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09963-11.2015-DGbFEIRu

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 Commissioning

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!

    

  In  order  to  prevent  shifts  in  concentration,  zeotropic  refrigerant 

blends (e.g. R407C) must always only be added to the refrigerating 

system in liquid form.

    

  Do  not  pour  liquid  refrigerant  through  the  suction  line  shut-off 

valve on the compressor.

      

  It is not permissible to mix additives with the oil and refrigerant.

6.5  Refrigerant filling

6.6 Commissioning

    

         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.

 

        ATTENTION!  If larger quantities of oil have to be topped up, there is a risk of oil 

impact effects. If this is the case, check the oil return!

6.7  Avoid slugging

                    ATTENTION! Slugging  can  result  in  damage  to  the  compressor  and  cause 

  

 

refrigerant to leak.

To prevent slugging:

  The complete refrigeration plant must be properly designed.
  All components must be compatibly rated with each other with regard to output (particularly the 

evaporator and expansion valves).

  Suction gas superheating at the compressor input 

should be min. 7 - 10

 K (check the setting of 

the expansion valve).

  The system must reach a state of equilibrium. 
   Particularly in critical systems (e.g. several evaporator points), measures such as the use of liquid 

traps, solenoid valve in the liquid line, etc. are recommended. 

 

There should be no movement of refrigerant in the compressor while the system is at a 
 standstill.

Summary of Contents for HG5/725-4

Page 1: ...engineering for a better world GEA Compressor HG5 Assembly instructions HG5 725 4 HG5 725 4 S HGX5 725 4 HGX5 725 4 S HG5 830 4 HG5 830 4 S HGX5 830 4 HGX5 830 4 S HG5 945 4 HG5 945 4 S HGX5 945 4 HGX...

Page 2: ...he 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...

Page 3: ...2 Standard motor design for direct or part winding start 5 3 Basic circuit diagram for part winding start with standard motor 5 4 Special motor design for direct or star delta start 5 5 Basic circuit...

Page 4: ...potential 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 t...

Page 5: ...frigerating 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...

Page 6: ...or Flange mounted drive motor on the compressor case Preferred application range normal refrigerating and air conditioning 2 1 Short description Dimension and connection values can be found in Chapter...

Page 7: ...otation speed 3 maximum operating current 8 Displacement 4 Starting current rotor blocked 9 Voltage circuit frequency Y Part winding 1 10 Nominal rotation speed YY Part windings 1 and 2 11 Displacemen...

Page 8: ...n not under certain circumstances ensure that sufficient oil is transported back to the compressor For operation with frequency converter The maximum current and power consumption must not be exceeded...

Page 9: ...ation Design for other areas on request R134a R407C R404A R507 R22 Fig 4 Fig 5 Fig 6 Fig 7 Unlimited application range Supplementary cooling or reduced suction gas temperature Supplementary cooling an...

Page 10: ...e compressor ventilation Do not use in a corrosive dusty damp atmosphere or a combustible environment Fig 10 Fig 11 Fig 12 ATTENTION Superheating can damage the valve Remove the pipe supports from the...

Page 11: ...ipes 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...

Page 12: ...e completely opened service connection closed The connection which cannot be shut off is intended for safety devices Fig 18 Opening the service connection Spindle Turn 1 turn clockwise Service connect...

Page 13: ...rtial winding 1 66 and part winding 2 33 This winding division reduces the start up current needed for a part winding start to approx 65 of that for a direct start INFO A mechanical unloaded start wit...

Page 14: ...e safety monitor F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor B1 Release switch thermostat Fig 19 nderung 0 Datum Name Datum Bearb Gepr Norm 1 20 Feb 2009 Kelich 0...

Page 15: ...r part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s S1 Control voltage switch E1 Oil sump heater PW MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 1 Bl 1 F5 K1 12 T2 13 N P l 14 L 15 M 16 S...

Page 16: ...do this results in opposed rotary fields and results in damage to the motor After the motor starts up via partial winding 1 partial winding 2 must be switched on after a maximum delay of one second F...

Page 17: ...l Zubeh r erforderlich Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Y Stern Dreieck Anlauf ist nur im Spannungsbereich 230 V m glich Beispiel 230 V Direktstart Stern Dreieck Start L3 L1 V...

Page 18: ...Safety chain high low pressure monitoring F5 Oil differential pressure monitor B1 Enabling switch thermostat Q1 Main switch nderung 0 Datum Name Datum Bearb Gepr Norm 1 20 Feb 2009 Kelich 09 M r 2010...

Page 19: ...relay S D changeover K5T Delay relay start unloader S1 Control voltage switch AL Start unloader E1 Oil sump heater D S MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 1 Bl 1 F5 K1 12 T2 13 N P l 14 L 15 M 16 S K1...

Page 20: ...essor 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 inadmissib...

Page 21: ...connection 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...

Page 22: ...n the compressor 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 circu...

Page 23: ...trols 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 comp...

Page 24: ...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 co...

Page 25: ...on lock 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 leve...

Page 26: ...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 standard oil types Recommended alternatives HFC...

Page 27: ...YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 66 33 L M H 5 Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request The spec...

Page 28: ...kseite absperrbar Connection discharge C Anschlu ldrucksicherheitsschalter OIL Connection oil pressu D Anschlu ldrucksicherheitsschalter LP Connection oil pressu D1 Anschlu lr ckf hrung vom labscheide...

Page 29: ...sure switch OIL 7 16 UNF D Connection oil pressure switch LP 7 16 UNF D1 Connection oil return from oil separator 1 4 NPTF E Connection oil pressure gauge 7 16 UNF F Oil drain M22 x 1 5 H Oil charge p...

Page 30: ...ards 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 regul...

Page 31: ...uestions about installation operation and accessories please contact our technical service or specialist wholesaler and or our representative The GEA service team can be contacted by phone with a toll...

Page 32: ...9454 137 refrigeration gea com www gea com We live our values Excellence Passion Integrity Responsibility GEA versity GEA Group is a global engineering company with multi billion euro sales and operat...

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