GEA HG34P/e Manuel utilisateur

96194-05.2021-Gb

Bock HG34P/e

Maintenance manual

96193-05.2021-D

colour the world

of tomorrow

BOCK®

96194-05.2021-Gb

About these instructions

Read these instructions before assembly and before using the

compressor. This will avoid misunderstandings and prevent dama-

ge. Improper assembly and use of the compressor can result in

serious or fatal injury.

Observe the safety instructions contained in these instructions.

Liability and warranty

Manufacturer's liability and warranty are excluded if

• Alterations and functional modifications have been carried out

• No original replacement parts have been used

Contents Page

1 Safety 3

2 Fault diagnosis 4

3 Disassembly of the compressor 8

4 Checking the compressor parts 19

5 Assembly of compressor 21

6 Exploded drawing 33

Contact

Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Telephone +49 7022 9454 0

Fax +49 7022 9454 137

[email protected]

www.bock.de

96194-05.2021-Gb

Identication of safety instructions

General safety instructions

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

will cause immediate fatal or serious injury.

DANGER! Indicates a dangerous situation which by electrical current, 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 / tips on simplifying work.

Safety instructions

Target group of these instructions

• Work on the compressor may only be carried out by persons whose technical training, skills and expe-

rience along with their knowledge of pertinent regulations and documentation means that they are capa-

ble of assessing the work to be carried out and detecting any possible dangers

• Specialist can mean a refrigeration technician for example. Note that electrical work may only be carried

out by a qualified electrician. Alternatively, on a country-specific basis, persons who have undergone elec-

trotechnical instruction and who have proof of their qualification are also permitted to carry out the work.

1 I Safety

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.

DANGER! Risk of electric shock

• Before you carry out any repair work, disconnect the compressor from the electricity network.

• Turn the main switch to "O" (OFF).

• Secure the main switch against an unauthorised restart.

96194-05.2021-Gb

2 I Fault diagnosis

Fault diagnosis

In case of malfunctions during compressor operation we recommend

to prepare a measurement record for aiding the fault search:

Pressure measurement: Discharge side, suction side,

oil pressure

Temperature measurement: Compressor casing,

discharge end temperature, suction gas overheating

According to the expected cause of the fault it may be necessary

to check the electrical systems for faults in the control.

In order to localize the causes of operating malfunctions as easy

as possible we have compiled the following table with suggestion

for remedying compressor malfunctions.

Function faults - Symptoms

Function faults arising most frequently and their symptoms are:

Compressor stoppage, compressor cutoff

- Compressor does not start

- Compressor starts and then stops again

Refrigerant performance too low

Too high compressor temperature

Oil problems

Abnormal compressor running noise

Compressor stand still

Compressor does not start

Problem Possible cause Remedy

Control circuit is interrupted Main- or control fuse is switched off or

tripped

-Setting / selection incorrect

- Motor overloaded

- Undervoltage

- Starter contacts / shorted contacts /

earthed contacts

Replace fuse

Determine and remove the cause

Cut off through:

- Low pressure switch

- High pressure switch

- Heat protection thermostat

- Control thermostat

- Other safety elements

Locate the interruption in the circuit

and remove

Main- or ontrol circuit is switched

off

switch on

Main- or control circuit is wired

incorrectly

wire correctly

Bridges / connection cable in

terminal box is wired incorrectly

wire correctly

Incorrect voltage connect to correct voltage

Phase or neutral is missing connect

Overload / motor safety is swit-

ched off

Setting / selection incorrect Check design

Function / drive not working Check cable, electronic system

Motor overloaded Check operating conditions

Undervoltage Determine and remove the cause

Short circuit ON / OFF Check control

Starter contacts / shorted contacts /

earthed contacts

Check motor for winding damages / check

shorted contacts

96194-05.2021-Gb

Compressor cutoff

Compressor starts and stops again

Problem Possible cause Remedy

Cutoff through lowpressure

switch

Suction pressure too low:

- Check the setting of the low pressure switch - Adjust the switching points or replace switch

- Suction valve of the compressor closed - Open suction valve

- Capacity of compressor too large - Check operating conditions

- Refrigerant deciency - Leak test / add refrigerant

- Filter / dryer in the liquid line blocked - Replace lter / dryer

- Expansion valve not functioning properly - Check the setting of the expansion valve

- Solenoid valve on the liquid line not opening - Check the control / function

Cutoff through highpressure

switch

Condensing pressure too high:

- Check the setting of the high-pressure switch - Adjust the switching points or replace switch

- Pressure valve of the compressor closed - Open the pressure valve

- Condenser fan not functioning - Check the control / replace motor

- Condenser fan is dirty - Cleaning of condenser

- Excessive refrigerant lling - Extract refrigerant to normal lling

- Non-condensible gases in refrigerant - Extract refrigerant and evacuate the

refrigeration plant / rell refrigerant

Cutoff through heatprotection

thermostat (accessory)

