Operating instructions
Contents
1. HER N Saimaa 6 Oye if 8 lt Intermediate pres Pty Jo sure chamber MP Line B er I co 1 Liquid subcooler 5 Expansion valve FUA liquid subcooler 2 Filter drier 6 temp sensor expansion valve Outlet 3 Solenoid valve 7 Pressure compensation connection FUE liquid subcooler Inlet 4 sight glasses General notes e Sensor lines wires etc should not be attached with cable binders directly to pipes or frames otherwise the thin pipes may be worn through Itis better to run them through spiral protective tubes e lf the compressor will be set up outside UV resistant materials should be used 17 18 Installation Factory installed liquid subcooler system optional design Liquid subcooler expansion valve solenoid valve and two sight glasses are mounted directly at the compressor piped and insulated FUE Liquid subcooler inlet FUA Liquid subcooler outlet Pipe connections e The pressure and suction shutoff valves have graduated inside diameters so that pipes in the customary millimeter and inch dimensions can be used The pipe will be immersed more or less deeply according to dimension The connection diameters of the shutoff valves are designed for the maximum compressor output The actually required Fig schematic pipe cross section must be adapted to the actually refrigeration capacity The same applies for non return valves Caution when soldering e Do not overheat the valve e Cool2. COMPRESSORS A Operating instructions Types HGZX7 1620 4 R404A R507 HGZX7 1620 4 R410A HGZ7 1620 4 R22 HGZX7 1860 4 R404A R507 HGZX7 1860 4 R410A HGZ7 1860 4 R22 HGZX7 2110 4 R404A R507 HGZX7 2110 4 R410A HGZ7 2110 4 R22 Dear Customer Bock compressors are top quality reliable service friendly quality products Please comply with the following operating and maintenance instructions so that you can benefit from all advantages to the full and use your refrigerating system throughout its entire service life If you have any questions about installation operation and accessories please contact our technical service or your refrigerating sys tem wholesale dealer or our representative The Bock service team is available by phone under 49 7022 9454 0 by e mail under mail bock de or on the internet under www bock de In addition for German speaking countries we have set up a toll free hotline under 00 800 800 000 88 from Monday to Saturday between 8 a m and 9 p m Any suggestions you may have regarding the on going devel opment of our compressor equipment and parts programme are welcome at any time QUALITY SYSTEM certified by DOS according to DIN EN ISO 9001 Reg No 2177 oe ke ah R Se J EE Bock Kaltemaschinen GmbH Postfach 11 61 D 72632 Frickenhausen Benzstr D 72636 Frickenhausen Fon 49 7022 9454 0 Fax 49 7022 9454 137 mail bock de www bock de Please read the information
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4. the use of stainless steel pipes with a wall of 1 mm is preferred The pipes must be free of tension during and after soldering to prevent possible breaks lateron Use only suitable hard solder and flux Solder under an inert gas atmosphere when copper components are to be soldered The accompanying expansion valve is designed and adjusted for the compressor and the listed refrigerant sensor charge nozzle Only use expansion valves approved and supplied by Bock The intermediate pressure line and intermediate pressure chamber are fully insulated at the factory To mount the expansion valve cut the insulation as shown in the marked area in ill 1 page 16 Correct sensor placement is marked by an unpainted area on the pipe 15 16 Installation X ad bi La oe Intermediate pressure chamber W Intermediate pressure line Shown without insulation R Connection of pressure compensation line for expansion valve lhe UNF w Refrigerant injection connection M22 x 1 5 Schrader connection for intermediate pressure gauge lhe UNF Position of temperature sensor unpainted Installation example liquid subcooler with accessories Dia 16 mm 4 Dia 16 mm RER _ Heat S D l E insulation Linea E gt 0 a o e Dia 16 mm 1 NA 4 a 5 Der Sl FU 7915 to the evaporator ni Dia 12 mm FUE F 7 4 Dia 12mm Dia 12mm 2 Y 7 Dia 16mm Dia 6 mm le Set
5. Geer fan Feb 2008 finderuns batun Name Norm ilursprs Bock COMPRESSORS ut 23 Oe Electronic trigger MP 10 The compressor motor and the high pressure side of the compressor are equipped with posistor temperature sensors PTC The temperature sensors are wired to the electronic trigger MP 10 in the terminal box In the event of overtemperature in the motor winding or on the hot gas side of the high pressure stage the unit switches the compressor off and the corresponding LEDs H1 or H2 light up When the device has triggered this indicates anoverload or intolerable opera ting conditions Ascertain and eliminate the cause The device has a reclosure preventing feature After eliminating the fault the device is quit by interrupting the mains power with the external alarm reset switch S1 see main line wiring diagram The reclosure preventing feature is unlocked and LEDs Hl or H2 go off again Connection of the electronic trigger MP 10 The electrical connection of MP 10 is to be completed according to the circuit diagram The trigger is to be protected with a fuse F of max 4 A slow acting To guarantee the protection function the electronic trigger is mounted as first element in the control power circuit Connections temperature monitoring e motor winding terminals 1 2 e hot gas side terminals 3 4 WARNING Terminals 1 6 on the electronic trigger MP 10 and terminals PTC 1 and PTC 2 on the compres
