GEA Bock HGZX7/1860-4 R410A Assembly Instructions Manual Download

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09726-09.2013-DGbF

engineering for a better world

GEA Refrigeration Technologies

Bock Compressor HGZ7

Assembly instructions

HGZX7/1620-4 R404A/R507

HGZX7/1620-4 R410A

HGZX7/1860-4 R404A/R507

HGZX7/1860-4 R410A

HGZX7/2110-4 R404A/R507

HGZX7/2110-4 R410A

HGZ7/1620-4 R22
HGZ7/1860-4 R22
HGZ7/2110-4 R22

Summary of Contents for Bock HGZX7/1860-4 R410A

Page 1: ...world GEA Refrigeration Technologies Bock Compressor HGZ7 Assembly instructions HGZX7 1620 4 R404A R507 HGZX7 1620 4 R410A HGZX7 1860 4 R404A R507 HGZX7 1860 4 R410A HGZX7 2110 4 R404A R507 HGZX7 2110 4 R410A HGZ7 1620 4 R22 HGZ7 1860 4 R22 HGZ7 2110 4 R22 ...

Page 2: ...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 bock gea com www bock de Manufactu...

Page 3: ...pe connections 5 6 Pipes 5 7 Laying suction and pressure lines 5 8 Operating the shut off valves 5 9 Operating mode of the lockable service connections 6 Electrical connection 21 6 1 Information for contactor and motor contactor selection 6 2 Circuit diagram for part winding start 6 3 Standard motor design for direct or partial winding start 6 4 Electronic trigger unit MP 10 6 5 Connecting of the ...

Page 4: ...ential 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 Identification of saf...

Page 5: ...igerating 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 h...

Page 6: ...on valve for subcooling adjusted for refrigerant and application range 2 1 Short description standard version Intermediate pressure chamber Terminal box Dimension and connection values can be found in Chapter 9 Oil pump Suction shut off valve Name plate Notice CE certification for piping only for HGZ7 2110 4 Oil sight glasses Oil drain plug Charge plug Valve plate Discharge shut off valve Intermed...

Page 7: ...t glasses 1 Standard version Compressor with intermediate pressure line mounted and insulated Fig 3 Liquid subcooler expansion valve solenoid valve filter drier and two sight glasses enclosed separately for individual external mounting 2 Optional version Liquid subcooler expansion valve solenoid valve filter drier and two sight glasses mounted directly to the compressor piped and insulated 2 2 Mai...

Page 8: ... 3 maximum operating current 8 Displacement 4 Starting current rotor blocked VND low pressure stage Partial winding 1 VHD High pressure stage YYY Partial windings 1 and 2 9 Voltage circuit frequency 5 ND LP max admissible operating pressure 10 Nominal rotation speed Low pressure side 11 Displacement HD HP max admissible operating pressure VND low pressure stage High pressure side VHD High pressure...

Page 9: ...r 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 filled a...

Page 10: ...9 19 28 bar Design for other areas on request Fig 7 Fig 8 Fig 9 3 Areas of application R404A R507 R410A R22 1 LP low pressure MP intermediate pressure HP high pressure tO Evaporation temperature C tC Condensing temperature C tOh suction gas superheat K Unlimited application range ...

Page 11: ... the diagram by approximately calculating the subcooling temperature arising in the relevant operating conditions t0 tc Diagrams for determining the subcooling temperature at the output of the liquid subcooler 3 4 Subcooling temperature tU Subcooling temperature at the subcooler outlet FUA tO Evaporating temperature Fig 10 Fig 11 Fig 12 ...

Page 12: ... 5 and compressed to the final pressure Liquid subcooler system The liquid subcooler system consists of the components liquid subcooler plate heat exchanger 6 expansion valve 7 sight glasses 8 9 solenoid valve 10 filter drier 11 After the refrigerant reciever 16 the liquid line will be splitted into two lines Line A leads through the liquid subcooler 6 and the subcooled refrigerant flows to the ev...

Page 13: ...11 Filter drier 12 Damper pressure line 13 Oil separator 14 Non return valve 15 Condenser 16 Refrigerant receiver 17 Filter drier 18 Solenoid valve 19 Sight glass 20 Expansion valve evaporator 21 Evaporator 22 Liquid separator 23 Damper suction line 24 Filter suction line LP Low pressure MP Intermediate pressure HP High pressure FUE Liquid subcooler inlet FUA Liquid subcooler outlet Scope of suppl...

