GEA Bock HG44e Series Assembly Instructions Manual
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GEA Bock HG44e Series Assembly Instructions Manual

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GEA Bock HG44e/HG56e (HC/LG)
Assembly instructions
96416-08.2020-Gb
Translation of the original instructions
HG(X)44e/475-4 (S)
HG(X)44e/565-4 (S)
HG(X)44e/665-4 (S)
HG(X)44e/770-4 (S)
HG44e/475-4 (S) HC ..................... HG44e/770-4 (S) HC
HG56e/850-4 (S) HC ..................... HG56e/1155-4 (S) HC
HGX44e/475 (S/ML) 9 LG .............. HGX44e/770 (S/ML) 22 LG
HGX56e/850 (S/ML) 18 LG ............ HGX56e/1155 (S/ML) 35 LG
HG(X)56e/850-4 (S)
HG(X)56e/995-4 (S)
HG(X)56e/1155-4 (S)

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  • Page 1 GEA Bock HG44e/HG56e (HC/LG) Assembly instructions 96416-08.2020-Gb Translation of the original instructions HG(X)44e/475-4 (S) HG(X)56e/850-4 (S) HG(X)44e/565-4 (S) HG(X)56e/995-4 (S) HG(X)44e/665-4 (S) HG(X)56e/1155-4 (S) HG(X)44e/770-4 (S) HG44e/475-4 (S) HC ..... HG44e/770-4 (S) HC HG56e/850-4 (S) HC ..... HG56e/1155-4 (S) HC HGX44e/475 (S/ML) 9 LG ....

  • Page 2: Table Of Contents

    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. Manufacturer GEA Bock GmbH 72636 Frickenhausen Contact GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Phone +49 7022 9454 0 Fax +49 7022 9454 137 gea.com/contact www.gea.com Contents Page Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use Safety instructions for use of flammable refrigerants 2.1 Safety instructions 2.2 Qualifications required of personnel Product description 3.1 Short description...
  • Page 3 Contents Page Areas of application 4.1 Refrigerants 4.2 Oil charge 4.3 Limits of application Areas of application on HC and LG compressors 5.1 Refrigerants 5.2 Oil charge 5.3 Limits of application Compressor assembly 6.1 Storage and transport 6.2 Setting up 6.3 Pipe connections 6.4 Pipes 6.5 Laying suction ans pressure lines 6.6 Operating the shut-off valves 6.7 Operating mode of the lockable service connections 6.8 Suction pipe filter and filter drier Electrical connection 7.1 Information for contactor and motor contactor selection 7.2 Standard motor, design for direct or partial winding start 7.3 Basic circuit diagram for partial winding start with standard motor 7.4 Special motor: design for direct or star-delta start 7.5 Basic circuit diagram for star-delta start with special motor 7.6 Electronic trigger unit INT69 G...

  • Page 4: Safety

    1| Safety 1.1 Identification 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. 1.2 Qualifications required of personnel WARNING Inadequately qualified personnel poses the risk of accidents, the consequence being serious or fatal injury. Work on compressors is therefore reserved for personnel which is qualified to work on pressurized refrigerant systems: • F or example, a refrigeration technician, refrigeration mechatronic engineer. As well as professions with comparable training, which enables personnel to assemble, install, maintain and repair refrigeration and air-conditioning systems. Personnel must be capable of assessing the work to be carried out and recognising any potential...

  • Page 5: General Safety Instructions

    The maximum permissible overpressure must not be exceeded, even for testing purposes. Risk of burns! - Depending on the operating conditions, surface temperatures of over 60°C on the discharge side or below 0°C on the suction side can be reached. - Avoid contact with refrigerant necessarily. Contact with refrigerant can cause severe burns and skin damage. 1.4 Intended use WARNING The compressor may not be used in potentially explosive environments! These assembly instructions describe the standard version of the compressor named in the title man- ufactured by GEA. GEA refrigerating compressors are intended for installation in a machine (within the EU according to the EU Directives 2006/42/EC Machinery Directive, 2014/68/EU Pressure Equipment Directive). Commissioning is permissible only if the compressor has been installed in accordance with these as- sembly instructions and the entire system into which it is integrated has been inspected and approved in accordance with legal regulations. The compressors are intended for use in refrigeration systems in compliance with the limits of application. Only the refrigerant specified in these instructions may be used. Any other use of the compressor is prohibited!

