GEA HGX6 /1240-4R134a Assembly Instruction Manual Download

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96181-01.2015-DGbFEI

engineering for a better world

GEA Refrigeration Technologies

GEA Bock Compressor HGX6 R134a

Assembly instructions

HGX6/1080-4 R134a
HGX6/1240-4 R134a
HGX6/1410-4 R134a

Summary of Contents for HGX6 /1240-4R134a

Page 1: ...81 01 2015 DGbFEI engineering for a better world GEA Refrigeration Technologies GEA Bock Compressor HGX6 R134a Assembly instructions HGX6 1080 4 R134a HGX6 1240 4 R134a HGX6 1410 4 R134a 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 2: ... 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 Man...

Page 3: ...d 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 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 Commissio...

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: ...ock 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 inte...

Page 6: ...the compressor case Application range normal refrigerating and air conditioning with R134a Fig 1 2 1 Short description Dimension and connection values can be found in Chapter 9 Name plate Valve plate Cylinder cover Terminal box Transport eyelet Discharge shut off valve Oil pump Suction shut off valve Oil sight glass Drive section Motor section 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 7: ...isplacement 4 Starting current rotor blocked 9 Voltage circuit frequency Y Part winding 1 10 Nominal rotation speed YY 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 type HD HP max admissible operating Electrical accessories can change pressure g High pressure side the IP protection cl...

Page 8: ...peration points Permissible ambient temperature 20 C 60 C Max permissible discharge end temperature 140 C Max permissible switching frequency 12x h A minimum running time of 3 min steady state condition continuous operation must be achieved For operation with supplementary cooling Use only oils with high thermal stability Avoid continuous operation near the threshold For operation with capacity re...

Page 9: ...st Unlimited application range Supplementary cooling or reduced suction gas temperature Fig 4 Evaporation temperature C Condensing temperature C Suction gas superheat K Suction gas temperature C Max permissible operating pressure LP HP 1 19 28 bar 1 LP Low pressure HP High pressure R134a ...

Page 10: ... compressor ventilation Do not use in a corrosive dusty damp atmosphere or a combustible environment Fig 7 Fig 8 Fig 9 ATTENTION Superheating can damage the valve Remove the pipe supports from the valve for soldering Only solder using inert gas to inhibit oxidation products scale 4 3 Pipe connections F E D C 1 2 3 4 2 Setting up 4 1 Storage and transport Use transport eyelet Do not lift manually U...

Page 11: ...d vibration behaviour of the system ATTENTION Improperly installed pipes can cause cracks and tears which can result in a loss of refrigerant 4 Compressor assembly 4 4 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 b...

Page 12: ...Spindle turn to the left counter clockwise as far as it will go Shut off valve completely opened service connection closed The connection which cannot be shut off is intended for safety devices Fig 15 Opening the service connection Spindle Turn 1 turn clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service connec tion...

Page 13: ...t or partial winding start The motor winding is subdivided into two parts Partial 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 with bypass solenoid valve is not required 5 1 Information for contactor and motor contactor selection All protection devices a...

Page 14: ...1V1 1W1 PE M Y YY 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 9 10 MP10 11 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 1 2 2 motor protection switches 66 33 of I A total F2 Control power circuit fuse F3 High pressure safety monitor F4 Safety chain high low pressure monito...

Page 15: ...2 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 Q1 Main switch M1 Compressor motor K1 Mains contactor part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s S1 Control voltage switch E1 Oil sump heater ...

Page 16: ...sely affect the service life of the motor The motor is wired for direct start YY at the factory For part winding start Y YY the bridges must be removed and the motor feed line connected according to the circuit diagram 400 V Direktstart YY Teilwicklungsstart Y YY 1V1 1W1 1U1 2W1 2V1 2U1 L3 L2 L1 L3 L2 L1 L3 L2 L1 1V1 1W1 1U1 2W1 2V1 2U1 400 V Direct start YY Part winding start Y YY 400 V Direktsta...

Page 17: ...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 Direktstart...

Page 18: ...1 V1 W1 M 3 M1 Y K3 1 2 3 4 R1 5 6 W2 U2 V2 D 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 9 10 MP10 11 Compressor terminal box R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 1 2 2 motor protection switches F2 Control power circuit fuse F3 High pressure safety monitor F4 Safety chain high low pressure m...

Page 19: ...5 M 16 S K1 K1 K3 P F3 K4T K3 K2 17 K4T K2 K3 18 19 K4T P F4 20 K5T AL 21 22 K5T P B1 23 24 K1 25 E1 26 L1 1 L2 1 L3 1 L1 2 N PE M1 Compressor motor K1 Mains contactor K2 contactor K3 Y contactor K4T Delay relay S D changeover K5T Delay relay start unloader S1 Control voltage switch AL Start unloader E1 Oil sump heater ...

Page 20: ...sor 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 7 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...

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: ...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 circumstances Operation mode The oil sump heater operates when the compressor is shut down The oil sump heater is switched off when the compressor starts Connection Connect the oil sump heater via an auxilia...

Page 23: ...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 24: ...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 25: ... 1 2 4 o 47 6 M6 x 10 je 3 mal 3 hole connection diagramm for ESK AC R and CARLY 3 hole diagramm for TraxOil Mechanical oil level regulator at the O connection 6 Commissioning Fig 20 3 times each 7 1 Preparation 7 2 Work to be carried out 7 Maintenance Inordertoguaranteeoptimumoperationalreliabilityandservicelifeofthecompressor we recommend carrying out servicing and inspection work at regular int...

Page 26: ... table below Available accessories can be found on the Internet at www gea com 7 4 Accessories 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 fastening screws of the shut off valves Remove the compressor using an appropri...

Page 27: ...ding 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 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 current max power consumption for design of...

Page 28: ...ungs dämpfer 290 ca 185 K B1 D J1 O D1 H F C P B E L ÖV 170 306 25 283 340 ca 405 4x 11 ca 450 X A1 SV M10 50 25 30 Schwingungs dämpfer 290 83 669 122 533 ca 185 ca 285 K B1 D J1 O D1 H F C P B E L ÖV 170 306 25 283 340 ca 405 4x 11 ca 450 Q B A DV ca 850 X A1 SV M10 50 25 30 Schwingungs dämpfer 290 83 669 122 533 ca 185 ca 285 K B1 D J1 O D1 H F C P B E L ÖV 170 306 25 283 340 ca 405 4x 11 ca 450...

Page 29: ...onnectoin oil pressure 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 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 O Connection oil level regulator 3 x M6 ÖV Connection oil ser...

Page 30: ...ssor HGX6 R134a complies with the basic require ments 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 Machine...

Page 31: ...tions 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 32: ...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 index ...

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