Operating instructions - Compressors for Commercial Refrigeration
Contents
1. certified by DQS according to DIN EN ISO 9001 Reg No 2177 Net2. COMPRESSORS pluscom Operating instructions Types HG12P 75 4 HG12P 90 4 HG12P 110 4 HG12P 60 4S HG12P 75 4S HG12P 90 4S HG12P 110 4S 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 Please read the information summarised for you in this manual before starting work It contains important instructions for safety installation initial commisioning and handling In addition you will find information 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 com
3. C Design for other areas on request Compressors are filled with protective gas ex works approx 3 bar nitrogen AN e Leave protective gas filling in the compressor up to evacuation e Do not open shutoff valves up to evacuation e Absolutely avoid entry of air Erection Use transport eyelet Do not lift manually Use lifting gear e Erecton a flat surface or frame with sufficient load bearing ability Only erect on a slant in consultation with the manu facturer e Single compressor preferably on vibration damper e Duplex and compound connection basically rigid e Ensure there is sufficient space for maintenance work e Ensure there is sufficient ventilation in the machine room e Do not operate in a corrosive atmosphere dust vapour or flammable environment 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 Fig schematic sor output The actually required pipe cross section must be adapted to the actually The connection diameters of the shutoff valves are designed for the maximum compres refrigeration capacity The same applies for non return valves 10 gt As short as Caution when soldering e Remove screw connections from the valve for soldering e Do notoverheat the valve e Cool the
4. valve body during and after soldering 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 A proper run of the suction and discharge line immediately after the compres sor is of great importance for the system s smooth running and freedom from vibration Improperly installed pipes can cause cracks and tears which results in refrige rant loss A rule of thumb Always lay the first pipe section starting from the compressor downward and parallel to the drive shaft A possible fixed point dh Fo Es lation Instal Shut off valves Comply with the safety instructions on page 9 Before opening or closing the shut off valve tum the valve spindle seal approx of a tum counte clockwise After activating the shut off valve tighten the valve spindle seal again clockwise Fig schematic Mode of operation of the screw down service connections Service connection g s closed E Opening the shutoff valve Tum the spinde to the left counterclockwise up to the stop Shutoff valve fully opened service connec SE tion do
5. 9 B eue p quaueuoz puo cmes H 9 Gy 01 sleuuou oluewWeppe eJ 9J0 9S N D 0by SE esseq eJmleledual 9J0 9S Ee CO COT DI Oo Out On st IT st TJ st It jl st a i KEEN YOul youl ww d SAPA SeUPS H W 7 IE amsesma ol punos u of 6uueplos 104 96ueJ 96ejloA y Jo anleA ue w y uo p seq ae ezep liv ov A oBej e9 solAJ9eS U9 IMS Sesnj pue speg SJ0 98 U09 Hulubisap UeUA uondwnsuos Jemod xew usJuno Hulyesado xewW 8U JO unoooe aye s nb uo lueJjno pue Se6ej oAJeUO 9DueJ uoisua y JO 36eJeAe 8U 0 pslldde 0 F 30UBJelol 01 8 02 9 Sh 220 240 V A 380 420 V Y 3 50 Hz 265 290 V A 440 480 V Y 3 60 Hz paa ee eee 20 H D1 K O Vibration absorbers 30 1 SV 90 rotatable Dimensions in mm Subject to change without notice Suction line Discharge line Connection suction side not lockable le NPTF Connection Suction side lockable Tne UNF Connection discharge side not lockable Je NPTF Technical specifications p 20 ES n Te jalan in w ES Ra EWE Oil filling bung Lia NP TF 22 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 W
6. 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 H1 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 4A 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 Terminals 1 6 on the electronic trigger MP 10 and terminals PTC 1 and PTC 2 on the compressor terminal board may not come into contact with mains voltage This would destroy the electronic trigger and the PTC sensors Fig schematic 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 Proced LED H1 LED H2 LED H3 roesoure red red green 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 sens
7. HZ n 1450 min Va 265 290VA 440 480VY n 1740 min Va IP65 Ol SP46 3 11 3myh 6 Voltage switching frequency 7 Rated speed 50 Hz 8 Swept volume 9 Voltage switching frequency 10 Rated speed 60 Hz 11 Swept volume 12 Oil grade filled by the manufacturer 13 Protection terminal box j Electrical accessories can change the IP safety class system HG X 12P 110 4S Stronger motor i Number of poles Swept volume pluscom Number of cylinders Size Oil filling 2 Series 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 gt Coolant e H FCKW H CFC R22 e HFKW HFC R134a R404A R507 R407C Oil filling e The compressors are filled with the following oil grades in the factory for R22 FUCHS Reniso SP 46 for R134a R404A R407C R507 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 HGX12P 110 4 e We recommended using the above oil grades for refilling Alternatives see excerpt the Bock lubricant table page 19 Limits of application diagrams e It is possible to operate the compressor within the operating limits shown in the diagrams Please note the significance of the shaded areas Thresholds Should not be
