GEA HGX34/110-4 ML CO2 T Assembly Instructions Manual Download

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D
GB
F
E

96459-08.2018-DGb

Contents

Page

Areas of application

3.1 Refrigerants

3.2 Oil charge

3.3 Limits of application

Compressor assembly

4.1 Storage and transportation

4.2 Setting up

4.3 Connecting the pipelines - solder system

4.4 Connecting the pipelines - cutting ring system

4.5 Pipes

4.6 Flange shut-off valves (HP/LP)

4.7 Laying suction and pressure lines

4.8 Operating the shut-off valves

4.9 Operating mode of the lockable service connections

4.10 Oil return

4.11 Suction pipe filter

Electrical connection

5.1 Information for contactor and motor contactor selection

5.2 Standard motor, designed for direct or part winding start

5.3 Basic circuit diagram for part winding start

5.4 Special motor: design for direct or star-delta start

5.5 Basic circuit diagram for star-delta start with special motor

5.6 Electronic trigger unit INT69 G

5.7 Connection of the electronic trigger unit INT69 G

5.8 Functional test of the electronic trigger unit INT69 G

5.9 Oil sump heater

6 Commissioning

6.1 Preparations for start-up

6.2 Pressure strength test

6.3 Leak test

6.4 Evacuation

6.5 Refrigerant charge

6.6 Start-up

6.7 Pressure switch

6.8 Decompression valves

6.9 Avoiding slugging

6.10 Filter dryer

7 Maintenance

7.1 Preparation

7.2 Work to be carried out

7.3 Accessories

7.4 Spare parts recommendation

7.5 Lubricants

7.6 Decommissioning

Technical data

Dimensions and connections

10 Declaration of installation

11 Service

Summary of Contents for HGX34/110-4 ML CO2 T

Page 1: ... ML CO2 T HGX34 170 4 S CO2 T HGX34 170 4 SH CO2 T HGX34 190 4 ML CO2 T HGX34 190 4 S CO2 T HGX34 190 4 SH CO2 T HGX34 210 4 ML CO2 T HGX34 210 4 S CO2 T HGX34 210 4 SH CO2 T HGX34 230 4 ML CO2 T HGX34 230 4 S CO2 T HGX34 230 4 SH CO2 T HGX34 290 4 ML CO2 T HGX34 290 4 S CO2 T HGX34 290 4 SH CO2 T GEA Bock HGX34 CO2 T Assembly instructions 96459 08 2018 Gb Translation of the original instructions ...

Page 2: ...ly and before using the compressor This will avoid misunder standings and prevent damage Improper assembly and use 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 Contents Page GEA Bock GmbH 72636 Frickenhausen GEA...

Page 3: ...r part winding start 5 3 Basic circuit diagram for part winding start 5 4 Special motor design for direct or star delta start 5 5 Basic circuit diagram for star delta start with special motor 5 6 Electronic trigger unit INT69 G 5 7 Connection of the electronic trigger unit INT69 G 5 8 Functional test of the electronic trigger unit INT69 G 5 9 Oil sump heater 6 Commissioning 28 6 1 Preparations for...

Page 4: ...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 serious inj...

Page 5: ...overpressure must not be exceeded even for testing purposes 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 Avoid the contact with refrigerant under any circumstances The contact with refrigerant can lead to severe burns and skin irritations Danger of suffocation CO2 is a nonflammable acidic ...

Page 6: ...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 atmos phere when inadmissibly high pressure levels are reached Fig 1 2 1 Short description Fig 2 Oil sight glass Valve plate Cylinder cover Motor section Dimension and connection values can be found in chapter 9 Transport...

Page 7: ... 20 1 24 1 CO2 C 85 E HGX34 230 4 S CO2 T 1 Type designation 2 Machine number 3 Maximum operating current 4 Starting current rotor blocked Y Part winding 1 YY Part winding 1 and 2 5 ND LP max permissible operating pressure g Low pressure side HD HP max permissible operating pressure g High pressure side Observe the limits of application diagrams 50 Hz 60 Hz 6 Voltage circuit frequency 7 Nominal ro...