  • Page 6: Safety Instructions For Use Of Flammable Refrigerants

    2 | Safety instructions for use of flammable refrigerants 2.1 Safety instructions DANGER • Explosion and fire risk! Hydrocarbons and synthetic HFO refrigerants are colourless, combustible gases which occur naturally and which are explosive in a certain blend! • Hydrocarbons are classified into the safety group A3 (highly- inflammable refrigerant) according to EN 378.

  • Page 7: Product Description

    3| Product description 3.1 Short description • HG44e: Semi-hermetic four-cylinder reciprocating compressor with suction-gas cooled drive motor. • HG56e: Semi-hermetic six-cylinder reciprocating compressor with suction-gas cooled drive motor. • Preferred application range: normal refrigerating and air-conditioning. Terminal box Transport eyelet Valve plate Cylinder cover Oil pump Name plate Oil sight glass Fig. 1 HG44e Discharge shut-off valve Suction shut-off valve Drive section Motor section Fig. 2 HG56e Dimension and connection values can be found in Chapter 12...

  • Page 8: Type Key

    3| Product description 3.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany HGX44e/770-4 S BB12345A001 67,0 35,0 A 80,4 101 A 174 A SE 55 Fig. 3 Type designation Voltage, circuit, frequency 50 Hz Machine number Nominal rotation speed maximum operating current Displacement Starting current (rotor blocked) Voltage, circuit, frequency 60 Hz Y: Part winding 1 10 Nominal rotation speed YY: Part windings 1 and 2 11 Displacement ND (LP): max. admissible operating pressure 12 Oil type filled at the factory...

  • Page 9: Type Key Hc Compressors

    3| Product description 3.4 Type key HC compressor (example) 770- Hydrocarbons Motor variant ² Number of poles Swept volume e-series Numbers of cylinders Size Series ¹ ¹ HG - Hermetic Gas-Cooled (suction gas-cooled) ² S - More powerful motor 3.5 Typ key LG compressor (example) HFO refrigerant Engine performance in HP Motor variant Swept volume e-series Numbers of cylinders Size Oil filling ² Series ¹ ¹ HG - Hermetic Gas-Cooled (suction gas-cooled) ² X - Ester oil charge 3) S - More powerful motor ML - Motor for normal cooling and deep freezing...

  • Page 10: Areas Of Application

    4 | Areas of application 4.1 Refrigerants • HFKW / HFC: R134a, R404A/R507, R407C, R407F • (H)FCKW / (H)CFC: 4.2 Oil charge The compressors are filled at the factory with the following oil type: - für R134a, R404A/R507, R407C, R407F FUCHS Reniso Triton SE 55 - für 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. HGX44e/770-4). INFO For refilling, we recommend the above oil types. Alternatives: see lubricants table, Chapter 7.5 ATTENTION The oil level must be in the max. HG44e visible part of the sight glass; 1,6 Ltr. damage to the compressor oil level HG56e is possible if overfilled or...
  • Page 11 4 | Areas of application ATTENTION When operating in the vacuum range, there is a danger of air e ntering 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! Maximum admissible LP = Low pressure operating pressure (g) HP = High pressure (LP/HP) : 19/28 bar...

  • Page 12: Areas Of Application On Hc And Lg Compressors

    5 | Areas of application at HC and LG compressors 5.1 Refrigerants • Hydrocarbons: R290, R1270 (Recommendation quality 2.5 (< 50 ppm H • HFO refrigerants: R1234ze, R1234yf, R455A, R454C 5.2 Oil charge The compressors are factory-charged with the following oil type: • HC compressors: FUCHS Reniso Synth 68 • LG compressors: FUCHS Reniso Triton SE 55 FUCHS Reniso C 85 E (from t > 15°C, must be specified in the order) 5.3 Operating limits ATTENTION Compressor operation is possible within the operating limits. These can be found in Bock compressor selection tool (VAP) under vap.bock.de.

