GEA HGX5/725-4 R134a User manual

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engineering for a better world GEA Refrigeration Technologies
Bock Compressor HGX5 R134a
Assembly instructions
HGX5/725-4 R134a
HGX5/830-4 R134a
HGX5/945-4 R134a
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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
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 Standardmotor,designfordirectorpartwindingstart
 5.3 Basiccircuitdiagramforpartwindingstartwithstandardmotor
 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
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

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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 Standardmotor,designfordirectorpartwindingstart
 5.3 Basiccircuitdiagramforpartwindingstartwithstandardmotor
 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HGX5R134a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
• Semi-hermeticfour-cylinderreciprocatingcompressorwithsuction-gascooleddrivemotor.
• Flange-mounteddrivemotoronthecompressorcase.
• Applicationrange:normalrefrigeratingandair-conditioningwithR134a.
Fig.1
2.1 Short description
DimensionandconnectionvaluescanbefoundinChapter9
Nameplate
Valveplate
Cylindercover
Terminalbox
Transporteyelet
Discharge
shut-offvalve
Oilpump
Suctionshut-
offvalve
Oilsightglass
Drivesection
Motorsection

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2|Product description
/
HG 5945-4 X
Fig.2
2.2 Name plate (example)
2.3 Typekey (example)
¹)HG-HermeticGas-cooled(suctiongas-cooled)
²)X -Esteroilcharge
1
2
3
4
5
6
7
8
9
10
11
12
13
R134a
HGX5/945-4 R134a
AS12345-001
SE 55
33 A
110 A 141 A
Version
Numberofpoles
Sweptvolume
Size
Oilcharge²)
Series¹)
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
 Y:Partwinding1 10 Nominalrotationspeed
 YY: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

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3|Areas of application
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.HGX5/945-4R134a).
3.1 Refrigerants
• HFKW/HFC:  R134a
3.2 Oil charge
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 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!
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

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3|Areas of application
Design for other
areasonrequest
Unlimitedapplicationrange
Supplementarycoolingor
reducedsuctiongastemperature
R134a
Fig.4
Evaporationtemperature(°C)
Condensingtemperature(°C)
Suctiongassuperheat(K)
Suctiongastemperature(°C)
Max. permissible operating
pressure (LP/HP)1): 19/28 bar
1) LP=Lowpressure
HP=Highpressure

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4|Compressor assembly
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.5
Fig.6
Fig.7
Fig.8
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.9:graduated
internaldiameter
F
E
D
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
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.