Page 14: ...mosphere or a combustible environment 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 Fig 14 Fig 15 Fig 16 Fig 17 F E D C B 1 2 3 Alternativbezug Baumustergeprüft Lieferantenzeichnung Entwicklungsstand Bearb Datu...

Page 15: ...d subcooler against condensation and heating and the related loss of performance For rigidity reasons the use of stainless steel pipes with a wall of 1 mm is preferred The pipes must be free of tension during and after soldering to prevent possible breaks lateron INFO Use only suitable hard solder and flux Solder under an inert gas atmosphere when copper components are to be soldered The accompany...

Page 16: ... pressure line Shown without insulation R Y 5 Compressor assembly R Connection of pressure compensation line for expansion valve 7 16 UNF W Refrigerant injection connection M22 x 1 5 X Schrader connection for intermedie pressure gauge 7 16 UNF Y Position of temperature sensor unpainted ...

Page 17: ...erwise the thin pipes may be worn through It is better to run them through spiral protective tubes If the compressor will be set up outside UV resistant materials should be used Ø 16 mm Ø 16 mm Ø 16 mm Ø 16 mm Ø 6 mm Ø 12 mm Ø 12 mm Ø 12 mm FUE Mitteldruckkammer MP Wärme dämmung Fig 20 5 Compressor assembly 5 3 Installation example liquid subcooler with accessories Dia 16 mm Dia 12 mm Heat insulat...

Page 18: ...ting can damage the valve Remove the pipe supports therefore from the valve for soldering Only solder using inert gas to inhibit oxidation products scale 5 5 Pipe connections The pipe connections have graduated inside diameters so that pipes with standart millimetre and inch dimensions can be used The connection diameters of the shut off valves are rated for maximum compressor output The actual re...

Page 19: ...ing cracked and broken by severe vibrations Ensure a proper oil return Keep pressure losses to an absolute minimum 5 7 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 ATTENTION Improperly installed pipes can cause cracks and tears which can result in a loss o...

Page 20: ...nections Fig 26 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 The connection which cannot be shut off is intended for safety devices Fig 27 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cannot be shu...

Page 21: ...s are the same 6 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 specifica tions Motor protection switch is required Motor contactors feed lines fuses and motor protection switches must be rated accor...

Page 22: ... S M X2 1 2 3 4 5 6 7 F1 1 F1 2 8 R2 4A F2 S1 R2 9 R2 10 MP10 11 6 2 Circuit diagram for part winding start Q1 Main switch F1 1 Motor protection switch part winding 1 F1 2 Motor protection switch part winding 2 F2 Fuse control current circuit F3 High pressure safety monitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor S1 Control voltage switch B1 Release switch...

Page 23: ...4 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE K1T Delay relay max 1 s slow release part winding 2 K2T Delay relay max 20 s slow release Open solenoid Y1 subcooler K3T Delay relay max 20 s slow release compresssor switch off suction subcooler Y1 Solenoid valve intermediate cooler M1 Compressor motor R1 Cold conductor PTC sensor R2 Thermal protection thermostat PTC sensor R3 Oil temperature NTC sensor ...

Page 24: ...ith resistance meter please note that part winding 1 and part winding 2 are internally connected 6 3 Standard motor design for direct or partial 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 Partial winding 1 60 and part winding 2 40 This windi...

Page 25: ...fault the device is quit by interrupting the mains power with the external alarm reset switch S1 see main line wiring diagram chap ter 5 3 The reclosure preventing feature is unlocked and LEDs H1 or H2 go off again Terminal box Fig 29 ATTENTION Terminals 1 6 on the trigger unit MP 10 and terminals PTC 1 and PTC 2 on the compres sor terminal board must not come into contact with mains voltage This ...

Page 26: ...nnection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or S1 ON Function check of motor temperature sensor operational ON Function check of hot gas temperature sensor operational ON 3 Interrupt power supply again L1 or S1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or S1 OFF OFF ON MP 10 is operational again B...

Page 27: ...l causing oil shocks under certain circumstances Operation The oil sump heater operates when the compressor is at a standstill When the compressor starts up the oil sump heating switches off Connection The oil sump heater must be connected via an auxiliary contact or parallel wired auxiliary contact of the compressor contactor to a separate electric circuit Electrical data 230 V 1 50 60 Hz 140 W A...