  • Page 13: Compressor Assembly

    6 | Compressor assembly INFO New compressors are factory-filled with inert gas. Leave this ser- vice 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. 6.1 Storage and transport 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. Use transport eyelet. Do not lift manually! Use lifting gear! 6.2 Setting up ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts, etc.) directly to the compressor are not permissible! Provide adequate clearance for maintenance work. Ensure adequate compressor ventilation. Do not use in a corrosive, dusty, damp atmosphere or a combustible environment. Setup on an even surface or frame with sufficient load- bearing capacity. Single compressor preferably on vibration damper.

  • Page 14: Pipe Connections

    6 | Compressor assembly 6.3 Pipe connections ATTENTION Damage possible. Superheating can damage the valve. Remove the pipe supports from the valve for soldering. Only solder using inert gas to inhibit oxidation products (scale). The pipe connections have graduated inside diameters so that pipes with standart millimetre and inch dimensions can be used. T he 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. 5: graduated internal diameter 6.4 Pipes Pipes and system components must be clean and dry inside and free of scale, swarf and layers of rust and phosphate. Only use air-tight parts. Lay pipes correctly. Suitable vibration compensators must be provided to prevent pipes being cracked and broken by severe vibrations. Ensure a proper oil return. Keep pressure losses to an absolute minimum.

  • Page 15: Operating The Shut-Off Valves

    6 | Compressor assembly A rule of thumb: Always lay the first pipe section starting from the shut-off valve downwards and parallel to the drive shaft. Rigid As short as fixed point possible Fig. 6 a) For HG44e a intermediate flange (height 27 mm) is optional available, Art-Nr. 81194. With this intermediate flange it is possible to lay the pressure line directly from the valve to the left or right. 6.6 Operating the shut-off valves Before opening or closing the shut-off valve, release the valve spindle seal by approx. ¼ of a turn counter-clockwise. After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise. Tighten Release Valve spindle seal Fig. 7 Fig. 8...

  • Page 16: Operating Mode Of The Lockable Service Connections

    6 | Compressor assembly 6.7 Operating mode of the lockable service connections Connection cannot Service connection be shut off closed Pipe connection Connection Spindle blocked Fig. 9 Opening the shut-off valve: Compressor Spindle: turn to the left (counter-clockwise) as far as it will go. —> Shut-off valve completely opened / service connection closed. The connection which cannot be shut off is intended for safety devices. Connection cannot Service connection be shut off opened Pipe connection Connection Spindle open Fig. 10 Opening the service connection Compressor Spindle: Turn ½ - 1 turn to the right clockwise. —> Service connection opened / shut-off valve opened. The connection which cannot be shut off is intended for safety devices. After activating the spindle, generally fit the spindle protection cap again and tighten with 14-16 Nm. This serves as a second sealing feature during operation. 6.8 Suction pipe filter and filter drier For systems with long pipes and higher degree of contamination, a filter on the suction-side is recommended. The filter has to be be renewed depending on the degree of contamination (reduced pressure loss).

