Download Operating instructions - Compressors for Commercial Refrigeration
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HG12P Operating instructions Types: D HG12P/75-4 HG12P/90-4 HG12P/110-4 GB F E HG12P/60-4S HG12P/75-4S HG12P/90-4S HG12P/110-4S I Foreword 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 system wholesale dealer or our representative. The Bock service team is available by phone under +49 7022 9454-0, by e-mail under [email protected] 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 development 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 Please readspare the information summarised for you in this addition you will find information on maintenance, parts and accessories. manual before starting work. Some instructions are identified by special symbols with the following meaning: It contains important instructions for safety, installation, initial WARNING! This symbol is used to indicate that inaccurate compliance or total commissioning and handling. In addition you will find informafailure to comply with the instructions could cause injury to persons or damage tion on maintenance, spare parts and accessories. to the comperssor or refrigerating machine. Some instructions are identified by special symbols with the DANGER! This symbol refers to instructions following meaning: for avoiding direct serve dangers to persons. WARNING! This symbol is used to indicate that inaccurate compliance or total failure to DANGER! This symbol refers to instrucion for avoiding direct serve dangers comply with the instructions could cause to injury persons or plant by electrical current. to persons or damage to the compressor or refrigerating machine This symbol indicates important additional should DANGER!instructions This symbolwhich refersyou to instructions for observe during your work. avoiding direct severe dangers to persons. The high quality standart of Bock compressors is guaranteed also by on-going furtherdevelopment DANGER! This symbol refers to instructions for of machine, features and accessories. This could possible results in non conformities between this avoiding direct severe dangers to persons or present manual and your compressor. Please understand tha it is not possible for any claims to be plant by electrical current. derived from the details, illstrations and descriptions. This symbol indicates important additional instructions which you should observe during Your team at your work. - Subject to modification Bock Kältemaschinen GmbH The high quality standard of Bock compressors is guaranteed also by on-going further development of machine, features Bock Kältemaschinen GmbH and accessories. This could possibly result in nonconformities Postfach 11 61 between this present manual and your compressor. Please D-72632 Frickenhausen understand that it is not possible for any claims to be derived Benzstr. 7 from the details, illustrations and descriptions. D-72636 Frickenhausen Your team at Fon: +49 7022 9454-0 Bock Kältemaschinen GmbH Fax: +49 7022 9454-137 [email protected] www.bock.de - Subject to modifications - D GB F E I Contents Safety instructions Product description Use as intended Short description Main and functional parts Name plate Type code Areas of application Coolant Oil filling Limits of application diagrams Installation Setting up Pipe connections Pipes Shut-off valves Electrical systems Electrical connection Connection of the driving motor Wiring diagram for direct start 230 V ∆ / 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-up Preparations for start-up Pressure strength test Tightness test Evacuation Filling with coolant Start-up Liquid sluggings Connection of the oil level regulator Maintenance Safety instructions Spare part recommendation Accessories Screwed unions Lubricants Decommissioning Technical data Dimensions and connections Conformity and manufacturer‘s declaration Page 4 5 7 9 12 16 18 D GB F 20 21 22 E I Safety instructions 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 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 training, 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 Safety instructions Any handling of the compressor is permissible only by skilled personnel! Observe national safety regulations, accident prevention regulations, generally recognized technical rules as well as specific regulations (EN 378, EN 60204, EN 60335 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. 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.). Before start-up evacuate the refrigeration plant with compressor carefully and then charge with refrigerant. Open discharge and suction shutoff valves before starting the compressor. Do not start the compressor in vacuum! Operate only with refrigerants charge. 