GEA HGX12P CO2, Assembly Instructions Manual

Page 1: ...D GB F E 1 09917 11 2015 DGbFEI engineering for a better world GEA Compressor HGX12P CO2 Assembly instructions HGX12P 30 4 CO2 HGX12P 40 4 CO2 HGX12P 50 4 CO2 HGX12P 75 4 CO2 ...

Page 2: ...ese 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 refrigeration gea com www gea com Manufacturer Contact 1 Safety 4 1 1 Identification of safety instructions 1 2 Qualifications required of personnel 1 3 ...

Page 3: ...ctronic trigger unit MP10 5 6 Functional test of the electronic trigger unit MP10 5 7 Circuit diagram for direct start 230 V Δ 400 V Y with INT69 G 5 8 Electronic trigger unit INT69 G 5 9 Connection of the electronic trigger unit INT69 G 5 10 Functional test of the electronic trigger unit INT69 G 5 11 Oil sump heater accessories 6 Commissioning 22 6 1 Preparations for start up 6 2 Pressure strengt...

Page 4: ...e of assessing thework to be carried out and recognising any potential dangers WARNING Refrigerating compressors are pressurised machines and therefore require particular caution and care in handling 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 The maximum permissible overpressure must not...

Page 5: ...ntended use WARNING The compressor may not be used in potentially explosive environments The GEA refrigerating compressor named in the title is intended for installing in a machine within the EU according to the EU Directives 2006 42 EC Machinery Directive 97 23 EC Pressure Equipment Directive and 2006 95 EC Low Voltage Directive Commissioning is only permissible if the compressor has been install...

Page 6: ...t off valve Oil pump Terminal box Suction shut off valve Drive section Motor section Dimension and connection values can be found in Chapter 9 Transport eyelet 2 Product description Semi hermetic two cylinder reciprocating compressor with oil pump lubrication Suction gas cooled drive motor 2 1 Short description ...

Page 7: ...pe designation 6 Voltage circuit frequency 2 Machine number 7 Nominal rotation speed 3 maximum operating current 8 Displacement 4 Starting current rotor blocked 9 Voltage circuit frequency 5 ND LP max permissible operating 10 Nominal rotation speed pressure g Low pressure side 11 Displacement HD HP max permissible operating 12 Oil type filled at the factory pressure g High pressure side 13 Termina...

Page 8: ...own 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 140 C Max permissible switching frequency 8x h A minimum running time of 3 min steady state condition continuous operation must be achieved For operation with frequency con...

Page 9: ...se transport eyelet Do not lift manually Use lifting gear Storage at 30 C 70 C maximum permissible relative humidity 10 95 no condensation Do not store in a corrosive dusty vaporous atmosphere or in a com bustible environment Fig 7 Fig 6 ATTENTION Attachments e g pipe holders additional units fastening parts etc directly to the compressor are not permissible 4 2 Setting up Setup on an even surface...

Page 10: ... assembly 4 4 Pipes Pipes and system components must be clean and dry inside and free of scale swarf and layers of rust and phosphate Only use air tight 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 The pipe connections have graduated in...

Page 11: ... lockable service connections Fig 15 Opening the shut off valve Spindle turn to the left counter clockwise as far as it will go Shut off valve completely opened service connection closed Fig 16 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened Service connec tion closed Connection blocked Spindle Service connec tion opened Spi...

Page 12: ...l safety regulations and established specifications e g VDE as well as with the manufacturer s infor mation Motor protection switches are required Motor contactors feed lines fuses and motor protection switches must be rated on the basis of the maximum working current see name plate For motor protection use a current dependent and time delayed overload protection device for moni toring all three p...

Page 13: ...ect start only Elektrischer Anschluss Electrical connection Raccordement 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 Electrical connection Raccordement 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 L2 L3 INFO The con...

Page 14: ... thermostat PTC sensor FC1 Load circuit safety switches FC2 Control power circuit fuse BP1 Safety chain high low pressure monitoring BP2 Release switch thermostat pressostat 0 1 2 3 4 Klemmenkasten Verdichter MP10 BT1 QA1 FC1 I I I QA2 PE FC1 A1 X1 L1 L1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 FC2 SF1 BT2 A2 BP1 P PE EC1 3 M Θ L1 L2 L3 N PE Compressor terminal box Fig 17 ...

Page 15: ...r motor QA2 Compressor contactor MP10 Electronic trigger unit MP10 EB1 Oil sump heater 5 6 7 8 9 A1 Alarm Motorschutz A2 Übertemperatur BT1 BT2 A3 Alarm Hochdruck A3 BP2 P PE QA2 1 2 EB1 QA2 3 4 L1 1 L2 1 L3 1 L1 2 N PE A1 Alarm motor protection A2 Overheating BT1 BT2 A3 Alarm high pressure ...