Page 8: ...missible discharge end temperature 160 C Min discharge end temperature 50 C Min oil temperature 30 C Max permissible switching frequency 12x h A minimum running time of 3 min steady state condition continuous operation must be achieved Avoid continuous operation in limit range For operation with frequency converter Frequency range 20 70 Hz The maximum current and power consumption must not be exce...

Page 9: ... LP HP 1 100 150 bar 1 LP Low pressure HP High pressure Compressor version ML 10 20 30 50 50 40 90 80 120 Einsatzgrenzen HGX34 46 CO2 T 100 70 60 40 po bar pV2 bar 110 130 140 60 0 10 20 30 40 10 to C 20 64 3 70 25 10 20 30 50 50 40 90 80 120 100 70 60 40 po bar pV2 bar 110 130 140 60 0 10 20 30 40 10 to C 20 64 3 70 25 90 120 100 pV2 bar 110 130 140 ML S t 10 K Oh t 10 K Oh t 10 K Oh 3 Areas of a...

Page 10: ...ure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure Compressor version S 10 20 30 50 50 40 40 po bar 60 0 10 20 30 40 10 to C 20 64 3 70 25 10 20 30 50 50 40 90 80 120 100 70 60 40 po bar pV2 bar 110 130 140 60 0 10 20 30 40 10 to C 20 64 3 70 25 10 20 30 50 50 40 90 80 120 100 70 60 40 po bar pV2 bar 110 130 140 60 0 10 20 30 40 10 to C 20 64 3 70 25 S SH t 10 K Oh t 10 K Oh 3 Areas of app...

Page 11: ...ig 7 Max permissible operating pressure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure Compressor version SH Evaporation temperatures 5 C 40 bar on request 10 20 30 50 50 40 40 po bar 60 0 10 20 30 40 10 to C 20 64 3 70 25 10 20 30 50 50 40 90 80 120 100 70 60 40 po bar pV2 bar 110 130 140 60 0 10 20 30 40 10 to C 20 64 3 70 25 SH t 10 K Oh 3 Areas of application ...

Page 12: ...pacity Single compressor preferably on vibration damper Compound connection basically rigid Provide adequate clearance for maintenance work Ensure adequate compressor ventilation Do not use in a corrosive dusty damp atmosphere or a com bustible environment Fig 10 Fig 11 Fig 12 F E D 1 2 3 4 1 Storage and transportation Use transport eyelet Do not lift manually Use lifting gear Storage at 30 C 70 C...

Page 13: ...ines cutting ring system Fig 14 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 and outside For thin walled steel pipes or soft pipes made of nonferrous metal reinforcing sleeves have to be used Pipe assembly Push union nut 5 and cutting ring 3 onto pipe 2 Insert pipe into socket 6 as far as it wil...

Page 14: ... the refrigerant system A B 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 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 Fig 15 Fig 16 4 Comp...

Page 15: ...ten 4 7 Laying suction and pressure lines A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft ATTENTION Property 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 integral to the ...

Page 16: ...Suction pipe filter Pipe connection Pipe connection 4 9 Operating mode of the lockable service connections Fig 20 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 The connection which cannot be shut off is intended for safety devices Fig 21 Opening the service connection Spindle Turn 1 2 1 turn to ...

Page 17: ...s disconnected from the power supply All protection equipment switching and monitoring devices must comply with the local safety reg ulations 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 protec tion switches must be rated according to the maximum operating current see name plat...

Page 18: ...n the terminal box Y YY Compressors marked in this way are suitable for direct or part winding start The motor winding is divided into two parts part winding 1 50 and part winding 2 50 This winding division reduces the start up current during a part winding start to approx 50 of the value for a direct start 5 Electrical connection ...

Page 19: ...perty damage possible Failure to comply results in reversed fields of rotation and can cause motor damage After the motor has started up with part winding 1 part winding 2 must be switched on after max 1 second delay Fail ure to comply can be detrimental to the service life of the motor Ensure that power is supplied via QA2 to winding 1 50 1U1 1V1 1W1 and via QA3 to winding 2 50 2U1 2V1 2W1 The mo...