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. D GB F E I Product description Use as intended This This operating operating manual manual describes describes the the compressor compressornamed namedininthe thetitle titleininthe thestandart standard version. Bock refrigerant compressors are intended for use in refrigeration version. Bock refrigerant compressors are intended for use in refrigerationplants plantsusing using the refrigerants stated below and under compliance with operating limits. Any use the refrigerants stated below and under compliance with the operating limits. other Any other of the is notispermitted! use ofcompressor the compressor not permitted! Do not use in explosion-risk environments! Short description ● Half-hermetic reciprocating oiloil pump lubrication. Half-hermetictwo-cylinder four-cylinder reciprocatingcompressor compressorwith with pump lubrication two● Suction gas cooled drive motor. Suction gas cooled drive motor. ● Compact Compactdimensions, dimensions,quiet quietrunning, running,high highefficiency. efficiency. ● Maximum permissible operating pressure (HD) 28 bar. Main and functional parts Transport eyelet Terminal Box Connection HP, Thermal protection thermostat Connection LP Valve plate Oilpump Oil drain Oil filler plug Connection oil sump heating Oil sight glass / Connection oil level regulator D Discharge shut-off valve GB F E I Suction shutoff valve Product description Nameplate (example) Name plate (example) 1 2 3 4 5 1 2 3 4 5 9,4 10,6/6,1A 26A 45A Type designation Machine number Maximum operating current Start-up current (rotor blocked) ND (LP): max. admissible stop period pressure intake side HD (HP): max. admissible working pressure high pressure side limitsofofapplication application diagramms! Notelimits note diagrams! 11,3 6 7 8 9 10 11 12 13 Voltage, switching, frequency Rated speed 0 Hz Swept volume volume Voltage, switching, frequency Rated speed 0 Hz Swept volume Oil grade filled by the manufacturer Protection terminal box Electrical accessories can change the IP safety class system! Type code (example) HG X 1 2 P / 110 - 4 S Stronger motor 3) Number of poles Swept volume Number of cylinders D Size GB Oil filling 2) F Series 1) E HG = H ermetic-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 1) I 6 7 8 9 10 11 12 13 Areas of application Coolant (H)FCKW / (H)CFC: HFKW / HFC: R22 R134a, R404A/R507, R407C Oil filling The compressors are filled with the following oil grades in the factory: for R22: Anschluss FUCHS Reniso SP 46; Elektrischer for R134a, R404A, R407C, R507: FUCHS Reniso Triton SE 55. Starkstrom! Arbeiten nuroilbei spannungslosem Anlage Compressors with ester filling (FUCHS Reniso Zustand Triton SEder 55) elektrischen are marked with an X vornehmen! 12P 110 in the type designation (e.g. HGX34P/ 315-4) Anschluss des Verdichtermotors gemäß Schaltplan (s. Innenseite Klemmenkasten) We recommended recommend using the the above oil grades for refi lling. Alternatives: see excerpt ● We using above oilSicherheitsbestimmungen grades for refilling. Alternatives: see from vornehmen. Beim Anschließen örtliche für Elektroarbeiten the Bock lubricant table page 18. excerpt the Bock lubricant table page 19. und die Sicherheitsnormen EN 60204, EN 60335 einhalten. Limits of application diagrams Für Kabeldurchführung am Klemmenkasten passende Kabelverschraubungen in Limits of application diagrams Typschild) verwenden. Zugentlastung einsetzen. richtiger Schutzartausführung Operation of the compressor is(s.possible within the limits shown in the diagrams. The ●limits It is possible toanoperate the compressor the operating limits shown Scheuerstellen KabelnThe vermeiden. must be observed. max. dischargewithin end temperature of 140°C must not in the Please note the significance ofthe thecompressor shadedund areas. Thresholds Bei derdiagrams. Dimensionierung derrange, Motorschütze, Sicherungen be exceeded. In the extended operation ofZuleitungen is possible with should not be selected as design continuous operating points. maximalen Betriebsstrom zugrunde legen (s. Typschild). reduced suction gas temperature or or additional cooling. Additional fans (accessories) - Max. end temperature the compressor: SpannungsFrequenzangaben mitofDaten des Stromnetzes can be permissible used und for additional cooling. Recommended for use140°C withvergleichen. additional cooling: - Use Max.ofnur permissible switching frequency: 8x /h bei Übereinstimmung anschließen. -Motor a heat protection thermostat (accessory) A minimum running timestable of 3 min. steady-state (continuous opera -- Use only thermally highly oils (see lubricant condition table) tion) must be achieved. - Avoid continuous operation in the limiting area. When using power ●-For operation with controllers additional reduce cooling:suction gas overheating under certain individual settingthermally required.stable -circumstances, Use only oils that are highly --Observe in operationoperation with frequency converters: Avoid continuous near the limits The operating limits are restricted due to reaching the maximum permissible current consumption of the drive motor ● For operation with frequency converter Max. permissible ON/OFF switching frequency of the drive motor: 8 switching cycles/ - Achieving the max. permissible power consumption of the drive motor can h, equilibrium (constant operating conditions) must be reached in the whole plant. Do restrict the operating limits. not go below the minimum running time of 3 min. ● During operation in vacuum the vacuum range, is a danger of aironentering on the In operation in the range therethere is a risk of air entry the suction suction side. canchemical cause chemical reactions, pressure in the conden side. This canThis cause reactions, pressure rise in rise the condenser and ser and an excessive temperature. Avoid absolutely any entry an excessive