  • Page 17: Electrical Connection

    7 | Electrical connection Electrical connection DANGER Risk of electric shock! High voltage! Only carry out work when the electrical system is disconnected from the power supply! ATTENTION When attaching accessories with an electrical cable, a minimum bending radius of 3 x the cable diameter must be maintained for laying the cable. INFO Connect the compressor motor in accordance with the circuit diagram (see inside of terminal box). Use suitable cable entry point of the correct protection type (see name plate) for routing cables into the terminal box. Insert the strain reliefs and prevent chafe marks on the cables. Compare the voltage and frequency values with the data for the mains power supply. Only connect the motor if these values are the same. 7.1 Information for contactor and motor contactor selection All protection equipment, switching and monitoring devices must comply with the local safety regula- tions and established specifications (e.g. VDE) and regulations as well as the manufacturer’s speci- fications. Motor protection switches are required! Motor contactors, feed lines, fuses and motor protection switches must be rated according to the maximum operating current (see name plate). For motor protection, use a current-independent, time-delayed overload protection device for monitor- ing all three phases. Adjust the overload protection device so that it must be actuated within 2 hours at 1.2 times the maximum working current. 7.2 Standard motor, design for direct or part winding start Designation on the name plate Sticker on the terminal box Y/YY...
  • Page 18 7.3 Basic circuit diagram for part winding start with standard motor FC1.2 FC1.1 I> I> I> I> I> I> FC1.1 FC1.2 L3 N PE Y/YY B1 B2 INT69 Compressor terminal box Anschlußkasten Verdichter Fig. 11 High pressure safety monitor Safety chain (high/low pressure monitoring ) Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Release switch (thermostat) Datum 20.02.2009 DELTA-P II Oil differential pressure sensor DELTA-P II (accessorie) Bearb. bauknecht Oil sump heater Gepr. 04.08.2017 Οnderung Datum Name Norm...
  • Page 19 L1.1 L2.1 L3.1 L1.2 P> DANGER Explosion risk! Θ Electronic trigger Θ INT69 G at HC and LG Θ compressors has to be installed outside any danger area! See also chapter 7.9. DELTA- P II 6.c.8 FC1.1/1.2 Motor protection switch Control power circuit fuse INT69 G Electronic trigger unit INT69 G Delay relay for contactor switchover Main switch PW INT69 HG44/66 Mains contactor (part winding 1) Mains contactor (part winding 2) BOCK COMPRESSORS Control voltage switch...
  • Page 20 7 | Electrical connection The motor is wired for direct start (YY) at the factory. For part winding start Y / YY, the bridges must be removed and the motor feed line connected according to the circuit diagram: 400 V Direktstart YY Teilwicklungsstart Y/YY Direct start YY Part winding start Y/YY ATTENTION Failure to do this results in opposed rotary fields and results in damage to the motor. After the motor starts up via partial winding 1, partial winding 2 must be switched on after a maximum delay of one second . Failure to comply can adversely affect the service life of the motor.

  • Page 21: Special Motor: Design For Direct Or Star-Delta Start

    7 | Electrical connection 5.4 Sondermotor: Ausführung für Direkt- oder Stern-Dreieck-Anlauf 5.4 Sondermotor: Ausführung für Direkt- oder Stern-Dreieck-Anlauf 5.4 Sondermotor: Ausführung für Direkt- oder Stern-Dreieck-Anlauf 5.4 Special motor: design for direct or star-delta start Für den Stern-Dreieck-Anlauf ist eine mechanische Anlaufentlastung mit Bypass-Magnetventil Für den Stern-Dreieck-Anlauf ist eine mechanische Anlaufentlastung mit Bypass-Magnetventil Für den Stern-Dreieck-Anlauf ist eine mechanische Anlaufentlastung mit Bypass-Magnetventil A mechanical unloaded start with bypass solenoid valve is required for the star-delta start.

