Danfoss BOCK UL-HGX12 CO2 T, Operating Manual

Page 1: ...O2 T UL HGX12 20 SH 3 CO2 T UL HGX12 30 ML 3 CO2 T UL HGX12 30 S 4 CO2 T UL HGX12 30 SH 4 CO2 T UL HGX12 40 ML 4 CO2 T UL HGX12 40 S 5 CO2 T UL HGX12 40 SH 5 CO2 T Operating guide Reciprocating Compressor BOCK UL HGX12 CO2 T Translation of the original instructions ...

Page 2: ...t safety labels Refer to local building codes for installation requirements Transcritical CO2 applications require a completely new kind of system and control They are not a general solution for the substitution of F gases Therefore we expressly point out that all information in these assembly instructions has been provided according to our current level of knowledge and may change due to further ...

Page 3: ...tor contactor selection 15 5 2 Connection of the driving motor 16 5 3 Circuit diagram for direct start 280 V Δ 460 V Y 18 5 4 Electronic trigger unit INT69 G 20 5 5 Connection of the electronic trigger unit INT69 G 20 5 6 Functional test of the electronic trigger unit INT69 G 21 5 7 Oil sump heater 21 5 8 Selection and operation of frequency converters 21 6 Commissioning 22 6 1 Preparations for st...

Page 4: ...gned or adjusted in accordance with EN 378 2 or appropriate national safety standards Risk of burns Depending on the operating conditions surface temperatures of over 140 F 60 C on the pressure side or below 32 F 0 C on the suction side can be reached Avoid contact with refrigerant under any circumstances Contact with refrigerant can lead to severe burns and skin irritations Indicates a dangerous ...

Page 5: ...ected and approved in accordance with legal regulations The compressors are intended for use with CO2 in transcritical and or subcritical systems in compli ance with the limits of application Only the refrigerant specified in these instructions may be used Any other use of the compressor is prohibited The compressor may not be used in potentially explosive environments Inadequately qualified perso...

Page 6: ...ure level specially during high load Oil pump independent of direction of rotation for reliable and safe oil supply One decompression valve each on the low and high pressure side which vent into the atmos phere when inadmissibly high pressure levels are reached 2 1 Short description Fig 2 Dimension and connection values can be found in chapter 9 2 Product description Fig 1 Oil sight glass Valve pl...

Page 7: ...ection type Electrical accessories can change the IP protection class 2 2 Name plate example 1 2 3 4 5 13 12 7 11 6 10 8 9 UL HGX12 40 S 5 CO2 T 17 5 10 1A 111A 64A BC12345A001 3 5 4 2 IP66 Fig 3 2 Product description HG Hermetic Gas Cooled suction gas cooled X Ester oil charge ML Normal cooling and deep freezing at low and medium evaporation temperatures S For frequency regulation and extended li...

Page 8: ...ompressor is possible if overfilled or underfilled Fig 4 max min Oil level 3 Areas of application 3 1 Refrigerants R744 CO2 Recommendation CO2 quality 4 5 5 ppm H2O The compressors are filled at the factory with the following oil type Compressor version ML and S BOCKlub E85 Compressor version SH Bock C170E Only these oils may be used 3 2 Oil charge 21 fl oz 0 6 Ltr ...

Page 9: ...F 140 F 20 C 60 C Max permissible discharge end temperature 320 F 160 C Min discharge end temperature 122 F 50 C Min oil temperature 86 F 30 C Max permissible switching frequency 12x h A minimum running time of 3 min steady state condition continuous operation must be achieved Avoid continuous operation in limit range 3 3 Limits of application 3 Areas of application 1 LP Low pressure HP High press...

Page 10: ... with sufficient load bearing capacity Single compressor preferably on vibration damper Compound connection basically rigid Provide adequate clearance for maintenance work Ensure adequate compressor ventilation Do not use in a corrosive dusty damp atmosphere or a com bustible environment F E D 1 2 3 4 1 Storage and transportation Use transport eyelet Do not lift manually Use lifting gear Storage a...

Page 11: ...ing the pipelines cutting ring system Fig 6 Figure similar Tube preparation The tube has to be sawn in a right angle An angular tolerance of 1 is permissible Slightly trim the pipe ends inside and outside For thin walled steel pipes or soft pipes made of nonferrous metal reinforcing sleeves have to be used Pipe assembly Push union nut 5 and cutting ring 3 onto pipe 2 Insert pipe into socket 6 as f...