6. correspond Connection of the drive motor The compressor is equipped with a motor in direct or part winding design Designation on the name plate Designation on the terminal box AIYYY AN eem wey dew Compressors marked in this way are suitable for direct or part winding start The motor winding is divided into two parts part winding 1 60 and part winding 2 40 This winding division reduces the start up current during a part winding start to approx 65 of the value for a direct start Mechanical start unloader with bypass solenoid is not required When testing the winding with resistance meter please note that part winding 1 and part winding 2 are internally connected In the factory the motor is connected for direct starting YYY For part winding start A YYY remove the bridges and connect the motor feed cable according to the circuit diagram direct start YYY part winding start A YYY 21 22 WARNING Failure to comply results in reversed fields of rotation and can cause motor damage After the motor has started up with part winding 1 part winding 2 must be Switched on after max 1 second delay Failure to comply can be detrimental to the service life of the motor Mainline circuit diagram for part winding start CAUTION Ensure that power is supplied via K1 to winding 1 60 1U1 1V1 1W1 and via K2 to winding 2 40 2U1 2V1 2W1 The motor contactors K1 K2 are each to be ra
7. oil filler plug oil sump heating M 22 x 1 5 100 Nm Sight glass connection oil level controller M6 15 Nm Flange connection ie 13 Nm soldered connection shut off valves M 10 60 Nm Plug screws bungs valve bodies AL LR plug 100 Nm 1 8 NPTF 25 Nm Live connections M6 3 Nm Rotor M 12 65 Nm Notes Cylinder head valve plate tighten screws from the middle outwards crosswise in at least two stages torque 50 100 Excerpt from the lubricant table The oil grade filled as standard in the factory is noted on the name plate This oil grade should be used preferably Alternatives to this are listed in the following excerpt from our lubricant table Lubricants Bock series oil grades Recommended alternatives For HCFCs R22 FUCHS Reniso SP 46 FUCHS Reniso z B KM HP SP 32 SHELL Clavus SD 22 12 TEXACO Capella WF 46 SUNOIL Suniso 3GS For HFCs R404A R507 R410A FUCHS Reniso Triton SE e FUCHS Reniso Triton SEZ 32 MOBIL Arctic EAL 32 ICI Emkarate RL 32 H S SHELL Clavus R 32 Refer to the Bock lubricant tables for information about further suitable oils Decommissioning For major repairs or when decommissioning Comply with the safety instructions on page 29 Close the shut off valve on the com pressor vacuum out the refrigerant do not blow out and dispose of correctly Open the screwed unions or flanges at the compressor valves and remove the compressor using hoisting gear if necessary When scrapping the compres
8. the valve body during and after soldering e Remove screw connections from the valve for soldering A soldering suppot for tube diameter 54 mm is mounted to the suction shut off valve of the compressor A soldering support for tube diameter 2 1 3 accompanies the compressor gt O As short as Stable Pipes e Pipes and system components must be clean and dry inside and free of scales metal chippings and coats of rust and phosphate Only use hermetically sealed parts e Lay pipes correctly Avoid strong vibrations because of the risk of cracks and breaks Provide suitable fixed points and or vibration compensators as required e Guarantee a correct oil retum e Keep pressure losses to an absolute minimum Laying suction and discharge line A proper run of the suction and discharge line immediately after the compressor is of great importance for the system s smooth running and freedom from vibration Improperly installed pipes can cause cracks and tears which result in refrigerant loss A rule of thumb Always lay the first pipe section starting from the compressor downward and parallel to the drive shaft possible fixed point 19 Installat Shut off valves AN Warning Comply with the safety instructions on page 14 Before opening or closing the shut off valve turn the valve spindle seal approx 1 4 of a turn counter clockwise After activating the shut off valve tighten the valve spindle seal agai
