GEA HG34e User manual

D
GB
F
E
1
96178-09.2013-DGbFEI
engineering for a better world GEA Refrigeration Technologies
Bock Compressor HG34e
Assembly instructions
HG34e/215-4 HGX34e/215-4 HGX34e/215-4 S R407C
HG34e/255-4 HGX34e/255-4 HGX34e/255-4 S R407C
HG34e/315-4 HGX34e/315-4 HGX34e/315-4 S R407C
HG34e/380-4 HGX34e/380-4 HGX34e/380-4 S R407C
HG34e/215-4 S HGX34e/215-4 S
HG34e/255-4 S HGX34e/255-4 S
HG34e/315-4 S HGX34e/315-4 S
HG34e/380-4 S HGX34e/380-4 S
1
2
3
4
5
6
7
8
9
10
1 1
12
13

2
D
GB
F
E
96178-09.2013-DGbFEI
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
 3.4 Refrigerants-designforR407C,35bar
 3.5 OilchargeforR407C,35bar
 3.6 Limitsofapplication,R407C,35bar
4Compressor assembly 12
 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 15
 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
 5.4 Startunloader
 5.5 ElectronictriggerunitMP10
 5.6 ConnectionoftheelectronictriggerunitMP10
 5.7 FunctionaltestoftheelectronictriggerunitMP10
6 Commissioning 20
 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 22
 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 24
9 Dimensions and connections 26
10 Declaration of conformity and installation 27
11 Service 28
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

D
GB
F
E
3
96178-09.2013-DGbFEI
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
 3.4 Refrigerants-designforR407C,35bar
 3.5 OilchargeforR407C,35bar
 3.6 Limitsofapplication,R407C,35bar
4Compressor assembly 12
 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 15
 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
 5.4 Startunloader
 5.5 ElectronictriggerunitMP10
 5.6 ConnectionoftheelectronictriggerunitMP10
 5.7 FunctionaltestoftheelectronictriggerunitMP10
6 Commissioning 20
 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 22
 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 24
9 Dimensions and connections 26
10 Declaration of conformity and installation 27
11 Service 28

4
D
GB
F
E
96178-09.2013-DGbFEI
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.

D
GB
F
E
5
96178-09.2013-DGbFEI
1|Safety
TheseassemblyinstructionsdescribethestandardversionoftheHG34e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!

6
D
GB
F
E
96178-09.2013-DGbFEI
1
2
3
4
5
6
7
8
9
10
1 1
12
13
2|Product description
• Semi-hermeticfour-cylinderreciprocatingcompressorwithoilpumplubrication.
• Suctiongascooleddrivemotor.
2.1 Short description
DimensionandconnectionvaluescanbefoundinChapter9
Nameplate
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
Transporteyelet

D
GB
F
E
7
96178-09.2013-DGbFEI
GEA Bock GmbH
72636 Frickenhausen, Germany
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pressur e 10 Nominalrotationspeed
(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 43 e 380-4 SX
2.3 Typekey (example)
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
1
2
3
4
513
12
7
11
6
10
8
9
19/28 SE 55
27,3
32,8
HGX34e/315-4
21,1/12,2A
111A 64A
IP66
Fig.3
AS38125A001
R407C
Refrigerant
Motorvariant3)
Numberofpoles
Sweptvolume
e-series
Numbersofcylinders
Size
Oilcharge²)
Series¹)

8
D
GB
F
E
96178-09.2013-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8x/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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!
 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.HGX34e/380-4).
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 com-
pressor is possible if over-
filled or underfilled!
max.oillevel
min.oillevel
ATTENTION!
Fig.4

D
GB
F
E
9
96178-09.2013-DGbFEI
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

10
D
GB
F
E
96178-09.2013-DGbFEI
D
GB
F
E
7
96157-02.2011-DGbFEI
2|Produktbeschreibung
1
2
3
4
513
12
7
11
6
10
8
9
/
HG 43 e 315- R407C 4 SX
19/35 SE 55
27,3
32,8
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Überdruck
Niederdruckseite
HD (HP): max. zulässiger Überdruck
Hochdruckseite
Beachten Sie hierzu die
Einsatzgrenzendiagramme!
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
Elektrisches Zubehör kann die IP-
Schutzklasse verändern!
HGX34e/315-4 S R407C
28,1/16,2A
134A 77A
}
}
Abb. 3
2.2 Typschild (Beispiel)
2.3 Typschlüssel (Beispiel)
¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)
²) X
- Esterölfüllung
3) S - Stärkerer Motor
Kältemittel
Motorvariante 3)
Polzahl
Hubraum
e-Serie
Zylinderzahl
Baugröße
Ölfüllung ²)
Baureihe ¹)
AS38125A001
Thecompressorsarelledatthefactorywiththefollowingoiltype:FUCHSRenisoTritonSE55
Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXinthetype
designation(e.g.HGX34e/380-4R407C).
3.4 Refrigerant-DesignforR407C,35bar
• HFKW/HFC: R407C
3.5 OilchargeforR407C,35bar
3.6 Limits of applicationforR407C,35bar
Only compressors with the additional designation
R407C(seenameplate,Fig.3and8)
Fig.9
D
GB
F
E
7
96157-02.2011-DGbFEI
2|Produktbeschreibung
1
2
3
4
513
12
7
11
6
10
8
9
/
HG 43 e 315- R407C 4 SX
19/35 SE 55
27,3
32,8
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Überdruck
Niederdruckseite
HD (HP): max. zulässiger Überdruck
Hochdruckseite
Beachten Sie hierzu die
Einsatzgrenzendiagramme!
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
Elektrisches Zubehör kann die IP-
Schutzklasse verändern!
HGX34e/315-4 S R407C
28,1/16,2A
134A 77A
}
}
Abb. 3
2.2 Typschild (Beispiel)
2.3 Typschlüssel (Beispiel)
¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)
²) X
- Esterölfüllung
3) S - Stärkerer Motor
Kältemittel
Motorvariante 3)
Polzahl
Hubraum
e-Serie
Zylinderzahl
Baugröße
Ölfüllung ²)
Baureihe ¹)
AS38125A001
D
GB
F
E
7
96157-02.2011-DGbFEI
2|Produktbeschreibung
1
2
3
4
513
12
7
11
6
10
8
9
/
HG 43 e 315- R407C 4 SX
19/35 SE 55
27,3
32,8
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Überdruck
Niederdruckseite
HD (HP): max. zulässiger Überdruck
Hochdruckseite
Beachten Sie hierzu die
Einsatzgrenzendiagramme!
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
Elektrisches Zubehör kann die IP-
Schutzklasse verändern!
HGX34e/315-4 S R407C
28,1/16,2A
134A 77A
}
}
Abb. 3
2.2 Typschild (Beispiel)
2.3 Typschlüssel (Beispiel)
¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)
²) X
- Esterölfüllung
3) S - Stärkerer Motor
Kältemittel
Motorvariante 3)
Polzahl
Hubraum
e-Serie
Zylinderzahl
Baugröße
Ölfüllung ²)
Baureihe ¹)
AS38125A001
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8x/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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!
INFO! Forrefilling,werecommendtheaboveoiltypes.
Alternatives: seelubricantstable,Chapter7.5.