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Related Manuals for GEA HG7 Series
Summary of Contents for GEA HG7 Series
- Page 1 Bock Compressor HG7 Assembly instructions HG7/1620-4 HG7/1620-4 S HGX7/1620-4 HGX7/1620-4 S HG7/1860-4 HG7/1860-4 S HGX7/1860-4 HGX7/1860-4 S HG7/2110-4 HG7/2110-4 S HGX7/2110-4 HGX7/2110-4 S engineering for a better world GEA Refrigeration Technologies...
- Page 2 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...
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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... -
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 HG7 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... -
Page 6: Product Description
2| Product description 2.1 Short description • Semihermetic six-cylinder reciporating compressor with oil pump lubrication. • The stream of coolant sucked out of the evaporator flows over the motor and cools it intensively. In this way, the motor can be kept at a relatively low temperature level, particularly under high loads. • Cylinder arrangement in pairs in W-design. Suction Terminal box shut-off valve Transport eyelet Cylinder Valve plate cover Motor section Discharge... -
Page 7: Type Key
2| Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany AS09529A001 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 Δ: Part winding 1 10 Nominal rotation speed... -
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. - Page 9 R134a Fig. 4 Unlimited application range Additional cooling or reduced suction gas temperature Additional cooling and reduced R407C suction gas temperature Motor variant - S (stronger motor) Fig. 5 Evaporation temperature (°C) Condensing temperature (°C) Suction gas superheat (K) Suction gas temperature (°C) Max.
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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. -
Page 11: Pipes
4| Compressor assembly INFO! For compressors HG7/2110-4 and HG7/2110-4 S, solder connections are mounted to the suction shut-off valve for pipe diameter 64. Solder connections for pipe diameter 2 5/8“ are enclosed with the compressor. 4.3 Pipes Pipes and system components must be clean and dry inside and free of scale, swarf and layers of rust and phosphate. -
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. Tighten Release Valve spindle seal Fig. -
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! 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. -
Page 14: Basic Circuit Diagram For Part Winding Start With Standard Motor Dgb
5.2 Basic circuit diagram for part winding start with standard motor F1.2 F1.1 I=33% I=66% F1.1 F1.2 X SS X1 L1 L1 N N 43 43 11 /YYY X2 1 MP10 R2 R2 R2 Compressor terminal box Anschluákasten Verdichter Fig. 18 Cold conductor PTC sensor motor winding Thermal protection thermostat (PTC sensor) F1.1 / 1.2 2 motor safety switches (60% / 40% of I... - Page 15 L1.1 L2.1 L3.1 L1.2 P> P< Pl Main switch Compressor motor K1 Mains contactor (part winding 1) K2 Mains contactor (part winding 2) K1T Delay relay max. 1s Control voltage switch Oil sump heater PW MP10 BOCK COMPRESSORS...
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Page 16: Standard Motor, Design For Direct Or Partial Winding Start
5| Electrical connection 5.3 Standard motor, design for direct or part winding start Designation on the name plate Sticker on the terminal box ∆/YYY Compressors with this marking are suitable for direct or partial winding start. The motor winding is subdivided into two parts: Part winding 1 = 60% and part winding 2 = 40%. This winding division reduces the start-up current needed for a part winding start to approx. -
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 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 Mechanical start unloader with bypass solenoid (accessories) is requiered for star delta... - Page 18 5.5 Basic circuit diagram for star-delta start with special motor F1.2 F1.1 I=33% I=66% F1.1 F1.2 X SS X1 L1 L1 N N 43 43 11 X2 1 MP10 R2 R2 R2 Compressor terminal box Anschluákasten Verdichter Fig. 19 Cold conductor PTC sensor motor winding Thermal protection thermostat (PTC sensor) F1.1 / 1.2 2 motor safety switches Control power circuit fuse...
- Page 19 L1.1 L2.1 L3.1 L1.2 P> P< Pl Main switch Compressor motor K1 Mains contactor ∆-contactor K2 K3 Y-contactor K4T Delay relay for contactor changeover Control voltage switch Oil sump heater PW MP10 BOCK COMPRESSORS...
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Page 20: Electronic Trigger Unit Mp
5| Electrical connection 5.4 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. - Page 21 5| Electrical connection 5.6 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) •...
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Page 22: Oil Sump Heater (Accessories)
5 | Electrical connection 5.9 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. -
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. -
Page 24: 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. -
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. 21). A sight glass on the oil level regulator is not required. -
Page 26: Spare Parts Recommendation
7| Maintenance 7.3 Spare part recommendation HG7 / ... 1620-4 (S) 1860-4 (S) 2110-4 (S) Designation Item No. Item No. Item No. Set of gaskets 80094 Valve plate kit 08498 Set piston/connecting rod 08995 08996 80112 Set connecting rod 08306 Oil pump set 80116 Oil sump heater set 230 V ~... -
Page 27: Technical Data
8| Technical data 380-420 V Δ/YYY - 3 - 50 Hz PW 440-480 V Δ/YYY - 3 - 60 Hz PW PW = Part Winding Winding ratio : 60% / 40%... -
Page 28: Dimensions And Connections
9| Dimensions and connections Centre of gravity ca.510 ca.510 ÖV ÖV ca.315 ca.315 ca.830 ca.830 Maße in mm Änderungen vorbehalten Dimensions in mm Subject to change without notice Cotes en mm Sous réserve de toutes modifications Maße in mm Änderungen vorbehalten Maße Zubehör/Dimensions Accessories/Dimension Acce ca.510 Dimensions in mm... - 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 suction side, not lockable 4 “ NPTF Connection discharge side, not lockable 8 “...
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Page 30: Declaration Of Conformity And Installation
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 HG7 complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. -
Page 31: 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 Sehr geehrter unde, 72636 Frickenhausen Bock- erdichter sind hochwertige, u verl ssige und se rvicefreundliche ualit tsprodu kte. - 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.
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