 Fan motor

6 Commissioning 18

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 20

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 22

9 Dimensions and connections 23

10 Declaration of conformity and installation 24

11 Service 25

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1|Safety

1.2 Qualicationsrequiredofpersonnel

1.3 General safety instructions

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

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

mustthereforeonlybeperformedbypersonnelwiththequalica-

tions listed below:

• For example, a refrigeration technician, refrigeration mechatron-

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

enable personnel to assemble, install, maintain and repair refrigeration

and air-conditioning systems. Personnel must be capable of assessing

thework to be carried out and recognising any potential 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 Identicationofsafetyinstructions:

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.

09636-12.2014-DGbFEIRu

1|Safety

These assembly instructions describe the standard version of the HA22P manufactured by

GEA Bock. The compressor is 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!

The GEA Bock 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 integrated has been inspected and

approved in accordance with legal regulations.

1.4 Intended use

WARNING! The compressor may not be used in potentially

explosive environments!

09636-12.2014-DGbFEIRu

2|Product description

2.1 Short description

• Semi-hermetic two-cylinder reciprocating 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

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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

SE 55

AS35830A001

HAX22P/160-4

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

}

Fig. 3

HA 22 P 160-4X

2.3 Typekey (example)

¹)HA-HermeticAir-cooled(air-cooled)fordeepfreezing

²)X

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

³) Additional declaration for Pluscom compressors

Number of poles

Swept volume

³)

Numbers of cylinders

Size

Oil charge ²)

Series ¹)

GEA Bock GmbH

72636 Frickenhausen, Germany

09636-12.2014-DGbFEIRu

3|Areas of application

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.

- Max. permissible ambient temperature 45 °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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!

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

- for R404A/R507 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. HAX22P/160-4).

3.1 Refrigerants

• HFKW/HFC:  R404A/R507

• (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.

The oil level must be in the

visible part of the sight

glass; damage to the com-

pressor is possible if over-

filled or underfilled!

max. oil level

min. oil level

ATTENTION!

Fig. 4

09636-12.2014-DGbFEIRu

Evaporationtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Design for other

areasonrequest

Unlimited application range

Reduced suction gas temperature

R404A/R507

R22

Fig. 5

Fig. 6

3|Areas of application

Max. permissible operating

pressure (LP/HP)1): 19/28 bar

1) LP = Low pressure

HP = High pressure

09636-12.2014-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.

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

combustible environment.

Fig. 9

Fig. 10

Fig. 11

4.3 Pipe connections

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

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! 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).

4.1 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. 8

Fig. 7

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

etc.) directly to the compressor are not permissible!

4.2 Setting up

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

 Ensureadequatecompressorventilation.

The compressor must not be in the air stream to another

componentoftherefrigerationsystem(e.g.condenser).

The cooling of the drive motor must be reliable guaranteed.

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