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GEA 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 |
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
1 Safety
1.1Identification of safety instructions
1.2Qualifications required of personnel
1.3General safety instructions
1.4Intended use
2 Product description
2.1Short description
2.2Name plate
2.3Type key
3 Areas of application
3.1Refrigerants
3.2Oil charge
3.3Limits of application
4 Compressor assembly
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
5.1Information for contactor and motor contactor selection
5.2Basic circuit diagram for part winding start with standard motor
5.3Standard motor, design for direct or partial winding start
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)
6 Commissioning
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
7 Maintenance
7.1Preparation
7.2Work to be carried out
7.3Spare parts recommendation
7.4Accessories
7.5Extract from the lubricants table
7.6Decommissioning
8Technical data
9Dimensions and connections
10Declaration of conformity and installation
11Service
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1| Safety
1.1 Identification of safety instructions:
DANGER |
Indicates a dangerous situation which, if not avoided, |
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will cause immediate fatal or serious injury. |
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WARNING |
Indicates a dangerous situation which, if not avoided, |
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may cause fatal or serious injury. |
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CAUTION |
Indicates a dangerous situation which, if not avoided, |
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may cause fairly severe or minor injury. |
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ATTENTION |
Indicates a situation which, if not avoided, |
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may cause property damage. |
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INFO |
Important information or tips on simplifying work. |
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 is therefore reserved for personnel which is qualified to work on pressurized refrigerant systems:
•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 the work to be carried out and recognising any potential dangers.
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1 | Safety
1.3 General safety instructions
WARNING |
Risk of accidents. |
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Refrigerating compressors are pressurised machines and as such |
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call for heightened caution and care in handling. |
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The maximum permissible overpressure must not be exceeded, |
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even for testing purposes. |
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Risk of burns! |
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- Depending on the operating conditions, surface temperatures of |
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over 60°C on the discharge side or below 0°C on the suction side |
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can be reached. |
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- Avoid contact with refrigerant necessarily. |
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Contact with refrigerant can cause severe burns and skin |
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damage. |
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1.4 Intended use |
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WARNING |
The compressor may not be used in potentially explosive |
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environments! |
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These assembly instructions describe the standard version of the compressor named in the title manufactured by GEA Bock. GEA Bock refrigerating compressors are intended for installation in a machine (within the EU according to the EU Directives 2006/42/EC Machinery Directive, 97/23/EC
Pressure Equipment 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.
The compressors are 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!
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2| Product description
2.1 Short description
•Semihermetic six-cylinder reciporating compressor with oil pump lubrication.
•Thestreamofcoolantsuckedoutoftheevaporatorflowsoverthemotorandcoolsitintensively.
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.
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Suction |
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Terminal box |
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shut-off valve |
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Transport eyelet |
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Cylinder |
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Valve plate |
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cover |
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Discharge |
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Motor section |
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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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AS09529A039 |
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12 |
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6 |
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SE 55 |
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Fig. 2
1Type designation
2Machine number
3Type code
4Maximum operating current
5Starting current (rotor blocked)
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Part winding 1 |
} until |
YYY: Part windings 1 and 2 |
A039 |
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Part winding 1 |
from |
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Part windings 1 and 2 |
} A040 |
6 ND (LP): max. admissible operating pressure (g) Low pressure side
HD (HP): max. admissible operating pressure (g) High pressure side
Observe the limits of application diagrams!
7Voltage, circuit, frequency
8 Nominal rotation speed } 50 Hz
9Displacement
10Voltage, circuit, frequency
11 Nominal rotation speed } 60 Hz
12Displacement
13Oil type filled at the factory
14Terminal box protection type
Electrical accessories can change the IP protection class!
2.3 Type key (example)
HG X 7 / 2110-4 S |
Motor variant 3)
Number of poles
Swept volume
Size
Ester oil filling ²)
Series ¹)
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
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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. HGX7/2110-4).
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For refilling, we recommend the above oil types. |
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Alternatives: see lubricants table, Chapter 7.5. |
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ATTENTION |
The correct oil level is shown |
max. |
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in figure 3. |
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oil level |
~ 2,3 Ltr. |
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Damage to the compressor |
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is possible if overfilled or |
min. |
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underfilled! |
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Fig. 3 |
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3.3 Limits of application |
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ATTENTION |
Compressor operation is possible within the operating limits |
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shown in the diagrams. Please note the significance |
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of the shaded areas. Thresholds should not be selected as |
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design or continuous operation points. |
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- 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.Inthecaseofoperationabovethemainsfrequency,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
Unlimited application range
Additional cooling or reduced suction gas temperature
Additional cooling and reduced suction gas temperature
Motor variant - S (stronger motor)
Evaporation
temperature
(°C)
Condensing temperature (°C)
Suction gas superheat
(K)
Suction gas temperature (°C)
Max. permissible operating pressure high pressure side (HP): 28 bar
Design for other areas on request
HG7 „Motor version S“ in the evaporation range of to = 5°C to 12,5°C
limited condensing temperature up to tc = 50°C.
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4| Compressor assembly
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. Check the compressor for transport |
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damage before starting any work. |
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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 Fittings (e.g. pipe holders, additional units, mounting parts etc.) on 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
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Setup on an even surface or frame with sufficient load- |
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bearing capacity. |
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Single compressor preferably on vibration damper. |
Fig. 12 |
Duplex and parallel circuits always rigid. |
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4.3 Pipe connections |
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ATTENTION Damage possible. |
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Superheating can damage the valve. |
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Remove the pipe supports from the valve for soldering. |
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Only solder using inert gas to inhibit oxidation products (scale). |
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4| Compressor assembly
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The pipe connections have graduated inside diameters so that pipes with |
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standart millimetre and inch dimensions can be used. |
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The connection diameters of the shut-off valves are rated for maximum |
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compressor output. The actual required pipe cross section must be |
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matched to the output. The same applies for non-return valves. |
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Fig. 13: graduated |
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internal diameter |
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INFO |
For compressors HG7/2110-4 and HG7/2110-4 S, solder connections |
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are mounted to the suction shut-off valve for pipe diameter 64. |
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Solder connections for pipe diameter 2 5/8“ are enclosed with the |
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compressor. |
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4.4 Pipes |
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Pipes and system components must be clean and dry inside and free of scale, swarf and layers of rust and phosphate. Only use air-tight parts.
Lay pipes correctly. Suitable vibration compensators must be provided to prevent pipes being cracked and broken by severe vibrations.
Ensure a proper oil return.
Keep pressure losses to an absolute minimum.
4.5 Laying suction and pressure lines
ATTENTION |
Improperly installed pipes can cause cracks and tears, the result |
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being a loss of refrigerant. |
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INFO |
Proper layout of the suction and discharge lines directly after |
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the compressor is integral to the system’s smooth running and |
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vibration behaviour. |
A rule of thumb: Always lay the first pipe section starting from the shut-off valve downwards and parallel to the drive shaft.
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As short as possible
Rigid fixed point
Fig. 14
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