Related Manuals for GEA HGX5/725-4 R134a
Summary of Contents for GEA HGX5/725-4 R134a
- Page 1 Bock Compressor HGX5 R134a Assembly instructions HGX5/725-4 R134a HGX5/830-4 R134a HGX5/945-4 R134a engineering for a better world GEA Refrigeration Technologies...
- Page 2 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 bock@gea.com www.bock.de...
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Page 3: Table Of Contents
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 Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application Compressor assembly 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 Electrical connection 5.1 Information for contactor and motor contactor selection... -
Page 4: Safety
1| Safety 1.1 Identification of safety instructions: Indicates a dangerous situation which, if not DANGER! avoided, will cause immediate fatal or serious injury. Indicates a dangerous situation which, if not WARNING! avoided, may cause fatal or serious injury. Indicates a dangerous situation which, if not CAUTION! avoided, may cause fairly severe or minor injury. Indicates a situation which, if not ATTENTION! avoided, may cause property damage. INFO! Important information or tips on simplifying work. 1.2 Qualifications required of personnel WARNING! I nadequately qualified 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 qualifica- tions listed below: • F or example, a refrigeration technician, refrigeration mechatron-... -
Page 5: Intended Use
1| Safety 1.4 Intended use 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 specified in these instructions may be used. Any other use of the compressor is prohibited! WARNING! The compressor may not be used in potentially explosive environments! 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 a ssembly instructions and the entire system into which it is integrated has been inspected and a pproved in accordance with legal regulations. -
Page 6: Product Description
2| Product description 2.1 Short 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. Terminal box Transport eyelet Suction shut- off valve Valve plate Motor section Cylinder cover Discharge shut-off valve Oil pump Name plate Drive section Oil sight glass Fig. 1 Dimension and connection values can be found in Chapter 9... -
Page 7: Type Key
2| Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany HGX5/945-4 R134a AS12345-001 33 A 110 A 141 A SE 55 Fig. 2 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... -
Page 8: Areas Of Application
3| Areas of application 3.1 Refrigerants • HFKW / HFC: R134a 3.2 Oil charge The compressors are filled 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). INFO! For refilling, we recommend the above oil types. Alternatives: see lubricants table, Chapter 7.5. The oil level must be in the visible ATTENTION! part of the sight glass; damage max. oil level to the compressor is possible if min. oil level overfilled or underfilled! Fig. 3... - Page 9 3| Areas of application R134a Fig. 4 Unlimited application range Supplementary cooling or reduced suction gas temperature Evaporation temperature (°C) 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...
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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 Setting up Use transport eyelet. Do not lift manually! Use lifting gear! Fig. 5 Provide adequate clearance for maintenance work. -
Page 11: Pipes
4| Compressor assembly 4.3 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. 4.4 Laying suction and pressure lines INFO! Proper layout of the suction and pressure lines directly after the compressor is integral to the smooth running and vibration behaviour of the system. -
Page 12: Operating The Shut-Off Valves
4| Compressor assembly 4.5 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. Release Tighten Valve spindle seal Fig. 11 Fig. 12 4.6 Operating mode of the lockable service connections Connection cannot be Service connec- shut off tion closed Pipe connection Connection Spindle blocked Fig. 13 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 be Service connec- shut off tion opened Pipe connection Connection... -
Page 13: Information For Contactor And Motor Contactor Selection
5| Electrical connection Electrical connection DANGER! H igh voltage! Risk of electric shock! Only carry out work when the electrical system is disconnected from the power supply! INFO! C onnect the compressor motor in accordance with the circuit diagram (see inside of terminal box). U se suitable cable entry point of the correct protection type (see name plate) for routing cables into the terminal box. I nsert the strain reliefs and prevent chafe marks on the cables. -
Page 14: Basic Circuit Diagram For Part Winding Start With Standard Motor
5.3 Basic circuit diagram for part winding start with standard motor 0 1 2 3 4 F1.2 F1.1 I=33% I=66% F1.1 F1.2 XSS X1 L1 L1 N N 43 43 11 Y/YY X2 1 MP10 Compressor terminal box AnschluastenVerdichter Fig. 15 R1 Cold conductor (PTC sensor) motor winding R2 Thermal protection thermostat (PTC sensor) F1.1 /1.2 2 motor protection switches (66% / 33% of I... - Page 15 5 6 7 8 9 L1.1 L2.1 L3.1 L1.2 P> P< Pl Q1 Main switch M1 Compressor motor K1 Mains contactor (part winding 1) K2 Mains contactor (part winding 2) K1T Delay relay max. 1s S1 Control voltage switch E1 Oil sump heater PWMP10 BKMPRESSRS...
- Page 16 5| 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 400 V 400 V Direct start YY Part winding start Y/YY Direktstart YY Teilwicklungsstart Y/YY Direktstart YY Teilwicklungsstart Y/YY ATTENTION! F ailure to do this results in opposed rotary fields and results in damage to the motor.