pressurecompressed-gas gas temperature as well as shifting of the refrigerant of air. limit into the critical range. Avoid absolutely entry of air! ignition D GB Key F Unrestricted area of application E Additional cooling or reduced suction gas temperature I Motor variant - S (stronger motor) to tc ∆toh toh - temperatura di evaporazione (°C) - temperatura di liquefazione (°C) - surriscaldamento del gas di aspirazione (K) - temperatura del gas di aspirazione (°C) Maximum allowed operating pressure (HP): 28 bar Unrestricted area of application D Additional cooling or reduced suction gas temperature GB F Additional cooling and reduced suction gas temperature E Motor variant - S (stronger motor) I evaporation temperature (°C) condensing temperature (°C) suction gas overheating (K) suction gas temperature (°C) Design for other areas on request Installation Compressors are filled with protective gas ex works (approx. 3 bar nitrogen! ● Leave protective gas filling in the compressor up to evacuation. ● Do not open shutoff valves up to evacuation. ● Absolutely avoid entry of air! Pipe connections Erection The pressure and suction shutoff valves have graduated inside diameters, so that pipes in the customary millimeter Useinch transport eyelet.can be used. The pipe will be and dimensions Do not lift more manually. immersed or less deeply according to dimension. Useconnection lifting gear.diameters of the shutoff valves are designed The for the maximum compressor output. The actually required pipe cross-section must be adapted to the actually Fig.: schematic refrigeration capacity. The same applies for non-return Erect on a flat surface or frame with sufficient load-bearing valves. ability. Only erect on a slant in consultation with the manuCaution when soldering! facturer Remove screw connections from the valve for soldering. Single compressor preferably on vibration damper. Do not overheat the valve. Duplex and compound compound connection connection basically basicallyrigid. rigid. Cool the valve body during and after soldering. Ensure there is sufficient space for maintenance work. Ensure there is sufficient ventilation in the machine room. Do not operate in a corrosive atmosphere, dust, vapour or flammable environment. Compressors are filled with protective gas ex works (approx. 3 bar nitrogen! ● Leave protective gas filling in the compressor up to evacuation. ● Do not open shutoff valves up to evacuation. ● Absolutely avoid entry of air! D GB Pipe connections 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. Elektrischer Anschluss The connection diameters of the shutoff valves are designed for the maximum compressor output. The actually required Starkstrom! Arbeiten nurpipe bei spannungslosem Zustand der elektrischen Anlage cross-section must be adapted to the actually Fig.: schematic vornehmen! refrigeration capacity. The same applies for non-return desdiameters Verdichtermotors gemäß Schaltplan (s. Innenseite Klemmenkasten) TheAnschluss connection ofvalves. the shutoff valves are designed for the maximum compresvornehmen. Beim Anschließen örtliche Sicherheitsbestimmungen für Elektroarbeiten Caution when sor output. The soldering! actually required pipe cross-section must be adapted to the actually und die Sicherheitsnormen EN 60204, EN einhalten. Remove screw connections from the valve for soldering. refrigeration capacity. The same applies for60335 non-return valves. Für Kabeldurchführung am Klemmenkasten passende Kabelverschraubungen in Do not overheat the valve. richtiger Typschild) verwenden. Zugentlastung einsetzen. Cool the Schutzartausführung valve body during and(s.after soldering. Scheuerstellen an Kabeln vermeiden. Bei der Dimensionierung der Motorschütze, Zuleitungen und Sicherungen F E I 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 pipe cross-section must be adapted to the actually refrigeration capacity. The same applies for non-return valves. Fig.: schematic Installation Caution when soldering! Remove screw connections from the valve for soldering. Do not overheat the valve. Cool the valve body during and after soldering. Pipes 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. Lay pipes correctly. Avoid strong vibrations because of the risk of cracks and breaks. Provide suitable fixed points and/or vibration compensators as required. Guarantee a correct oil return. Keep pressure losses to an absolute minimum. 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 results in refrigerant loss. A rule of thumb: Always lay the first pipe section starting from the compressor downward and parallel to the drive shaft. D As short as possible GB F E I 10 Stable fixed point Installation Shut- off valves Comply with the safety instructions on page 9! Before opening or closing the shut-off valve, turn the valve spindle seal approx. ¼ of a turn counter-clockwise. After activating the shut-off valve, tighten the valve spindle seal again clockwise. Valve spindle seal loosen lösen tighten anziehen loosen Valve spindle seal tighten Fig.: schematic Fig.: schematic Mode of operation of the screw-down service connections Opening the shutoff valve: Turn the spindle to the left (counterclockwise) up to the stop. Shutoff valve fully opened, service connection closed. Service connection closed Pipe connection Connection closed Compressor Opening the service connection: Turn spindle ½ – 1 turn to the right. Service connection opened, shutoff valve opened. Service connection opened D GB F Pipe connection E I Connection opened Compressor Fig.: schematic 11 Electrical system Electrical connection High voltage! Perform work only with the electrical installation disconnected from the power supply! 