GEA Bock HG12P/75-4 User manual

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engineering for a better world
GEA Bock Compressor HG12P
Assembly instructions
HG12P/75-4 HG12P/60-4 S HGX12P/75-4 HGX12P/60-4 S
HG12P/90-4 HG12P/75-4 S HGX12P/90-4 HGX12P/75-4 S
HG12P/110-4 HG12P/90-4 S HGX12P/110-4 HGX12P/90-4 S
HG12P/110-4 S HGX12P/110-4 S

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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
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.gea.com
Manufacturer
Contact
Contents Page

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Contents Page
3 Areas of application 8
 3.1 Refrigerants
 3.2 Oilcharge
 3.3 Limitsofapplication
4Compressor assembly 10
 4.1 Storageandtransport
 4.2 Settingup
 4.3 Pipeconnections
 4.4 Pipes
 4.5 Layingsuctionandpressurelines
 4.6 Operatingtheshut-offvalves
 4.7 Operatingmodeofthelockableserviceconnections
5 Electrical connection 13
 5.1 Informationforcontactorandmotorcontactorselection
 5.2 Connectionofthedrivingmotor
 5.3 Circuitdiagramfordirectstart230VΔ/400VY-->with MP10
 5.4 ElectronictriggerunitMP10
 5.5 ConnectionoftheelectronictriggerunitMP10
 5.6 FunctionaltestoftheelectronictriggerunitMP10
 5.7 Circuitdiagramfordirectstart230VΔ/400VY-->with INT69 G
 5.8 ElectronictriggerunitINT69G
 5.9 ConnectionoftheelectronictriggerunitINT69G
 5.10 FunctionaltestoftheelectronictriggerunitINT69G
6 Commissioning 22
 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 24
 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 26
9 Dimensions and connections 27
10 Declaration of conformity and installation 28
11 Service 29

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1|Safety
1.2 Qualicationsrequiredofpersonnel
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.
WARNING Inadequatelyqualied personnelposesthe riskof accidents,the
consequencebeingseriousorfatalinjury.Workoncompressors
isthereforereservedforpersonnelwhichisqualied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.
1.1 Identicationofsafetyinstructions:

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1|Safety
1.4 Intended use
1.3 General safety instructions
WARNING Risk of accidents.
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.
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.
- Avoid contact with refrigerant necessarily.
Contact with refrigerant can cause severe burns and skin
damage.
WARNING The compressor may not be used in potentially explosive
environments!
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and2006/95/EC–LowVoltageDirective).
Commissioningispermissibleonlyifthecompressorhasbeeninstalledinaccordancewiththeseas-
sembly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speciedintheseinstructionsmaybeused.
Any other use of the compressor is prohibited!

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2|Product description
• Semi-hermetictwo-cylinderreciprocatingcompressorwithoilpumplubrication.
• Suctiongascooleddrivemotor.
2.1 Short description
Fig.1
Fig.2
Oilsightglass
Valveplate
Cylindercover
Discharge
shut-offvalve
Oilpump
Terminalbox
Suction
shut-offvalve
Drivesection
Motorsection
DimensionandconnectionvaluescanbefoundinChapter9
Transporteyelet
Nameplate

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2|Product description
2.2 Name plate (example)
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
5 ND(LP):max.admissibleoperating 10 Nominalrotationspeed
 pressure(g)Lowpressureside 11 Displacement
 HD(HP): max.admissibleoperating  12 Oiltypelledatthefactory
pressur e(g)Highpressureside 13 Terminalboxprotectiontype
Observe the limits of application Electrical accessories can change
diagrams! the IP protection class!
50 Hz
}
60 Hz
}
/
HG 21 P 110- 4 SX
2.3 Type key (example)
¹) HG-HermeticGas-cooled(suctiongas-cooled)forthenormal-/airconditioningapplications
²) X
-Esteroilcharge(HFCrefrigerant,e.g.R134a,R404A/R507,R407C)
³) AdditionaldeclarationforPluscomcompressors
4) S - Morepowerfulmotor,e.g.forair-conditioningapplications
Motorvariant4)
Numberofpoles
Sweptvolume
³)
Numbersofcylinders
Size
Oilcharge²)
Series¹)
Typschild (Beispiel)
1
2
3
4
513
12
7
11
6
10
8
9
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Stillstandsdruck
Saugseite
HD (HP): max. zulässiger Betriebsdruck
Hochdruckseite
Einsatzgrenzendiagramme beachten!
50 Hz
60 Hz
6 Spannung, Schaltung, Frequenz
7 Nenndrehzahl
8 Hubvolumen
9 Spannung, Schaltung, Frequenz
10 Nenndrehzahl
11 Hubvolumen
12 Werkseitig eingefüllte Ölsorte
13 Schutzart Klemmenkasten
10,6/6,1A
45A 26A
9,4
11,3
HGX12P/110-4S
AS35830A001
SE 55
AS35830A001
GEA Bock GmbH
72636 Frickenhausen, Germany
1
2
3
4
5
6
7
8
9
10
12
13
11
Fig.3

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3|Areas of application
 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.HGX12P/110-4).
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
ATTENTION The oil level must be in the
visible part of the sight glass;
damage to the compressor is
possible if overfilled or under-
filled! Fig.4
max.
min.
0,5Ltr.
oillevel ~
~
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.
- 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 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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Evaporationtemperature(°C)
Condensingtemperature(°C)
Suctiongassuperheat(K)
Suctiongastemperature(°C)
3|Areas of application
Design for other
areasonrequest
R134a
R407C
R404A/R507
R22
Fig.5
Fig.6
Fig.7
Fig.8
Unlimitedapplicationrange
Supplementarycoolingor
reducedsuctiongastemperature
Supplementarycoolingand
reducedsuctiongastemperature
MotorversionS
(morepowerfulmotor)
Max. permissible operating
pressure (LP/HP)1): 19/28 bar
1) LP=Lowpressure
HP=Highpressure

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4|Compressor assembly
 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.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
 Donotuseinacorrosive,dusty,dampatmosphereora
combustibleenvironment.
Fig.11
Fig.12
Fig.13
F
E
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C
B
A
1 2
3
4
F
E
D
C
4
3
2
1
A
B
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
30 6
-
±0.3
120
30
±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
s
25
z y x w u t
0,05
Rz 1,6
0,3
0,7
1,6
2
Rz 16
6,3
Rz 63
Rz 6,3
Rz 12,5
F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage
4.2 Setting up
?
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
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.
ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
ATTENTION Damage possible.
Do not solder as long as the compressor is under pressure.
Superheating can damage the valve. Remove the pipe supports
therefore from the valve for soldering and accordingly cool the
valve body during and after soldering.
Only solder using inert gas to inhibit oxidation products (scale).
4.3 Pipe connections