Page 16: ...ignalled by the H3 LED green after the power supply is applied In the case of excess temperature in the motor winding the unit switches off the compressor and the H1 LED lights red The hot gas side of the compressor can also be protected against overtemperature using a thermal protection thermostat accessory The H2 LED red is provided for the protection function The unit trips when an overload or ...

Page 17: ...nnection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or SF1 ON Function check of motor temperature sensor operational ON Function check of hot gas temperature sensor operational ON 3 Interrupt power supply again L1 or SF1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or SF1 OFF OFF ON MP 10 is operational agai...

Page 18: ... L1 L2 L3 N PE 5 7 Circuit diagramm for direct start 230 V 400 V Y compressor with INT69 G Fig 19 BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor FC1 Load circuit safety switches FC2 Control power circuit fuse BP1 Safety chain high low pressure monitoring BP2 Release switch thermostat pressostat Compressor terminal box ...

Page 19: ... A3 Alarm Hochdruck A3 BP2 P PE QA2 1 2 EB1 QA2 3 4 L1 L2 L3 L1 1 N PE QA1 Main switch SF1 Control voltage switch EC1 Compressor motor QA2 Compressor contactor INT69 G Electronic trigger unit INT69 G EB1 Oil sump heater A1 Alarm motor protection A2 Overheating BT1 BT2 A3 Alarm high pressure ...

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 ...

Page 21: ...z 50 120 W PTC heater adjusting ATTENTION The oil sump heater must generally be connected and operated Relay position INT69 G B2 12 14 11 Fig 21 5 10 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 check using a continuity tester or gauge 5 Electrical connect...

Page 22: ...n for test purposes must only be operated with refrigerant Under vacuum the spark over and creepage current distances of the terminal board connection bolts shorten this can result in winding and terminal board damage DANGER Risk of bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximum permissible overpressure of the compressor m...

Page 23: ...ing bottle with without tubing CO2 can be filled in liquid after weight or gaseously Use only high dried CO2 quality ATTENTION Avoid overfilling the machine with refrigerant Do not charge liquid refrigerant into the suction side on the compressor Do not mix additives with the oil and refrigerant WARNING Never exceed the max permissible pressures while charging Precautions must be taken in time eg ...

Page 24: ...d in accordance with EN 378 2 or appro priate safety standards Failure to observe can result in risk of injury from CO2 streaming out of the two decompression valves 6 7 Decompression valves 6 6 Start up WARNING Ensure that both shut off valves are open before starting the compressor Check that the safety and protection devices pressure switch motor protection electrical contact protection measure...

Page 25: ...erly designed All components must be compatibly rated with each other with regard to output particularly the evaporator and expansion valves Suction gas superheating at the compressor input should be min 15 20 K check the setting of the expansion valve The system must reach a state of equilibrium Particularly in critical systems e g several evaporator points measures such as the use of liquid trap...

Page 26: ...ose of used oil according to the regulations observe national regulations Annual checks Oil level leak tightness running noises pressures temperatures function of auxiliary devices such as oil sump heater pressure switch 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...

Page 27: ...he piping on the pressure and suction side e g dismantling of the shut off valve etc and remove the compressor using an appropriate hoist Dispose of the oil inside in accordance with the applicable national regulations When decommissioning the compressor eg for service or replacement of the compressor larger amounts of CO2 in the oil can be set free If the decompression of the compressor is not su...

Page 28: ... 5 4 6 4 9 5 5 5 3 2 45 26 49 HGX12P 75 4 CO 2 6 7 8 1 10 6 6 1 3 6 45 26 49 1 2 3 2 4 220 240 V 380 420 V Y 3 50 Hz 265 290 V 440 480 V Y 3 60 Hz 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...

Page 29: ...gestellten Der Lieferant muß sichers einwandfreiem Zustand an Maße in mm 1 SV 90 drehbar 1 08 Massenschwerpunkt 1 SV J A1 208 318 ca 415 66 ca 30 Schwingungsdämpfer M8 30 30 SI1 B O K E H D1 F DV L1 B1 98 ca 280 192 162 244 4x 10 ca 240 SI2 A ca 135 ca 115 100 schutz Verpackung für si 4 3 5 6 7 3 4 5 6 7 Abnehmer oder Dritte ist n Numéro Tol Ang DIN ISO 2768 mK Revisionsdurchlauf Ra Rz Maß Passung...

Page 30: ...dards referenced 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 T...

Page 31: ...tions 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 refrigeration gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 11 Service ...

Page 32: ...4 137 refrigeration gea com www gea com We live our values Excellence Passion Integrity Responsibility GEA versity 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 ...