GEA HGX5/725-4 R134a Bedienungsanleitung

96180-09.2013-DGbFEI

engineering for a better world GEA Refrigeration Technologies

Bock Compressor HGX5 R134a

Assembly instructions

HGX5/725-4 R134a

HGX5/830-4 R134a

HGX5/945-4 R134a

1 112

96180-09.2013-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

4Compressor assembly 10

 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 13

 5.1 Informationforcontactorandmotorcontactorselection

 5.2 Standardmotor,designfordirectorpart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

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

96180-09.2013-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

4Compressor assembly 10

 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 13

 5.1 Informationforcontactorandmotorcontactorselection

 5.2 Standardmotor,designfordirectorpart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

96180-09.2013-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.

96180-09.2013-DGbFEI

1|Safety

TheseassemblyinstructionsdescribethestandardversionoftheHGX5R134a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!

96180-09.2013-DGbFEI

2|Product description

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

• Flange-mounteddrivemotoronthecompressorcase.

• Applicationrange:normalrefrigeratingandair-conditioningwithR134a.

Fig.1

2.1 Short description

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

Nameplate

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

96180-09.2013-DGbFEI

2|Product description

HG 5945-4

Fig.2

2.2 Name plate (example)

2.3 Typekey (example)

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

²)X -Esteroilcharge

R134a

HGX5/945-4 R134a

AS12345-001

SE 55

33 A

110 A 141 A

Version

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

}

GEA Bock GmbH

72636 Frickenhausen, Germany

96180-09.2013-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.HGX5/945-4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.

- 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

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 compressor is possible if

overfilled or underfilled!

ATTENTION!

Fig.3

max.oillevel

min.oillevel

96180-09.2013-DGbFEI

3|Areas of application

Design for other

areasonrequest

Unlimitedapplicationrange

Supplementarycoolingor

reducedsuctiongastemperature

R134a

Fig.4

Evaporationtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Max. permissible operating

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

1) LP=Lowpressure

HP=Highpressure

96180-09.2013-DGbFEI

4|Compressor assembly

4.1 Setting up

 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.

 Usetransporteyelet.

 Donotliftmanually!

 Useliftinggear!

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

 Ensureadequatecompressorventilation.

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

combustibleenvironment.

Fig.5

Fig.6

Fig.7

Fig.8

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).

4.2 Pipe connections

The pipe connectionshavegraduatedinsidediameterssothatpipeswith

standartmillimetreandinchdimensionscanbeused.

Theconnectiondiametersoftheshut-offvalvesareratedformaximum

compressoroutput.Theactualrequiredpipecrosssectionmustbe

matched to the output. The same applies for non-return valves.

Fig.9:graduated

internaldiameter

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.

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GEA

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Sparmax

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KAESER

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Briggs & Stratton

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Fini

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Industrial Air

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Campbell Hausfeld

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Ingersoll-Rand

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Hitachi

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Parkside

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Clas Ohlson

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Ferm

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RIDGID

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Johnson Controls

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Sears

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Ring Automotive

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Craftsman

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Alkin

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