Page 12: ...to the refrigerant system 4 5 Pipes Pipes and system components must be clean and dry inside and free of scale swarf and layers of rust and phosphate Only use hermetically sealed parts Lay pipes correctly Suitable vibration compensators must be provided to prevent pipes being cracked and broken by severe vibrations Ensure a proper oil return Keep pressure losses to an absolute minimum 4 Compressor...

Page 13: ...n cause cracks and tears which can result in a loss of refrigerant Proper layout of the suction and pressure lines directly after the compressor is integral to the smooth running and vibration behaviour of the system 4 Compressor assembly 4 8 Operating the shut off valves example Before opening or closing the shut off valve release the valve spindle seal by approx 1 4 of a turn counter clockwise A...

Page 14: ...pindle Spindle Connection open Compressor Compressor Service connec tion closed Service connec tion opened 4 Compressor assembly To ensure the oil return function will work reliably no matter what kind of system configuration you are using Bock recommends incorporating oil separators or oil level monitoring equipment The O connection is already available from the factory for the purpose of install...

Page 15: ...ttaching accessories with an electrical cable a minimum bending radius of 3 x the cable diameter must be maintained for laying the cable 5 Electrical connection 5 1 Information for contactor and motor contactor selection All protection equipment switching and monitoring devices must comply with the local safety reg ulations and established specifications e g VDE as well as the manufacturer s speci...

Page 16: ...450438405295en US0201 Danfoss Climate Solutions 2023 06 5 Electrical connection Designation on the name plate Y 5 2 Connection of the driving motor The compressor is designed with a motor for star delta circuits ...

Page 17: ...ere Spannung Low voltage Bas voltage Y Hohe Spannung High voltage Haut voltage L3 L1 L2 L3 L1 L2 ical connection rdement électrique Y 96027 11 06 DGbF Niedere Spannung Low voltage Bas voltage Y Hohe Spannung High voltage Haut voltage L3 L1 L2 L3 L1 L2 L1 L2 L3 L1 Insulator Insulators L2 L3 INFO The supplied insulators must be mounted according to the illustrations as shown The connection examples ...

Page 18: ... 1 I I I 1 2 QA2 3 4 5 6 EC1 3 M Θ 5 3 Circuit diagramm for direct start 280 V 460 V Y Fig 14 Compressor terminal box BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor FC1 Load circuit safety switches FC2 Control power circuit fuse BP1 High pressure safety monitor BP2 Safety chain high low pressure monitoring BT3 Release switch thermostat pressostat Y ...

Page 19: ...6 AQ450438405295en US0201 19 BP1 P QA2 BP2 P L1 1 L2 1 L3 1 L1 2 N PE BT3 BT2 Θ BT2 Θ EB1 QA1 Main switch SF1 Control voltage switch EC1 Compressor motor QA2 Compressor contactor INT69 G Electronic trigger unit INT69 G EB1 Oil sump heater ...

Page 20: ...edy the cause The relay switching output is executed as a floating changeover contact This electrical circuit operates according to the quiescent current principle i e the relay drops into a the idle position and deactivates the motor contactor even in case of a sensor break or open circuit Connect the trigger unit INT69 G in accordance with the circuit dia gram Protect the trigger unit with a del...

Page 21: ... oil sump heater must generally be connected and operated 5 8 Selection and operation of compressors with frequency converters For safe operation of the compressor the frequency converter must be able to apply an overload of at least 160 of the compressor s maximum current I max for at least 3 seconds When using frequency converters the following things must also be observed 1 The maximum permissi...

Page 22: ...elief devices 6 2 Pressure strength test The compressor has been tested in the factory for pressure integrity If however the entire system is to be subjected to a pressure integrity test this should be carried out in accordance with UL CSA Standards or a corresponding safety standard without the inclusion of the compressor 6 3 Leak test Carry out the leak test on the refrigerating plant in accorda...

Page 23: ...ling according to system To eliminate the possibility of dry ice formation when the system is operating during and after the filling process the shut off point of the low pressure switch should be set to a value of at least 75 psig 5 2 bar A refrigerant supplement which may become necessary after start up can be topped up in vapor form on the suction side Do not start the compressor if it is under...

Page 24: ... reduced capacity of the refrigerating system Ensure that both shut off valves are open before starting the compressor If larger quantities of oil have to be topped up there is a risk of oil impact effects If this is the case check the oil return 6 6 Start up 6 Commissioning 6 7 Pressure switch Suitably adjusted pressure switches according to UL 207 EN 378 or national standards that switch off the...

Page 25: ...tivates repeatedly check valve and replace if necessary as during blow off extreme condi tions can occure which may result in a permanent leak Always check system for refrigerant loss after activation of pressure relief valve The pressure relief valves do not replace any pressure switches and the additional safety valves in the system Pressure switches must always be installed in the system and de...

