GEA Bock HA6 Manuel utilisateur

09912-09.2013-DGbFEI

engineering for a better world GEA Refrigeration Technologies

Bock Compressor HA6

Assembly instructions

HA6/1080-4 HAX6/1080-4

HA6/1240-4 HAX6/1240-4

HA6/1410-4 HAX6/1410-4

1 1

09912-09.2013-DGbFEI

1 Safety 4

 1.1 Identicationofsafetyinstructions

 1.2 Qualicationsrequiredofpersonnel

 1.3 Generalsafetyinstructions

 1.4 Intendeduse

2 Product description 6

 2.1 Shortdescription

 2.2 Nameplate

 2.3 Typekey

3 Areas of application 8

 3.1 Refrigerants

 3.2 Oilcharge

 3.3 Limitsofapplication

4Compressor assembly 10

 4.1 Settingup

 4.2 Pipeconnections

 4.3 Pipes

 4.4 Layingsuctionandpressurelines

 4.5 Operatingtheshut-offvalves

 4.6 Operatingmodeofthelockableserviceconnections

5 Electrical connection 13

 5.1 Informationforcontactorandmotorcontactorselection

 5.2 Standardmotor,designfordirectorpartial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)

 5.10 Fanmotor

6 Commissioning 23

 6.1 Preparationsforstart-up

 6.2 Pressurestrengthtest

 6.3 Leaktest

 6.4 Evacuation

 6.5 Refrigerantcharge

 6.6 Start-up

 6.7 Avoidingslugging

 6.8 Connectionofoillevelregulator

7 Maintenance 25

 7.1 Preparation

 7.2 Worktobecarriedout

 7.3 Sparepartsrecommendation

 7.4 Accessories

 7.5 Extractfromthelubricantstable

 7.6 Decommissioning

8 Technical data 27

9 Dimensions and connections 28

10 Declaration of conformity and installation 30

11 Service 31

About these instructions

Readtheseinstructionsbeforeassemblyandbeforeusingthecompressor.Thiswillavoidmisunder-

standings andpreventdamage.Improperassemblyanduseof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

[email protected]

www.bock.de

Manufacturer

Contact

09912-09.2013-DGbFEI

Contents Page

1 Safety 4

 1.1 Identicationofsafetyinstructions

 1.2 Qualicationsrequiredofpersonnel

 1.3 Generalsafetyinstructions

 1.4 Intendeduse

2 Product description 6

 2.1 Shortdescription

 2.2 Nameplate

 2.3 Typekey

3 Areas of application 8

 3.1 Refrigerants

 3.2 Oilcharge

 3.3 Limitsofapplication

4Compressor assembly 10

 4.1 Settingup

 4.2 Pipeconnections

 4.3 Pipes

 4.4 Layingsuctionandpressurelines

 4.5 Operatingtheshut-offvalves

 4.6 Operatingmodeofthelockableserviceconnections

5 Electrical connection 13

 5.1 Informationforcontactorandmotorcontactorselection

 5.2 Standardmotor,designfordirectorpartial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)

 5.10 Fanmotor

6 Commissioning 23

 6.1 Preparationsforstart-up

 6.2 Pressurestrengthtest

 6.3 Leaktest

 6.4 Evacuation

 6.5 Refrigerantcharge

 6.6 Start-up

 6.7 Avoidingslugging

 6.8 Connectionofoillevelregulator

7 Maintenance 25

 7.1 Preparation

 7.2 Worktobecarriedout

 7.3 Sparepartsrecommendation

 7.4 Accessories

 7.5 Extractfromthelubricantstable

 7.6 Decommissioning

8 Technical data 27

9 Dimensions and connections 28

10 Declaration of conformity and installation 30

11 Service 31

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1|Safety

1.2 Qualicationsrequiredofpersonnel

1.3 General safety instructions

WARNING! Inadequately qualied personnel poses the risk of accidents, the

consequence being serious or fatal injury. Work on compressors

mustthereforeonlybeperformedbypersonnelwiththequalica-

tions listed below:

 •For example, a refrigeration technician, refrigeration mechatron-

icsengineer.Aswellasprofessionswithcomparabletraining,which

enablepersonneltoassemble,install,maintainandrepairrefrigeration

andair-conditioningsystems.Personnelmustbecapableofassessing

theworktobecarriedoutandrecognisingany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 Identicationofsafetyinstructions:

DANGER! Indicatesadangeroussituationwhich,ifnot

 avoided,willcauseimmediatefatalorseriousinjury.