9. at the subcooler outlet FUA ty C 70 65 60 55 50 45 40 35 30 25 20 Evaporating temperature t C Subcooling temperature The design of the expansion valve on the compressor can be defined with the help of the diagram by approximately calculating the subcooling temperature arising in the relevant operating conditions to t 11 12 The refrigerant suctioned out of the evaporator 21 is compressed by the 4 cylinders of the LP stage 2 to intermediate pressure MP After that the superheated refrigerant flows through the intermediate pressure chamber 3 where it is cooled by the liquid subcooler system to reduce the discharge end temperature The refrigerant then flows through the intermediate pressure line 4 to the electric motor of the compressor for to cool the motor After this the refrigerant is suctioned in by the two HP cylinders 5 and compressed to the final pressure Liquid subcooler system The liquid subcooler system consists of the components liquid subcooler plate heat exchanger 6 expansion valve 7 sight glasses 8 9 solenoid valve 10 filter drier 11 After the refrigerant reciever 16 the liquid line will be splitted into two lines Line A leads through the liquid subcooler 6 and the subcooled refrigerant flows to the evaporator 21 Through line B refrigerant is expanding through the expansion valve 7 into the liquid subcooler 6 in order
10. damage e Before start up check that all components mounted by the user are installed correctly and connected pressure tight with the compressor pipes plugs union nuts replaced components etc e Before start up evacuate the refrigeration plant with compressor carefully and then charge with refrigerant e Open discharge and suction shutoff valves before starting the compressor e Do not start the compressor in vacuum Operate only with refrigerants charge e Corresponding to the conditions of use surface temperatures of more than 100 C on the discharge side and below 0 C on the suction side can be reached Models available 1 Standard design Compressor with intermediate pressure line mounted and insulated Liquid subcooler expansion valve solenoid valve filter drier and two sight glasses enclosed separately for individual external mounting 2 Optional design Liquid subcooler expansion valve solenoid valve filter drier and two sight glasses mounted directly to the compressor piped and insulated Proper Use BOCK refrigerating compressors are designed for use in cooling systems using the refrigerants specified below and in compliance with the operating limits Only refrigerants specified on the name plate may be used No other use of the compressor is permitted Warning Do not use in potentially explosive areas Short Description e Semi hermetic two stage six cylinder reciprocating compressor with suction gas co
11. e factory and all functions have been tested There are therefore no special running in instructions Before starting up check the compressor for any signs of transport damage To protect the compressor from intolerable operating conditions high and low pressure pressostats Comply with the accident prevention regulations Pressure strength test The compressor was tested in the factory for pressure strength If the entire plant should be subjected in addition to a pressure strength test then observe the following e Test the cold circuit according to EN 378 2 or a corresponding safety standard e Perform the pressure strength test preferably with dry nitrogen e Under no circumstances press off the compressor with air e Do not mix any refrigerant with the testing medium since otherwise shifting the ignition limit into the critical range Is possible Danger The maximum permissible operating pressure of the compressor may not be exceeded during the entire testing process see name plate infor mation Tightness test e Perform the tightness test of the refrigeration plant according to EN 378 2 ora corresponding safety standard without inclusion of the compressor preferably dried with N2 e Do not add any refrigerant to the testing medium since otherwise shifting the ignition limit into the critical range is possible Evacuation e Firstly evacuate the plant then include the compressor in the evacuation process Press
12. e in a corrosive atmosphere dust vapour or flammable environment Warning Compressors are filled with protective gas ex works approx 3 bar nitrogen e Leave inert gas charge in the compressor up to evacuation e Do not open shutoff valves up to evacuation e Absolutely avoid entry of air Installation of the liquid subcooler system standard version Separately enclosed components t 1 Liquid subcooler amp 2 Expansion valve 3 Solenoid valve O 4 Filter drier 5 2 sight glasses pm emm G O Screw in sleeve solder adapter and seals 6 Op Please check for completeness of parts before beginning installation Observe manufacturer s instructions To avoid vibration cracks in the subcooler system the individual components must be mounted directly to the compressor or installed as a decoupled unit Installation The points listed here represent general guidelines and information on how to pipe and connect the subcooler unit To perform this work technical knowledge and skill as well as proof of a hard soldering test certificate in accordance with DIN EN 13133 is required Pipe connections For connections see dimension diagram page 34 36 e System design piping and necessary support points for the individual components must be carefully planned and carried out e Properly insulate liquid subcooler against condensation and heating and the related loss of performance e For rigidity reasons