Page 26: ...refrigerant in the compressor while the system is at a standstill Slugging can result in damage to the compressor and cause refrigerant to leak 6 10 Filter dryer Gaseous CO2 has a significantly lower solubility in water than other refrigerants At low temperatures it can therefore cause blocking of valves and filters due to ice or hydrate For this reason we recom mend the use of an adequately sized...

Page 27: ... essential to ensure good ventilation or conduct the CO2 into the outdoors to avoid danger of suffocation When releasing CO2 avoid a fast drop in pressure to prevent oil from exiting with it If the compressor is unpressurized remove the piping on the pressure and suction side e g dismantling of the shut off valve etc and remove the compressor using an appro priate hoist Dispose of the oil inside i...

Page 28: ...ine SV 50 60 Hz Y Y cfh V A kW HP A Hz lb mm inch mm inch Ltr fl oz Ltr fl oz 20 ML 2 CO2 T 2 61 73 265 290 V 440 480 V Y 3 60 Hz 9 8 5 7 2 5 3 4 111 64 30 70 207 19 3 4 22 7 8 1 3 46 1 1 39 20 S 3 CO 2 T 10 7 6 2 3 0 4 1 111 64 207 20 SH 3 CO 2 T 10 7 6 2 3 0 4 1 111 64 206 30 ML 3 CO 2 T 100 120 12 7 7 4 4 0 5 4 111 64 207 30 S 4 CO 2 T 14 6 8 4 4 8 6 5 111 64 207 30 SH 4 CO 2 T 14 6 8 4 4 8 6 5...

Page 29: ... current on request The specifications for max power consumption apply for 60 Hz operation Take account of the max operating current max power consumption for design of fuses supply lines and safety devices Fuse Consumption category AC3 1 4 3 2 5 All specifications are based on the average of the voltage range Cutting ring connector for steel tubes For solder connections ...

Page 30: ...uss Saugseite ab Connection suction side B Anschluss Druckseite ni Connection discharge sid B1 Anschluss Druckseite ab Connection discharge sid D1 Anschluss Ölrückführung Connection oil return from E Anschluss Öldruckmanom Connection oil pressure g F Ölablass Oil drain I Anschluss Heißgastemp Connection hot gas temp J Anschluss Ölsumpfheizu Connection oil sump hea J1 Ölsumpfheizung oil sump heater...

Page 31: ...oil separator 1 4 NPTF E Connection oil pressure gauge 1 8 NPTF F Oil drain M12x1 5 I Connection hot gas temperature sensor 1 8 NPTF J1 Oil sump heater 3 8 NPTF K Sight glass 2 x 1 1 8 18 UNEF L Connection thermal protection thermostat 1 8 NPTF O Connection oil level regulator 2 x 1 1 8 18 UNEF Q Connection oil temperature sensor 1 8 NPTF SI1 Decompression valve HD M24x1 5 SI2 Decompression valve ...

Page 32: ...FK X 20 120 K N TK FK X 50 980 K N TK Serial number BC00000A001 BN99999Z999 complies with the following provisions of the above mentioned Directive According to Annex I points 1 1 2 1 1 3 1 1 5 1 3 2 1 3 3 1 3 7 1 5 1 1 5 2 1 5 13 and 1 7 1 to 1 7 4 excepted 1 7 4 f are fulfilled Applied harmonised standards in particular EN ISO 12100 2010 Safety of machinery General principles for design Risk ass...

Page 33: ...X 20 120 K N TK FK X 50 980 K N TK Serial number BC00000A001 BN99999Z999 complies with the following provisions of the above mentioned Statutory instrument According to Schedule 2 part1 points 1 1 2 1 1 3 1 1 5 1 3 2 1 3 3 1 3 7 1 5 1 1 5 2 1 5 13 and 1 7 1 to 1 7 4 excepted 1 7 4 f are fulfilled Designated standards EN ISO 12100 2010 Safety of machinery General principles for design Risk assessme...

Page 34: ...Danfoss Climate Solutions 2023 06 11 UL Certificate of Compliance Dear customer the Certificate of Compliance can be downloaded by the following QR Code https vap bock de stationaryapplication Data DocumentationFiles COC CO2 trans pdf ...

Page 35: ...D US Danfoss Climate Solutions 2023 06 AQ450438405295en US0201 35 ...

Page 36: ...D US 36 AQ450438405295en US0201 Danfoss Climate Solutions 2023 06 ...