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Related Manuals for GEA Bock HG12P/75-4
Summary of Contents for GEA Bock HG12P/75-4
- Page 1 GEA Bock Compressor HG12P Assembly instructions HG12P/75-4 HG12P/60-4 S HGX12P/75-4 HGX12P/60-4 S HG12P/90-4 HG12P/75-4 S HGX12P/90-4 HGX12P/75-4 S HG12P/110-4 HG12P/90-4 S HGX12P/110-4 HGX12P/90-4 S HG12P/110-4 S HGX12P/110-4 S engineering for a better world...
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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 Telephone +49 7022 9454 0 Fax +49 7022 9454 137 refrigeration@gea.com 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 Product description 2.1 Short description 2.2 Name plate 2.3 Type key... - Page 3 Contents Page Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application Compressor assembly 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 Electrical connection 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 --> with MP10 5.4 Electronic trigger unit MP10 5.5 Connection of the electronic trigger unit MP10 5.6 Functional test of the electronic trigger unit MP10 5.7 Circuit diagram for direct start 230 V Δ / 400 V Y --> with INT69 G 5.8 Electronic trigger unit INT69 G...
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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. -
Page 5: General Safety Instructions
1| Safety 1.3 General safety instructions WARNING Risk of accidents. Refrigerating compressors are pressurised machines and as such call for heightened caution and care in handling. 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. -
Page 6: Product Description
2| Product description 2.1 Short description • Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication. • Suction gas cooled drive motor. Transport eyelet Valve plate Name plate Oil pump Oil sight glass Fig. 1 Cylinder cover Terminal box Discharge shut-off valve Drive section Motor section Suction shut-off valve Fig. 2 Dimension and connection values can be found in Chapter 9... -
Page 7: Type Key
2| Product description Typschild (Beispiel) 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany HGX12P/110-4S AS35830A001 AS35830A001 10,6/6,1A 11,3 SE 55 Fig. 3 Typbezeichnung Spannung, Schaltung, Frequenz Type designation Voltage, circuit, frequency 50 Hz Maschinennummer Nenndrehzahl 50 Hz Machine number Nominal rotation speed maximaler Betriebsstrom Hubvolumen... -
Page 8: Areas Of Application
3| Areas of application 3.1 Refrigerants • HFKW / HFC: R134a, R404A/R507, R407C • (H)FCKW / (H)CFC: 3.2 Oil charge The compressors are filled 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. HGX12P/110-4). 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. - Page 9 3| Areas of application R134a Fig. 5 R407C Fig. 6 Unlimited application range Supplementary cooling or reduced suction gas temperature Supplementary cooling and R404A/R507 reduced suction gas temperature Motor version S (more powerful motor) Evaporation temperature (°C) Fig. 7 Condensing temperature (°C) Suction gas superheat (K) Suction gas temperature (°C) Max. permissible operating pressure (LP/HP) : 19/28 bar LP = Low pressure HP = High pressure Design for other areas on request Fig. 8...
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Page 10: Compressor Assembly
4| Compressor assembly INFO New compressors are factory-filled 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 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. -
Page 11: Pipes
4| Compressor assembly 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. 14: graduated internal diameter 4.4 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. -
Page 12: Operating The Shut-Off Valves
4| Compressor assembly 4.6 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. 16 Fig. 17 4.7 Operating mode of the lockable service connections Service connec- tion closed Pipe connection Spindle Connection blocked Compressor Fig. 18 Opening the shut-off valve: Spindle: turn to the left (counter-clockwise) as far as it will go. —> Shut-off valve completely opened / service connection closed. Service connec- tion opened Pipe connection... -
Page 13: Electrical Connection
5| 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! 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. 5.1 Information for contactor and motor contactor selection All protection devices and switching or monitoring units must be fitted in accordance with the local safety regulations and established specifications (e.g. VDE) as well as with the manufacturer’s infor-... - Page 14 5.3 Circuit diagramm for direct start 230 V ∆ / 400 V Y --> compressor with MP10 I> I> I> X1 L1 L1 N N 43 43 11 -EC1 Θ MP10 X2 1 Compressor terminal box Klemmenkasten Verdichter Fig. 20 Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Load circuit safety switches Control power circuit fuse Safety chain (high/low pressure monitoring) Release switch (thermostat/pressostat)
- Page 15 L1.1 L2.1 L3.1 L1.2 A1 Alarm Motorschutz Alarm motor protection Overheating BT1, BT2 A2 Übertemperatur BT1, BT2 P< Alarm high pressure A3 Alarm Hochdruck Main switch Control voltage switch Compressor motor Compressor contactor MP10 Electronic trigger unit MP10 Oil sump heater...