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. 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. Motor contactors, feed lines and fuses are to be rated according to the maximum operating current (see compressor nameplate). 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. Connection of the driving motor The compressor is implemented with an engine for star-delta connection. Recognition characteristics: ∆ Niedere Spannung Low voltage Bas voltage ∆/Y Star-delta starting is only possible in ∆ - voltage-range. Example: D Elektrischer Anschluss Electrical connection Raccordement électrique 230 V ∆ direct start star delta start L3 L1 GB L2 L1 L2 L1 L2 L3 ∆/Y Y Hohe Spannun High voltage Haut voltage 12 L3 Y I L1 L2 L3 96027-11.06-DGbF ∆/Y ∆ E L1400L2V Y L3 only direct start Hohe Spannung High voltage Haut voltage Niedere Spannung Low voltage Bas voltage F Electrical connection Raccordement électrique Designation on the yellow label on the terminal box Designation on the nameplate Electrical system Wiring diagram for direct start 230 V ∆ / 400 V Y 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 (only HA 12 P) M.1 Fan HA (only HA12P) K1 Mains contactor A1 Electronic trigger MP10 E Oil sump heater X3 Terminal strip in the terminal box D GB F E I 13 Electrical system 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 overtemperature 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 operating 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 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. 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: motor winding: terminals 1 - 2 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. D GB F E Terminal board I Fig.: schematic 14 Electrical system 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: LED H1 LED H2 LED H3 Pos Procedure red red green 1 ● Interrupt the power supply (L1 or S1) ● Disconnect the motor temperature sensor connection (terminal 1 or 2) ● Disconnect the hot gas temperature sensor (if installed) (terminal 3 or 4) OFF 2 ● Switch the power supply on again (L1 or S1). ● Function check motor temperature sensor: stand-by ● Function check hot gas temperature sensor: stand-by 3 ● Interrupt mains voltage again (L1 or S1) ● Connect terminals 1 or 2 respectively 3 or 4 again 4 ● Switch the power supply on again (L1 or S1): OFF OFF ON ● MP 10 in stand-by mode The compressor and the motor protection unit MP10 are ready for use if the LED control lamps signal perfect operating functions. ON OFF OFF OFF ON ON OFF OFF Information contactor and motor contactor selection Hinweise fürfor Schaltund Schutzeinrichtungen All protection equipementmSchaltswitching monitoring devices must local Alle Schutzeinrichtungen, undand Überwachungsgeräte sind comply gemäß with denthe örtlichen safety regulations and established specifications (e.g. VDE) regulations as well as Sicherheitsbestimmungen und gängigen Vorschriften (z.B.and VDE) und Bestimmungen the manufacturer‘s Use motor protector switch! Motor contactors, sowie gemäß den specifications. Herstellerangaben auszuführen. Motorschutzschalter sind feed erforlines and Bei fusesder areDimensionierung to be rated according the maximm operating current (see name und derlich! der to Motorschütze, Zuleitungen, Sicherungen plate). A max. 7 times the operating current according to thezu compressor Motorschutzschaltern istpermissible der maximale Betriebsstrom zugrunde legen (siehe name plate Als is setKurzschlussauslösestrom as short circuit triggering ist current. Typschild). der max. 7-fache zulässige Betriebsstrom laut Verdichter-Typschild einzustellen. D GB F E I 15 Start-up Vorbereitungen Inbetriebnahme Preparations forzur start-up The compressoristhas undergone trials in theund factory and all functions havegeprüft been tested. Der Verdichter im Werk probegelaufen auf sämtliche Funktionen worden. There are therefore no special running-in instructions. Besondere Einlaufvorschriften müssen daher nicht beachtet werden. Check the compressor for any signs of transport damage! Vor Inbetriebnahme Verdichter auf Transportschäden kontrollieren! To the compressor from intolerable operating conditions, high- andsind lowUmprotect den Verdichter vor unzulässigen Betriebsbedingungen zu schützen, pressure pressostats. Hoch- und Niederdruck-Pressostate zwingend erforderlich. UnfallverhütungsComply with the accident prevention regulations! vorschriften beachten! Druckfestigkeitsprüfung Pressure strength test The compressorwurde was tested in the for pressure strength. If the entire plant Der Verdichter im Werk auf factory Druckfestigkeit geprüft. Sofern zusätzlich die should be subjected in addition to a pressure strength test, then observe thesoll, following: gesamte Anlage einer Druckfestigkeitsprüfung unterzogen werden ist zu beachten: ● Test the cold circuit according to EN 378-2 a correspondingSicherheitsnorm) safety standard).prüfen. Kältekreislauf gemäß EN 378-2 (oder