GEA Bock HG22P A Manuel utilisateur

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engineering for a better world GEA Refrigeration Technologies

GEA Bock Compressor HG22P A

Assembly instructions

HG22P/125-4 A HG22P/125-4 S A HGX22P/125-4 A HGX22P/125-4 S A

HG22P/160-4 A HG22P/160-4 S A HGX22P/160-4 A HGX22P/160-4 S A

HG22P/190-4 A HG22P/190-4 S A HGX22P/190-4 A HGX22P/190-4 S A

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About these instructions

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

misunderstandings and prevent damage. Improper assembly and use of the compressor can lead to

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

compressor 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.gea.com

Manufacturer

Contact

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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 code

3 Areas of application 8

3.1 Refrigerants

3.2 Oil charge

3.3 Operating limits

4Compressor assembly 10

4.1 Storage and transport

4.2 Setting up

4.3 Maximum permissible inclination

4.4 Pipe connections

4.5 Pipes

4.6 Laying suction and discharge lines

4.7 Operating the shut-off valves

4.8 Operating mode of the lockable service connections

5 Electrical connection 14

5.1 Information for contactor and motor contactor selection

5.2 Connecting the drive motor

5.3 Circuit diagram

5.4 Electronic trigger unit MP 10

5.5 Connecting the trigger unit MP 10

5.6 External connection of the MP 10 for terminal boxes at reduced height

5.7 Functional test of the trigger unit MP 10

6 Commissioning 20

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liquidshocks

7 Maintenance 22

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 24

9 Dimensions and connections 25

10 Declaration of conformity and installation 26

11 Service 27

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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.

1|Safety

1.2 Qualicationsrequiredofpersonnel

WARNING! Inadequatelyqualiedpersonnelposetheriskof

 accidents,theconsequencebeingseriousorfatalinjury.

Work on compressors is therefore reserved for personnel

 withthequalicationslistedbelow:

• For example, a refrigeration technician, refrigeration mechatronic

engineer.

As well as professions with comparable training, which enables

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.

1.3 General safety instructions

DANGER! • Refrigerating compressors are pressurised machines and as such

call for heightened caution and care in handling.

The maximum permissible overpressure must not be exceeded,

even for testing purposes.

WARNING! • Risk of burns! Depending on the operating conditions, surface

temperatures of over 60°C on the discharge side or below 0°C on

the suction side can be reached.

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1|Safety

These assembly instructions describe the standard version of the HG22P A manufactured by

GEA Bock. The compressor is intended for mobile applications in cooling systems in compli-

ance with the operating limits. Only the refrigerant specied in these instructions may be used.

Any other use of the compressor is prohibited!

The GEA 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 permissible only 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!

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2|Product description

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

• Lightweight aluminum design

• Suction gas-cooled drive motor

2.1 Brief description

Motor part

Dimension and connection values can be found in Chapter 9

Transport

eyelet

Fig. 1

Fig. 2

Name plate

Oil sightglass

Discharge

shut-off

valve

Oil pump

Terminal box

Suction

shut-off valve

Cylinder cover

Valveplate

Drive motor

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2|Product description

HG 22 P 190- 4 S AX

1 Type designation

2 Machine number

3 Maximum operating current

4 Start-upcurrent(rotorblocked)

5 ND(LP):Maximumadmissibleoperating

  pressure(g)Lowpressure

 HD(HP):Maximumadmissibleoperating

  pressure(g)Highpressure

Observe the

limit of application diagrams!

50 Hz

60 Hz

6 Voltage,switching,frequency

7 Nominal rotation speed

8 Displacement

9 Voltage,switching,frequency

10 Rated speed

11 Displacement

12 Oiltypelledatfactory

13 Protection system terminal box

Electrical accessories can change

the IP protection class!

}

2.2 Name plate(example)

2.3 Type code(example)

¹)HG-HermeticGas-cooled(suctiongas-cooled)

²)X- Esteroilcharge(HFCrefrigerant,e.g.R134a,R404A,R507,R407C)

³) AdditionalspecicationforPluscomcompressors

4)S - More powerful motor, e.g. for air-conditioning applications

Lightweight aluminum design

Motor version 4)

Number of poles

Swept volume

³)

Number of cylinders

Size

Oil charge ²)

Series ¹)

19/28 SE 55

16,5

19,8

HGX22P/190-4 S A

16,1/9,3 A

67A 40A

IP66

GEA Bock GmbH

72636 Frickenhausen, Germany

Fig. 3

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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 operating points.

- Permissible ambient temperature (-20°C) - (+60°C)

    -Max.permissibledischargeendtemperature:140°C

    -Max.permissibleswitchingfrequency:8x/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frequencyconverter:

- The potential control range of the compressor is 30-70 Hz.

- Max. permissible current consumption must not be exceeded.

At max. rotation speed therefore, the application limit can

be reduced.

- Use a thermal protection thermostat.

- Do not operate an additional capacity controller.

    -Oilreturnatlowfrequencymustbeguaranteed.

- Consultation with GEA Bock.

Foroperationwithcapacityregulator:

- The suction gas superheat temperature may need to be

reduced or set individuallywhen operating near to the threshold

When operating in the vacuum range, there is a danger of air en-

tering 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withthefollowingoiltypeatthefactory:

- for R134a, R404A/R507, R407C 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. HGX22P/190-4A).

3.1 Refrigerants

• HFKW/HFC:  R134a,R404A/R507,R407C

• (H)FCKW/(H)CFC: R22

3.2 Oil charge

3.3 Operating limits

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 com-

pressor is possible if over-

filled or underfilled!

ATTENTION!max.

min.

0,7 Ltr.

oil level

Fig. 4

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Design for other

areasonrequest

Unlimited

application range

Supplementary cooling or

reduced suction gas temperature

Supplementary cooling and

reduced suction gas temperature

Motor version S

(morepowerfulmotor)

Evaporatingtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

R134a

R407C

R404A/R507

R22

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Max. permissible operating

pressure (LP/HP)1):19/28bar

1) LP = Low pressure

HP = High pressure

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4|Compressor assembly

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

bearing capacity.

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

 Ensureadequatecompressorventilation.

Do not use in a dusty, damp atmosphere or a combustible

environment.

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.

Fig. 11

Fig. 12

Fig. 13

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

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 condensation

Do not store in a corrosive, dusty, vaporous atmosphere or in a com-

bustible environment.

Fig. 10

Fig. 9

ATTENTION! Attachments (e.g. pipe holders, additional units, fastening parts,

etc.) directly to the compressor are not permissible!

4.2 Setting up

Ce manuel convient aux modèles suivants

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