Discharge end temperatures is too high

- Operating limits of compressor exceeded

- Adapt the operating conditions

to the operating range

- Suction gas overheating - Check expansion valve / check

insulation on the suction side

- Refrigerant of the condenser insufcient - Check fan motors / Clean the condenser

- Valve plate damage - Replace valve plate

- Internal safety valve has opened - Replace safety valve

-> Check compressor and refrigeration plant

Determine and remove the cause for the

inadmissible high pressure in the high-

pressure side

Cutoff through control

thermostat

Temperature over / below the desired range Check operating points

Cooling control or other switch /

control devices are switched off

Setting / selection incorrect - Check control design

- Change control

Function / drive incorrect - Check drive / function

- Check cables, contacts etc.

2 I Fault diagnosis

Problem Possible cause Remedy

Overload / Motor safety switch

is tripped

Two phase run Ensure three phase run

Very unequal phase runs Determine and remove the cause

96194-05.2021-Gb

2 I Fault diagnosis

Refrigerant temperature too high

Problem Possible cause Remedy

Suction gas temperature

too high

- Suction gas overheating - Adjust expansion valve

Insulate the gas suction line

- Too little refrigerant lling - Establish the operating lling (see Operating

Instruction for the refrigeration plant)

Localize leak

- Liquid lter blocked - Clean / replace lter / dryer

- Shortage of refrigerant - Run leakage test / rell

refrigerant

Discharge pipe temperature

too high

- Suction gas temperature too high

(Condensing pressure too high)

- Adjust expansion valve

Insulate the gas suction line

- see „Cutoff through high-pressure switch“

- Operating limits of compressor exceeded - see „Cutoff through heat-protection

thermostat“

Refrigerant performance too low

Problem Possible cause Remedy

Suction pressure too high - Evaporator iced up - Remove the cause

- Expansion valve not functioning properly - Check expansion valve setting;

replace valve, if necessary

- Lack of compressor capacity - Check the function of the compressor by

evacuating to vacuum.

Check function of capacity regulator

(accessory)

- Shortage of refrigerant - Run leakage test / rell

refrigerant

Suction pressure too low - See „Cutoff through low-pressure switch“ - Checking

High-pressure too high - See „Cutoff through high-pressure switch“ - Checking

High-pressure too low - Condenser being cooled to much - Adjust the control of condenser cooling

- Lack of compressor capacity - Check compressor / Check the functioning

of capacity regulator

- Pressure laminations of valve plate leaking - Replace valve plate

- By-pass between suction and discharge side - Localize leak between the discharge and

suction side and repair it

Problem Possible cause Remedy

MP10 switched off Function / drive not working Check function / drive

Motor overloaded Check operating conditions

Undervoltage Determine and remove the cause

Short circuit ON / OFF check control

Starter contacts / shorted contacts /

earthed contacts

Check motor for winding damage / check

shorted contacts

Two-phase run Ensure three phase run

Very unequal phase runs Determine and remove the cause

96194-05.2021-Gb

Oil problems

Problem Possible cause Remedy

Oil pressure too low - Refrigerant in oil - see „Oil foams“

- Too little oil in compressor - Add oil and search for the cause of oil loss

- Oil lter dirty / blocked - Clean / replace oil lter

Change oil

Oil foams during start-up phase - Liquid refrigerant has moved into the oil sump - Check the laying of pipes

- Installation of the check valve in the

discharge line

- Installation of the solenoid valve in the

liquid line

- Check the control

Oil foams during operating - Expansion valve not functioning - Adjust / replace expansion valve

Oil level decreases - During start-up, a portion of the oil is carried

to the refrigeration plant with the refrigerant

- Refrigerant and oil get mixed. After some time

the oil level should stabilize.

Add oil, if necessary.

- Refrigerant in oil - see „Oil foams during start-up phase“

- Piston rings worn - Replace piston rings

- Suction / discharge laminations of the valve

plate leaking

- Replace valve plate

2 I Fault diagnosis

Abnormal running noise from compressor

Problem Possible cause Remedy

Fixation of compressor is loose - Screwed connections have become loose

- Securing elements for screwed connections

missing

- Tighten the screwed connections and secure

them anew

- Vibration metals defective - Replace vibrations metals

Liquid shock - Liquid refrigerant reaching the compressor - Adjust / check expansion valve

Check refrigerant lling

Check evaporator fan

- Icing-up of the evaporator

- Oil shocks because of too much oil - Check oil level

Check the dimensioning of pipes (gas velocity)

Replace worn piston rings

Capacity regulator (accessory) - Switching on and off constantly / oscillating - Check the control

- Defective - Replace capacity regulator valve

Problem Possible cause Remedy

Discharge pipe temperature

too high

- Cooling insufcient - Check refrigerant lling

- Adjust expansion valve

- Short circuit between the discharge and the

suction side of the compressor

- Check gaskets on valve plate /

change

- Valve plate damage - Replace valve plate

96194-05.2021-Gb

3 I Disassembly of the compressor

Disassembly and assembly of the compressor

Important Notes

WARNING! Before starting any work on the compressor:

• Switch of the compressor and guard it against switching on.