Page 20: ...igh low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat BT3 Release switch thermostat DELTA PII Oil differential pressure sensor DELTA P II accessory EB1 Oil sump heater EC1 Compressor motor Fig 22 With several connect them in series Οnderung 2 0 Datum Name Datum Bearb Gepr Norm 1 20 02 2009 bauknecht 22 08 2017 Urspr 2 Ers f 3 Ers d 4 Anschlußkast...

Page 21: ...r protection switch FC2 Control power circuit fuse INT69 G Electronic trigger unit INT69 G KF1 Delay relay for contactor switch over QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch PW INT69 HGX34 46 CO2T 5 6 7 BOCK COMPRESSORS 8 9 Bl 6 c Bl 4 3 DELTA P II BP2 P QA2 BP3 P QA2 KF1 KF1 2 8 6 c 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT3 BT2 Θ Θ ...

Page 22: ...22 D GB F E 96459 08 2018 DGb 5 4 Special motor design for direct or star delta start Designation on the name plate Sticker on the terminal box Δ Y 5 Electrical connection ...

Page 23: ... delta start up is only possible for 230 V power supply Example 400 V Y Direct start only L1 L3 L2 PTC 230 V Δ Direct start Star delta start L1 L2 L3 L1 L2 L3 L1 L3 L2 PTC PTC W2 U2 V2 W1 U1 V1 W2 U2 V2 W1 U1 V1 5 Electrical connection ...

Page 24: ... 9 PE 6 5 4 3 PE 2 1 FC1 1 I I I 1 2 QA2 FC1 2 I I I 3 4 5 6 1 2 QA4 Y 3 4 5 6 1 2 QA3 D 3 4 5 6 EC1 M 3 8 7 Οnderung 3 0 Datum Name Datum Bearb Gepr Norm 1 20 02 2009 bauknecht 22 08 2017 Urspr 2 Ers f 3 Ers d 4 Anschlußkasten Verdichter BT1 INT69G QA1 L1 L2 L3 N PE 1U1 1V1 1W1 PE 2U1 2V1 2W1 FC1 1 FC1 2 FC2 SF1 QA2 11 12 14 L N B1 B2 12 11 10 9 PE 6 5 4 3 PE 2 1 FC1 1 I I I 1 2 QA2 FC1 2 I I I 3...

Page 25: ...L1 2 N PE BT3 BT2 Θ Θ vio bn bu gr pk og Θ EB1 QA2 QA2 6 a 7 6 b 7 QA4 KF1 QA4 QA3 6 a 8 6 b 8 KF1 QA3 QA4 6 a 8 6 b 8 KF1 D S INT69 HGX34 46 CO2T 5 6 7 BOCK COMPRESSORS 8 9 Bl 6 c Bl 6 a 4 DELTA P II BP2 P BP3 P L1 1 L2 1 L3 1 L1 2 N PE BT3 BT2 Θ Θ vio bn bu gr pk og Θ EB1 QA2 QA2 6 a 7 6 b 7 QA4 KF1 QA4 QA3 6 a 8 6 b 8 KF1 QA3 QA4 6 a 8 6 b 8 KF1 D S INT69 HGX34 46 CO2T 5 6 7 BOCK COMPRESSORS 8 ...

Page 26: ...e using thermal protection thermostats accessory The unit trips when an overload or inadmissible operating conditions occur Find and remedy the cause INFO Connect the trigger unit INT69 G in accordance with the circuit dia gram Protect the trigger unit with a delayed action fuse FC2 of max 4 A In order to guarantee the protection function install the trigger unit as the first element in the contro...

Page 27: ...n 11 14 Relay position INT69 G B2 12 14 11 Fig 25 5 9 Oil sump heater In order to avoid damage to the compressor the compressor is equipped with an oil sump heater as a standard feature Operation The oil sump heater operates when the compressor is at a standstill When the compressor starts up the oil sump heating switches off Connection The oil sump heater must be connected via an auxiliary contac...

