GEA HGX12e S CO2 Assembly Instructions Manual Download Page 1

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96282-10.2013-DGbFEI

engineering for a better world

GEA Refrigeration Technologies

Bock Compressor HGX12e S CO

Assembly instructions

HGX12e/20-4 S CO

HGX12e/30-4 S CO

HGX12e/40-4 S CO

HGX12e/50-4 S CO

HGX12e/60-4 S CO

HGX12e/75-4 S CO

Summary of Contents for HGX12e S CO2

Page 1: ...DGbFEI engineering for a better world GEA Refrigeration Technologies Bock Compressor HGX12e S CO2 Assembly instructions HGX12e 20 4 S CO2 HGX12e 30 4 S CO2 HGX12e 40 4 S CO2 HGX12e 50 4 S CO2 HGX12e 60 4 S CO2 HGX12e 75 4 S CO2 ...

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: ... 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 accessories 6 Commissioning 18 6 1 Preparations for start up 6 2 Pressure strength test 6 3 Leak test 6 4 Evacuation ...

Page 4: ...age INFO Important information or tips on simplifying work WARNING Inadequately qualified personnel poses the risk of accidents the consequence being serious or fatal injury Work on compressors is therefore reserved for personnel which is qualified to work on pressurized refrigerant systems For example a refrigeration technician refrigeration mechatronic engineer As well as professions with compar...

Page 5: ...e with the limits of application Only the refrigerant specified in these instructions may be used Any other use of the compressor is prohibited 1 4 Intended use 1 3 Safety instructions WARNING Risk of accidents Refrigerating compressors are pressurised machines and as such call for heightened caution and care in handling The maximum permissible overpressure must not be exceeded even for testing pu...

Page 6: ...oil pump lubrication Suction gas cooled drive motor Name plate Fig 1 2 1 Short description Fig 2 Oil sight glass Valve plate Cylinder cover 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 ...

Page 7: ...uit 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 2 2 Name plate example Fig 3 1 2 3 4 5 7 6 10 8 9 13 12 11 HG 2 1 e 75 4 CO2 X 2 3 Type key example HG Hermetic Gas Cooled suction gas cooled X Ester oi...

Page 8: ...t of the sight glass damage to the com pressor is possible if over filled or underfilled ATTENTION Compressor operation is possible within the operating limits shown in the diagrams Please note the significance of the shaded areas Thresholds should not be selected as design or continuous operation points Max permissible discharge end temperature 160 C Max permissible switching frequency 12x h A mi...

Page 9: ...ection must be matched to the output The same applies for non return valves Fig 10 graduated internal diameter 4 2 Pipe connections 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 ng 400 Benennung 0 8 1000 Zeichn Nr Teile Nr x xxxx xxxxx x Maßstab 1 1 Wasserwaage für Indesign INF...

Page 10: ...ators 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 A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft ATTENTION Improperly installed pipes can cause cracks and tears the result being a loss of refrigerant INFO Proper lay...

Page 11: ...y opened service connection closed Fig 15 Opening the service connection Spindle Turn 1 turn clockwise Service connection opened shut off valve opened Connection blocked Spindle Spindle Connection open Compressor Compressor Service connection closed Service connection opened 4 5 Operating the shut off valves Before opening or closing the shut off valve release the valve spindle seal by approx of a...

Page 12: ...oring of all three phases not set higher than the rated current of the machine which must respond at 1 2 times the set current within 2 hours and must not have responded at 1 05 times the set current within 2 hours or another comparable device INFO Connect the compressor motor in accordance with the circuit diagram see inside of terminal box Use suitable cable entry point of the correct protection...

Page 13: ...her 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 5 Electrical connection INFO The con...

Page 14: ...V Y Fig 16 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: ... red is provided for the protection function The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause 5 5 Connection of the trigger unit MP 10 ATTENTION Terminals 1 6 on the trigger unit MP 10 and terminals PTC 1 and PTC 2 on the compres sor terminal board must not come into contact with mains voltage This would destroy the trigger unit and PTC sensors T...

Page 17: ...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 Function ...

Page 18: ... transport damage INFO Toprotectthecompressoragainstinadmissibleoperatingconditions high pressure and low pressure pressostats are mandatory on the installation side 6 2 Pressure strength test 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...

Page 19: ...quid 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 A refrigerant supplement which may become necessary after start up can be topped up in vapour form on the suction s...

Page 20: ...ped up there is a risk of oil hammer effects If this is the case check the oil return 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 see also Chapter 7 6 In the event that a pressure relief valve activate...

Page 21: ...ting of the expansion valve 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 ATTENTION Slugging can damage the compressor and cause refrigerant to leak ...

Page 22: ...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 function of auxiliary devices such as oil sump heater pressure switch...

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: ... 43 25 50 HGX12e 60 4 S CO 2 5 4 6 5 13 3 7 7 3 9 69 40 54 HGX12e 75 4 S CO 2 6 4 7 7 15 7 9 0 4 7 69 40 54 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 t...

Page 25: ... gauge F Ölablass mm M8 Oil drain H Stopfen Ölfüllung Zoll inch 1 4 NPTF Oil charge plug J Anschluss Ölsumpfheizung mm 15 Connection oil sump heater K Schauglas Zoll inch 1 1 8 18 UNEF Sight glass L Anschluss Wärmeschutzthermostat Zoll inch 1 8 NPTF Connection thermal protection thermostat O Anschluss Ölspiegelregulator Zoll inch 1 1 8 18 UNEF Connection oil level regulator SI1 Druckentlastungsven...

Page 26: ...ssor HGX12e CO2 complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006 42 EC Applied harmonised standard EN 12693 2008 and the corresponding standards 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 Machiner...

Page 27: ...chnet WARNUNG Dieses Symbol weist darau dass ungenaues Befolgen oder Nichtb von Anweisungen zu Schäden an Perso am Verdichter oder an der Kälteanlage kann GEFAHR Dieses Symbol weist auf Anw gen hin um unmittelbare schwere Gefä gen von Personen zu vermeiden GEFAHR Dieses Symbol weist auf Anw gen hin um unmittelbare schwere Gefä dungen von Personen oder Anlagen du elektrischen Strom zu vermeiden Die...

Page 28: ...54 0 Fax 49 7022 9454 137 bock gea com www bock de 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 ...

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