GEA HGX22P/125-4 S R410A Assembly Instructions Manual Download

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96166-05.2012-DGbFEI

engineering for a better world

GEA Refrigeration Technologies

Bock Compressor HGX22P R410A

Assembly instructions

HGX22P/125-4 R410A

HGX22P/125-4 S R410A

HGX22P/160-4 S R410A

HGX22P/190-4 R410A

HGX22P/190-4 S R410A

Summary of Contents for HGX22P/125-4 S R410A

Page 1: ...eering for a better world GEA Refrigeration Technologies Bock Compressor HGX22P R410A Assembly instructions HGX22P 125 4 R410A HGX22P 125 4 S R410A HGX22P 160 4 S R410A HGX22P 190 4 R410A HGX22P 190 4 S R410A 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: ...ion for contactor and motor contactor selection 5 2 Connection of the driving motor 5 3 Circuit diagram direct start 230 V 400 V Y 5 4 Electronic trigger unit MP 10 5 5 Connecting of the trigger unit MP 10 5 6 Function test of the trigger unit MP 10 5 7 Oil sump heater 6 Commissioning 18 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak test 6 4 Evacuation 6 5 Refrigerant charge 6 ...

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: ...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 integrat...

Page 6: ...ubrication Suction gas cooled drive motor Compact dimensions quiet running high efficiency Fig 1 2 1 Short description 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: ... of poles Swept volume Number of cylinders Size Ester oil filling Series IP66 1 Type designation 2 Machine number 3 maximum operating current 4 Starting current rotor blocked 5 ND LP max admissible operating pressure g Low pressure side HD HP max admissible operating pressure g High pressure side Observe the limits of application diagrams 50 Hz 60 Hz 6 Voltage circuit frequency 7 Nominal rotation ...

Page 8: ...y Avoid continuous operation near the threshold For operation with frequency converter The maximum current and power 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 conden...

Page 9: ...d application range Supplementary cooling or reduced suction gas temperature Motor version S more powerful motor Evaporation temperature C Condensing temperature C Suction gas temperature C Max permissible operating pressure LP HP 1 27 43 bar 1 LP Low pressure HP High pressure ...

Page 10: ...standart millimetre and inch dimansions can 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 9 graduated internal diameter 4 2 Pipe connections F E D C B 1 2 3 Alternativbezug Baumustergeprüft Lieferantenzeichnung PL Entwicklungsstand Bearb ...

Page 11: ...nsure a proper oil return Keep pressure losses to an absolute minimum Fig 10 Rigid fixed point As short as possible 4 4 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 ...

Page 12: ...clockwise Fig 11 Fig 12 Pipe connection Pipe connection 4 6 Operating mode of the lockable service connections Fig 13 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 Fig 14 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened Con...

Page 13: ... Only carry out work when the electrical system is disconnected from the power supply INFO Connect the compressor motor in accordance with the circuit diagram see inside of terminal box Use suitable cable entry point of the correct protection type see name plate for routing cables into the terminal box Insert the strain reliefs and prevent chafe marks on the cables Compare the voltage and frequenc...

Page 14: ... V Y Fig 15 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 Motor safety switches F2 Control power circuit fuse F3 Safety chain high low pressure monitoring B1 Release switch thermostat pressostat Q1 Main switch Terminal box compressor ...

Page 15: ... voltage switch M1 Compressor motor K1 Mains contactor MP10 Trigger unit MP 10 E1 Oil sump heater X3 Terminal block in the terminal box A1 Alarm motor protection A2 Temperature rise R1 R2 A3 Alarm high pressure X SS Terminal strip switch cabinet ...

Page 16: ... 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 inadmissibl...

Page 17: ...e operational when the H3 LED green lights 5 6 Function test of the trigger unit MP 10 Pos Procedure LED H1 LED H2 LED H3 red red green 1 Interrupt power supply L1 or S1 OFF OFF OFF Release the motor temperature sensor 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 Functio...

Page 18: ...igerant with the testing medium as this could cause the ignition limit to shift into the critical range 6 4 Evacuation First evacuate the system and then include the compressor in the evacuation process Relieve the compressor pressure Open the suction and pressure line shut off valves Evacuate the suction and discharge pressure sides using the vacuum pump At the end of the evacuation process the v...

Page 19: ...efore 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...

Page 20: ...ompressor Release switch on lock 6 8 Connection of oil level regulator 6 Commissioning The connection O is provided for installing an oil level regulator A corresponding adapter must be obtained from the trade 7 2 Work to be carried out Inordertoguaranteeoptimumoperationalreliabilityandservicelifeofthecompressor we recommend carrying out servicing and inspection work at regular intervals Oil chang...

Page 21: ... standard oil types Recommended alternatives HFKW R410A Fuchs Reniso Triton SE 55 Fuchs SEZ 32 ICI Emkarate RL 46 S Mobil Arctic AL 46 Shell Clavus R 46 7 Maintenance 7 6 Decommissioning Close the shut off valves on the compressor Drain the refrigerant it must not be discharged into the environment and dispose of it according to the regulations When the compressor is depressurised undo the fasteni...

Page 22: ...0A 16 5 19 8 24 6 14 2 8 4 121 70 81 HGX22P 190 4 S R410A 29 3 16 9 9 7 134 77 84 Type 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 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 th...

Page 23: ... 4 R410A Dimensions in only for HGX22P 125 4 R410A Massensch Centre of g Centre de g H D1 SV A1 223 328 361 109 ca 505 470 ca 20 J DV F L1 E B A O K B1 115 88 198 264 ca 240 4x 12 ca 310 4 5 6 7 4 5 6 7 Tol Ang DIN ISO 2768 mK 1 Revisionsdurchlauf Betrifft nur Blatt 2 Transportwinkel geändert Betrifft Blatt 2 Maß Passung 120 400 0 5 bis 6 Be Layh Layh Layh Layh Schaich Büttner Schni Büttner Bau Bü...

Page 24: ...R410A complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006 42 EC The following harmonised standards have been applied EN ISO 12100 1 EN ISO 12100 2 EN 12693 EN 349 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 Mach...

Page 25: ...enden Sie sich bitte an unsere Anwendungstechnik oder a Kältefachgroßhandel bzw unsere Vertretung Das Bock Serviceteam erreichen Sie direkt u 49 7022 9454 0 via e mail mail bock de oder im Internet www bock de Für den deut chigen Raum steht darüber hinaus die kostenlose Bock Hotline 00 800 800 000 88 von mo bis samstags zwischen 8 und 21 Uhr zur Verfügung Für Anregungen zur Weiterentwicklung Verdi...

Page 26: ...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 96166 05 2012 DGbFEI GEA Group AG All rights reserved GEA Refrigeration Technologies GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 bock gea com www bock de ...

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