GEA HG22e Series Assembly Instructions Manual Download

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96188-09.2013-DGbFEI

engineering for a better world

GEA Refrigeration Technologies

Bock Compressor HG22e

Assembly instructions

HG22e/125-4

HG22e/125-4 S

HGX22e/125-4

HGX22e/125-4 S

HG22e/160-4

HG22e/160-4 S

HGX22e/160-4

HGX22e/160-4 S

HG22e/190-4

HG22e/190-4 S

HGX22e/190-4

HGX22e/190-4 S

Summary of Contents for HG22e Series

Page 1: ...EA Refrigeration Technologies Bock Compressor HG22e Assembly instructions HG22e 125 4 HG22e 125 4 S HGX22e 125 4 HGX22e 125 4 S HG22e 160 4 HG22e 160 4 S HGX22e 160 4 HGX22e 160 4 S HG22e 190 4 HG22e 190 4 S HGX22e 190 4 HGX22e 190 4 S 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

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 Manufact...

Page 3: ...rmation for contactor and motor contactor selection 5 2 Connection of the driving motor 5 3 Circuit diagram for direct start 230 V 400 V Y 5 4 Start unloader 5 5 Electronic trigger unit MP 10 5 6 Connection of the electronic trigger unit MP 10 5 7 Functional test of the electronic trigger unit MP 10 6 Commissioning 18 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak test 6 4 Evacu...

Page 4: ...tential 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 sa...

Page 5: ...rigerating 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 ...

Page 6: ...ompressor with oil pump lubrication Suction gas cooled drive motor 2 1 Short description Name plate Fig 1 Fig 2 Oil sight glass Cylinder cover Oil pump Terminal box Suction shut off valve Drive section Motor section Dimension and connection values can be found in Chapter 9 Transport eyelet Valve plate Discharge shut off valve ...

Page 7: ...metic Gas cooled suction gas cooled for the normal air conditioning applications X Ester oil charge HFC refrigerant e g R134a R404A R507 R407C S More powerful motor e g for air conditioning applications Motor variant Number of poles Swept volume e series Numbers of cylinders Size Oil charge Series Typschild Beispiel 1 2 3 4 5 13 12 7 11 6 10 8 9 1 Typbezeichnung 2 Maschinennummer 3 maximaler Betri...

Page 8: ... 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 at the factory with the following oil type for R134a R404A R507 R407C FUCHS Reniso Tri...

Page 9: ...on Design for other areas on request R134a R407C R404A R507 R22 Fig 5 Fig 6 Fig 7 Fig 8 Unlimited application range Supplementary cooling or reduced suction gas temperature Supplementary cooling and reduced suction gas temperature Motor version S more powerful motor 1 LP Low pressure HP High pressure Max permissible operating pressure LP HP 1 19 28 bar ...

Page 10: ... required pipe cross section must be matched to the output The same applies for non return valves Fig 13 graduated internal diameter F E D C B 1 2 3 Alternativbezug Baumustergeprüft Lieferantenzeichnung Entwicklungsstand Bearb Datum Änderungs Nr Werkstoff Ausgangsteil bzw Rohteil Gepr Zone 1 x Blatt ung 400 Benennung 0 8 1000 Zeichn Nr Teile Nr x xxxx xxxxx x Maßstab 1 1 Wasserwaage für Indesign I...

Page 11: ...e of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft 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 broke...

Page 12: ...rvice connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened Service connec tion closed Connection blocked Spindle Service connec tion opened Spindle Connection open Compressor Compressor Valve spindle seal Release Tighten Before opening or closing the shut off valve release the valve spindle seal by approx of a turn counter clockwise After activating...

Page 13: ... be rated according to the maximum operating current see name plate Use the following overload protection device A current dependent time delayed overload protection device for monitoring of all three phases not set higher than the rated current of the machine which must respond at 1 2 times the set current within 2 hours and must not have responded at 1 05 times the set current within 2 hours or ...

Page 14: ...V Y Fig 19 Compressor terminal box R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 Load circuit safety switches F2 Control power circuit fuse F3 Safety chain high low pressure monitoring B1 Release switch thermostat pressostat Q1 Main switch ...

Page 15: ...K1 Compressor contactor MP10 Electronic trigger unit MP 10 E Oil sump heater X3 Terminal strip in terminal box XSS Terminal strip in the external switch cabinet A1 Alarm Motor protection A2 Overheating R1 R2 A3 Alarm high pressure XSS Terminal strip in the external switch cabinet ...

Page 16: ...cted 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 5 6 Connection of the trigger unit MP10 INFO Connect the trigger unit MP10 in accordance with the circuit dia gram Protect the trigger unit with a delayed action fuse ...

Page 17: ...onnection 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 ...

Page 18: ...ation 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 N2 Never pressurise with oxygen or other gases The maximum permissible overpressure of the compressor must n...

Page 19: ... 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 ATTENTION If larger quantities of oil have to be topped up there is a risk of oil impact effec...

Page 20: ...leak tightness running noises pressures temperatures function of auxiliary devices such as oil sump heater pressure switch 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...

Page 21: ...tenance 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 Bock standard oil types Recommended alternatives HFC e g R134a R407C R404A Fuchs Reniso Triton SE 55 Fuchs Reniso Triton SEZ 32 Esso Mobil EAL Arctic ...

Page 22: ...40 V 380 420 V Y 3 50 Hz 265 290 V 440 480 V Y 3 60 Hz 5 L M H Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request The specifications for max power consumption apply for 50Hz operation For 60Hz operation the specifications have to be multiplied by the factor 1 2 The max working current remains unchanged Take account of the max operating curre...

Page 23: ...tion oil level regulator Raccord régula L Lötanschluß L Brazing connection L Raccord Maße Zubehör D Halbhermetischer Verdichter HG Semi hermetic compressor HG Compresseur semi herméti Massenschwerpunkt Centre of gravity Centre de gravité ca 5 4 5 6 7 4 5 über 0 5 Tol Ang DIN ISO 2768 mK 1 Revisionsdurchlauf Transportwinkel geändert Betrifft Blatt 2 Betrifft Blatt 3 BS Befestigungsteile Maß Passung...

Page 24: ...ssor HG22e 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 Dir...

Page 25: ...r 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 Prod...

Page 26: ...54 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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GEA HG22e Series, Assembly Instructions Manual

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