Page 28: ...erant 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 subjected to a pressure integrity test this should be carried out in accordance with EN 378 2 or a corresponding safety standard without the inclusion of the compressor 6 3 Leak test Carry out the leak test on the refrigeratin...

Page 29: ... 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 side ATTENTION Do not start the compressor if it is under vacuum Do not apply any voltage even for test purposes must ...

Page 30: ... shocks reduced capacity of the refrigerating system WARNING Ensure that both shut off valves 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 Suitably adjusted pressure switches according to EN 378 that switch off the compressor before reaching the maximum ...

Page 31: ...tedly 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 activation of pressure relief valve The decompression valves do not replace any pressure switches and the additional safety valves in the system Pressure switches must always be installed in the system and designed or adjust...

Page 32: ... a standstill ATTENTION Slugging can result in damage to the compressor and cause refrigerant to leak 6 10 Filter dryer Gaseous CO2 has a significantly lower solubility in water than other refrigerants At low temperatures it can therefore cause blocking of valves and filters due to ice or hydrate For this reason we recom mend the use of an adequately sized filter drier and a sight glass with a moi...

Page 33: ... 81176 81177 Set oil pump kit 80774 Set oil sump heater 230 V AC 80854 7 5 Lubricants 7 6 Decommissioning Close the shut off valves on the compressor CO2 does not need to be recycled and can therefore be blown off into the environment It is essential to ensure good ventilation or conduct the CO2 into the outdoors to avoid danger of suffocation When releasing CO2 avoid a fast drop in pressure to pr...

Page 34: ...Hz PW PW Part Winding Winding ratio 50 50 24 6 14 4 87 149 196 22 7 8 28 1 1 8 2 3 1 8 HGX34 110 4 S CO 2 T 28 6 17 2 101 174 199 HGX34 110 4 SH CO 2 T 28 6 17 7 101 174 199 HGX34 130 4 ML CO 2 T 11 30 13 60 27 8 16 5 87 149 196 HGX34 130 4 S CO 2 T 32 7 19 7 101 174 199 HGX34 130 4 SH CO 2 T 33 2 20 3 101 174 199 HGX34 150 4 ML CO 2 T 12 90 15 40 31 0 18 7 101 174 199 HGX34 150 4 S CO 2 T 37 8 22...

Page 35: ... the voltage range Cutting ring connector for steel tubes For solder connections 8 Technical data HGX34 190 4 ML CO 2 T 4 16 30 19 50 380 420 V Y YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 50 50 40 2 23 6 125 209 206 22 7 8 28 1 1 8 2 3 1 8 HGX34 190 4 S CO 2 T 47 8 28 1 149 247 208 HGX34 190 4 SH CO 2 T 47 8 29 0 149 247 208 HGX34 210 4 ML CO 2 T 18 20 21 80 44 5 26 7 1...

Page 36: ...tube L SW SR A Anschluss Saugseite nicht absperrbar Connection suction side not lockable A1 Anschluss Saugseite absperrbar Connection suction side lockable A2 Anschluss Saugseite nicht absperrbar Connection suction side not lockable B Anschluss Druckseite nicht absperrbar Connection discharge side not lockable B1 Anschluss Druckseite absperrbar Connection discharge side lockable B2 Anschluss Druck...

Page 37: ...ide lockable 7 16 UNF B2 Connection discharge side not lockable 1 8 NPTF D1 Connection oil return from oil separator 1 4 NPTF E Connection oil pressure gauge 1 8 NPTF F Oil drain M22x1 5 J1 Oil sump heater 3 8 NPTF K Sight glass 1 1 8 18 UNEF L Connection thermal protection thermostat 1 8 NPTF O Connection oil level regulator 1 1 8 18 UNEF X1 Connection for Schrader valve suction side 7 16 UNF X2 ...

Page 38: ...ferenced 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 The speci...

Page 39: ...uestions 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 40: ...usen Germany Phone 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 ...

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