GEA HG7 Assembly Instructions Manual Download Page 1 | Manualshive

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09706-09.2013-DGbFEI

engineering for a better world

GEA Refrigeration Technologies

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

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Summary of Contents for HG7

Page 1: ...g for a better world GEA Refrigeration Technologies 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 ...

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: ... for part winding start with standard motor 5 3 Standard motor design for direct or partial winding start 5 4 Special motor design for direct or star delta start 5 5 Basic circuit diagram for star delta start with special motor 5 6 Electronic trigger unit MP 10 5 7 Connecting the trigger unit MP 10 5 8 Functional test of the trigger unit MP 10 5 9 Oil sump heater accessories 6 Commissioning 23 6 1...

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: ...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: ...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 Name plate Fig 1 2 1 Short description Valve plate Cylinder cover Terminal box Dimension and connection values can be found in Chapter 9 Transport eyelet Discharge shut off valve Oil pump Suction shut off valve Oil sight glass Motor section ...

Page 7: ...1 Type designation 6 Voltage circuit frequency 2 Machine number 7 Nominal rotation speed 3 maximum operating current 8 Displacement 4 Starting current rotor blocked 9 Voltage circuit frequency Δ Part winding 1 10 Nominal rotation speed YYY Part windings 1 and 2 11 Displacement 5 ND LP max admissible operating 12 Oil type filled at the factory pressure g Low pressure side 13 Terminal box protection...

Page 8: ...er consumption must not be exceeded In the case of operation above the mains frequency the application limit can therefore be limited During operation in the vacuum range there is a danger of air entering on the suction side This can cause chemical reactions pressure rise in the condenser and an excessive compressed gas temperature Avoid absolutely any entry of air The compressors are filled at th...

Page 9: ...C Suction gas superheat K Suction gas temperature C R134a R407C R404A R507 R22 Fig 4 Fig 5 Fig 6 Fig 7 HG7 Motor version S in the evaporation range of to 5 C to 12 5 C limited condensing temperature up to tc 50 C Additional cooling and reduced suction gas temperature Unlimited application range Additional cooling or reduced suction gas temperature Motor variant S stronger motor ...

Page 10: ...n be used The connection diameters of the shut off valves are rated for maximum compressor output The actual required pipe cross section must be matched to the output The same applies for non return valves Fig 12 graduated internal diameter F E D C B 1 2 3 K Alternativbezug Baumustergeprüft Lieferantenzeichnung K Auftrag PL Entwicklungsstand 20 00 5 Bearb Datum Änderungs Nr Werkstoff Ausgangsteil ...

Page 11: ...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 of refrigerant A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft 4 3 Pipes Pipes and system components must be clean and dry inside and free of scale swarf and layers of rust...

Page 12: ...g 17 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service connec tion closed Connection blocked Spindle Connection cannot be shut off Connection cannot be shut off Service connec tion opened Spindle Connection open Compressor Compressor Before opening ...

Page 13: ...es are the same 5 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 acco...

Page 14: ...1W1 PE M YYY M1 R1 2U1 2V1 2W1 I 33 F1 2 K2 1 2 4 3 4 5 5 6 6 X1 L1 L1 N N 43 43 11 12 14 L 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 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 1 2 2 motor safety switches 60 40 of I A total F2 Control power circuit fuse F3 High pressure safety monitor F4 Safety chain high low pressure monitorin...

Page 15: ...rt 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 2 Bl 2 1 F5 K1 12 T2 13 N P l 14 L 15 M 16 S P F3 17 18 19 K1 P F4 20 K1 K1T K2 21 22 K1T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE ...

Page 16: ...ing start Δ YYY the bridges must be removed and the motor feed line connected according to the circuit diagram INFO When testing coils with resistance tester please note that partial winding 1 and partial winding 2 are wired internally in HG7 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 su...

Page 17: ... L2 V1 W1 U1 V2 U2 W2 L3 L2 L1 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 5 4 Sondermotor Ausführung für Direkt oder Stern Dreieck Anlauf Für den Stern Dreieck Anlauf ist eine mechanische Anlaufentlastung mit Bypass Magnetventil Zubehör erforderlich Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Y Stern Dreieck Anlauf ist nur im Spannungsbereich 230 V möglich Beispiel 230 V Dire...

Page 18: ...V1 W1 M 3 M1 Y K3 1 2 PE R1 3 4 5 6 W2 U2 V2 I 33 F1 2 K2 1 2 4 3 4 5 5 6 6 X1 L1 L1 N N 43 43 11 12 14 L 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 60 40 Compressor terminal box R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 1 2 2 motor safety switches F2 Control power circuit fuse F3 High pressure safety monitor F4 Safety chain hi...

Page 19: ...actor K3 Y contactor K4T Delay relay for contactor changeover S1 Control voltage switch E1 Oil sump heater PW MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 2 Bl 2 F5 K1 12 T2 13 N P l 14 L 15 M 16 S P F3 17 K1 K1 18 K3 19 P F4 K4T K3 K2 20 K4T K2 K3 21 22 K4T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE ...

Page 20: ...lled 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 inad...

Page 21: ...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 22: ...nding 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 Operation The oil sump heater operates when the compressor is at a standstill When the c...

Page 23: ...n and discharge pressure sides using the vacuum pump At the end of the evacuation process the vacuum should be 1 5 mbar when the pump is switched off Repeat this process as often as is required 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 24: ... 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 25: ... operating hours Dispose of used oil according to the regulations observe national regulations Annual checks Oil level 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 ...

Page 26: ...e of it according to the regulations When the compressor is depressurised undo the fastening screws of the shut off valves Remove the compressor using an appropriate hoist Dispose of the oil inside in accordance with the applicable national regulations 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 ...

Page 27: ... Δ YYY 3 50 Hz PW 440 480 V Δ YYY 3 60 Hz PW PW Part Winding Winding ratio 60 40 L M H 5 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 ...

Page 28: ...renzdrucksensor Connection oil pressure differential sensor Raccord sonde de pressostat différentiel d huile mm M22x1 5 Centre of gravity Centre de gravité Maße Zubehör Dimensions Accessories Dimension Accesso Massenschwerpunkt 3 4 5 6 SV A2 Änderungen vorbehalten Subject to change without notice Sous réserve de toutes modifications 439 Cotes en mm Dimensions in mm F P L C K O D1 H B1 E A1 D B X M...

Page 29: ...tch 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 plug M22 x 1 5 J1 Oil sump heater accessories M22 x 1 5 K Sight glass L Connection thermal protection thermostat 1 8 NPTF N Connection capacity controller M45 x 1 5 O Connection oil level regulator 3 x M6 ÖV C...

Page 30: ...ssor HG7 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 31: ...ni e Hinweise sind besonders e kennzeichnet ie e mbol wei da a da e a e e ol e ode i c be o o wei e c de a e o e am e dic e ode a de l ea la e e ka ie e mbol wei a we e i m mi elba e c we e e d e o e o e e meide ie e mbol wei a we e i m mi elba e c we e e d e o e o e ode la e d c elek i c e o m e meide ie e mbol e wei a wic i e a i wei e die bei de bei bedi be ck ic i e i d Das hohe ualit ätsni ea...

Page 32: ...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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