einer(orentsprechenden ● Perform the pressure strength test preferably with dry nitrogen. Druckfestigkeitsprüfung vorzugsweise mit trockenem Stickstoff (N2) durchführen. ● Do notPrüfmedium mix any refrigerant the testing medium, since otherwise shifting the ignition Dem (N2) keinwith Kältemittel beimischen, da sonst die Verschiebung der limit into the critical is possible. Zündgrenze in den range kritischen Bereich möglich ist. darf keinesfalls oder anderen Under no circumstances press offmit theSauerstoff compressor with air. technischen Der Verdichter Gasen abgepresst werden! Danger! The maximum permissible operating pressure of the compressor may not Während desduring gesamten Prüfvorgangs darf der maximal zulässige Betriebsbe exceeded the entire testing process (see name plate information)! druck des Verdichters nicht überschritten werden (siehe Typschildangabe)! Dichtheitsprüfung Tightness test ● PDichtheitsprüfung erforme the tightness test of the refrigeration to entsprechenden EN 378-2 (or a der Kälteanlage gemäß EN plant 378-2according (oder einer corresponding safety standard) without inclusion of(vorzugsweise the compressor Sicherheitsnorm) ohne Einbezug des Verdichters mit(preferably N2 getrocknet) dried with N2). durchführen. ● DDem o notPrüfmedium add any refrigerant to the testing mediumdaince otherwise shifting the der ignition kein Kältemittel beimischen, sonst die Verschiebung Zündlimit intointhe critical rangeBereich is possible. grenze den kritischen möglich ist. Evacuation Evakuieren ● Firstly the plant, then the compressor in the evacuation process. Zuerstevacuate Anlage evakuieren, danninclude Verdichter in den Evakuiervorgang einbeziehen: - Pressure the compressor. Verdichterrelieve druckentlasten - Open and pressure shutoff valve. Saug-suction und Druckabsperrventil öffnen. - Evacuate with the vacuum theHochdruckseite suction and high pressure side. Mit der Vakuumpumpe auf pump Saug-on und evakuieren. - Vacuum shutoff pump.Pumpe. Vakuum < 1,5 mbar with bei abgesperrter - Repeat serveral times if necessary. Vorgangthe ggf.process mehrfach wiederholen. D GB F Verdichter nicht Vakuum starten. Keine Spannung anlegen auch -nicht WARNING! Do notimstart the compressor in vacuum. Apply no voltage also zu not for Prüfzwecken (darfbe nuroperated mit Kältemittel betrieben werden). test purpose (may only with refrigerant). In vacuum the spark-over creepage current distances of the terminal board Imthe Vakuum verkürzen sich dieand Überschlagsund Kriechstromstrecken der Klemmconnection bolts shorten,dies thiskann can lead to winding und and Klemmbrettschäden terminal board damage. brett-Anschlussbolzen, zu Wicklungsführen. E I 16 Start-up Kältemittelfüllung Filling with coolant Persönliche Schutzausrüstung tragen! Kältemittelfüllung Wear personal safety gear! und tragen! Persönliche Schutzausrüstung Vergewissern, dass SaugDruck-Absperrventile geöffnet sind. Persönliche Schutzausrüstung tragen! Einfüllen des Kältemittels (Vakuum brechen) bei abgeschaltetem Verdichter - flüssig ● Check that the compressor suction and discharge shutt-off valves are open. Vergewissern, dass Saugund Druck-Absperrventile geöffnet sind. direkt in den Verflüssiger bzw. Sammler. ● With compressor switched off, fillbrechen) thewerdende liquidbei coolant directly intoVerdichter the condenser or Einfüllen des Kältemittels (Vakuum abgeschaltetem flüssig Eine the nach Inbetriebnahme erforderlich Kältemittelergänzung kann- entwereceiver, breaking theSaugseite vacuum. direkt in den Verfl üssiger bzw. Sammler. der gasförmig in die oder - unter entsprechenden Vorsichtsmaßnahmen ● IfEine the nach coolant needs toppingerforderlich up after starting thewerden. compressor, it can be topped in werdende Kältemittelergänzung kann up entweauch flüssigInbetriebnahme am Verdampfereingang eingefüllt vapour from oninthe suction side,oder or, taking suitable precautions, also in liquid from atder gasförmig die Saugseite unter entsprechenden Vorsichtsmaßnahmen ● Überfüllung der Anlage mit Kältemittel vermeiden! the to the auchinlet flüssig amevaporator. Verdampfereingang eingefüllt werden. ● Um Konzentrationsverschiebungen zu vermeiden, dürfen zeotrope Kältemit● Überfüllung der Anlage mit Kältemittel vermeiden! telgemische (z.B. grundsätzlich ● Avoid overfilling theR407C) machine with coolant.nur flüssig in die Kälteanlage befüllt ● Um Konzentrationsverschiebungen zu vermeiden, dürfen(e.g. zeotrope werden. ● To avoid shifts in concentration, zeotropic coolant blends R407C)Kältemitmust telgemische (z.B. R407C) grundsätzlich nur fl üssig in die Kälteanlage befüllt filled into the refrigerantingam system in liquid form. ● always Nicht flonly üssigbeüber das Saugabsperrventil Verdichter befüllen. werden. ●● Do not fill liquid in the suction shut-off valve on the Beimischen voncoolant Additiven in das Öl und das Kältemittel istcompressor. nicht zulässig. Nicht üssig über das Saugabsperrventil am Verdichter befüllen. ●● Do notflmix additives with the oil and coolant. ● Beimischen von Additiven in das Öl und das Kältemittel ist nicht zulässig. Start-up Inbetriebsetzung Both valves - the suction the discharge shut-off valve be Beideshut-off Absperrventile - Saug und and Druckabsperrventil - müssen vor- must dem Start opened before starting thewerden! compressor! des Verdichters geöffnet ● Check