GEA Bock HGX2 CO2 T Series, Assembly Instructions Manual

Page 1: ...GB F E 1 96458 03 2019 DGb GEA Bock HGX2 CO2 T Assembly instructions 96458 03 2019 Gb Translation of the original instructions GEA Bock GmbH 72636 Fricke nhau sen Germ any HGX2 70 4 CO2 T HGX2 90 4 CO2 T ...

Page 2: ...ions These instructions must be passed onto the end customer along with the unit in which the compres sor is installed GEA Bock GmbH 72636 Frickenhausen GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 info gea com www gea com Manufacturer Contact 1 Safety 4 1 1 Identification of safety instructions 1 2 Qualifications required of personnel 1 3 Sa...

Page 3: ...ctor and motor contactor selection 5 2 Standard motor designed for direct or part winding start 5 3 Basic circuit diagram for part winding start 5 4 Electronic trigger unit INT69 G 5 5 Connection of the electronic trigger unit INT69 G 5 6 Functional test of the electronic trigger unit INT69 G 5 7 Oil sump heater 6 Commissioning 22 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak t...

Page 4: ...ing which enable personnel to assemble install maintain and repair refrigeration and air conditioning systems Personnel must be capable of assessing the work to be carried out and recognising any potential dangers DANGER Indicates a dangerous situation which if not avoided will cause immediate fatal or serious injury WARNING Indicates a dangerous situation which if not avoided may cause fatal or s...

Page 5: ... and therefore require particular caution and care in handling The maximum permissible overpressure must not be exceeded even for testing purposes Risk of burns Depending on the operating conditions surface temperatures of over 60 C on the pressure side or below 0 C on the suction side can be reached Avoid the contact with refrigerant under any circumstances The contact with refrigerant can lead t...

Page 6: ...n especially intensive cooling of the motor Therefore the motor temperature remains on a relatively low level especially at 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 atmosphere when these inadmissibly high printing pressures are reached 2 1 Short description Discharge s...

Page 7: ...le operating pressure g Low pressure side HD HP max permissible operating pressure g High pressure side Observe the limits of application diagrams 50 Hz 60 Hz 6 Voltage circuit frequency 7 Nominal rotation speed 8 Displacement 9 Voltage circuit frequency 10 Nominal rotation speed 11 Displacement 12 Oil type filled at the factory 13 Terminal box protection type Electrical accessories can change the...

Page 8: ...of the shaded areas Thresholds should not be selected as design or continuous operation points Permissible ambient temperature 20 C 60 C Max permissible discharge end temperature 160 C Min discharge end temperature 50 C Min oil temperature 30 C Max permissible switching frequency 12x h A minimum running time of 3 min steady state condition continuous operation must be achieved For operation with s...

Page 9: ...e operating pressure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure Fig 5 Unlimited application range 3 Areas of application to Evaporation temperature C toh Suction gas superheat K po Suction pressure bar pv2 Discharge end pressure bar ...

Page 10: ...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 Fig 8 Fig 9 Fig 10 F E D 1 2 3 4 1 Storage and transportation Use transport eyelet Do not lift manually Use lifting gear Storage...

Page 11: ... 4 4 Connecting the pipelines cutting ring system 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 Cut Ring 3 onto Pipe 2 Insert pipe into Socket 6 as far as it will...

Page 12: ...ompensators 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 A B Fig 13 Fig 14 4 7 Option cutting ring screw joint HP LP Remove Schrader connection HP Remove Schrader connection LP Fig 15 Fig 16 ATTENTION Property damage possible The compressor as delivered is equipped with Schrader valves on the ...

Page 13: ...l clockwise Fig 18 Fig 19 4 8 Laying suction and pressure lines A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft ATTENTION Property damage possible Improperly installed pipes can cause cracks and tears which can result in a loss of refrigerant INFO Proper layout of the suction and pressure lines directly after the compress...

Page 14: ...ve opened The connection which cannot be shut off is intended for safety devices Spindle Connection cannot be shut off Connection blocked Service connec tion closed Pipe connection Spindle Connection cannot be shut off Connection offen Service connec tion opened Fig 20 Fig 21 After activating the spindle generally fit the spindle protection cap again and tighten with 40 50 Nm This serves as a seco...

Page 15: ...ply 5 1 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 as well as the manufacturer s specifications Motor protection switches are required Motor contactors feed lines fuses and motor protection switches must be rated according to the maximum operat...

Page 16: ...nal box Y YY Compressors marked in this way are suitable for direct or part winding start The motor winding is divided into two parts part winding 1 50 and part winding 2 50 This winding devision red uces the start up current during a part winding start to approx 50 of the value for a direct start INFO Mechanical start unloader with bypass solenoid is not required ...

Page 17: ...perty damage possible Failure to comply results in reversed fields of rotation and can cause motor damage After the motor has started up with part win ding 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 Ensure that power is supplied via QA2 to winding 1 50 1U1 1V1 1W1 and via QA3 to winding 2 50 2U1 2V1 2W1 The mo...