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Page 17: Special Motor: Design For Direct Or Star-Delta Start
5| 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 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... - Page 18 5.5 Basic circuit diagram for star-delta start with special motor 0 1 2 3 4 F1.1 F1.1 F1.2 F1.2 XSS X1 L1 L1 N N 43 43 11 X2 1 MP10 AnschluastenVerdichter Compressor terminal box Fig. 16 R1 Cold conductor (PTC sensor) motor winding R2 Thermal protection thermostat (PTC sensor) F1.1 /1.2 2 motor protection switches Control power circuit fuse F3 High pressure safety monitor...
- Page 19 5 6 7 8 9 L1.1 L2.1 L3.1 L1.2 P> P< Pl M1 Compressor motor K1 Mains contactor ∆ K2 -contactor K3 Y-contactor K4T Delay relay S/D changeover K5T Delay relay, start unloader S1 Control voltage switch AL Start unloader E1 Oil sump heater MP10 BKMPRESSRS...
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Page 20: Electronic Trigger Unit Mp
5| Electrical connection 5.6 Electronic trigger unit MP 10 The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the electronic trigger unit MP 10 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. -
Page 21: Functional Test Of The Trigger Unit Mp
5| Electrical connection 5.8 Function test of the trigger unit MP 10 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 S1) • 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 S1) •... -
Page 22: Oil Sump Heater (Accessories)
5| Electrical connection 5.9 Oil sump heater (accessories) During compressor standstill and depending on the pressure and ambient temperature, r efrigerant diffuses into the compressor's lubricating oil. This reduces the oil's lubricating ability. When the c ompressor is started, the refrigerant contained in the oil evaporates due to the decline in pressure. This can result in oil foaming and oil exodus which can result in oil hammer in certain circumstances. Operation mode: The oil sump heater operates when the compressor is shut down. The oil sump heater is switched off when the compressor starts. Connection: Connect the oil sump heater via an auxiliary contact (or parallel-wired auxiliary Anschlussschema für Ölsumpfheizung c ontactor) of the compressor contactor to a separate current path. Connection diagramm for oil sump heater Electrical data: 230 V - 1 - 50/60 Hz, 140 W. Plan de raccordement pour résistance de carter d‘huile Fig. 18 ATTENTION! Connection to the current path of the safety control chain is not permitted... -
Page 23: Commissioning
6| Commissioning 6.1 Preparations for start-up INFO! In order to protect the compressor against inadmissible operating conditions, high-pressure and low-pressure pressostats controls 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! Bursting! The compressor must only be pressurised using nitrogen ). - Page 24 6| Commissioning 6.5 Refrigerant filling 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. INFO! Avoid overfilling the system with refrigerant! I n order to prevent shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always only be added to the refrigerating system in liquid form.
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Page 25: Connection Of Oil Level Regulator
6| Commissioning 6.8 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. 18). 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“ vorgesehen (siehe Maßzeichnung). je 3 mal 3 times each Alle gängigen Ölspiegelregulatoren von AC&R, ESK sowie das elek-... -
Page 26: Accessories
7| Maintenance 7.3 Recommended spare parts HGX5 / ... R134a 725-4 830-4 925-4 Designation Ref. No. Ref. No. Ref. No. Set of gaskets 08961 Valve plate kit 80719 Oil pump kit 08384 Oil sump heater kit 08426 230 V ~ Only use genuine Bock spare parts! 7.4 Accessories Available accessories can be found on the Internet at www.bock.de. 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. -
Page 27: Technical Data
8| Technical data 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW PW = Part Winding Winding ratio: 66% / 33%... -
Page 28: Dimensions And Connections
13740 HG5/830-4 13742 HG5/945-4 13744 HGX5/725-4 R134a 14730 View X: Possibility of connection of oil level regulator View X: Possibility of connection of oil level regulator Vibration absorbers Vue X : Raccord pour régulateur de niveau d’huile Vue X : Raccord pour régulateur de niveau d’huile... - Page 29 9| Dimensions and connections Suction line see technical data, Chapter 8 Discharge line Connection suction side, not lockable 8 “ NPTF Connection suction side, lockable 16 “ UNF Connection discharge side, not lockable 8 “ NPTF Connection discharge side, lockable 16 “ UNF Connectoin oil pressure switch OIL 16 “ UNF Connection oil pressure switch LP 16 “ UNF Connection oil return from oil separator 4 “ NPTF Connection oil pressure gauge 16 “ UNF Oil drain M22 x 1,5 Oil charge plug M22 x 1,5...
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Page 30: Declaration Of Conformity And Installation
10| Declaration of conformity and installation DECLARATION OF CONFORMITY CE 96 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: HGX5 R134a 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 HGX5 R134a complies with the basic require- ments 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 31: Service
11| 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 with a toll-free hotline 00 800 / 800 000 88 or via e-mail: bock@gea.com. Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany We also provide information on the Internet at www.bock.de. For example, under the "Documentation" link you will find: - Technical information - Product information - Product brochures - and much more... - Page 32 • • 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® Europe 600 index.