that theund safety and protection devices (pressure switch, motor elektrische protection, SicherheitsSchutzeinrichtungen (Druckschalter, Motorschutz, electrical contact protection measures tec.) are all functioning. Berührungsschutzmaßnahmen u.a.) auf einwandfreie Funktion kontrollieren. ● Switch the compressor Verdichter einschalten.on. ● Check the oil level inÖlstand the compressor. It should besichtbar visible sein. in the sight glass. Ölstandskontrolle: muß im Schauglas IfWenn largergrößere quantities of oil have to be topped up, there is a risk of oilGefahr liquid von shocks. Ölmengen nachgefüllt werden müssen, besteht InÖlschlägen. this case, the oil returnFalle has Ölrückführung to be checked. überprüfen! In diesem ● On reaching equilibrium (constant operating(kontinuierliche conditions), check that the system Anlage Nach Erreichen des Beharrungszustands Betriebsbedingung) maintains the permitted operating conditions. auf Einhaltung der zulässigen Betriebsbedingungen prüfen. ● When the whole system running wewir recommend drawing up a mit finalallen Bei einwandfreiem Lauf isder Anlageperfectley, empfehlen ein Abschlussprotokoll protocol important data and measured values. wichtigenstating Datenallund Messwerten zu erstellen. Liquid sluggings Vermeidung von Flüssigkeitsschlägen D Flüssigkeitsschläge können zu Schäden am Verdichter führen sowie KältemitLiquid slugging can cause damage to the compressor and leakage of coolant. telaustritt verursachen. To liquid slugging, the following points be observed: Zuravoid Vermeidung von Flüssigkeitsschlägen istshould zu beachten: ● The whole plant must be properly designed. Die komplette Kälteanlagenauslegung muß fachgerecht ausgeführt sein. ● AAlle ll components mustmüssen be rated to be compatible with eachabgestimmt other with regard to output Komponenten leistungsmäßig aufeinander sein (insbeson(particulary evaporator and expansion valve). dere Verdampfer und Expansionsventil). ● SDie uction gas overheating atam theVerdichtereingang compressor entrance 7 - 10 K (check Sauggasüberhitzung soll should min. 7 be - 10min. K betragen. (Einstelsetting of the expansion valve). lung des Expansionsventils prüfen). ● The machine reach a state oferreichen. equilibrium. Anlage mussmust Beharrungszustand ● PBesonders articulary inbeicritical systems (e.g. serveral evaporator points), measures recomkritischen Anlagen (z.B. mehrere Verdampferstellen) sindare Maßnahmen mended such as replacement of liquid traps, solenoid in the liquid line etc. wie Einsatz von Flüssigkeitsfallen, Magnetventil in der Flüssigkeitsleitung u.a. empCoolant should move in the machine is a standstill. fehlenswert. Die not Verlagerung voncompressor Kältemittelwhen in denthe Verdichter beiatAnlagenstill- GB stand ist zu vermeiden. F E I 17 Startup Start-up connection ”O” ”O” isis provided providedfor forinstalling installingan anoil oillevel levelregulator. regulator.AAcorresponding corresponding The connection ust ebeo obtained tained from fro the the trade. trade. adapter must Maintenance Safety instructions Before starting any work on the compressor: ● Switch the machine off an secure it against being switched back on. ● Relieve machine from the system pressure. After maintenance has been performed: ● Connect safety switch. ● Evacuate compressor. ● Cancel switch-on aufheben. blockage. Einschaltsperre Lufteintritt vermeiden! Avoid entry of in airdie intoAnlage the plant! Esteröl verhält very sich strongly stark hygroskopisch. DieThe im Öl gebundene Feuchtigkeit Ester oil behaves hygroscopically. humidity bonded in the oil lässtbe sich durch den nicht ausreichend entfernen. Daher ist cannot removed suffiEvakuiervorgang ciently by the evacuation process. Therefore very careful sehr sorgfältiger Umgang erforderlich! handling is requiered! The compressor is Betriebssicherheit to be kept in a clean, orderly condition des by suitable care.zu In order to Um eine optimale und Lebensdauer Verdichters gewährleisguarantee optimum safety life ofethe compressor, ten empfehlen i roperating in regelmä igenand eit service abständen r iceund ber we pr recommend ungsar beiten that you carry out the following servicing and checks at regular intervals: o rzunehmen Öl ● Oil echse changel including cleaning the oil intake filter: -- not bei mandatory abri mä ig in hergestellten e rienanlagen zwingend series machines produced innicht the factory bei field eldinst allationen oder Betrieb im application n wendungsgrenzbereich erstmals -- for installation or operation in the limit range, first oil changenach after bis triebsstunden danach cathen alle approx. ahre bz w 3 years-or 10,000Betriebsstunapprox.Be100 - 200 operating hours, every - 12,000 den l t l ohours. rschri tsmä ig entsorgen nationale Vorschri ten beachten operating gelmä ofige o ntrollen theit with Lau geräusche r c e e mperaturen u n -eDispose used oil properly,ichcomply national regulations. tion der checks: u satzeinrichtungen wie l sump r uc schalter ährfunction lich ationale ● Regular Tightness, running noise,heizung pressures, temperatures, of the Vorschri ten beachten additional equipment such as oil sump heating, pressure switches: annually. Observe national regulations. Spare part recommendation D GB F 60-4 S, 75-4 (S) 90-4 (S), 110-4 (S) Designation Art.-No. Art.