8. ains the permitted operating conditions e When the whole system is running perfectley we recommend drawing up a final protocol stating all important data and measured values Liquid sluggings Liquid slugging can cause damage to the compressor and leakage of coolant 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 particulary evaporator and expansion 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 Particulary in critical systems e g serveral evaporator points measures are recom mended such as replacement of liquid traps solenoid in the liquid line etc Coolant should not move in the compressor when the machine is at a standstill 17 18 Q Connection of oil level regulator The connection is provided for installing an oil level regulator A corresponding adapter must be obtained from the trade Safety instructions Before starting any work on the compressor e Switch the machine off an 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 Este
9. e 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 II 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 Itis 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 PED CLASSIFICATION as per EU Pressure Equipment Directive 97 23 EEC The compressor is not subject to the EU Pressure Equipment Directive Frickenhausen 07 05 2004 Cec oa gt Dr Harald Kaiser Technical director 23 COMPRESSORS VAY VAY MN olo od que l Bock Kaltemaschinen GmbH Benzstra e 7 D 72636 Frickenhausen Telefon 49 7022 9454 0 Telefax 49 7022 9454 137 mail bock de Art Nr 09652 11 08 DGbFEI Subject to change without notice QUALITY SYSTEM
10. horten this can lead to winding and terminal board damage Filling with coolant Gi Wear personal safety gear e Check that the compressor suction and discharge shutt off valves are open e With the compressor switched off fill the liquid coolant directly into the condenser or receiver breaking the vacuum e f the coolant needs topping up after starting the compressor it can be topped up in vapour from on the suction side or taking suitable precautions also in liquid from at the inlet to the evaporator e Avoid overfilling the machine with coolant e To avoid shifts in concentration zeotropic coolant blends e g R407C must always only be filled into the refrigeranting system in liquid form e Do not fill liquid coolant in the suction shut off valve on the compressor e Do not mix additives with the oil and coolant Start up Both shut off valves the suction and the discharge shut off valve must be opened before starting the compressor e Check that the safety and protection devices pressure switch motor protection electrical contact protection measures tec are all functioning e Switch the compressor on e Check the oil level in the compressor It should be visible in the sight glass If larger quantities of oil have to be topped up 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 maint
11. ion 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 Do not mix any refrigerant with the testing medium since otherwise shifting the ignition limit into the critical range is possible Under no circumstances press off the compressor with air Danger The maximum permissible operating pressure of the compressor may not be exceeded during the entire testing process see name plate information Tightness test e Performe the tightness test of the refrigeration plant according to EN 378 2 or a corresponding safety standard without inclusion of the compressor preferably dried with N e Do not add any refrigerant to the testing medium ince 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 Pressure 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 serveral times if necessary WARNING Do not start the compressor in vacuum Apply no voltage also not for test purpose may be operated only with refrigerant In the vacuum the spark over and creepage current distances of the terminal board connection bolts s