  • Page 22: Basic Circuit Diagram For Star-Delta Start With Special Motor

    7.5 Basic circuit diagram for star-delta start with special motor FC1.1 I> I> I> FC1.1 FC1.2 FC1.2 I> I> I> L3 N PE ˜ B1 B2 INT69G Compressor terminal box Anschlußkasten Verdichter Fig. 12 High pressure safety monitor Safety chain (high/low pressure monitoring ) Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Release switch (thermostat) DELTA PII Oil differential pressure sensor DELTA-P II (accessorie) Datum 20.02.2009 Oil sump heater Bearb. bauknecht Gepr. 04.08.2017 Compressor motor Οnderung Datum Name...
  • Page 23 L1.1 L2.1 L3.1 L1.2 P> DANGER Explosion risk! Θ Electronic trigger Θ INT69 G at HC and LG Θ compressors has to be installed outside any danger area! See also chapter 7.9. DELTA- P II 6.b.7 6.b.8 6.b.8 Control power circuit fuse INT69 G Electronic trigger unit INT69 G Delay relay for contactor switchover Main switch Mains contactor Δ-contactor D/S INT69 HG44/66 neu Y-contactor BOCK COMPRESSORS Control voltage switch...
  • Page 24 7 | Electrical connection 7.6 Electronic trigger unit INT69 G The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the electronic trigger unit INT69 G in the terminal box. In case of excess temperature in the motor winding, the INT69 G deactivates the motor contactor. Once cooled, it can be restarted only if the electronic lock of the output relay (terminals B1+B2) is released by interrupting the supply voltage. The hot gas side of the compressor can also be protected against overtemperature using thermal protection thermostats (accessory).
  • Page 25 7 | Electrical connection 7.8 Function test of the trigger unit INT69 G Before commissioning, after troubleshooting or making changes to the control power circuit, check the functionality of the trigger unit. Perform this check using a continuity tester or gauge. Relay position INT69 G Gauge state Relay position Deactivated state 11-12 INT69 G switch-on 11-14 B2 12 14 11 Remove PTC connector 11-12 Fig. 14 Insert PTC connector 11-12 Reset after mains on 11-14 7.9 Electronic trigger unit INT69 G at HC and LG compressors The supplied INT69 G must be connected according to the wiring diagram shown here in a separate control cabinet, which must be installed outside each danger zone. ATTENTION Install heat protection thermostats and cold conductor motor winding in series! Schaltschrank Schaltschrank Switch cabinet INT69G INT69G Cold conductor (PTC 10 11 12 13 20 21 sensor) motor winding 10 11 12...

  • Page 26: Oil Sump Heater (Accessories)

    7 | Electrical connection 7.10 Oil sump heater (accessories) When the compressor is at a standstill, refrigerant diffuses into the lubricating oil of the compressors housing, depending on pressure and ambient temperature. This reduces the lubricating capacity of the oil. When the compressor starts up, the refrigerant contained in the oil evaporates out throught the reduction in pressure. The consequences can be foaming and migration of the oil, causing oil shocks under certain circumstances. Operation: The oil sump heater operates when the compressor is at a standstill. When the compres- sor starts up, the oil sump heater switches off again automatically. Connection: The oil sump heater must be connected via an auxiliary contact (or parallel wired auxili- Anschlussschema für Ölsumpfheizung ary contact) of the compressor contactor to a seperate electric circuit. Connection diagramm for oil sump heater El. data: 230 V - 1 - 50/60 Hz, 160 W. Plan de raccordement pour résistance de carter d‘huile Fig. 16 ATTENTION Connection to the current path of the safety control chain is not permitted.

  • Page 27: Oil Sump Heater On Hc And Lg Compressors

    7 | Electrical connection 7.11 Oil sump heater at HC and LG compressors As the solubility of hydrocarbons and HFO refrigerants in oil can be very high, especially at high suction pressures, the compressor must be equipped with an oil sump heater. For this reason, a pump-down circuit is recommended during standstill to reduce the suction-side standstill pressures. ATTENTION The oil sump heater must generally be connected and operated! • In a TT- or TN system, a residual current protection device (RCD) must be used.

  • Page 28: Commissioning

    8 | Commissioning 8.1 Preparations for start-up INFO To protect the compressor against inadmissible operating conditions, high pressure and low pressure pressostats are mandatory on the installation side. The compressor has undergone trials in the factory and all functions have been tested. There are therefore no special running-in instructions. Check the compressor for transport damage! 8.2 Pressure integrity test The compressor has been tested in the factory for pressure integrity. If however the entire system is to be subjected to a pressure integrity test, this should be carried out in accordance with EN 378-2 or a corresponding safety standard without the inclusion of the compressor. 8.3 Leak test DANGER Risk of bursting! The compressor must only be pressurised using nitrogen (N Never pressurise with oxygen or other gases! The maximum permissible overpressure of the compressor must not be exceeded at any time during the testing process (see name plate data)! Do not mix any refrigerant with the nitrogen as this could cause the ignition limit to shift into the critical range.

