GEA HG7 Manuel utilisateur

09706-09.2013-DGbFEI

engineering for a better world GEA Refrigeration Technologies

Bock Compressor HG7

Assembly instructions

HG7/1620-4 HG7/1620-4 S HGX7/1620-4 HGX7/1620-4 S

HG7/1860-4 HG7/1860-4 S HGX7/1860-4 HGX7/1860-4 S

HG7/2110-4 HG7/2110-4 S HGX7/2110-4 HGX7/2110-4 S

09706-09.2013-DGbFEI

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

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 Basic circuit diagram for part winding start with standard motor

5.3 Standard motor, design for direct or partial winding start

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 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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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 Basic circuit diagram for part winding start with standard motor

5.3 Standard motor, design for direct or partial winding start

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 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.

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1|Safety

These assembly instructions describe the standard version of the HG7 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!

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2|Product description

• Semihermeticsix-cylinderreciporatingcompressorwithoilpumplubrication.

• Thestreamofcoolantsuckedoutoftheevaporatorowsoverthemotorandcoolsitintensively.

In this way, the motor can be kept at a relatively low temperature level, particularly under high

loads.

• CylinderarrangementinpairsinW-design.

Name plate

Fig. 1

2.1 Short description

Valve plate Cylinder

cover

Terminal box

Dimension and connection values can be found in Chapter 9

Transport eyelet

Discharge

shut-off valve

Oil pump

Suction

shut-off valve

Oil sight glass

Motor section

Drive section

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2|Product description

HG 72110-4

Fig. 2

2.2 Name plate (example)

2.3 Typekey (example)

1) HG - Hermetic-Gas-cooled (suction gas cooled) for the normal- / air conditioning applications

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

3) S - Stronger motor e.g. air conditioning applications

Motor variant 3)

Number of poles

Swept volume

Size

Esteroillling²)

Series ¹)

SE 55

AS09529A001

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

Δ: Part winding 1 10 Nominal rotation speed

YYY: Part windings 1 and 2 11 Displacement

5 ND (LP):

max. admissible operating

 12 Oiltypelledatthefactory

pressur

e (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

}

GEA Bock GmbH

72636 Frickenhausen, Germany

09706-09.2013-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 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 additional cooling:

- Use only oils that are highly thermally stable.

- Avoid continuous operation near the limits.

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.

During operation in the vacuum range, there is a danger of air

    enteringonthesuctionside.Thiscancausechemicalreactions,

pressure rise in the condenser and an excessive compressed-gas

temperature. Avoid absolutely any entry of air.

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

- 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. HGX7/2110-4).

3.1 Refrigerants

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

• (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

09706-09.2013-DGbFEI

Design for other

areasonrequest

Max. permissible operating

pressure high pressure

side (HP): 28 bar

Evaporation temperature (°C)

Condensing temperature (°C)

Suction gas superheat(K)

Suction gas temperature (°C)

R134a

R407C

R404A/R507

R22

Fig. 4

Fig. 5

Fig. 6

Fig. 7

HG7 „Motor version S“

in the evaporation range of

to= 5°C to 12,5°C

limited condensing temperature

up to tc= 50°C.

Additional cooling and reduced

suction gas temperature

Unlimited application

range

Additional cooling or reduced

suction gas temperature

Motor variant - S

(stronger motor)

09706-09.2013-DGbFEI

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. 8

Fig. 9

Fig. 10

Fig. 11

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. 12: 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

4|Compressor assembly

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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