13. e key Areas of application Refrigerant Oil filling Operating limits Description of functions Two stage refrigeration circuit with liquid subcooler Installation Setting up Installation of the liquid subcooler system standard design Factory installed liquid subcooler system optional design Pipe connections Pipes Shut off valves Electrical Electrical connection Connection of the drive motor Circuit diagram Motor protection unit MP 10 Connection motor protection unit MP10 Functional test of the MP 10 References for contactor selection Oil sump heater Start up Preparations for start up Pressure strength test Leak test Evacuation Refrigerant charge Putting into operation Avoiding liquid shocks Maintenance Safety instructions Service intervals Spare parts recommendation Replacement of the valve plates Screw connections Extract from the lubricants table Taking out of operation Accessories Technical data Dimensions and connections Conformity and manufacturer s declaration The Bock refrigerating compressors named in the title are intended for installation in machines within the EU according to EU directive 98 37 EC Machinery Directive 97 23 EC Pressure Equipment Directive and 73 23 EC Low Voltage Directive Initial commissioning is only allowed when the compressor has been installed according to these instructions and the whole machine in which it is integrated has been tested and accepted acco
14. ector for oil level regulator Products ESK AC R CARLY 3x M6 10 deep Fan l 47 6 a s 35 SV Suction line DV Discharge line Please refer to technical data page 33 Liquid subcooler ON 316mm SV 5 3 0 36 DECLARATION OF CONFORMITY CE 96 for use of the compressors within the European Union as per EU low voltage directive 73 23 EEC in the version 93 68 EEC We herewith declare that the hermetic refrigerating compressors named in the title comply with the low voltage directive 73 23 EEC in the version 93 68 EEC Applied harmonised standard EN 60335 2 34 When installing our products in a machine the following manufacturer declaration must be taken into consideration MANUFACTURER DECLARATION for use of the compressors within the European Union refering to the EU machinery directive 98 37 EEC annex Il B We herewith declare that the hermetic refrigerating compressors named in the title in the version supplied by us are intended for installation in a machine which complies with the machinery directive 98 37 EEC Applied harmonised standards EN ISO 12100 1 EN 349 EN 60529 EN ISO 12100 2 EN 60204 1 It is however not permitted to start up our products before the machine in which they are integrated has been tested according to the corresponding statutory regulations and declared to be conforming in all points Frickenhausen 27 11 2006 Cea ae Dr Harald Kaiser Technical D
15. ed 3 Maximum operating current 8 Displacement 50 Hz 4 Starting current rotor blocked Vun low pressure stage A Partial winding 1 Vao High pressure stage YYY Partial windings 1 and2 9 Voltage connection frequency 5 ND LP Max allowable standstill pressure 10 Nominal rotation speed Suction side 11 Displacement 60 Hz HD HP Max allowable operating pressure Vun low pressure stage High pressure side Vao High pressure stage G Observe operating limits diagrams 12 Oil tvoe charged at factor 13 Protection class terminal box G Electrical accessories of the compres sor can change the IP protective class Type code example HGZX7 2110 4 R410A Ester oil charge 2 Frame size Swept volume Number of poles Refrigerants 3 0 HGZ Hermetic gas cooled suction gas cooled two stage 2X Ester oil filling HFC refrigerant R404A R507 R410A 39 Possible alternative refrigerants R404A R507 R410A R22 A Refrigerants e H CFC R22 e HFC R404A R507 R410A Oil charge e The compressors are charged with the following oil types at the factory for R22 FUCHS Reniso SP 46 for R404A R507 R410A FUCHS Reniso Triton SE 55 Compressors with ester oil filling FUCHS Reniso Triton SE 55 are marked with an X in the type designation e g HGZX7 2110 4 R410A e For charge we recommend the above oil types Alternatives See extract from the Bock lubricants table p 31 Operating limits e The compressor may be opera
