GEA HGX4 R134a Bedienungsanleitung

96179-01.2015-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

96179-01.2015-DGbFEI

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

96179-01.2015-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

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 Standard 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 Commissioning 23

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 25

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 27

9 Dimensions and connections 28

10 Declaration of conformity and installation 30

11 Service 31

96179-01.2015-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.

96179-01.2015-DGbFEI

1|Safety

These assembly instructions describe the standard version of the HGX4 R134a 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!

96179-01.2015-DGbFEI

2|Product description

• Semi-hermetic four-cylinder reciprocating compressor with suction-gas cooled drive motor.

• Flange-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

96179-01.2015-DGbFEI

AS35830A006

HGX4/650-4 R134a

22,0A

84 A 109 A

56,6

67,9

SE 55

2|Product description

Fig. 2

2.3 Typekey (example)

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

²) X - Ester oil charge

Design

Number of poles

Swept volume

Size

Oil charge ²)

Series ¹)

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

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lledatthefactory

pressur

e (g) Low pressure side 13 Terminal box protection type

HD (HP):

max. admissible operating

Electrical accessories can change

pressur

e(g) High pressure side the IP protection class!

Observe the limits of application

diagrams!

50 Hz

}

60 Hz

}

HG 4650-4

XR134a

2.2 Name plate (example)

GEA Bock GmbH

72636 Frickenhausen, Germany

96179-01.2015-DGbFEI

3|Areas of application

 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. HGX4/650-4 R134a).

3.1 Refrigerants

• HFKW / HFC: R134a

3.2 Oil charge

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12x/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 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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!

3.3 Limits of application

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!

ATTENTION!max.

min.

1,8 Ltr.

oil level

Fig. 3

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

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

96179-01.2015-DGbFEI

Evaporation temperature (°C)

Condensing temperature (°C)

Suction 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

96179-01.2015-DGbFEI

4|Compressor assembly

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.

 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. 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

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. 6

Fig. 5

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

etc.) directly to the compressor are not permissible!

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