  • Page 29: Refrigerant Charge

    8 | Commissioning 8.5 Refrigerant charge CAUTION Wear personal protective clothing such as goggles and protective gloves! Make sure that the suction and pressure line shut-off valves are open. With the compressor switched off, add the liquid refrigerant directly to the condenser or receiver, breaking the vacuum. If the refrigerant needs topping up after starting the compressor, it can be topped up in vapour form on the suction side, or, taking suitable precautions, also in liquid form at the inlet to the evaporator. ATTENTION Avoid overfilling the system with refrigerant! To avoid shifts in concentration, zeotropic refrigerant blends must always only be filled into the refrigerating plant in liquid form. Do not pour liquid coolant through the suction line valve on the compressor. It is not permissible to mix additives with the oil and refrigerant. 8.6 Start-up WARNING Ensure that both shut-off valves are open before starting the compressor! Check that the safety and protection devices (pressure switch, motor protection, electrical contact protection measures, etc.) are all functioning properly. Switch on the compressor and allow to run for a minimum of 10 min. Check the oil level by: The oil must be visible in the sightglass. ATTENTION I f larger quantities of oil have to be topped up, there is a risk of oil hammer effects. If this is the case check the oil return!

  • Page 30: Connection Of Oil Level Regulator

    8 | Commissioning 8.7 Avoiding slugging ATTENTION Slugging can damage the compressor and cause refrigerant to leak. To prevent slugging: The complete refrigeration system must be properly designed. All components must be compatibly rated with each other with regard to output (particularly the evaporator and expansion valves). Suction gas superheat at the compressor input should be min. 7 - 10 K. (check the setting of the expansion valve). For HC and LG compressors see chapter 5.3. The system must reach a state of equilibrium. Particularly in critical systems (e.g. several evaporator points), measures are recommended such as replacement of liquid traps, solenoid valve in the liquid line, etc. There should be no movement of coolant whatsoever while the compressor is at a standstill. 8.8 Connection of oil level regulator Oil level regulation systems have proven themselves with parallel circuits of several compressors. The connection "0" is provided for installing an oil level regulator (see dimensions drawing). All common oil level regulators from AC&R, ESK and Carly as well as the OM3 TraxOil oil level regulation system from Alco can be connected directly without adapters (see Fig. 17). A sight glass on the oil level regulator is not required. Anschluss Ölspiegelregulator Bei Verbundschaltungen von mehreren Verdichtern haben sich Ölstandsregulierungssysteme bewährt. Für die Montage eines Ölspie- M6 x 10 gelregulators ist der Anschluss „O“...

  • Page 31: Maintenance

    9 | Maintenance 9.1 Preparation WARNING Before starting any work on the compressor: Switch off the compressor and secure it to prevent a restart. Relieve compressor of system pressure. Prevent air from infiltrating the system! After maintenance has been performed: Connect safety switch. Evacuate compressor. Release switch lock. 9.2 Work to be carried out In order to guarantee optimum operational reliability and service life of the compressor, we r ecommend carrying out servicing and inspection work at regular intervals: Oil change: -...

  • Page 32: Extract From The Lubricants Table

    9 | Maintenance 9.4 Extract from the lubricants table The oil type filled as standard in the factory is marked on the name plate . This oil type should be used as a preference. Alternatives are stated in the extract from our lubricants table below. Do not mix oils with each other, use only one type of oil. Refrigerants Bock standard oil types Recommended alternatives Fuchs Reniso Triton SEZ 32 Esso/Mobil EAL Arctic 46 (e.g. R134a, R407C, Fuchs Reniso Triton SE 55 Sunoco Suniso SL 46 R404A) Texaco Capella HFC 55 HFO (e.g. R1234yf, Fuchs Reniso Triton SE 55 R1234ze, R455A, Fuchs Reniso C85E (from t > 15°C) R454C)) Fuchs Reniso SP 32 BP Energol LPT 46 HCFC (e.g. R22) Fuchs Reniso SP 46 Sunoco Suniso 3,5 GS Texaco Capella WF 46 HC (e.g. R290) Fuchs Synth 68 CPI 1516-68 9.5 Decommissioning Close the shut-off valves on the compressor. Drain the refrigerant (it must not be discharged into the environment) and dispose of it according to the regulations. When the compressor is depressurised, undo the fastening screws of the shut-off valves. Remove the compressor using an appropriate hoist.