WARNING!

 Indicatesadangeroussituationwhich,ifnot

 avoided,maycausefatalorseriousinjury.

CAUTION!

 Indicatesadangeroussituationwhich,ifnot

 avoided,maycausefairlysevereorminorinjury.

ATTENTION! Indicatesasituationwhich,ifnot

 avoided,maycausepropertydamage.

INFO! Importantinformationortipsonsimplifyingwork.

09912-09.2013-DGbFEI

1|Safety

TheseassemblyinstructionsdescribethestandardversionoftheHA6manufacturedbyBock.The

compressorisintendedforuseinrefrigerationsystemsincompliancewiththelimitsofapplication.

Onlytherefrigerantspeciedintheseinstructionsmaybeused.

Any other use of the compressor is prohibited!

The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 integrated has been inspected and

approvedinaccordancewithlegalregulations.

1.4 Intended use

WARNING! The compressor may not be used in potentially

explosive environments!

09912-09.2013-DGbFEI

1 1

2|Product description

• Semi-hermeticfour-cylinderreciprocatingcompressorwithoilpumplubrication.

• Flange-mounteddrivemotoronthecompressorcase.

• Speciallyordeepcoolingwithair-cooledmotoranddirectsuctionatthecylinder.

Nameplate

Fig.1

2.1 Brief description

Oilsightglass

Valveplate Cylinder

cover

Terminalbox

Suctionshut-

offvalve

DimensionandconnectionvaluescanbefoundinChapter9

Transporteyelet

Discharge

shut-offvalve

Oilpump

Airguidehood

withfan

Drivesection

09912-09.2013-DGbFEI

2|Product description

Fig.2

2.2 Name plate (example)

2.3 Typekey (example)

¹)HA-HermeticAir-Cooled(fordeep-freezing)

²)X -Esteroilcharge(HFCrefrigerant,e.g.R404A/R507)

Numberofpoles

Sweptvolume

Size

Oilcharge²)

Series¹)

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

 Y:Partwinding1 10 Nominalrotationspeed

 YY:Partwindings1and2 11 Displacement

5 NDLP:

max.admissibleoperatingpressur

e 12 Oiltypelledatthefactory

(g)Lowpressureside 13 Terminalboxprotectiontype

 HD(HP):

max.admissibleoperating

Electrical accessories can change

pressur

e(g)Highpressureside  the IP protection class!

Observe the limits of application

diagrams!

50 Hz

}

60 Hz

}

HAX6/1410-4

AS12345-001

SE 55

HA 61410-4

GEA Bock GmbH

72636 Frickenhausen, Germany

09912-09.2013-DGbFEI

3|Areas of application

ATTENTION! Compressor operation is possible within the operating limits

shown in the diagrams. Please note the signicance

of the shaded areas. Thresholds should not be selected as design

or continuous operation points.

- Max. permissible ambient temperature 45 °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 capacity regulator:

- The suction gas superheat temperature may need to be reduced

or set individually when operating near to 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 condenser and an elevated compressed-gas

temperature. Prevent the ingress of air at all costs!

 Thecompressorsarelledatthefactorywiththefollowingoiltype:

-forR404A/R507 FUCHSRenisoTritonSE55

 -forR22 FUCHSRenisoSP46

Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXinthetypedesignation

(e.g.HAX6/1410-4).

3.1 Refrigerants

• HFKW/HFC:  R404A/R507

• (H)FCKW/(H)CFC: R22

3.2 Oil charge

3.3 Limits of application

INFO! Forrefilling,werecommendtheaboveoiltypes.

Alternatives: seelubricantstable,Chapter7.5.

The oil level must be in the visible

part of the sight glass; damage

to the compressor is possible if

overfilled or underfilled!

ATTENTION!

Fig.3

max.oillevel

min.oillevel

09912-09.2013-DGbFEI

Unlimited

applicationrange

Reducedsuctiongas

temperature

Evaporationtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Fig.5

Fig.4

3|Areas of application

Design for other

areasonrequest

R404A

R507

R22

Max. permissible operating

pressure (LP/HP)1): 19/28 bar

1) LP=Lowpressure

HP=Highpressure

09912-09.2013-DGbFEI

4|Compressor assembly

4.1 Setting up

 Setuponanevensurfaceorframewithsufcientload-

bearingcapacity.