12. must therefore be performed with complianse with the given safety instructions The screw starting torques are to be considered Current table under www bock de Lubricants 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 Bock series oil grades Recommended alternatives For HCFCs e g R22 FUCHS Reniso SP 46 MOBIL SHC 425 SUNOIL Suniso 4GS SHELL Clavus SD 22 12 TEXACO Capella WF 46 For HFCs e g R 134a R404A R407C FUCHS Reniso Triton SE a FUCHS SEZ 32 MOBIL Arctic AL 46 ICI Emkarate RL 46 S SHELL Clavus R 46 Information about further suitable oils on request Decommissioning For major repairs or during shutdown Observe safety instructions p 18 Close shut off valves at the compressor Suction off refrigerant do not blow off and dispose of it according to regulations Open screw connections or fl anges on the com pressor valves and remove compressor if necessary with lifting gear If the compressor oil dispose correctly Environmental regulations and national regulations consider 19 YW gpz ezueJellol 3lpew OUOS IUOIZEDIPU 87 WrOPyY WUEIaDuIg U09 JeJnsIw WOE JuuupepLl ZH OG e olusWeuolzunmj 3J0SSejJduoo wp ID ensi IP ezuelsIp eun pe 0U09SJ9JIJ IS 3 De JUoleA OU09SIn I SO9 IUOIZEDIDU 9 9uolSSellu slqleje eJnsIW ID eyes eun ul eleJnSIW SJI
13. or stand by e Function check hot gas temperature sensor stand by 3 e Interrupt mains voltage again L1 or S1 OFF FF OFF e Connect terminals 1 or 2 respectively 3 or 4 again e Switch the power supply on again L1 or S1 OFF 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 equipementm 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 maximm operating current see name plate A max 7 times the permissible operating current according to the compressor name plate is set as short circuit triggering current 15 16 Preparations for start up The compressor has undergone trials in the factory and all functions have been tested There are therefore no special running in instructions Check the compressor for any signs of transport damagel 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 addit
14. pliance or total failure to comply with the instructions could cause injury to persons or damage to the comperssor or refrigerating machine DANGER This symbol refers to instructions for avoiding direct serve dangers to persons DANGER This symbol refers to instrucion for avoiding direct serve dangers to persons or plant by electrical current This symbol indicates important additional instructions which you should observe during your work The high quality standart of Bock compressors is guaranteed also by on going furtherdevelopment of machine features and accessories This could possible results in non conformities between this present manual and your compressor Please understand tha it is not possible for any claims to be derived from the details illstrations and descriptions Your team at GB Bock K ltemaschinen GmbH Subject to modification Page Safety instructions 4 Product description 5 Use as intended Short description Main and functional parts Name plate Type code Areas of application 7 Coolant Oil filling Limits of application diagrams Installation 9 Setting up Pipe connections Pipes Shut off valves Electrical systems 12 Electrical connection Connection of the driving motor Wiring diagram for direct start 230 V A 400 V Y Electronic trigger MP 10 Connection of the electronic trigger MP 10 Functional test of the electronic trigger MP 10 Recommendation for contactor selection Start
15. r oil behaves very strongly hygroscopically The humidity bonded in the oil cannot be removed suffi ciently by the evacuation process Therefore very careful handling is requiered The compressor is to be kept in a clean orderly condition by suitable care In order to guarantee optimum operating safety and service life of the compressor we recommend that you carry out the following servicing and checks at regular intervals e Oil change including cleaning the oil intake filter not mandatory in series machines produced in the factory for field installation or operation in the application limit range first oil change after approx 100 200 operating hours then approx every 3 years or 10 000 12 000 operating hours Dispose of used oil properly comply with national regulations e Regular checks Tightness running noise pressures temperatures function of the additional equipment such as oil sump heating pressure switches annually Observe national regulations Spare part recommendation HG12P 60 4 S 75 4 S 90 4 S 110 4 S Designation Aen am Valve plate kit 80352 80353 80339 Oil pump kit 08324 Oil sump heater kit 110 240 V Ge Only use original Bock spare parts Accessories Information to available accessories finds you in our product catalog as well as under www bock de Screwed unions Various installation maintenance and servicing work entails intervention in the compres sor All work