16. irector 37 38 PED CLASSIFICATION as per EU Pressure Equipment Directive 97 23 EC DECLARATION OF CONFORMITY for use of the compressors within the European Union as per EU Pressure Equipment Directive 97 23 EC We hereby declare that piping of the refrigerant compressors HGZX7 2110 4 R404A R507 HGZX7 2110 4 R410A and HGZ7 2110 4 R22 agrees with the Pressure Equipment Directive 97 23 EG dated 29 May 1997 Valid for Category piping Evaluation procedure module A The other parts of the piping fall under article 3 3 of the Guideline and correspond to good engineering practice MANUFACTURER DECLARATION for use of the compressors within the European Union as per EU Pressure Equipment Directive 97 23 EC We hereby declare that piping of the refrigerant compressors HGZX7 1620 4 R404A R507 HGZX7 1620 4 R410A HGZ7 1620 4 R22 HGZX7 1860 4 R404A R507 HGZX7 1860 4 R410A and HGZ7 1860 4 R22 agrees with the Pressure Equipment Directive 97 23 EG dated 29 May 1997 Vallid for piping corresponding to article 3 3 Cee aes Dr Harald Kaiser Technischer Leiter 39 a COMPRESSORS WWW bock de Bock K ltemaschinen GmbH Benzstra e 7 D 72636 Frickenhausen Telephone 49 7022 9454 0 Fax 49 7022 9454 137 mail bock de Art Nr 09726 05 07 DGbF Subject to change without notice
17. ith refrigerant To avoid shifts in concentration zeotropic refrigerant blends e g R407C must always only be filled into the refrigerating system in liquid form Warning Do not fill liquid refrigerant into the suction shut off valve on the compressor Do not mix additives with the oil and refrigerant 2 28 o gt PRP P gt Start up Warning Open pressure and suction shutoff valves before starting the compressor e Check that the safety and protection devices pressure switch motor protection electrical contact protection measures etc are all functioning e Switch the compressor on e Check the oil level in the compressor It must be visible in the sight glass Caution If larger quantities of oil have to be refilled there is a risk of oil liquid Shocks In this case the oil return has to be checked e On reaching equilibrium constant operating conditions check that the system main tains the permitted operating conditions e When the whole system is running perfectly we recommend drawing up a final proto col stating all important data and measured values Liquid sluggings WARNING Liquid slugging can cause damage to the compressor and leakage of refrigerant To avoid liquid slugging the following points should be observed e The whole plant must be properly designed e All components must be rated to be compatible with each other with regard to output particularly evaporator and ex
18. lations or operating in the application limit area for the first time after 100 to 200 operating hours then approx every 3 years or 10 000 12 000 operating hours Dispose of old oil according to the regulations observe national regulations e Regular checks Tightness running noise pressures temperatures function of the additional equipment such as oil sump heater pressure switches annually Observe national regulations Spare part recommendation Designation tN 80197 set valve plate low pressure side LP 80193 set valve plate high pressure side HP 80194 set Oil pump 80116 set Oil sump heater 08426 29 30 Safety bolt Replacing the valve plates The compressors are divided into an LP and an HP compressor stage Different valve plate designs are required because of the different ducts in the individual compressor Stages The valve plates have been fitted with safety bolts to prevent any confusion The safety bolts engage in the corresponding bores on the cylinder heads the safety bolts must not be removed Installation of the valve plates Safety valve Safety bolt Safety valve A Screwed unions Various installation maintenance and servicing work entails intervention in the compressor All work must therefore be performed with strict compliance with the given safety instructions The following torques must be used when re assembling the compressor Connecting rod screws M6 15 Nm Oil drain plug
19. n clockwise Valve spindle seal Mode of operation of the screw down service connections Opening the shut off valve SettingA 2 B Pipe connection Open spindle 1 turning to the left Fe ER counter clockwise as far as it will go Shut off valve is fully open service connection 2 closed setting A Opening the service connection 2 Turn spindle 1 approx to 1 turn to the right clockwise Service connection 2 is now open the shut off valve is also open setting B Compressor Fig schematic G Connection 3 is intended for safeguard systems and cannot be shut off o gt Electrical connection Warning High voltage Perform work only with the electrical installation disconnected from the power supply e Make connection of the compressor motor according to the circuit diagram see inside of terminal box Comply with local safety regulations for electrical work and the safety standards EN 60204 EN 60335 when connecting e For cable lead through at the terminal box use suitable cable screw connections in correct protective version see name plate Use strain relief Avoid abrasion points on cables e Motor contactors feed lines and fuses are to be rated according to the maxi mum operating current see compressor nameplate e Compare the details for voltage and frequency on the nameplate with the details for the electricity mains supply The motor may only be connected up when these details
