GEA Bock HGX46 CO2 T Series, Assembly Instructions Manual

Page 1: ...SH CO2 T HGX46 310 4 ML CO2 T HGX46 310 4 S CO2 T HGX46 310 4 SH CO2 T HGX46 345 4 ML CO2 T HGX46 345 4 S CO2 T HGX46 345 4 SH CO2 T HGX46 440 4 ML CO2 T GEA Bock HGX46 CO2 T Assembly instructions 96460 08 2018 Gb Translation of the original instructions ...

Page 2: ...d misunder standings and prevent damage Improper assembly and use of the compressor can result in serious or fatal injury Observe the safety instructions contained in these instructions These instructions must be passed onto the end customer along with the unit in which the compres sor is installed 1 Safety 4 1 1 Identification of safety instructions 1 2 Qualifications required of personnel 1 3 Sa...

Page 3: ...r part winding start 5 3 Basic circuit diagram for part winding start 5 4 Special motor design for direct or star delta start 5 5 Basic circuit diagram for star delta start with special motor 5 6 Electronic trigger unit INT69 G 5 7 Connection of the electronic trigger unit INT69 G 5 8 Functional test of the electronic trigger unit INT69 G 5 9 Oil sump heater 6 Commissioning 28 6 1 Preparations for...

Page 4: ...ng 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 se...

Page 5: ...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 to severe burns and skin irritations Danger of suffocation CO2 is a nonflammable acidic ...

Page 6: ...be kept on a relatively low temperature 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 Oil sight glass Valve plate Cylinder cover Motor section Transport eyelet Oil pump Drive section Disch...

Page 7: ...ure side Observe the limits of application diagrams 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 IP protection class Transcritical CO2 version Compressor version Number of poles Swept volume Number of cy...

Page 8: ...its shown in the diagrams Please note the significance 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 con...

Page 9: ... 40 po bar pV2 bar 110 130 140 60 0 10 20 30 40 10 to C 20 64 3 70 25 90 120 100 pV2 bar 110 130 140 ML S t 10 K Oh t 10 K Oh t 10 K Oh to Evaporation temperature C toh Suction gas superheat K po Suction pressure bar pv2 Discharge end pressure bar Max permissible operating pressure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure Compressor version ML Unlimited application range 3 Areas of a...

Page 10: ...20 30 50 50 40 90 80 120 100 70 60 40 po bar pV2 bar 110 130 140 60 0 10 20 30 40 10 to C 20 64 3 70 25 S SH t 10 K Oh t 10 K Oh to Evaporation temperature C toh Suction gas superheat K po Suction pressure bar pv2 Discharge end pressure bar Unlimited application range Fig 6 Max permissible operating pressure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure Compressor version S 3 Areas of app...

Page 11: ...0 20 30 40 10 to C 20 64 3 70 25 SH t 10 K Oh to Evaporation temperature C toh Suction gas superheat K po Suction pressure bar pv2 Discharge end pressure bar Unlimited application range Fig 7 Max permissible operating pressure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure Compressor version SH Evaporation temperatures 5 C 40 bar on request 3 Areas of application ...

Page 12: ...icient 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 10 Fig 11 Fig 12 F E D 1 2 3 4 1 Storage and transportation Use transport eyelet Do not lift manually Use lifting gea...

Page 13: ...ines cutting ring system Fig 14 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 far as it wil...

Page 14: ...r to connecting to the refrigerant system 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 Comp...

Page 15: ...t in a loss of refrigerant INFO 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 8 Operating the shut off valves Before opening or closing the shut off valve release the valve spindle seal by approx 1 4 of a turn counter clockwise After activating the shut off valve re tighten the adjustable valv...

Page 16: ...t The O connection is already available from the factory for the purpose of installing the additional oil level monitoring component Oil should be returned from the oil separator to the compressor via the D1 connection provided for this purpose on the compressor For systems with long pipes and higher degree of contamination a filter on the suction side is recommended The filter has to be be renewe...

Page 17: ... the electrical system is disconnected from the power supply 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 specifications Motor protection switches are required Motor contactors feed lines fuses and motor protec tion switches must be rated according to the maximum operati...

Page 18: ...n the terminal 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 division reduces the start up current during a part winding start to approx 50 of the value for a direct start 5 Electrical connection ...

Page 19: ...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 winding 1 part winding 2 must be switched on after max 1 second delay Fail ure 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 20: ...m 1 20 02 2009 bauknecht 22 08 2017 Urspr 2 Ers f 3 Ers d 4 Anschlußkasten Verdichter BT1 INT69 QA1 L1 L2 L3 N PE FC1 1 I I I QA2 1U1 1V1 1W1 PE EC1 M Y YY 2U1 2V1 2W1 FC1 2 I I I QA3 FC1 1 FC1 2 FC2 SF1 QA2 11 12 14 L N B1 B2 12 11 10 9 7 6 5 4 3 PE 2 1 8 PE BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal prote...

Page 21: ... 46 CO2T 5 6 7 BOCK COMPRESSORS 8 9 Bl 6 c Bl 4 3 DELTA P II BP2 P QA2 BP3 P QA2 KF1 KF1 2 8 6 c 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT3 BT2 Θ Θ vio bn bu gr Θ EB1 pk og FC1 1 1 2 Motor protection switch FC2 Control power circuit fuse INT69 G Electronic trigger unit INT69 G KF1 Delay relay for contactor switch over QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF...

Page 22: ...22 D GB F E 96460 08 2018 DGb 5 4 Special motor design for direct or star delta start Designation on the name plate Sticker on the terminal box Δ Y 5 Electrical connection ...

