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© Danfoss | Climate Solutions | 2023.12

AQ452526009526en-000401| 21

   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.

Only dry test gases may be used for the leak test, e.g. nitrogen N2 min. 4.6 (= purity 99.996 % or 
higher).

6.4 Evacuation

  First evacuate the 

system

 and then include 

the compressor in the evacuation process.

  Relieve the compressor pressure.
  Open the suction and pressure line shut-off valves.
  Turn on the oil sump heater.
  Evacuate the suction and discharge pressure sides using the vacuum pump.
  The vacuum has to be broken with nitrogen several times between the evacuation.
  At the end of the evacuation process, the vacuum should be < 1.5 mbar when the pump is switched off.

  Repeat this process as often as is required.

  Make sure that the suction and pressure line shut-off valves are open.

6.5  Refrigerant charge

 

Filling the liquid refrigerant: It is recommended 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 according to 

system. 

    To eliminate the possibility 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. 

ATTENTION

Do not start the compressor if it is under vacuum. Do not apply 
any voltage - even 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.

CAUTION

Wear personal protective clothing such as goggles and protective 
gloves!

WARNING

Never exceed the max. permissible pressures while charging. 
Precautions must be taken in time.

INFO

Depending upon design of the CO

2

  refrigerant  filling  bottle 

(with/without tubing) CO

2

  can  be  filled  in  liquid  after  weight  or 

 

gaseously.

Use only high-dried CO

2

 quality 

(see chapter 3.1)!

6

|

 Commissioning

Summary of Contents for BOCK HGX24 CO2 T

Page 1: ...S CO2 T HGX24 90 4 SH CO2 T HGX24 110 4 ML CO2 T HGX24 90 4 S CO2 T HGX24 110 4 SH CO2 T HGX24 110 4 S CO2 T HGX24 55 MLP 6 CO2 T HGX24 55 SP 7 CO2 T HGX24 55 SHP 7 CO2 T HGX24 70 MLP 7 CO2 T HGX24 70...

Page 2: ...afety instructions 1 2 Qualifications required of personnel 1 3 Safety instructions 1 4 Intended use 2 Product description 6 2 1 Short description 2 2 Name plate 2 3 Type key 2 4 Type key compressors...

Page 3: ...lectronic trigger unit INT69 G 5 7 Oil sump heater 5 8 Selection and operation of compressors with frequency converters 6 Commissioning 20 6 1 Preparations for start up 6 2 Pressure strength test 6 3...

Page 4: ...damage INFO Important information or tips on simplifying work 1 Safety 1 2 Qualifications required of personnel WARNING Inadequately qualified personnel poses the risk of accidents the consequence be...

Page 5: ...lar 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...

Page 6: ...ture 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...

Page 7: ...y 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...

Page 8: ...il charge MLP Normal cooling and deep freezing at low and medium evaporation temperatures SP For frequency regulation and extended limits of application SHP For high evaporating temperatures eg heat p...

Page 9: ...min steady state condition continuous operation must be achieved Avoid continuous operation in limit range 3 3 Limits of application ATTENTION Property damage possible The oil level must be in the vis...

Page 10: ...e or frame with sufficient load bearing capacity Single compressor preferably on vibration damper Compound connection basically rigid Provide adequate clearance for maintenance work Ensure adequate co...

Page 11: ...onnecting the pipelines cutting ring system Fig 6 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 a...

Page 12: ...necting to the refrigerant system 4 5 Pipes 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 pip...

Page 13: ...ty 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 compressor is...

Page 14: ...Spindle Spindle Connection open Compressor Compressor Service connec tion closed Service connec tion opened 4 Compressor assembly To ensure the oil return function will work reliably no matter what ki...

Page 15: ...r supply Only connect the motor if these values are the same DANGER Risk of electric shock High voltage Only carry out work when the electrical system is disconnected from the power supply ATTENTION W...

Page 16: ...FC1 1 I I I 1 2 QA2 3 4 5 6 EC1 3 M 5 3 Circuit diagramm for direct start 230 V 400 V Y Fig 14 Compressor terminal box BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC...

Page 17: ...3 12 AQ452526009526en 000401 17 BP1 P QA2 BP2 P L1 1 L2 1 L3 1 L1 2 N PE BT3 BT2 BT2 EB1 QA1 Main switch SF1 Control voltage switch EC1 Compressor motor QA2 Compressor contactor INT69 G Electronic tri...

Page 18: ...s 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...

Page 19: ...must also be observed 1 The maximum permissible operating current of the compressor I max see type plate or technical data must not be exceeded 2 If abnormal vibrations occur in the system the affect...

Page 20: ...ank a 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 subj...

Page 21: ...quid refrigerant It is recommended 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 liqui...

Page 22: ...lves 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 Suit...

Page 23: ...lve activates repeatedly check valve 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 activ...

Page 24: ...pecially for heat pump applications Otherwise there is a risk of back condensation which can cause compressor damage ATTENTION Slugging can result in damage to the compressor and cause refrigerant to...

Page 25: ...off valve etc and remove the compressor using an appro priate hoist Dispose of the oil inside in accordance with the applicable national regulations When decommissioning the compressor eg for service...

Page 26: ...20 V Y 3 50 Hz 265 290 V 440 480 V Y 3 60 Hz 15 4 8 9 5 1 111 64 30 70 112 19 3 4 22 7 8 1 5 1 3 55 4 ML CO 2 T 4 6 5 5 19 5 11 3 8 3 111 64 112 55 4 S CO 2 T 24 8 14 3 9 9 169 98 116 55 4 SH CO 2 T 2...

Page 27: ...y 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 consu...

Page 28: ...6 CO 2 T 4 4 8 5 7 220 240 V 380 420 V Y 3 50 Hz 265 290 V 440 480 V Y 3 60 Hz 19 5 11 3 6 8 111 64 30 70 112 19 3 4 22 7 8 1 5 1 3 55 SP 7 CO 2 T 24 8 14 3 8 2 169 98 116 55 SHP 7 CO 2 T 24 9 14 4 8...

Page 29: ...y 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 consu...

Page 30: ...Verdichter HG Semi hermetic compressor HG SV DV A A1 B B1 D1 E F I J J1 K L O Q SI1 SI2 X1 X2 nd Sub Ma e und Anschl sse f r UL HGX24 CO2 T Version mit Absperrventilen und UL HGX24e CO2 LT dimensions...

Page 31: ...om oil separator 1 4 NPTF E Connection oil pressure gauge 1 8 NPTF F Oil drain M12x1 5 I Connection hot gas temperature sensor 1 8 NPTF J1 Oil sump heater 3 8 NPTF K Sight glass 1 1 8 18 UNEF L Connec...

Page 32: ...TK FK X 50 980 K N TK Serial number BC00000A001 BN99999Z999 complies with the following provisions of the above mentioned Directive According to Annex I points 1 1 2 1 1 3 1 1 5 1 3 2 1 3 3 1 3 7 1 5...

Page 33: ...N TK FK X 50 980 K N TK Serial number BC00000A001 BN99999Z999 complies with the following provisions of the above mentioned Statutory instrument According to Schedule 2 part1 points 1 1 2 1 1 3 1 1 5...

Page 34: ...34 AQ452526009526en 000401 Danfoss Climate Solutions 2023 12...

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