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GEA Bock Compressor HG4
Assembly instructions
HG4/310-4 |
HG4/310-4 S |
HGX4/310-4 |
HGX4/310-4 S |
HG4/385-4 |
HG4/385-4 S |
HGX4/385-4 |
HGX4/385-4 S |
HG4/465-4 |
HG4/465-4 S |
HGX4/465-4 |
HGX4/465-4 S |
HG4/555-4 |
HG4/555-4 S |
HGX4/555-4 |
HGX4/555-4 S |
HG4/650-4 |
HG4/650-4 S |
HGX4/650-4 |
HGX4/650-4 S |
engineering for a better world |
GEA Refrigeration Technologies |
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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 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 compressor is installed.
Manufacturer
GEA Bock GmbH
72636 Frickenhausen
Contact
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Telephone +49 7022 9454 0
Fax |
+49 7022 9454 137 |
refrigeration@gea.com
www.gea.com
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Contents |
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1 Safety |
4 |
1.1Identification of safety instructions
1.2Qualifications required of personnel
1.3General safety instructions
1.4Intended use
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Product description |
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2.1Short description
2.2Name plate
2.3Type key
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Areas of application |
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3.1Refrigerants
3.2Oil charge
3.3Limits of application
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Compressor assembly |
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4.1Storage and transport
4.2Setting up
4.3Pipe connections
4.4Pipes
4.5Laying suction and pressure lines
4.6Operating the shut-off valves
4.7Operating mode of the lockable service connections
5 |
Electrical connection |
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5.1Information for contactor and motor contactor selection
5.2Standard motor, design for direct or part winding start
5.3Basic circuit diagram for part winding start with standard motor
5.4Special motor: design for direct or star-delta start
5.5Basic circuit diagram for star-delta start with special motor
5.6Electronic trigger unit MP 10
5.7Connecting the trigger unit MP 10
5.8Functional test of the trigger unit MP 10
5.9Oil sump heater (accessories)
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Commissioning |
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6.1Preparations for start-up
6.2Pressure strength test
6.3Leak test
6.4Evacuation
6.5Refrigerant charge
6.6Start-up
6.7Avoiding slugging
6.8Connection of oil level regulator
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Maintenance |
25 |
7.1Preparation
7.2Work to be carried out
7.3Spare parts recommendation
7.4Accessories
7.5Extract from the lubricants table
7.6Decommissioning
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Technical data |
27 |
9 |
Dimensions and connections |
28 |
10 |
Declaration of conformity and installation |
30 |
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11 Service |
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1| Safety
1.1 Identification of safety instructions:
DANGER! |
Indicates a dangerous situation which, if not |
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Indicates a dangerous situation which, if not |
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WARNING! |
avoided, may cause fatal or serious injury. |
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Indicates a dangerous situation which, if not |
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CAUTION! |
avoided, may cause fairly severe or minor injury. |
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ATTENTION! |
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avoided, may cause property damage. |
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INFO! |
Important information or tips on simplifying work. |
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1.2 Qualifications required of personnel
WARNING! Inadequately qualified 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 qualifications listed below:
• For example, a refrigeration technician, refrigeration mechatronics 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.
1.3 General safety instructions
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.
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1| Safety
1.4 Intended use
These assembly instructions describe the standard version of the HG4 manufactured by GEA Bock. The compressor is intended for use in refrigeration systems in compliance with the limits of application. Only the refrigerant specified in these instructions may be used.
Any other use of the compressor is prohibited!
WARNING! The compressor may not be used in potentially explosive environments!
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 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.
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2| Product description
2.1 Short description
•Semi-hermetic four-cylinder reciprocating compressor with suction-gas cooled drive motor.
•Flange-mounted drive motor on the compressor case.
•Preferred application range: normal refrigerating and air-conditioning.
