GEA HGX22P CO2 Series, Assembly Instructions Manual

Page 1: ... 2012 DGbFEI engineering for a better world GEA Refrigeration Technologies Bock Compressor HGX22P CO2 Assembly instructions HGX22P 110 4 CO2 HGX22P 125 4 CO2 HGX22P 160 4 CO2 HGX22P 190 4 CO2 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 2: ... 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 GEA Bock GmbH 72636 Frickenhausen GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 bock gea com www bock de Manufact...

Page 3: ...ntactor and motor contactor selection 5 2 Connection of the driving motor 5 3 Circuit diagram for direct start 230 V Δ 400 V Y 5 4 Electronic trigger unit MP 10 5 5 Connection of the electronic trigger unit MP 10 5 6 Functional test of the electronic trigger unit MP 10 5 7 Oil sump heater 6 Commissioning 18 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak test 6 4 Evacuation 6 5 R...

Page 4: ...ed 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 be exceeded even for testing purposes 1 1 Identification of safety instructions DANGER Indicates a dangerous situation which ...

Page 5: ...ntended use WARNING The compressor may not be used in potentially explosive environments The Bock 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 instal...

Page 6: ...r Discharge shut 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: ...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 Terminal box protection type Observe the limits of application Electrical accessories can change diagrams the IP protection class 50 Hz 60 Hz HG 2 2 P 125 4 CO2 X CO2 Version Num...

Page 8: ...operation must be achieved For operation with frequency converter The maximum current and power consumption must not be exceeded In the case of operation above the mains frequency the application limit can therefore be limited The compressors are filled at the factory with the following oil type Bock C 85 E only this oil may be used 3 1 Refrigerants CO2 R744 3 2 Oil charge 3 3 Limits of applicatio...

Page 9: ...required pipe cross section must be matched to the output The same applies for non return valves Fig 9 graduated internal diameter F E D C B 1 2 3 Alternativbezug Baumustergeprüft Lieferantenzeichnung Entwicklungsstand Bearb Datum Änderungs Nr Werkstoff Ausgangsteil bzw Rohteil Gepr Zone 1 x Blatt ung 400 Benennung 0 8 1000 Zeichn Nr Teile Nr x xxxx xxxxx x Maßstab 1 1 Wasserwaage für Indesign INF...

Page 10: ...e of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft 4 Compressor assembly 4 3 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 broke...

Page 11: ...ng the shut off valves Pipe connection Pipe connection 4 6 Operating mode of the lockable service connections Fig 13 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 14 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened Serv...

Page 12: ...mpare the voltage and frequency values with the data for the mains power supply Only connect the motor if these values are the same 5 1 Information for contactor and motor contactor selection All protection equipment switching and monitoring devices must comply with the local safety regula tions and established specifications e g VDE and regulations as well as the manufacturer s specifica tions Mo...

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: ...V Y Fig 15 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 Load circuit safety switches F2 Control power circuit fuse F3 Safety chain high low pressure monitoring B1 Release switch thermostat pressostat Q1 Main switch Compressor terminal box ...

Page 15: ...K1 Compressor contactor MP10 Electronic trigger unit MP 10 E Oil sump heater X3 Terminal strip in terminal box XSS Terminal strip in the external switch cabinet A1 Alarm motor protection A2 Overheating R1 R2 A3 Alarm high pressure XSS Terminal strip in the external switch cabinet ...

Page 16: ...signalled 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: ...re operational when the H3 LED green lights 5 6 Function test of the trigger unit MP 10 Pos Procedure LED H1 LED H2 LED H3 red red green 1 Interrupt power supply L1 or S1 OFF OFF OFF Release the motor temperature sensor connection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or S1 ON Function check of motor temperature sensor operational ON Functi...

Page 18: ...r other technical gases The maximum permissible overpressure of the compressor must not be exceeded at any time during the testing process see name plate data The compressor has been factory tested for pressure resistance The following must be observed if the entire plant is subjected to an additional pressure strength test Test the refrigeration circuit according to EN 378 2 or a corresponding sa...

Page 19: ...e Filling the liquid refrigerant It is recommend that the system first be filled at standstill with gas on the high pressure side up to a system pressure of at least 5 2 bar if it is filled below 5 2 bar with liquid there is a risk of dry ice formation Further filling by system To eliminate the possibility of dry ice formation when the system is operating during and after the filling process the s...

Page 20: ... 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 measures...

Page 21: ...roperly 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 t...

Page 22: ...l change not mandatory for factory produced series systems for field installations or when operating near the application limit for the first time after 100 to 200 operating hours then approx every 3 years or 10 000 12 000 operating hours Dispose of used oil according to the regulations observe national regulations Annual checks Oil level leak tightness running noises pressures temperatures functi...

Page 23: ...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 24: ... 8 8 121 70 82 HGX22P 190 4 CO 2 16 5 19 8 29 9 17 3 9 9 134 77 84 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 2 The max...

Page 25: ...aßte Radien Änderungs Nr Gepr Zone Änderungsbeschreibung 400 Benenn 0 8 30 0 3 120 30 Zeichn 6 1 08 Zust Gußtoleranzen 1000 0 2 Oberflä R s 25 Diese Ze Sie darf oh gebildet ve gänglich ge dieser Zeic Zeichnung Der Lieferan einwandfreie SV A1 H D1 109 ca 505 361 223 ca 20 ca 135 ca 135 E DV F O K L1 J B1 88 264 115 198 ca 250 4x 12 ca 310 B SI1 SI2 A Schwingungsdämpfer 30 40 M10 Massenschwerpunkt 1...

Page 26: ...CO2 complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006 42 EC The following harmonised standards have been applied EN ISO 12100 1 EN ISO 12100 2 EN 12693 EN 349 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 Machin...

Page 27: ...e sich bitte an unsere Anwendungstechnik oder an Kältefachgroßhandel bzw unsere Vertretung Das Bock Serviceteam erreichen Sie direkt un 49 7022 9454 0 via e mail mail bock de oder im Internet www bock de Für den deuts chigen Raum steht darüber hinaus die kostenlose Bock Hotline 00 800 800 000 88 von mo bis samstags zwischen 8 und 21 Uhr zur Verfügung Für Anregungen zur Weiterentwicklung Verdichter...

Page 28: ... 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 96019 05 2012 DGbFEI GEA Group AG All rights reserved GEA Refrigeration Technologies GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 bock gea com www bock de ...