16. ram for direct start 230 V A goo VY PE we ee ee ee eee ee ee ee eee EE E Me a Sa dee EE EEN KEEN GG ei GES OR E WEE et ELI ed eg Ai Motor Protection MP 10 fir M1 L for M 1 pour M1N TT Z4 a esra Sr q n mi 1 2 Connections for PTC sensor R1 PTC sensor motor winding R2 Heat protection thermostat PTC sensor F1 Safety device load stabilisation circuit F2 Fuse control power circuit F3 Safety chain high low pressure monitoring B1 Enable switch thermostat Q1 Main switch S1 Switch control voltage M1 Compressor motor M 1 Fan HA only HA12P K1 Mains contactor Al Electronic trigger MP 10 E Oilsump heater X3 Terminal strip in the terminal box 13 Oe Electronic trigger MP 10 The compressor motor is equipped with posistor temperature sensors PTC which are wired to the electronic trigger MP 10 in the terminal box The stand by mode is indicated by the light diode H3 green when mains voltage is applied In the event of overtempe rature in the motor winding the device switches the compressor off and signal lamp H1 lights up red In addition the hot gas side of the compressor can be protected from overheating by a heat protection thermostat accessories The signal lamp H2 red is intended for this function When the device has triggered this indicates an overload or intolerable opera ting conditions Ascertain and eliminate the cause The device has a reclosure preventing feature
17. ription Use as intended This operating manual describes the compressor named in the title in the standart version Bock refrigerant compressors are intended for use in refrigeration plants using the refrigerants stated below and under compliance with operating limits Any other use of the compressor is not permitted ZA Do not use in explosion risk environments Short description e Half hermetic two cylinder reciprocating compressor with oil pump lubrication e Suction gas cooled drive motor e Compact dimensions quiet running high efficiency e Maximum permissible operating pressure HD 28 bar Main and functional parts A Terminal Box Transporteyelet _ D A Connection HP Thermal protection thermostat Connection LP Valve plate Oil filler plug Connection oil sump heating Oilpump Oil sight glass Connection oil level regulator Oil drain Discharge shut off valve Suction shut off valve Name plate example D 72636 Frickenhausen Made in Germany HG12P 110 4S AK35830A001 10 6 6 1A A 45A Y 26A ND LP HD HP 19 28 bar Ln ES W N Fr 1 Type designation 2 Machine number 3 Maximum operating current 4 Start up current rotor blocked 5 ND LP max admissible stop period pressure intake side HD HP max admissible working pressure high pressure side j Note limits of application diagramms Type code example BOCK COMPRESSORS 220 240VA 380 420VY 50
18. sed Pipe connection Service connection opened Opening the service connection Tum spinde 1 2 1tum to the right Service connection opened shutoff valve opened Connection opened Compressor Fig schematic 11 12 Electrical connection 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 correspond e Connection of the driving motor The compressor is implemented with an engine for star delta connection Recognition characteristics Designation on the nameplate Designation on the yellow label on the terminal box Star delta starting is only possible in A voltage range Example lt Lu Wiring diag
19. selected as design or continuous operating points Max permissible end temperature of the compressor 140 C Max permissible switching frequency 8x h A minimum running time of 3 min steady state condition continuous opera tion must be achieved e For operation with additional cooling Use only oils that are highly thermally stable Avoid continuous operation near the limits e For operation with frequency converter Achieving the max permissible power consumption of the drive motor can restrict the operating limits e During operation in the vacuum range there is a danger of air entering on the suction side This can cause chemical reactions pressure rise in the conden ser and an excessive compressed gas temperature Avoid absolutely any entry of air t C 2 e o 30 20 10 0 10 20 30 t C t C R404A R507 t 20 C 50 40 30 20 10 0 10 t 45 5 7 5 t CO t C R407C t 20 C 30 20 10 20 t _ CB io 0 ds 20 4 00 j j 1 o g 40 20 20 o 0 19 20 t C Maximum allowed operating pressure HP 28 bar Unrestricted area of application Additional cooling or reduced suction gas temperature u Additional cooling and reduced N N suction gas temperature mm Motor variant 9 stronger motor to evaporation temperature C te condensing temperature C Aton suction gas overheating K ton suction gas temperature
20. 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 60835 etc Carry compressors only with hoists with sufficient lifting power Operate compressors only in refrigeration plants with approved refrigerants Do not exceed permissible operating pressure even for testing purposes 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 Before start up check compressor for transport 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 Product desc
21. up 16 Preparations for start up Pressure strength test Tightness test Evacuation Filling with coolant Start up Liquid sluggings Connection of the oil level regulator Maintenance 18 Safety instructions Spare part recommendation Accessories Screwed unions Lubricants Decommissioning Technical data 20 Dimensions and connections 21 Conformity and manufacturer s declaration 22 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 itis integrated has been tested and accepted according 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
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