Terminal box
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Suction shut- |
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off valve |
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Transport eyelet |
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Valve plate |
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Motor section |
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Discharge |
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Cylinder cover |
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shut-off valve |
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Name plate |
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Oil pump |
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Drive section |
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Oil sight glass |
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Fig. 1 |
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Dimension and connection values can be found in Chapter 9
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2| Product description
2.2 Name plate (example)
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GEA Bock GmbH |
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72636 Frickenhausen, Germany |
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HGX4/310-4 |
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AS35830A006 |
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27,1 |
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17,0A |
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SE 55 |
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Fig. 2 |
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Type designation |
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Voltage, circuit, frequency |
} 50 Hz |
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Machine number |
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Nominal rotation speed |
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maximum operating current |
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Displacement |
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Starting current (rotor blocked) |
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Voltage, circuit, frequency |
} 60 Hz |
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Y: Part winding 1 |
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Nominal rotation speed |
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YY: Part windings 1 and 2 |
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Displacement |
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ND (LP): max. admissible operating |
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Oil type filled at the factory |
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pressure (g) Low pressure side |
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Terminal box protection type |
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HD (HP): max. admissible operating |
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Electrical accessories can change |
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pressure (g) High pressure side |
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the IP protection class! |
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diagrams! |
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2.3 Type key (example)
HG X 4 / 650-4 S |
Motor variant 3)
Number of poles
Swept volume
Size
Oil charge ²)
Series ¹)
¹) HG - Hermetic Gas-cooled (suction gas-cooled)
²) X - Ester oil charge (HFC refrigerant, e.g. R134a, R404A/R507, R407C) 3) S - More powerful motor, e.g. for air-conditioning applications
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3| Areas of application
3.1 Refrigerants |
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HFKW / HFC: |
R134a, R404A/R507, R407C |
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(H)FCKW / (H)CFC: |
R22 |
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3.2 Oil charge |
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The compressors are filled at the factory with the following oil type: |
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- for R134a, R404A/R507, R407C |
FUCHS Reniso Triton SE 55 |
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- for R22 |
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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. HGX4/650-4).
INFO! For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.5.
ATTENTION! The oil level must be in the |
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visible part of the sight |
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oil level |
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glass; damage to the com- |
~ 1,8 Ltr. |
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pressor is possible if over- |
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filled or underfilled! |
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Fig. 3 |
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3.3 Limits of application
ATTENTION! 
Compressor operation is possible within the operating limits shown in the diagrams. Please note the significance of the shaded areas. Thresholds should not be selected as design or continuous operation 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 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!
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R134a
Fig. 4
R407C
Fig. 5
R404A/R507
Fig. 6
R22
Fig. 7
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Unlimited application range |
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Supplementary cooling or |
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reduced suction gas temperature |
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Supplementary cooling and |
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reduced suction gas temperature |
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Motor version S |
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(more powerful motor) |
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Evaporation temperature (°C) |
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Condensing temperature (°C) |
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Suction gas superheat (K) |
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Suction gas temperature (°C) |
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Max. permissible operating pressure (LP/HP)1): 19/28 bar
1)LP = Low pressure HP = High pressure
Design for other areas on request
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4| Compressor assembly
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INFO! |
New compressors are factory-filled with inert gas (3 bar nitrogen). |
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Leave this service charge in the compressor for as long as possible |
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and prevent the ingress of air. |
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Check the compressor for transport damage before starting any |
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work. |
4.1 Storage and transport
Fig. 8
Fig. 9 ?
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 combustible environment.
Use transport eyelet. Do not lift manually! Use lifting gear!
4.2 Setting up
ATTENTION! Attachments (e.g. pipe holders, additional units, fastening parts, etc.) directly to the compressor are not permissible!
Provide adequate clearance for maintenance work.
Ensure adequate compressor ventilation.
Fig. 10
Do not use in a corrosive, dusty, damp atmosphere or a combustible environment.
Fig. 11
Setup on an even surface or frame with sufficient loadbearing capacity.
Single compressor preferably on vibration damper.
Duplex and parallel circuits always rigid.
Fig. 12
4.3 Pipe connections
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).
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