Page 23: ... delta start up is only possible for 230 V power supply Example 400 V Y Direct start only L1 L3 L2 PTC 230 V Δ Direct start Star delta start L1 L2 L3 L1 L2 L3 L1 L3 L2 PTC PTC W2 U2 V2 W1 U1 V1 W2 U2 V2 W1 U1 V1 5 Electrical connection ...

Page 24: ...B1 B2 12 11 10 9 PE 6 5 4 3 PE 2 1 FC1 1 I I I 1 2 QA2 FC1 2 I I I 3 4 5 6 1 2 QA4 Y 3 4 5 6 1 2 QA3 D 3 4 5 6 EC1 M 3 8 7 Οnderung 3 0 Datum Name Datum Bearb Gepr Norm 1 20 02 2009 bauknecht 22 08 2017 Urspr 2 Ers f 3 Ers d 4 Anschlußkasten Verdichter BT1 INT69G QA1 L1 L2 L3 N PE 1U1 1V1 1W1 PE 2U1 2V1 2W1 FC1 1 FC1 2 FC2 SF1 QA2 11 12 14 L N B1 B2 12 11 10 9 PE 6 5 4 3 PE 2 1 FC1 1 I I I 1 2 QA2...

Page 25: ...BT2 Θ Θ vio bn bu gr pk og Θ EB1 QA2 QA2 6 a 7 6 b 7 QA4 KF1 QA4 QA3 6 a 8 6 b 8 KF1 QA3 QA4 6 a 8 6 b 8 KF1 D S INT69 HGX34 46 CO2T 5 6 7 BOCK COMPRESSORS 8 9 Bl 6 c Bl 6 a 4 DELTA P II BP2 P BP3 P L1 1 L2 1 L3 1 L1 2 N PE BT3 BT2 Θ Θ vio bn bu gr pk og Θ EB1 QA2 QA2 6 a 7 6 b 7 QA4 KF1 QA4 QA3 6 a 8 6 b 8 KF1 QA3 QA4 6 a 8 6 b 8 KF1 FC1 1 1 2 Motor protection switch FC2 Control power circuit fus...

Page 26: ...e using thermal protection thermostats accessory The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause INFO Connect the trigger unit INT69 G in accordance with the circuit dia gram Protect the trigger unit with a delayed action fuse FC2 of max 4 A In order to guarantee the protection function install the trigger unit as the first element in the contro...

Page 27: ...n 11 14 Relay position INT69 G B2 12 14 11 Fig 25 5 9 Oil sump heater In order to avoid damage to the compressor the compressor is equipped with an oil sump heater as a standard feature Operation The oil sump heater operates when the compressor is at a standstill When the compressor starts up the oil sump heating switches off Connection The oil sump heater must be connected via an auxiliary contac...

Page 28: ...secondary refrigerant system or pressure relief 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 EN 378 2 or a corresponding safety standard without the inclusion of the compressor 6 3 Leak test Carry out the leak test on ...

Page 29: ... 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 test purposes must ...

Page 30: ... shocks reduced capacity of the refrigerating system WARNING Ensure that both shut off valves are open before starting the compressor ATTENTION 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 Suitably adjusted pressure switches according to EN 378 that switch off the compressor before reaching the maximum ...

Page 31: ...and replace if necessary as during blow off extreme con ditions can occur 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 designed or adjusted in accordance w...

Page 32: ...e system is at a standstill ATTENTION 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 filter drier and a sight gl...

Page 33: ...ccessories Only use genuine GEA spare parts 7 5 Lubricants 7 6 Decommissioning Close the shut off valves on the compressor CO2 does not need to be recycled and can therefore be blown off into the environment It is 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...

Page 34: ...YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 50 50 59 3 35 5 170 275 235 22 7 8 28 1 1 8 2 6 2 3 HGX46 280 4 S CO 2 T 73 0 43 1 196 335 240 HGX46 280 4 SH CO 2 T 73 4 43 4 196 335 240 HGX46 310 4 ML CO 2 T 27 20 32 60 66 2 39 8 170 275 235 28 1 1 8 35 1 3 8 HGX46 310 4 S CO 2 T 81 4 48 4 196 335 240 HGX46 310 4 SH CO 2 T 82 0 48 8 196 335 240 HGX46 345 4 ML CO 2 T 30 20 36...

Page 35: ... consumption apply for 50 Hz operation For 60 Hz operation the specifications have to be multiplied by the factor 1 2 The max working current remains unchanged Take account of the max operating current max power consumption for design of fuses supply lines and safety devices Fuse Consumption category AC3 All specifications are based on the average of the voltage range Cutting ring connector for st...

Page 36: ...chrader valve L SW SR Löt Schweissa L SW SR solder welding Kein Anschluss Druckseit No connection discharge 4 5 6 7 4 5 6 7 Der Lieferant muss sicherstellen dass die Ware in einwandfreiem Zustand angeliefert wird Korrosionsschutz Verpackung für sicheren Transport The supplier has to ensure the delivery of parts in proper conditions corrosion prevention packaging for safe transportation Weitergabe ...

Page 37: ...side lockable 7 16 UNF B2 Connection discharge side not lockable 1 8 NPTF D1 Connection oil return from oil separator 1 4 NPTF E Connection oil pressure gauge 1 8 NPTF F Oil drain M22x1 5 J1 Oil sump heater 3 8 NPTF K Sight glass 11 8 18 UNEF L Connection thermal protection thermostat 1 8 NPTF O Connection oil level regulator 11 8 18 UNEF X1 Connection for Schrader valve suction side 7 16 UNF X2 C...

Page 38: ...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 39: ... 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 ...

Page 40: ...one 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 ...