20. oled drive motor e Stages divided into LP HP at the ratio of 2 1 e Two stage operation with liquid subcooler e Expansion valve for subcooling adjusted for refrigerant and application range Product description Main and functional parts standard version Liquid subcooler expansion valve solenoid valve filter drier and two sight glasses ill from left to right enclosed separately for individual external mounting Terminal box Intermediate pressure chamber Notice CE certification for piping only for Oil pump HGZ7 2110 4 Oil sump heater Name plate Charge plug Oil sight glasses Oil drain plug Suction shut off valve Discharge shut off valve Intermediate pressure line Product description Main and functional parts optional version Liquid subcooler expansion valve solenoid valve filter drier and two sight glasses mounted directly to the compressor piped and insulated Filter drier Expansion valve Liquid subcooler sight glasses Solenoid valve Name plate example Frickenhausen I Germany COMPRESSORS Typ HGZ7 2110 4 R22 380 420V A YYY 3 50HZ r AN35455A018 1450 min Vno Vho 122 4 61 2 m h 1 65 0A 440 480V A YYY 3 60HZ I A 191A YYY 286A 1740 min Mal 146 9 73 5 m h Pma ND LP HD HP 19 28 bar jpsq4 01 SP46 1 Type desi nation 6 Voltage connection frequency 2 Machine number 7 Nominal rotation spe
21. pansion valve e Suction gas overheating at the compressor entrance should be min 7 10 K check setting of the expansion valve e The machine must reach a state of equilibrium e When selecting the evaporator expansion valve pay attention to correction factors for liquid subcooling e Avoid transfer of refrigerant into the compressor when the system is at a standstill e The use of a liquid separator is recommended To avoid liquid shocks on the HP stage the expansion valve may only be opened approx 15 20 seconds after the compressor is switched on full load operation At compressor shut down Close the solenoid valve approx 15 20 seconds before the compressor is Switched off Safety instructions Before starting any work on the compressor e Switch the machine off and secure it against being switched back on e Relieve machine from the system pressure After maintenance has been performed e Connect safety switch e Evacuate compressor e Cancel switch on blockage Avoid entry of air into the plant Ester oil behaves very strongly hygroscopically The humidity bonded in the oil cannot be removed sufficiently by the evacuation process Therefore very careful handling is required To guarantee optimum operating safety and life of the compressor we recommend performing service and checking work at regular intervals of time e Oil change In series plants produced in the factory not mandatory In field instal
22. rding to the statutory regulations Bock refrigerating compressors have been designed to state of the art engineering Safety for the user is given particular priority during the design stage However it is always possible for the refrigerating machine and operation thereof to pose unavoidable residual risks This is why these instructions must be observed carefully by every person working at the compressor Work on the compressor may only be carried out by persons whose technical train ing skills and experience together with their knowledge of pertinent regulations and documentation means that they are capable of assessing the work to be carried out and detecting any possible dangers Safety instructions e Any handling of the compressor is permissible only by skilled personnel e Observe national safety regulations accident prevention regulations generally recognized technical rules as well as specific regulations EN 378 EN 60204 EN 60355 etc e Carry compressors only with hoists with sufficient lifting power e Operate compressors only in refrigeration plants with approved refrigerants e Do not exceed permissible operating pressure even for testing purposes e Caution Compressors are filled with protective gas ex works approx 3 bar nitrogen Avoid possible injuries to skin and eyes Wear goggles Relieve pressure of compressors before connection to the refrigeration system e Before start up check compressor for transport
23. sor drain the oil and dispose of correctly Comply with the national regulations WARNING Compressor is under pressure Avoid injures to skin and eyes Wear goggles 31 32 Heat protection thermostat If desired the compressor is equipped with a thermal protection thermostat PTC resistor It protects the compressor from unacceptably high pressure gas temperatures The thermal protection thermostat is mounted on the hot gas side of the compressor at the cylinder head and connected to the MP 10 trigger unit Switching points Switch off temperature approx 145 C 5K Switch back on temperature approx 130 C MP 54 oil pressure switch add on kit art no 08920 230 V 1 50 60 Hz IP 20 If installed at the factory the switch is mounted directly to the compressor and piped The electrical connection must be made in accordance with the accompanying description If a retrofit the switch is supplied with the corresponding fastening bracket and connection tubes The oil pump cover is equipped to permit screwing on of oil pressure difference sensors Oil differential pressure sensor Ap switch Kriwan make 220 240 V 1 50 60 Hz Oil pressure monitoring ensures a reliable and secure oil supply The device simultane ously measures both the suction and high pressure of the oil pump aHuel a6e 0A y JO anjeA ue w y 0 saJeja 0 F BOUeII O LC OF 09 sol es DUDU lt M OYL ZH 09 09 L ADE 7P duns IO