Page 28: ...nst 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 7 2 Pressure strength test DANGER Bursting The compressor must only be pressurised using...

Page 29: ...ator 7 5 Refrigerant charge 7 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 con tact protection measures etc are functioning properly Switch on the compressor and let it run for at least 10 minutes Check the oil level The oil must be visible in the sight glass ATTE...

Page 30: ...n 7 10 K check the setting of the expansion valve The system must reach a state of equilibrium When selecting the evaporator expansion valve pay attention to correction factors for liquid subcooling Avoid transfer of refrigerant into the compressor when the system is at a standstill The use of a liquid separator is recommended 7 Commissioning ATTENTION To avoid liquid shocks on the HP stage the ex...

Page 31: ...t servicing and inspection work at regular intervals Oil change not mandatory for factory produced series systems for field installations or when operating near the application limit for the first time after 100 to 200 operating hours then approx every 3 years or 10 000 12 000 operating hours Dispose of used oil according to the regulations observe national regulations Annual checks Oil level leak...

Page 32: ...ty bolt 8 4 Replacing the valve plates The compressors are divided into an LP and an HP compressor stage Different valve plate designs are required because of the different ducts in the individual compressor stages The valve plates have been fitted with safety bolts to prevent any confusion The safety bolts engage in the corresponding bores on the cylinder heads the safety bolts must not be remove...

Page 33: ...tions 8 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 Available accessories can be found on the Internet at www bock de 8 7 Accessories Refrigerants Bock standard oil types Recommended alternatives HFKW e g R134a R404A ...

Page 34: ...ces A ll specifications are based on the average of the voltage range 380 420 V YYY 3 50 Hz PW 440 480 V YYY 3 60 Hz PW Winding ratios 60 40 HGZ7 1620 4 6 93 7 46 9 112 5 56 2 50 27 0 185 278 294 35 1 3 8 54 2 1 8 4 5 HGZ7 1860 4 107 6 53 8 129 1 64 6 55 30 0 185 278 291 HGZ7 2110 4 122 4 61 2 146 9 73 5 65 36 0 191 286 289 Type No of cylin ders 50 Hz 1450 rpm LP HP 60 Hz 1740 rpm LP HP Volt age M...

Page 35: ... X Connection possibility for oil level regulator Three hold connector for oil level regulator Products ESK AC R CARLY 3x M6 10 deep 10 1 Compressor in standard design Intermediate pressure mixed line mounted and insulated Liquid subcooler with accessories as an extra item Centre of gravity ...

Page 36: ...iew X Connection possibility for oil level regulator Three hold connector for oil level regulator Products ESK AC R CARLY 3x M6 10 deep 10 2 Compressor in optional design Liquid subcooler with accessories attached directly to the compressor Dimensions in mm Fig 33 ...

Page 37: ...ection oil pressure gauge 7 16 UNF F Oil drain M22 x 1 5 FS Sight glass liquid line Ø 12 mm H Oil charge plug M22 x 1 5 J Oil sump heater accessories M22 x 1 5 K Sight glass 3 hole M6 L Connection thermal protection thermostat 1 8 NPTF L1 Thermal protection thermostat 1 8 NPTF N Filter drier Ø 12 mm O Connection oil level regulator see view X ÖV Connection oil service valve 1 4 NPTF ÖV1 Oil servic...

Page 38: ...sor HGZ7 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 regulations of the Machinery Direc...

Page 39: ...at piping of the refrigerant compressors HGZX7 2110 4 R404A HGZX7 2110 4 R410A und HGZ7 2110 4 R22 agrees with the Pressure Equipment Directive 97 23 EG dated 29 May 1997 Valid for Category I piping Evaluation procedure module A The other parts of the piping fall under article 3 3 of the Guideline and correspond to good engineering practice Frickenhausen 01 11 2011 ppa Wolfgang Sandkötter Chief De...

Page 40: ... 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 Produ...

Page 41: ...D GB F E 41 09726 09 2013 DGbF ...

Page 42: ... 0 Fax 49 7022 9454 137 bock gea com www bock de We live our values Excellence Passion Integrity Responsibility GEA versity 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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