• Relieve the compressor from system pressure

• Prevent air from infiltrating the system

• Move and transport the compressor using an appropriate hoist

After the work is finished:

• Connect the safety switch and check its function

• Evacuate the compressor

• Before commissioning, check whether all the components installed by the user have been

mounted expertly and are connected pressure-tight to the compressor

• Open the pressure and suction shut-off valves

• Set off the switching-on lock

INFO! Use only new gaskets for assembly.

For 2 pole compressors the stator is built at factory in while it is still warm.

A removal is therefore not possible.

For 4 pole compressors, the stator screw (Pos. 1020 in the parts list) has to be replaced.

Because of the coating, tighten stator screw once only. Note hardening time!

The following illustrations show a HG34 compressor in standard design.

Components of other designs (z.B. aluminium design) can differ from these illustrations.

However, the procedure for disassembly and assembly of the compressor is identical.

96194-05.2021-Gb

Removal of the compressor from the refrigerant system

Removal of the compressor from the system, shut-off valves remaining on the compressor

- Extract the refrigerant from the system into a container which may be used for this refrigerant

- Evacuate the systems including the compressor

- Cut off the vacuum, humid air should not get into the system

- Close the shut-off valves on the suction and discharge side; remove the compressor

- Close the suction and discharge line connection points on the system with stoppers

- Relieve the pressure before dismounting the compressor

Removal of the compressor from the system, shut-off valves for compressor remaining at the system

- Close shut-off valves on the suction and discharge side

- Extract the refrigerant from the compressor into a container which may be used for this refrigerant

- Evacuate the compressor

- Cut off the vacuum

- Remove the compressor from the system

- Close the suction and discharge shut-off ports on the compressor with stoppers

Disassembly of compressor

The disassembly of the compressor is explained in separate steps on the following pages. The indicated parts list

positions refer to the spare parts lists, repair set lists, special accessories part lists and are available online at

vap.bock.de

You can find the exploded drawing at the end of the maintenance manual.

3 I Disassembly of the compressor

Preparation: Necessary tools

Pos. Tool Size

Oil collection container

Spanner

Allen key

Needle-nosed pliers

Magnet

> 1,5 ltr.

SW 10, 13, 14, 17, 19

6 mm, 10 mm

96194-05.2021-Gb

1Draining the oil

Position in

parts list

Parts list position: 480

Tools: Spanner SW 17, Oil collection container > 1,5 liter

Working course

480, 482

- The compressor has to be depressurized

- Place the container in a way that the oil can ow into it

- Loosen oil drain screw and unscrew

- Drain off oil

3 I Disassembly of the compressor

CAD-Zeichnung - Darf nur maschinell geändert werden.

Montageanleitung E-Motor (Pluscom)

Zeichnung 2

1:2

Maßstab:

Rz 6,3

Rz 63

6,3

Rz 16

Rz 25

1,6

Rz 12,5

0,7

0,3

±0.1

Gewicht: (kg)

Gußtoleranzen:

Zust.

x.xxxx-xxxxx.x

nach DIN ISO 1302

Oberflächenangaben

Zeichn.-Nr. Teile-Nr.

±0.2

120

±0.3

1000

±0.8

Benennung:

400

Änderungsbeschreibung

Blatt:

Oberflächenbehandlung / Härte:

1/1

Zone

Kurz

Geprüft

2009

Erstellt

Ersetzt durch:

Ersatz für:

DIN ISO 13715

Werkstückkanten

Rz 1,6

0,05

02.02.

Datum

Name

Gepr.

Ausgangsteil, bzw. Rohteil:

Werkstoff:

Änderungs-Nr.

Datum

Bearb.

Diese Zeichnung ist unser Eigentum!

Sie darf ohne unsere Genehmigung weder nach-

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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.

Unbemaßte Radien:

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

bis 6

über 0.5

±0.5

400

120

Teil keine Serie

Entwicklungsstand

Zeichnung ungültig

PL:

K.-Auftrag:

Lieferantenzeichnung

Teil inaktiv

Baumustergeprüft

Alternativbezug:

Freigabe

Passung

Maß

Ra Rz

Rz 160

Revisionsdurchlauf:

Tol.-Ang. DIN ISO 2768-mK

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Alternativer Link: http://www.youtube.com/watch?v=JNS9-4mNX7c

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