GEA HG34P Series Bedienungsanleitung

09618-05.2012-DGbFEI

engineering for a better world GEA Refrigeration Technologies

Bock Compressor HG34P

Assembly instructions

HG34P/125-4 HG34P/125-4 S HGX34P/125-4 HGX34P/125-4 S

HG34P/255-4 HG34P/255-4 S HGX34P/255-4 HGX34P/255-4 S

HG34P/315-4 HG34P/315-4 S HGX34P/315-4 HGX34P/315-4 S

HG34P/380-4 HG34P/380-4 S HGX34P/380-4 HGX34P/380-4 S

1 1

09618-05.2012-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

09618-05.2012-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 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 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

09618-05.2012-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.

09618-05.2012-DGbFEI

1|Safety

These assembly instructions describe the standard version of the HG34P 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!

09618-05.2012-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

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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

AS38125A001

GEA Bock GmbH

72636 Frickenhausen, Germany

21,1/12,2A

121A 70A

27,3

32,8

HGX34P/315-4

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

pressur

e (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

HG 43 P 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) Additional declaration for Pluscom compressors

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

Motor variant 4)

Number of poles

Swept volume

³)

Numbers of cylinders

Size

Oil charge ²)

Series ¹)

09618-05.2012-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 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. HGX34P/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.

09618-05.2012-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. 4

Fig. 5

Fig. 6

Fig. 7

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

09618-05.2012-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. 8

Fig. 9

Fig. 10

Fig. 11

4.2 Pipe connections

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. 12: 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.

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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