24. sor terminal board may not come into contact with mains voltage This would destroy the electronic trigger and the PTC sensors Fig schematic LO Rez Function test of the electronic trigger MP 10 Before starting up and after any faults or changes to the control power circuit of the machine check the electronic trigger to ensure that it functions properly eas e Interrupt the power supply L1 or S1 OFF OFF OFF e Disconnect the motor temperature sensor connection terminal 1 or 2 e Disconnect the hot gas temperature sensor if installed terminal 3 or 4 e Switch the power supply on again L1 or S1 ON e Function check motor temperature sensor stand by e Function check hot gas temperature sensor stand by 3 e Interrupt mains voltage again L1 or S1 OFF OFF OFF e Connect terminals 1 or 2 respectively 3 or 4 again le e Switch the power supply on again L1 or S1 ON e MP 10 in stand by mode The compressor and the motor protection unit MP 10 are ready for use if the LED control lamps signal perfect operating functions Information for contactor and motor contactor selection All protection equipment switching and monitoring devices must comply with the local safety regulations and established specifications e g VDE and regulations as well as the manufacturer s specifications Use motor protector switch Motor contactors feed lines and fuses are to be rated according to the maximum operating current see name pla
25. summarised for you in this manual before starting work It contains important instructions for safety installation initial commissioning and handling In addition you will find informa tion on maintenance spare parts and accessories Some instructions are identified by special symbols with the following meaning WARNING This symbol is used to indicate that inaccurate compliance or total failure to comply with the instructions could cause Injury to persons or damage to the compressor or refrigerating machine DANGER This symbol refers to instructions for fA avoiding direct severe dangers to persons DANGER This symbol refers to instructions for avoiding direct severe dangers to persons or plant by electrical current This symbol indicates important additional instructions which you should observe during your work The high quality standard of Bock compressors is guaranteed also by on going further development of machine features and accessories This could possibly result in nonconformities between this present manual and your compressor Please understand that it is not possible for any claims to be derived from the details illustrations and descriptions Your team at Bock Kaltemaschinen GmbH Subject to modifications Page 12 14 21 26 29 32 33 34 37 Safety instructions Product description Available versions Proper Use Short description Main and functional parts Name plate Typ
26. te A max 7 times the permissible operating current according to the compressor name plate is set as the short circuit triggering current Attention Always install all electrical peripheral devices in an external control cabinet outside the explosion endangered area 25 26 Oil sump heating When the compressor is at a standstill refrigerant diffuses into the lubrication oil of the compressor housing depending on pressure and ambient temperature This reduces the lubrication capacity of the oil When the compressor starts up the refrigerant contained in the oil evaporates out through the reduction in pressure The consepuences can be foaming and migration of the oil causing oil shocks under certain circumstances In order to avoid damage to the compressor the compressor is equipped with an oil sump heater as a standart feature The oil sump heater should always be connected up and operated Operation The oil sump heater operates when the compressor is at a standstill When the compressor starts up the oil sump heating switches off Connection The oil sump heater must be connected via an auxiliary contact or paral lel wired auxiliary contact of the compressor contactor to a separate electric circuit El data 230 V 1 50 60 Hz 140 W WARNING The oil sump heater must not be connected to the electrical circuit of the safety control chain Preparations for Initial commissioning The compressor has undergone trials in th