-No. Valve plate kit 80352 80353 HG12P / ... E I Seal kit 80339 Oil pump kit Oil sump heater kit, 110 - 240 V 08324 Only use original Bock spare parts! 18 08028 Maintenance 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 compressor. All work 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. Excerpt from the lubricant table Lubricants Excerpt fromfilled theas lubricant The oil grade standard table in the factory is noted on the name plate. This oil The oil grade as inin the factory on the name This grade grade be used preferably. to this the following The oil should grade filled filled as standard standard theAlternatives factoryisisnoted noted onare thelisted nameinplate. plate. Thisoil oilexcerpt from our lubricant table. preferably. Alternatives to this are listed in the following excerpt grade should be used Schmierstoffe Lubricants from our lubricant table. Lubricants Bock oil grade Recommended o k standard erien lsorte m f o lene l alternatives ternati en Lubricants Bock series oil grades Recommended alternatives ür HFCKWs Ws Bock series (e.g. oil grades Recommended alternatives For HCFCs S e iso SR22) uniso FUCHS Reniso 46 MOBIL SHC SUNOIL Suniso For HCFCs (e.g. SP R22) la us425 D a ella W4GS SHELL Clavus SD 22-12 TEXACO Capella4GS WF 46 FUCHS Reniso SP 46 MOBIL SHC 425 SUNOIL Suniso uniso For HFCs (e.g. R 134a, R404A, R407C) SHELL Clavus SD 22-12 TEXACO Capella WF 46 ür HFKWs Ws (z.B.R404A, a R407C) For HFCsReniso (e.g. RTriton 134a, SE R404A, R407C) SEZ 32 FUCHS 55 FUCHS MOBIL Arctic AL 46 S e iso r ito S r ti ICI Emkarate RL 46 S SHELL Arctic ClavusAL R FUCHS Reniso Triton SE 55 FUCHS SEZ 32 MOBIL mkarate la us 46 ICIoils Emkarate RL 46 S SHELL Clavus R 46 about further suitable on request. Information on further suitable oils on request. Information on further suitable oils on request. uskun ft ü er eitere geeignete Öle sind den o k mierst offta ellen u entne men Information about further suitable oils on request. Decommissioning Decommissioning Auserbetriebnahme Decommissioning Auserbetriebnahme Formajor majorrepairs repairsor orduring duringshutdown: shutdown:Observe Observesafety safetyinstructions, instructions p. For For major repairs or during shutdown: Observe safety instructions, p. 18 18 Close Close shut-off shut-off valves valves at at the the compressor. compressor. Suction Suction off off refrigerant refrigerant (do (do not not blow blow off!) off!) and and dispose of it according to regulations. Open screw connections or fl anges on dispose of it according to regulations. Open screw connections or fl anges on the the comcompressor pressor valves valves and and remove remove compressor, compressor, ifif necessary necessary with with lifting lifting gear. gear. IfIf the the compressor compressor is be the oil and available for Observe oil correctly. regulations and consider! is to todispose be scrapped, scrapped, theEnvironmental oil must must be be drained drained and made made availableregulations for recycling. recycling. Observe oil dispose correctly. Environmental regulations and national national regulations consider! environmental and national regulations! environmental and national regulations! D GB F E I 19 F E I 20 9,40 / 11,30 9,40 / 11,30 HG12P/110-4 HG12P/110-4 S 1 Voltage kW 2,2 A 6,8 / 3,9 10,6 / 6,1 9,2 / 5,3 8,8 / 5,1 8,5 / 4,9 8,0 / 4,6 3,6 3,1 2,9 2,8 2,6 2,3 2 7,1 / 4,1 Max. power consumption Max. working current 2 ∆/Y Electrical Data 3 1 Tolerance (± 10 %) applied to the average of the tension range. Other voltages and current on request. 2 Take account of the max. operating current / max. power consumption when designing contactors, leads and fuses. Switch: Service category AC3. 3 All data are based on the mean value of the voltage range. 4 For soldering joint. 8,00 / 9,60 HG12P/90-4 S 8,00 / 9,60 6,70 / 8,10 HG12P/75-4 S 2 6,70 / 8,10 HG12P/75-4 HG12P/90-4 5,40 / 6,40 m3/h HG12P/60-4 S Cylinders Swept volume 50 / 60 Hz (1450 / 1740 1/min) GB Type Technical Data D 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz 49 49 49 49 49 48 48 kg Weight 12 (1/2) mm (inch) Discharge valve DV 16 (5/8) mm (inch) Suction valve SV 0,9 l Oil filling 60 / 59 / 58 60 / 59 / 58 59,5 / 59 / 58 59,5 / 59 / 58 59 / 58,5 / 58 59 / 58,5 / 58 58,5 / 58 / 57 dB(A) L/M/H 5 Sound pressure level 5 L = settore temperatura bassa (-35 / 40°C), M = settore raffreddamento normale (-10 / 45°C), H = settore condizionamento d‘aria. Valeirs misurate in una sala di misura àfaible riflessione. Le indicazioni costituiscono valori medi e si riferiscono ad una distanza di misura di 1m, il compressore funzionamento a 50 Hz (1450tr/mn). Valori misurati con réfrigérant R404A. Le indicazioni sono medie, tolleranza ±2dB (A). 