GEA HGX34e/255-4 S CO2, Assembly Instructions Manual

Page 1: ...2e 105 4 S CO2 HGX22e 130 4 S CO2 HGX34e 145 4 S CO2 HGX34e 170 4 S CO2 HGX34e 210 4 S CO2 HGX34e 255 4 S CO2 Assembly instructions 96422 07 2018 Gb Translation of the original instructions GEA Bock HGX22e S CO2 HGX34e S CO2 ...

Page 2: ...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 GEA Bock GmbH 72636 Frickenhausen GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Phone 49 7022 9454 0 Fax 49 7022 9454 137 info gea com www gea com Manufactur...

Page 3: ...12 5 1 Information for contactor 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 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 accessories 6 Commissioning 18 6 1 Preparations for start up 6 2 Pressure stren...

Page 4: ...ning 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 ...

Page 5: ...stallations are designed or adjusted in accordance with EN 378 2 or appropriate safety standards These assembly instructions describe the standard version of the compressor named in the title manufactured by GEA GEA refrigerating compressors are intended for installation in a machine within the EU according to the EU Directives 2006 42 EC Machinery Directive 2014 68 EU Pressure Equipment Directive...

Page 6: ...latively low temperature level Oil pump independent of direction of rotation for reliable and safe oil supply One pressure relief valve each on the low and high pressure side which vent into the atmosphere when these inadmissibly high printing pressures are reached 2 Product description Name plate 2 1 Short description Oil sight glass Cylinder cover Discharge shut off valve Oil pump Suction shut o...

Page 7: ...sure g High pressure side 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 Fig 3 2 2 Name plate example Observe the limits of application diagrams Electrical accessories can change the IP protection class HG 4 3 e 255 4 CO2 X S 2 3 T...

Page 8: ... 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 oil temperature 30 C Min pressure gas temperature 50 C Max permissible switching frequency 8x h A minimum running time of 3 min steady state condition continuous ope...

Page 9: ...nsation Do not store in a corrosive dusty vaporous atmosphere or in a com bustible environment Sun protection If the compressor is set up outdoors it has to be protected from direct sunlight 4 3 Pipe connections ATTENTION Damage possible Superheating can damage the valve Remove the pipe supports therefore from the valve for soldering and accordingly cool the valve body during and after soldering O...

Page 10: ... standart millimetre and inch dimensions can be used The connection diameters of the shut off valves are rated for maximum compressor output The actual required pipe cross section must be matched to the output The same applies for non return valves Fig 6 graduated internal diameter 4 5 Laying suction and pressure lines A rule of thumb Always lay the first pipe section starting from the shut off va...

Page 11: ... lockable service connections Fig 10 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 11 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened Connection blocked Spindle Spindle Connection open Compressor Compressor Service con...

Page 12: ...ust 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 operating current see name plate For motor protection use a current independent time delayed overload protection device for monit...

Page 13: ...2 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 5 2 Connection of the driving motor The compressor is designed with a motor for star delta circuits Star delta start up is only possible on 230 V voltage supply Example 5 Electrical connection INFO The con...

Page 14: ...7 6 5 4 3 2 1 FC1 1 I I I 1 2 QA2 3 4 5 6 EC1 3 M Θ 5 3 Circuit diagramm for direct start 230 V 400 V Y Fig 12 BP2 High pressure safety controller BP3 Safety chain high low pressure monitoring BT2 Thermal protection thermostat PTC sensor BT3 Release switch thermostat pressostat EB1 Oil sump heater EC1 Compressor motor Compressor terminal box ...

Page 15: ...bFEI BP1 P QA2 BP2 P L1 1 L2 1 L3 1 L1 2 N PE BT3 BT2 Θ BT2 Θ EB1 FC1 1 Motor protection switch FC2 Control power circuit fuse INT69 G Electronic trigger unit INT69 G QA1 Main switch QA2 Mains contactor SF1 Control voltage switch ...

Page 16: ... 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 17: ...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 14 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 check using a continuity tester or gauge 5 Electrical connecti...

Page 18: ...stats are mandatory on the installation side 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 permissibl...

Page 19: ...g 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 Avoid overfilling the machine with refrigerant Do not charge liquid refrigerant into the suction side on the compressor Do not mix additives ...

Page 20: ...act effects If this is the case check the oil return 6 6 Start up 6 7 Decompression valves ATTENTION The compressor is fitted with two decompression valves One valve each on the suction and discharge side If excessive pressures are reached the valves open and prevent further pressure increase Thereby CO2 is blown off to the ambient In the event that a pressure relief valve activates repeatedly che...

Page 21: ...emperature is 30 C The system must reach a state of equilibrium Particularly in critical systems e g several evaporator points measures are recommended such as replacement of liquid traps solenoid valve in the liquid line etc There should be no movement of coolant whatsoever while the compressor is at a standstill 6 10 Connection of oil level regulator The connection O is provided for installing a...

Page 22: ... restart Relieve compressor of system pressure Prevent air from infiltrating the system After maintenance has been performed Connect safety switch Evacuate compressor Release switch on lock 7 2 Work to be carried out In order to guarantee optimum operational reliability and service life of the compressor we recommend carrying out servicing and inspection work at regular intervals Oil change not ma...

Page 23: ...ast 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 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 compress...

Page 24: ... 64 83 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 4 3 All specifications are based on the average of the voltage range For solder connections Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request These are preliminary values and can differ from the actual values The specifications for max power consumption apply for 5...

Page 25: ...O 2 22 3 26 8 44 8 25 9 15 8 178 103 105 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 4 3 All specifications are based on the average of the voltage range For solder connections Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request These are preliminary values and can differ from the actual values The specifications for...

Page 26: ... Gewicht Weight kg Zeichnungs Nr Indication of surface texture Oberflächenbehandlung Härte Treatment of surface Hardness Scale MC HGX22e 130 4 S CO2 Rz 25 Rz 160 25 0 05 Rz 1 6 0 3 0 7 1 6 2 Rz 16 6 3 Rz 63 Rz 6 3 Rz 12 5 Status in Bearbeitung CAD Nein No 2 MK HGX22e 130 4 S CO2 1 Maß Oberflächenangaben Teile Nr Layh Maße in mm Dimensions in mm Änderungen vorbehalten Subject to change without noti...

Page 27: ... reserved in the event Änd Nr Mod No Geprüft Appr 30 104 9 0 3 120 30 0 2 of the grant of a patent utility Zust Rev Gußtoleranzen General casting tolera Gewicht Weight kg 6 Nein No Weitergabe sowie Vervielfältigung dieses Dokuments Verwertung und Mitteilung seines Inhalts sind ver boten soweit nicht ausdrücklich gestattet Zuwider handlungen verpflichten zu Schadenersatz Alle Rechte für den Fall de...

Page 28: ...ndards 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 ...

Page 29: ... 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 11 Service ...

Page 30: ...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 ...