 Singlecompressorpreferablyonvibrationdamper.

 Duplexandparallelcircuitsalwaysrigid.

 Usetransporteyelet.

 Donotliftmanually!

 Useliftinggear!

 Provideadequateclearanceformaintenancework.

 Ensureadequatecompressorventilation.

 Donotuseinacorrosive,dusty,dampatmosphereora

combustibleenvironment.

Fig.6

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).

4.2 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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.10:graduated

internaldiameter

Tol.-Ang. DIN ISO 2768-mK

Ra Rz

Maß

Passung

Freigabe

Alternativbezug:

Baumustergeprüft

Teil inaktiv

Lieferantenzeichnung

K.-Auftrag:

PL:

Zeichnung ungültig

Entwicklungsstand

Teil keine Serie

120

400

±0.5

über 0.5

bis 6

Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de

Unbemaßte Radien:

Diese Zeichnung ist unser Eigentum!

Sie darf ohne unsere Genehmigung weder nach-

gebildet, vervielfältigt, oder Dritten Personen zu-

gänglich gemacht werden. Der Nachbau nach

dieser Zeichnung, oder an Hand der nach dieser

Zeichnung hergestellten Gegenstände durch den

Abnehmer oder Dritte ist nicht gestattet.

Wir behalten uns alle Rechte, gemäß DIN ISO 16016

an dieser Zeichnung vor.

Bearb.

Datum

Änderungs-Nr.

Werkstoff:

Ausgangsteil, bzw. Rohteil:

Gepr.

Name

Datum

19.04.

Werkstückkanten

DIN ISO 13715

Ersatz für:

Ersetzt durch:

Erstellt

2010

Geprüft

Kurz

Zone

1/x

Oberflächenbehandlung / Härte:

Blatt:

Änderungsbeschreibung

400

Benennung:

±0.8

1000

±0.3

120

±0.2

Zeichn.-Nr. Teile-Nr.

Oberflächenangaben ISO 1302

x.xxxx-xxxxx.x

Zust.

Gußtoleranzen:

Gewicht: (kg)

±0.1

Maßstab:

1:1

Wasserwaage

für Indesign

Der Lieferant muß sicherstellen, dass die Ware in

einwandfreiem Zustand angeliefert wird (Korrosions-

schutz, Verpackung für sicheren Transport).

Rz 25

Rz 160

0,05

Rz 1,6

0,3

0,7

1,6

Rz 16

6,3

Rz 63

Rz 6,3

Rz 12,5

F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage

INFO! Newcompressorsarefactory-lled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.

Ce manuel convient aux modèles suivants

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GEA Bock

GEA Bock HG34e Series Manuel utilisateur

GEA Bock

GEA Bock HGX44e CO2 Series Manuel utilisateur

GEA Bock

GEA Bock EX-HG44e Series Manuel utilisateur

GEA Bock

GEA Bock HG12P/75-4 Manuel utilisateur

GEA Bock

GEA Bock Bock HA5 Manuel utilisateur

Manuels Compresseur d'air populaires d'autres marques

Sparmax

Sparmax DC-25XR Manuel utilisateur

KAESER

KAESER M122 Manuel utilisateur

GMC

GMC GAC1500 Manuel utilisateur

Briggs & Stratton

Briggs & Stratton Air Compressor Manuel utilisateur

Fini

Fini F3GST2TK Manuel utilisateur

Industrial Air

Industrial Air CP1580325 Manuel de programmation

Campbell Hausfeld

Campbell Hausfeld RP3300 Guide de démarrage rapide

Ingersoll-Rand

Ingersoll-Rand UP6 20 HP Manuel utilisateur

Hitachi

Hitachi EC99S Manuel de l'opérateur

Parkside

Parkside PKO 270 A1 Manuel utilisateur

Sullair

Sullair 185 Manuel utilisateur

Clas Ohlson

Clas Ohlson QIE-ZTH-15 Manuel utilisateur

Ferm

Ferm CRM1046 Manuel utilisateur

BE AC153 Manuel utilisateur

RIDGID

RIDGID OF25150A Manuel utilisateur

Johnson Controls

Johnson Controls QUANTUM LX Manuel

Sears

Sears Craftsman 919.167463 Manuel utilisateur

Ring Automotive

Ring Automotive RAC700 Manuel utilisateur