GEA HGX4 CO2 Series Assembly Instructions Manual Download Page 1

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96020-09.2013-DGbFEI

engineering for a better world

GEA Refrigeration Technologies

Bock Compressor HGX4 CO

Assembly instructions

HGX4/310-4 CO

HGX4/385-4 CO

HGX4/465-4 CO

HGX4/555-4 CO

Summary of Contents for HGX4 CO2 Series

Page 1: ...20 09 2013 DGbFEI engineering for a better world GEA Refrigeration Technologies Bock Compressor HGX4 CO2 Assembly instructions HGX4 310 4 CO2 HGX4 385 4 CO2 HGX4 465 4 CO2 HGX4 555 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: ...election 5 2 Standard motor design for direct or partial winding start 5 3 Basic circuit diagram for partial winding start with standard motor 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 Le...

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: ...tended 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 install...

Page 6: ...nnection values can be found in Chapter 9 Transport eyelet 2 Product description Semi hermetic four cylinder reciprocating compressor with suction gas cooled drive motor Flange mounted drive motor on the compressor case The stream of refrigerant sucked out of the evaporator flows over the motor and cools it intensively In this way the motor can be kept at a relatively low temperature level particu...

Page 7: ...chine number 7 Nominal rotation speed 3 maximum operating current 8 Displacement 4 Starting current rotor blocked 9 Voltage circuit frequency Y Part winding 1 10 Nominal rotation speed YY Part windings 1 and 2 11 Displacement 5 ND LP max admissible operating 12 Oil type filled at the factory pressure g Low pressure side 13 Terminal box protection type HD HP max admissible operating Electrical acce...

Page 8: ...d 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 application Evaporation temperature C Condensing temperature C Suction gas superheat K Fig 5 R744 1 2 Max permissible operating pressure ...

Page 9: ...10 graduated internal diameter F E D C B 1 2 3 K Alternativbezug Baumustergeprüft Lieferantenzeichnung K Auftrag PL Entwicklungsstand 120 400 0 5 Bearb Datum Änderungs Nr Werkstoff Ausgangsteil bzw Rohteil Gepr Zone 1 x Oberflächenbehandlung Härte Blatt hreibung 400 Benennung 0 8 1000 Zeichn Nr Teile Nr x xxxx xxxxx x Maßstab 1 1 Wasserwaage für Indesign Der Lieferant muß sicherstellen dass die Wa...

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: ...nections Fig 14 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 15 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cannot be shu...

Page 12: ...es 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 Motor protection switch is required Motor contactors feed lines fuses and motor protection switches must be rated acco...

Page 13: ...nical unloaded start with bypass solenoid valve is not required 400 V Direktstart YY Teilwicklungsstart Y YY 1V1 1W1 1U1 2W1 2V1 2U1 L3 L2 L1 L3 L2 L1 L3 L2 L1 1V1 1W1 1U1 2W1 2V1 2U1 Direct start YY Part winding start Y YY ATTENTION Failure to do this results in opposed rotary fields and results in damage to the motor After the motor starts up via partial winding 1 partial winding 2 must be switc...

Page 14: ...TC sensor MP 10 R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1 1 F1 2 Load circuit safety switches F2 Control power circuit fuse F3 F4 Safety chain high low pressure monitoring F5 Oil differential pressure monitor B1 Release switch thermostat pressostat Q1 Main switch Compressor terminal box ...

Page 15: ...Control voltage switch M1 Compressor motor K1 Mains contactor part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s MP10 Electronic trigger unit MP 10 E1 Oil sump heater XSS Terminal strip in the external switch cabinet ...

Page 16: ...een 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 inadmissible operating co...

Page 17: ...en 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 check of hot g...

Page 18: ...ssor for transport damage 6 2 Pressure strength test DANGER Bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximum permissible overpressure of the compressor must not be exceeded at any time during the testing process see name plate data Do not mix any refrigerant with the nitrogen as this could cause the ignition limit to shift i...

Page 19: ...f 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 6 4 Evacuation ATTENTION Do not start the compressor if it is under vacuum Do n...

Page 20: ...8 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 etc are functioning prop...

Page 21: ...measures such as the use of liquid traps solenoid valve in the liquid line etc are recommended There should be no movement of refrigerant in the compressor while the system is at a standstill 6 Commissioning Mechanical oil level regulator at the O connection Fig 19 fahr von Anschluss Ölspiegelregulator Bei Verbundschaltungen von mehreren Verdichtern haben sich Ölstandsregulierungssystemebewährt Fü...

Page 22: ...00 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 WARNING Before starting any work on the compressor Switch off the compressor and secure it...

Page 23: ... the oil Bock C 85 E is necessary Available accessories can be found on the Internet at www bock de 7 4 Accessories 7 Maintenance HGX4 310 4 CO2 385 4 CO2 465 4 CO2 555 4 CO2 Designation Item No Item No Item No Item No Set of gaskets 80472 08913 Valve plate kit 80473 80438 80438 80439 Set piston connecting rod 80399 80399 80433 80434 Set connecting rod 80424 ...

Page 24: ...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 25: ...on category AC3 1 2 3 4 Type No of cylin ders Displacement 50 60 Hz 1450 1740 rpm Electrical data Weight Connections Oil charge Voltage Max Operating current PW 1 2 Max power consump tion Starting current rotor locked PW 1 PW 1 2 Discharge line DV Suction line SV m 3 h A kW A kg mm inch mm inch Ltr HGX4 310 4 CO 2 4 27 1 32 5 28 2 16 5 82 107 152 22 7 8 28 1 1 8 2 7 HGX4 385 4 CO 2 33 5 40 2 31 6 ...

Page 26: ... ca 170 Schwingungsdämpfer Vibration absorbers Amortisseurs de vibration 30 M10 40 20 Ansicht X Anschlußmöglichkeit für Ölspiegelregulator View X Possibility of connection of oil level regulator Vue X Raccord pour régulateur de niveau d huile Dreilochanschluß für TRAXOIL 3xM6x10 Three hole connection for TRAXOIL 3xM6x10 Raccord à trois rainures pour TRAXOIL 3xM6x10 z Dreilochanschluß für ESK AC R ...

Page 27: ...ction oil pressure switch LP 7 16 UNF D1 Connection oil return from oil separator 1 4 NPTF E Connection oil pressure gauge 1 8 NPTF F Oil drain M22 x 1 5 H Oil charge plug M22 x 1 5 J1 Oil sump heater accessories M22 x 1 5 K Sight glass L1 Thermal protection thermostat 1 8 NPTF O Connection oil level regulator 3 x M6 P Connection oil differential pressure sensor M20 x 1 5 ÖV Connection oil service...

Page 28: ...ssor HGX4 CO2 complies with the basic require ments 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 Machinery...

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Page 30: ...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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