45 / 26 43 / 25 45 / 26 43 / 25 43 / 25 40 / 23 40 / 23 A ∆/ Y bloccato) (rotore Starting current Connections 4 5 5 6 6 7 7 4 4 Dimensions and connections Vibration absorbers Amortisseurs de vibration M8 M830 A1 66 8 66 DV A A H,D1 H,D1 K,O K,O F F 4x 208 318 208 ca.415 7 318 ca.415 Maße Zubehör Maße Zubehör B,L B,L E E 98 98 SV 1) SV A1 ca.280 ca.280 244 244 30 J J ca.220 76 ca.220 DV76 B1 B1 30 30 Schwingungsdämpfer Vibration absorbers Amortisseurs de vibration Schwingungsdämpfer 4x 6 Anschlüsse SV Saugabsperrventil, Rohr c c 10 162 10 192 162 192 5 Connections Suction line valve, tube (L)* Discharge line valve, tube (L)* Connections Connection suction side, not lockable Suction line valve, tube (L)* Connection suction side, lockable Discharge line valve, tube (L)* B Anschluß Druckseite, nicht absperrbar Connection discharge side, not lockable A Anschluß Saugseite, nicht absperrbar Connection suction side, not lockable B1 Anschluß Druckseite, absperrbar Connection discharge side, lockable A1 Anschluß Saugseite, absperrbar Connection suction side, lockable D1 Anschluß Ölrückführung vom Ölabscheider Connection oil return from oil separator B Anschluß Druckseite, nicht absperrbar Connection discharge side, not lockable E Anschluß Öldruckmanometer Connection oil pressure gauge B1 Anschluß Druckseite, absperrbar Connection discharge side, lockable F Ölablaß Oil drain D1 Anschluß Ölrückführung vom Ölabscheider Connection oil return from oil separator H Stopfen Ölfüllung Oil charge plug E Anschluß Öldruckmanometer Connection oil pressure gauge J Ölsumpfheizung Oil sump heater F Ölablaß Oil drain K Schauglas Sight glass H Stopfen Ölfüllung Oil charge plug L Anschluß Wärmeschutzthermostat Connection thermal protection thermostat J Ölsumpfheizung Oil sump heater O Anschluß Ölspiegelregulator Connection oil level regulator K Schauglas Sight glass (L)* = Lötanschluß (L)* = Brazing connection L Anschluß Wärmeschutzthermostat Connection thermal protection thermostat O Anschluß Ölspiegelregulator Connection oil level regulator (L)* = Lötanschluß (L)* = Brazing connection (L)* Schwingungsdämpfer DV Druckabsperrventil, Rohr Anschlüsse Vibration absorbers (L)* Vibration absorbers A Anschluß Saugseite, nicht absperrbar (L)* SV Saugabsperrventil, Rohr A1 Anschluß Saugseite, absperrbar Amortisseurs de vibration DV Druckabsperrventil, Rohr (L)* 30 Revisionsdurchlauf: 1 Revisionsdurchlauf: 1 i Dimensions in mm - Subject to change without notice SV 90° rotatable B,L A Connection suction A1 Connection suction side, lockable B Connection discharge side, not lockable B1 Connection discharge side, lockable D1 Connection oil return from oil J seperator E Connection 66 oil pressure gauge F Oil drain H Oil filling bung J Oil sump heater ca.280 244 Suction line Discharge line Typ Teile Nr. TypHG / Semi-hermetic Teile Nr. Typ Nr. Typ semi-hermétiq Te Halbhermetischer Verdichter HG / Teile Compresseur Technical specifications, p. 20S 14549 compressor 14544 HGX12P/90-4 14 HG12P/60-4 S 14541 HGX12P/60-4 HG12P/90-4 Typ Teile Teile Te HG12P/75-4 14542Nr. Typ HGX12P/75-4 14550Nr. Typ HG12P/90-4 S Teile 14545Nr. Typ HGX12P/90-4 S 14 HG12P/75-4 S S 14541 14543 HGX12P/60-4 HGX12P/75-4 S 14549 14551 HG12P/90-4 HG12P/110-4 14546 HGX12P/90-4 HGX12P/110-4 14 14544 14 HG12P/60-4 1/ S“ NPTF HG12P/110-4S 14547 HGX12P/110-4 S 14 HG12P/75-4 14542 HGX12P/75-4 14550 HG12P/90-4 14545 HGX12P/90-4 S 14 side, not lockable 8 HG12P/75-4 S 14543 HGX12P/75-4 S 14551 HG12P/110-4 14546 HGX12P/110-4 14 7 S 14547 HGX12P/110-4 S 14 HG12P/110-4 SV 98 208 318 ca.415 K Sight glass L 6 7Connection heat protection thermostat 7Connection oil level regulator6 E /A1 16“ UNF Gußtoleranzen: 1/ “ NPTF 8 Gewicht: (kg) D Gußtoleranzen: F -7/ “ UNF Tol.-Ang. DIN ISO 2768-mK Gewicht: (kg) 16 GB -über 0.5 6 30 120 1/ “ NPTF 120 400 bis 6 DIN30 Tol.-Ang. ISO 2768-mK F 4 6 ±0.3 30 ±0.5 120 über±0.1 0.5 ±0.2 30 120 400 bis 6 1/ “ NPTF Unbemaßte Radien: E8 ±0.1 ±0.2 ±0.3 ±0.5 M8 I Unbemaßte Radien: - 1/ “ NPTF 4 Ø 15 mm - h Div. Änderungen (Betrifft Bl. 2+3) i nur Blatt 2 Zust. Betrifft Änderungsbeschreibung h Div. Änderungen (Betrifft Bl. 2+3) Zone - Zust. Änderungsbeschreibung Zone O Chauffage d Raccord rég Voyant (L)* = Racco Raccord de t Raccord régu (L)* = Racco Halbhermetischer Verdichter HG / Semi-hermetic compressor HG / Compresseur semi-hermétiq SV DV Betrifft nur Blatt 2 Vanne d’arrê Vanne d’arrê Raccords Raccord côt Vanne d’arrê Raccord côt Vanne d’arrê Raccord côt Raccord côté Raccord côt Raccord côté Raccord reto Raccord côté Raccord du Raccord côté Vidange d’h Raccord reto Bouchon de Raccord du m Chauffage d Vidange d’hu Voyant Bouchon de Raccord de B1 M8 30 1) Änderu Subjec Sous ré Änderun Subject Sous ré Raccords 7266, 7283 Layh Layh 21.11.07 Bau 02.04.08 Büttner Layh 7266, 7283 Bearb. Gepr. Änderungs-Nr. Datum 7022,7090,7176,7181 21.11.07 Layh Bau 7022,7090,7176,7181 5 5 Änderungs-Nr. Datum Anschlüsse SV Saugabsperrventil, Roh DV Druckabsperrventil, Ro A Anschluß Saugseite, ni Maß Passung A1 Anschluß Saugseite, ab B Anschluß Druckseite, n Maß Passung B1 Anschluß Druckseite, a D1 Anschluß Ölrückführun E Anschluß Öldruckmano F Ölablaß H Stopfen Ölfüllung 1 1/8“- 18 UNEF 1/ “ NPTF 8 4 Bearb. Gepr. 1 1 /8“- 18 UNEF 4 02.04.08 Büttner 21 J Ölsumpfheizung Conformity and manufacturer‘s declaration 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 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 ISO 12100-2 EN 349 EN 60204-1 EN 60529 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. D GB PED CLASSIFICATION F (as per EU Pressure Equipment Directive 97/23/EEC) E I The compressor is not subject to the EU Pressure Equipment Directive. Frickenhausen, 07.05.2004 22 Dr. Harald Kaiser Technical director D GB F E I 23 www.bock.de Bock Kältemaschinen GmbH Benzstraße 7 D-72636 Frickenhausen Telefon +49 7022 9454-0 Telefax +49 7022 9454-137 [email protected] D GB F E I Art. Nr. 09652-11.08-DGbFEI Subject to change without notice 24