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Page 16: Electronic Trigger Unit Mp10
5| Electrical connection 5.4 Electronic trigger unit MP10 The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the elec- tronic trigger unit MP10 in the terminal box. Readiness to operate is signalled by the H3 LED (green) after the power supply is applied. In the case of excess temperature in the motor winding, the unit switches off the compressor and the H1 LED lights red. The hot gas side of the compressor can also be protected against overtemperature using a thermal protection thermostat (accessory). The H2 LED (red) is provided for the protection function. The unit trips when an overload or inadmissible operating conditions occur. Find and remedy the cause. INFO The unit has a restart prevention device. After you have rectified the fault, interrupt the mains voltage. This unlocks the restart prevention device and the LEDs H1 and H2 go out. - Page 17 5| Electrical connection 5.6 Function test of the trigger unit MP10 Before start-up, troubleshooting or making changes to the control power circuit, check the functionality of the trigger unit: LED H1 LED H2 LED H3 Procedure green • Interrupt power supply (L1 or SF1) • Release the motor temperature sensor connection (1 or 2) • Release the hot gas temperature sensor (if installed) (3 or 4) • Restore the power supply (L1 or SF1) •...
- Page 18 5.7 Circuit diagramm for direct start 230 V ∆ / 400 V Y --> compressor with INT69 G I> I> I> B1 B2 -EC1 INT69 G Θ Compressor terminal box Klemmenkasten Verdichter Fig. 22 Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Load circuit safety switches Control power circuit fuse Safety chain (high/low pressure monitoring) Release switch (thermostat/pressostat)
- Page 19 L1.1 Alarm motor protection A1 Alarm Motorschutz Overheating BT1, BT2 A2 Übertemperatur BT1, BT2 P< Alarm high pressure A3 Alarm Hochdruck Main switch Control voltage switch Compressor motor Compressor contactor INT69 G Electronic trigger unit INT69 G Oil sump heater...
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Page 20: Electronic Trigger Unit Int69 G
5| Electrical connection 5.8 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. - Page 21 5| Electrical connection 5.10 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. 24 Insert PTC connector 11-12 Reset after mains on 11-14...
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Page 22: Preparations For Start-Up
6| Commissioning 6.1 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! 6.2 Pressure strength test DANGER Risk of bursting! The compressor must only be pressurised using nitrogen (N Never pressurise with oxygen or other gases! -
Page 23: Refrigerant Charge
6| Commissioning 6.5 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 (e.g. R407C) 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. 6.6 Start-up WARNING Ensure that both shut-off valves are open before starting the... -
Page 24: Connection Of Oil Level Regulator
Annual checks: Oil level, leak tightness, running noises, pressures, temperatures, function of a uxiliary devices such as oil sump heater, pressure switch. 7.3 Spare parts recommendation HG12P / ... 60-4 S 75-4 (S) 90-4 (S) 110-4 (S) Designation Ref. No. Ref. No. Ref. No. Ref. No. Set of gaskets 80339 Valve plate kit 80352 80353 Oil pump kit 08324 Only use genuine GEA Bock spare parts! -
Page 25: Accessories
7| Maintenance 7.4 Accessories Available accessories can be found on the Internet at www.gea.com 7.5 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. Refrigerants GEA Bock standard oil types Recommended alternatives Fuchs Reniso Triton SEZ 32 Esso/Mobil EAL Arctic 46 Fuchs Reniso Triton SE 55 (e.g. R134a, R407C, Sunoco Suniso SL 46 R404A) -
Page 26: Technical Data
8| Technical data 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz... -
Page 27: Dimensions And Connections
14545 HGX12P/90-4 S 14553 HG12P/75-4 an dieser Zeichnung vor. 14542 HGX12P/75-4 14550 HG12P/90-4 S 14545 HGX12P/90-4 S 14553 Geprüft 17.01.05 Layh HG12P/75-4 S 14543 HGX12P/75-4 S 14551 HG12P/110-4 14546 HGX12P/110-4 14554 Maß Passung HG12P/75-4 S 14543 HGX12P/75-4 S 14551 HG12P/110-4... -
Page 28: Declaration Of Conformity And Installation
10| Declaration of conformity and installation DECLARATION OF CONFORMITY CE 04 for using the compressors within the European Union (in accordance with Low Voltage Directive 2006/95/EC) We hereby declare that the following refrigerating compressors Product designation: HG12P comply with the Low Voltage Directive 2006/95/EC. Applied harmonised standard: EN 60034-1:2010 EN 60204-1:2006 DECLARATION OF INSTALLATION for using the compressors within the European Union (in accordance with Machinery Directive 2006/42/EC) The manufacturer: GEA Bock GmbH, Benzstraße 7 72636 Frickenhausen, Tel.: 07022/9454-0 hereby declares that the refrigerating compressor HG12P complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. Applied harmonised standard: EN 12693:2008 and the corresponding standards referenced A partly completed machine may only be put into operation when it has been established that the machine, into which the partly completed machine is to be installed, conforms to the r egulations of the Machinery Directive (2006/42/EC). The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery on request. The special technical documentation required for partly completed machinery has been created in accordance with Appendix VII Part B. -
Page 29: Service
11| Service Dear customer, GEA Bock compressors are top-quality, reliable and service-friendly quality products. If you have any questions about installation, operation and accessories, please contact our techni- cal service or specialist wholesaler and/or our representative. The GEA Bock service team can be contacted by phone with a toll-free hotline 00 800 / 800 000 88 or via e-mail: refrigeration@gea.com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany... - Page 30 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 Europe 600 index. ® GEA Bock GmbH Benzstraße 7, 72636 Frickenhausen, Germany Telephone: +49 7022 9454-0, Fax: +49 7022 9454-137 refrigeration@gea.com, www.gea.com...