Page 18: ... 1V1 1W1 PE EC1 M Y YY 2U1 2V1 2W1 FC1 2 I I I QA3 FC1 1 FC1 2 FC2 SF1 QA2 EB1 11 12 14 L N B1 B2 BT2 Θ BT2 Θ Fig 22 5 Electrical connection Compressor terminal box BP1 Oil pressure safety switch BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat BT3 Release switch thermostat EB1 Oil sump heat...

Page 19: ...6 1 8 6 2 8 6 4 8 6 5 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT3 T2 N L M S PE QA2 FC1 1 Motor protection switch part winding 1 FC1 2 Motor protection switch part winding 2 FC2 Control power circuit fuse KF1 Delay relay max 1s QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch ...

Page 20: ...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 INFO Connect the trigger unit INT69 G in accordance with the circuit dia gram Protect the trigger unit with a delayed action f...

Page 21: ...e connected and operated 5 7 Oil sump heater In order to avoid damage to the compressor the compressor is equipped with an oil sump heater as a standart feature Relay position INT69 G B2 12 14 11 Fig 24 5 6 Function test of the trigger unit INT69 G Before commissioning after troubleshooting or making changes to the control power circuit check the functionality of the trigger unit Perform this chec...

Page 22: ...secondary refrigerant system or pressure relief devices 6 3 Leak test Carry out the leak test on the refrigerating plant in accordance with EN 378 2 or a corresponding safety standard while always observing the maximum permissible overpressure for the compressor DANGER Risk of bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximum...

Page 23: ...ility 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 5 2 bar A refrigerant supplement which may become necessary after start up can be topped up in vapour form on the suction side ATTENTION Do not start the compressor if it is under vacuum Do not apply any voltage even for tes...

Page 24: ...ed off danger of oil liquid shocks reduced capacity of the refrigerating system Suitably adjusted pressure switches that switch off the compressor before reaching the maximum permissible operating pressure must be installed in the system The pressure reduction for the pressure switches can occur either at the suction and pressure lines between the shut off valve and compressor or at the non lockab...

Page 25: ... activates 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 decompression 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 d...

Page 26: ...nt in the compressor while the system is at a standstill ATTENTION Slugging can result in damage to the compressor and cause refrigerant to leak WARNING Before starting any work on the compressor Switch off the compressor and secure it to prevent a restart Relieve compressor of system pressure Prevent air from infiltrating the system After maintenance has been performed Connect safety switch Evacu...

Page 27: ...sed shut off valves may lead to intolerable excessive pressure For this reason the suction side LP and the high pressure side HP of the compressor have to be secured by decompression valves 7 5 Lubricants For operation with CO2 the GEA oil C 85 E is necessary 7 2 Work to be carried out In order to guarantee optimum operational reliability and service life of the compressor we recommend carrying ou...

Page 28: ...0 18 3 10 9 65 109 145 18 22 7 8 2 6 2 3 HGX2 90 4 CO 2 T 7 70 9 30 23 8 13 9 87 149 160 8 Technical data 1 2 3 2 4 Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request The specifications for max power consumption apply for 50Hz operation For 60Hz operation the specifications have to be multiplied by the factor 1 2 The max working current rema...

Page 29: ... Halbhermetischer Verdichter HG Semi hermetic compressor HG 1 0 Maße in mm Dimensions in mm Änderungen vorb Subject to change Massenschwerpu Centre of gravity Maße und Anschlüsse mit Absperrventilen measures and connections with shut off valves Typ type Teile Nr part no HGX2 70 4 CO2 T 16248 HGX2 90 4 CO2 T 16249 Anschlüsse Connections SV Saugabsperrventil Rohr L Suction line valve tube L DV Druck...

Page 30: ...kable 7 16 UNF B1 Connection discharge side lockable 7 16 UNF B2 Connection discharge side not lockable 1 8 NPTF E Connection oil pressure gauge 7 16 UNF F Oil drain M22 x 1 5 H Oil charge plug 1 8 NPTF J1 Oil sump heater Ø 15 mm K Sight glass G 1 L Connection thermal protection thermostat 1 8 NPTF M Oil filter M22 x 1 5 O Connection oil level regulator G 1 X1 Connection for schrader valve suction...

Page 31: ...ferenced A partly completed machine may only be put into operation when it has been established that the machine into which the partly completed machine is to be installed conforms to the regulations of the Machinery Directive 2006 42 EC The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery on request The speci...

Page 32: ... have any questions about installation operation and accessories please contact our technical service or specialist wholesaler and or our representative The GEA service team can be contacted by phone with a toll free hotline 00 800 800 000 88 or via e mail info gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany ...

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Page 34: ...usen Germany Phone 49 0 7022 9454 0 Fax 49 0 7022 9454 137 info gea com gea com GEA Group is a global engineering company with multi billion euro sales and operations in more than 50 countries Founded in 1881 the company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index ...