GEA HG12P Assembly Instructions Manual Download

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engineering for a better world

GEA Refrigeration Technologies

GEA Bock Compressor HG12P

Assembly instructions

HG12P/75-4

HG12P/60-4 S

HGX12P/75-4

HGX12P/60-4 S

HG12P/90-4

HG12P/75-4 S

HGX12P/90-4

HGX12P/75-4 S

HG12P/110-4

HG12P/90-4 S

HGX12P/110-4

HGX12P/90-4 S

HG12P/110-4 S

HGX12P/110-4 S

Summary of Contents for HG12P

Page 1: ...world GEA Refrigeration Technologies GEA Bock Compressor HG12P Assembly instructions HG12P 75 4 HG12P 60 4 S HGX12P 75 4 HGX12P 60 4 S HG12P 90 4 HG12P 75 4 S HGX12P 90 4 HGX12P 75 4 S HG12P 110 4 HG12P 90 4 S HGX12P 110 4 HGX12P 90 4 S HG12P 110 4 S HGX12P 110 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 refrigeration gea com www gea com ...

Page 3: ...al connection 13 5 1 Information for contactor and motor contactor selection 5 2 Connection of the driving motor 5 3 Circuit diagram for direct start 230 V Δ 400 V Y 5 4 Electronic trigger unit MP 10 5 5 Connection of the electronic trigger unit MP 10 5 6 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...

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 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...

Page 5: ...Bock refrigerating 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 int...

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

Page 7: ...e normal air conditioning applications X Ester oil charge HFC refrigerant e g R134a R404A R507 R407C Additional declaration for Pluscom compressors 4 S More powerful motor e g for air conditioning applications Motor variant 4 Number of poles Swept volume 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: ...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 at the factory with the following oil type for R134a R404A R5...

Page 9: ...cation 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 Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure ...

Page 10: ...w 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 2 Setting up 4 1 Storage and transport Use transport eyelet Do not lift manually Use lifting gear Storage at 30 C 70 C maximum permissible relative humidity 10 95 no con...

Page 11: ...ompensators must be provided to prevent pipes being cracked and broken by severe vibrations Ensure a proper oil return Keep pressure losses to an absolute minimum Fig 15 Rigid fixed point As short as possible 4 3 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 valve...

Page 12: ... service 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 Before opening or closing the shut off valve release the valve spindle seal by approx of a turn counter clockwise After activating the shut off valve re tighten t...

Page 13: ...ors feed lines fuses and motor protection switches must be rated on the basis of the maximum working current see name plate For motor protection use a current dependent and time delayed overload protection device for moni toring all three phases Set the overload protection device so that it must be actuated within 2 hours if there is 1 2 times the max working current 5 2 Connection of the driving ...

Page 14: ...00 V Y Fig 20 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: ...tor 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: ... 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 inadmissible operating conditions occur Find and remedy the cause 5 5 Connection of the trigger unit MP10 INFO Connect the trigger unit...

Page 17: ...r 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 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 aga...

Page 18: ...tallation 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 mu...

Page 19: ...pen 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 ef...

Page 20: ... 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 swi...

Page 21: ...ntenance 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 GEA 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 Ar...

Page 22: ... 3 6 45 26 49 60 59 58 1 2 3 2 4 220 240 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 T...

Page 23: ... Stopfen Ölfüllung J Ölsumpfheizung K Schauglas L Anschluß Wärmeschutzthermostat O Anschluß Ölspiegelregulator L Lötanschluß F E B L B1 DV 76 244 98 4x c ca 280 A1 J SV 66 208 318 ca 415 Schwingungsdämpfer Vibration absorbers Amortisseurs de vibration 30 M8 30 E D C B A 4 3 2 1 5 Maßstab Numéro de plan Tol Ang DIN ISO 2768 mK Rz 160 Ra Rz s 25 Maß Passung Freigabe Alternativbezug Baumustergeprüft ...

Page 24: ...mpressor HG12P 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...

Page 25: ...uestions about installation operation and accessories please contact our techni cal service or specialist wholesaler and or our representative The GEA Bock service team can be contacted by phone with a toll free hotline 00 800 800 000 88 or via e mail refrigeration gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 11 Service ...

Page 26: ...54 0 Fax 49 7022 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 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 i...

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