27. ted for approx 70 of the max operating current A1 Electronic trigger MP10 Q1 Main switch F1 1 Motor protection switch part winding 1 F1 2 Motor protection switch part winding 2 F2 Fuse control current circuit F3 Safety chain high low pressure monitoring F4 Oil differential pressure switch S1 Switch control voltage B1 Release switch thermostat K1 Mains contactor part winding 1 K1A Auxiliary contactor K2 Mains contactor part winding 2 K1T Delay relay max 1 s slow release part winding 2 K2T Delay relay max 20 s slow release Open solenoid Y1 supcooler K3T Delay relay max 20 s slow release compresssor switch off suction subcooler Y1 Solenoid valve intermediate cooler Mi Compressor motor Ri PTC sensor R1 1 Heat protection thermostat PTC sensor R1 2 Heat protection thermostat PTC sensor R1 3 Heat protection thermostat PTC sensor R3 Oil temperature NTC sensor _ _ Deu ET 1 gt 2 1 SS et gt N GEELEN PE an St CN mune Motor Protection MP10 SSC ES EN i e F1 1 F1 2 A sr R1 2 a N 13 K1 Nu lt P X SS L1 L2 bis PE T 1 F3 Network 400v 50Hz 1 fot K3T kiret pe CS 7 6 18 14 33 15 K2T K1 K1 a g K1T K2 ee Nk GER ee GE 0 5 1 sec 15 20sec 15 20sec 13 14 GER DA Me 8 8 Bearb Kelich PT
28. ted within the range of the diagrams shown Care must be taken to assign the refrigerant correctly The operating limits must be observed The maximum discharge end temperature of 140 C must not be exceeded Use only oils that are highly thermally stable see lubricants table Avoid continuous operation near the limits The expansion valve of the liquid subcooler is designed for the corresponding refrigerant see name plate and is set at the factory for the entire range of application Subsequent adjustment is unnecessary Do not exceed the compressor s maximum permissible switching frequency 12 swit ching cycles per hour The system must reach a steady state condition continuous operation Do not go below the minimum operating time of 3 minutes e During operation below ambient pressure there is a danger of air entering on the suction side This can cause chemical reactions pressure rise in the condenser and an excessive pressure gas temperature as well as shifting of the refrigerant ignition limit into the critical range Avoid absolutely any entry of air Areas of application t CO 60 50 40 30 20 2 CO t CC 5960 50 40 30 60 50 40 30 20 L C 65 60 55 50 A 40 CO t evaporating temperature C Unrestricted area te condensing temperature C of application Atoh suction gas superheat K Design for other areas on request 10 Subcooling temperature
29. to subcool the refrigerant of line A Afterwards the refrigerant of line B flows to the intermediate pressure chamber MP and through the intermediate pressure line MP to cool the superheated refrigerant which is compressed from low pressure to intermediate pressure Two stage refrigeration cycle with liquid subcooler Scope of supply 23 22 14 13 24 Explanations CONDO Om ZS WD 9 Compressor Cylinder LP stage Intermediate pressure chamber MP Intermediate pressure line MP Cylinder HP stage Liquid subcooler Expansion valve Sight glass Sight glass 10 Solenoid valve 11 Filter drier 12 Damper pressure line 13 Oil separator 14 Non return valve 15 Condenser 21 20 19 18 17 16 Refrigerant receiver 17 Filter drier 18 Solenoid valve 19 Sight glass 20 Expansion valve evaporator 21 Evaporator 22 Liquid separator 23 Damper suction line 24 Filter suction line LP Low pressure MP Intermediate pressure HP High pressure FUE Liquid subcooler inlet FUA Liquid subcooler outlet 16 13 14 Setting up Use transport eyelet Do not lift manually Use lifting gear Erect on a flat surface or frame with sufficient load bear ing ability Only erect on a slant in consultation with the manufacturer Compressor install basically rigid Ensure there is sufficient space for maintenance work Ensure there is sufficient ventilation in the machine room Do not operat
30. ure relieve the compressor Open suction and pressure shutoff valve Evacuate with the vacuum pump on the suction and high pressure side Vacuum lt 1 5 mbar with shutoff pump Repeat the process several times if necessary In addition to the suction or high pressure side the intermediate pressure area of the compressor must also be evacuated Use connection X see fig 1 p 16 The solenoid valve of the subcooling system p 17 fig 2 item 3 must be opened WARNING Do not start the compressor in vacuum Apply no voltage also not for test purposes may be operated only with refrigerant In the vacuum the spark over and creepage current distances of the terminal board connection bolts shorten this can lead to winding and terminal board damage Filling with refrigerant Caution Wear personal safety gear e Check that the compressor suction and discharge shut off valves are open e With the compressor switched off fill the liquid refrigerant directly into the condenser or receiver breaking the vacuum e Pay attention to adequate refrigerant fill before starting up the compressor During operation refrigerant must be free of bubbles in sight glasses 1 and 2 of the liquid subcooler e f the refrigerant needs topping up after starting the compressor it can be topped up in vapour form on the suction side or taking suitable precautions also in liquid form at the inlet to the evaporator Avoid overfilling the machine w
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