GEA HG34e Bedienungsanleitung

96178-09.2013-DGbFEI

engineering for a better world GEA Refrigeration Technologies

Bock Compressor HG34e

Assembly instructions

HG34e/215-4 HGX34e/215-4 HGX34e/215-4 S R407C

HG34e/255-4 HGX34e/255-4 HGX34e/255-4 S R407C

HG34e/315-4 HGX34e/315-4 HGX34e/315-4 S R407C

HG34e/380-4 HGX34e/380-4 HGX34e/380-4 S R407C

HG34e/215-4 S HGX34e/215-4 S

HG34e/255-4 S HGX34e/255-4 S

HG34e/315-4 S HGX34e/315-4 S

HG34e/380-4 S HGX34e/380-4 S

1 1

96178-09.2013-DGbFEI

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

 3.4 Refrigerants-designforR407C,35bar

 3.5 OilchargeforR407C,35bar

 3.6 Limitsofapplication,R407C,35bar

4Compressor assembly 12

 4.1 Settingup

 4.2 Pipeconnections

 4.3 Pipes

 4.4 Layingsuctionandpressurelines

 4.5 Operatingtheshut-offvalves

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

5 Electrical connection 15

 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

6 Commissioning 20

 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 22

 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 24

9 Dimensions and connections 26

10 Declaration of conformity and installation 27

11 Service 28

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.bock.de

Manufacturer

Contact

96178-09.2013-DGbFEI

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

 3.4 Refrigerants-designforR407C,35bar

 3.5 OilchargeforR407C,35bar

 3.6 Limitsofapplication,R407C,35bar

4Compressor assembly 12

 4.1 Settingup

 4.2 Pipeconnections

 4.3 Pipes

 4.4 Layingsuctionandpressurelines

 4.5 Operatingtheshut-offvalves

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

5 Electrical connection 15

 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

6 Commissioning 20

 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 22

 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 24

9 Dimensions and connections 26

10 Declaration of conformity and installation 27

11 Service 28

96178-09.2013-DGbFEI

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.

96178-09.2013-DGbFEI

1|Safety

TheseassemblyinstructionsdescribethestandardversionoftheHG34emanufacturedby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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!

96178-09.2013-DGbFEI

1 1

2|Product description

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

• Suctiongascooleddrivemotor.

2.1 Short description

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

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

Motorsection

Transporteyelet

96178-09.2013-DGbFEI

GEA Bock GmbH

72636 Frickenhausen, Germany

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pressur

e 10 Nominalrotationspeed

(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 43 e 380-4 SX

2.3 Typekey (example)

¹)HG-HermeticGas-cooled(suctiongas-cooled)

²)X

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

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

513

19/28 SE 55

27,3

32,8

HGX34e/315-4

21,1/12,2A

111A 64A

IP66

Fig.3

AS38125A001

R407C

Refrigerant

Motorvariant3)

Numberofpoles

Sweptvolume

e-series

Numbersofcylinders

Size

Oilcharge²)

Series¹)

96178-09.2013-DGbFEI

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 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 additional cooling:

- Use only oils that are highly thermally stable.

- Avoid continuous operation near the limits.

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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.HGX34e/380-4).

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.

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

96178-09.2013-DGbFEI

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

96178-09.2013-DGbFEI

96157-02.2011-DGbFEI

2|Produktbeschreibung

513

HG 43 e 315- R407C

4 SX

19/35 SE 55

27,3

32,8

1 Typbezeichnung

2 Maschinennummer

3 maximaler Betriebsstrom

4 Anlaufstrom (Rotor blockiert)

5 ND (LP): max. zulässiger Überdruck

Niederdruckseite

HD (HP): max. zulässiger Überdruck

Hochdruckseite

Beachten Sie hierzu die

Einsatzgrenzendiagramme!

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

Elektrisches Zubehör kann die IP-

Schutzklasse verändern!

HGX34e/315-4 S R407C

28,1/16,2A

134A 77A

}

Abb. 3

2.2 Typschild (Beispiel)

2.3 Typschlüssel (Beispiel)

¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)

²) X

- Esterölfüllung

3) S - Stärkerer Motor

Kältemittel

Motorvariante 3)

Polzahl

Hubraum

e-Serie

Zylinderzahl

Baugröße

Ölfüllung ²)

Baureihe ¹)

AS38125A001

Thecompressorsarelledatthefactorywiththefollowingoiltype:FUCHSRenisoTritonSE55

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

designation(e.g.HGX34e/380-4R407C).

3.4 Refrigerant-DesignforR407C,35bar

• HFKW/HFC: R407C

3.5 OilchargeforR407C,35bar

3.6 Limits of applicationforR407C,35bar

Only compressors with the additional designation

R407C(seenameplate,Fig.3and8)

Fig.9

96157-02.2011-DGbFEI

2|Produktbeschreibung

513

HG 43 e 315- R407C

4 SX

19/35 SE 55

27,3

32,8

1 Typbezeichnung

2 Maschinennummer

3 maximaler Betriebsstrom

4 Anlaufstrom (Rotor blockiert)

5 ND (LP): max. zulässiger Überdruck

Niederdruckseite

HD (HP): max. zulässiger Überdruck

Hochdruckseite

Beachten Sie hierzu die

Einsatzgrenzendiagramme!

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

Elektrisches Zubehör kann die IP-

Schutzklasse verändern!

HGX34e/315-4 S R407C

28,1/16,2A

134A 77A

}

Abb. 3

2.2 Typschild (Beispiel)

2.3 Typschlüssel (Beispiel)

¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)

²) X

- Esterölfüllung

3) S - Stärkerer Motor

Kältemittel

Motorvariante 3)

Polzahl

Hubraum

e-Serie

Zylinderzahl

Baugröße

Ölfüllung ²)

Baureihe ¹)

AS38125A001

96157-02.2011-DGbFEI

2|Produktbeschreibung

513

HG 43 e 315- R407C

4 SX

19/35 SE 55

27,3

32,8

1 Typbezeichnung

2 Maschinennummer

3 maximaler Betriebsstrom

4 Anlaufstrom (Rotor blockiert)

5 ND (LP): max. zulässiger Überdruck

Niederdruckseite

HD (HP): max. zulässiger Überdruck

Hochdruckseite

Beachten Sie hierzu die

Einsatzgrenzendiagramme!

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

Elektrisches Zubehör kann die IP-

Schutzklasse verändern!

HGX34e/315-4 S R407C

28,1/16,2A

134A 77A

}

Abb. 3

2.2 Typschild (Beispiel)

2.3 Typschlüssel (Beispiel)

¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)

²) X

- Esterölfüllung

3) S - Stärkerer Motor

Kältemittel

Motorvariante 3)

Polzahl

Hubraum

e-Serie

Zylinderzahl

Baugröße

Ölfüllung ²)

Baureihe ¹)

AS38125A001

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 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 additional cooling:

- Use only oils that are highly thermally stable.

- Avoid continuous operation near the limits.

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!

INFO! Forrefilling,werecommendtheaboveoiltypes.

Alternatives: seelubricantstable,Chapter7.5.

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