GEA HG Series Bedienungsanleitung

96166-05.2012-DGbFEI

engineering for a better world GEA Refrigeration Technologies

Bock Compressor HGX22P R410A

Assembly instructions

HGX22P/125-4 R410A HGX22P/125-4 S R410A

HGX22P/160-4 S R410A

HGX22P/190-4 R410A HGX22P/190-4 S R410A

1 1

96166-05.2012-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.bock.de

Manufacturer

Contact

96166-05.2012-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 Connection of the driving motor

5.3 Circuit diagram direct start 230 V ∆/ 400 V Y

5.4 Electronic trigger unit MP 10

5.5 Connecting of the trigger unit MP 10

5.6 Function test of the trigger unit MP 10

5.7 Oil sump heater

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liquitsluggings

6.8 Connection of oil level regulator

7 Maintenance 20

7.1 Preparation

7.2 Work to be carried out

7.3 Spare part 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

Contents Page

96166-05.2012-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.

96166-05.2012-DGbFEI

1|Safety

These assembly instructions describe the standard version of the HG22P R410A 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!

96166-05.2012-DGbFEI

1 1

2|Product description

• Half-hemetic two-cylinder reciprocating compressor with oil pump lubrication.

• Suction-gas-cooled drive motor

• Compactdimensions,quietrunning,highefciency

Fig. 1

2.1 Short description

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

96166-05.2012-DGbFEI

2|Product description

Fig. 3

2.2 Name plate (example)

513

27/43

AS33567A001

HGX22P/125-4 S R410A

19,2/11,1A

121 A 70 A

Öl: SE 55

HG 22 P 125-4 S R410AX

2.3 Typekey (example)

¹) HG - Hermetic Gas-cooled (suction gas-cooled) for normal and air conditioning applications

²) Additional declaration for Pluscom compressors

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

R410A version

Motor variant ³)

Number of poles

Swept volume

²)

Number of cylinders

Size

Esteroillling

Series ¹)

IP66

1 Type designation

2 Machine number

3 maximum operating current

4 Starting current (rotor blocked)

5 ND (LP):

max. admissible operating

pressur

e (g) Low pressure side

HD (HP):

max. admissible operating

pressur

e(g) High pressure side

Observe the limits of

application diagrams!

50 Hz

60 Hz

6 Voltage,circuit,frequency

7 Nominal rotation speed

8 Displacement

9 Voltage,circuit,frequency

10 Nominal rotation speed

11 Displacement

12 Oiltypelledatthefactory

13 Terminal box protection type

Electrical accessories can change

the IP protection class!

}

GEA Bock GmbH

72636 Frickenhausen, Germany

96166-05.2012-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 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!

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

Fuchs Reniso SE 55

3.1 Refrigerants

• R410A

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.

96166-05.2012-DGbFEI

Fig. 4

R410A

3|Areas of application

Unlimited application range

Supplementary cooling or

reduced suction gas temperature

Motor version S

(more powerful motor)

Evaporation temperature (°C)

Condensing temperature (°C)

Suction gas temperature (°C)

Max. permissible operating pressure (LP/HP)1): 27/43 bar

1) LP = Low pressure HP = High pressure

96166-05.2012-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.

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

The pipe connections have graduated inside diameters so that pipes

with standart millimetre and inch dimansions 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

4.2 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

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).

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