  • Page 33: Accessories

    10 | Accessories 10.1 Capacity regulator ATTENTION If the capacity regulator is installed at the factory, it is subsequently installed and connected by the customer. CR 1 CR 1 CR 2 Fig. 18 HG44e HG56e Fig. 19 Fig. 20 Delivery condition 1 (from the factory): Before commissioning, the blind flange with Cylinder cover prepared for capacity regulator. screws must be removed and replaced by the new set capacity regulator with O-ring joints and screws. Observe position and construction of the capacity regulator. Attention! Compressor is under pressure! Depressurize the compressor first. Fig. 21 Delivery condition 2 (from the factory): Connect capacity regulator in terminal box or switch cabinet.
  • Page 34 LR1 60s LR2 Swiching off LR2 60s ATTENTION Capacity-regulated operation alters the gas speeds and pressure r atios of the refrigerating plant: Adjust the suction line routing and dimensioning accordingly, do not set the control intervals too close and do not let the system switch more than 12 times per hour (refrigerating plant must have reached a state of equilibrium). Continuous operation in the control stage is not recommended as the gas velocity in the plant system under certain circumstances does not guarantee sufficient oil return to the compressor with activated capacity regulator. W e recommend switching to unregulated operation (100% capac- ity) for at least 5 minutes per capacity-regulated operating hour. An assured oil return can also be realised by a 100% capacity requirement after each compressor restart. E lectrical actuation of the solenoid valve: Normally open, (cor- responds to 100 % compressor capacity). Special accessories are only premounted in the factory if ordered specially by customer. Retrofitting is possible in full compliance with the safety instructions and repair instructions enclosed with the kits. Information about the use, operation, maintenance and servicing of the components is available in the printed literature or on the internet under www.gea.com. For the capacity regulator a step protection is optional available, Art-Nr. 81449. Fig. 22...

  • Page 35: Technical Data

    11 | Technical data Oil charge (sight glass centre) Oil charge (ex works) Suction line Discharge line Weight Starting current (rotor locked) Max. power consumption Max. operating current 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW Voltage PW = Part Winding Winding ratio : 50 % / 50 % Displacement (1450 / 1740 rpm) No. of cylinders Type...
  • Page 36 11 | Technical data Oil charge (sight glass centre) Oil charge (ex works) Suction line Discharge line Weight Starting current (rotor locked) Max. power consumption Max. operating current 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW Voltage PW = Part Winding Winding ratio : 50 % / 50 % Displacement (1450 / 1740 rpm) No. of cylinders Type...

  • Page 37: Dimensions And Connections

    12 | Dimensions and connections HG44e (Dimensions and connections for HC and LG compressors are identical to the standard compressors) Anschlüsse / Anschlüsse / Connections Connections Saugabsperrventi Saugabsperrventi Centre of gravity B B1 DV B B1 DV Suction line valve Suction line valve Druckabsperrvent Druckabsperrvent Discharge line val Discharge line val Anschluss Saugse Anschluss Saugse Connection suctio Connection suctio Anschluss Saugse...
  • Page 38 6e/850-4 Rechte für den Fall der Patent-, Gebrauchsmuster- Freigabe / Approved A. Layh A. Layh GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de 24.01.17 -Nr. / Mod-No. Datum / Date Bearb. / Edited Geprüft / Appr.

  • Page 39: Declaration Of Incorporation

    13 | Declaration of incorporation Declaration of incorporation for incomplete machinery in accordance with EC Machinery Directive 2006/42/EC, Annex II 1. B Manufacturer: GEA Bock GmbH Benzstraße 7 72636 Frickenhausen, Germany We, as manufacturer, declare in sole responsibility that the incomplete machinery...

  • Page 40: Service

    14 | Service Dear customer, Bock compressors are top-quality, reliable and service-friendly quality products. If you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The Bock service team can be contacted by phone, +49 (0)7022 9454-0 or via gea.com/contact Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany...
  • Page 42 • • GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX ®...

This manual is also suitable for:

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