GEA Bock HGX44e CO2 Series Assembly Instructions Manual Download

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Assembly instructions

"FIELD TEST COMPRESSOR"

96507-11.2019-Gb

Translation of the original instructions

HGX44e/320-4 S CO

HGX44e/390-4 S CO

HGX44e/475-4 S CO

HGX44e/565-4 S CO

GEA Bock HGX44e CO

(subcritical)

Summary of Contents for HGX44e CO2 Series

Page 1: ...mbly instructions FIELD TEST COMPRESSOR 96507 11 2019 Gb Translation of the original instructions HGX44e 320 4 S CO2 HGX44e 390 4 S CO2 HGX44e 475 4 S CO2 HGX44e 565 4 S CO2 GEA Bock HGX44e CO2 subcritical ...

Page 2: ...ns 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 info gea com www gea com Manufacturer Contact Contents Page 1 Safety 4 1 1 Identification of safety instructions 1 2 Qualifications required of pers...

Page 3: ...sic circuit diagram for partial winding start with standard motor 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 20 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 Decompre...

Page 4: ...or injury ATTENTION Indicates a situation which if not avoided may cause property damage INFO Important information or tips on simplifying work 1 2 Qualifications required of personnel WARNING Inadequately qualified personnel poses the risk of accidents the consequence being serious or fatal injury Work on compressors must therefore only be performed by personnel with the qualifications listed bel...

Page 5: ...y be used Any other use of the compressor is prohibited 1 4 Intended use 1 3 Safety instructions WARNING The compressor may not be used in potentially explosive environments 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 purposes Risk...

Page 6: ...or The flow of refrigerant sucked in from the evaporator is led over the engine and provides for a particularlyintensivecooling Thustheenginecanbekeptspecialduringhighloadonarelatively low temperature level 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 atmosphere when these inadmissi...

Page 7: ...ber of cylinders Size Oil charge Series S 1 Type designation 6 Voltage circuit frequency 2 Machine 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...

Page 8: ... be found in GEA Bock compressor selection tool VAP under vap gea com Observe the information given there 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 operation must be achieved Max permiss...

Page 9: ...Leave this service charge in the compressor for as long as possible and pre vent the ingress of air Check the compressor for transport damage before starting any work 4 1 Storage and transportation Use transport eyelet Do not lift manually Use lifting gear Storage at 30 C 70 C maximum permissible relative humidity 10 95 no condensation Do not store in a corrosive dusty vaporous atmosphere or in a ...

Page 10: ...g and welding 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 Abb 5 graduated internal diameter 4 3 Pipe connections ATTENTION Damage possible Superheating can damage the valve Remove the pipe supports therefore from the valve for soldering welding Onl...

Page 11: ...osing the shut off valve release the valve spindle seal by approx of a turn counter clockwise After activating the shut off valve re tighten the adjustable valve spindle seal clockwise Fig 7 Fig 8 Valve spindle seal Release Tighten A rule of thumb Always lay the first pipe section starting from the shut off valve downwards and parallel to the drive shaft ...

Page 12: ...opened shut off valve opened The connection which cannot be shut off is intended for safety devices Service connec tion closed Connection blocked Spindle Connection cannot be shut off Connection cannot be shut off Service connec tion opened Spindle Connection open Compressor Compressor After activating the spindle generally fit the spindle protection cap again and tighten with 14 16 Nm This serves...

Page 13: ... protection type see name plate for routing cables into the terminal box Insert the strain reliefs and prevent chafe marks on the cables Compare the voltage and frequency values with the data for the mains power 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 5...

Page 14: ... I I I QA2 1U1 1V1 1W1 PE EC1 M Y YY 2U1 2V1 2W1 FC1 2 I I I QA3 FC1 1 FC1 2 FC2 SF1 QA2 11 12 14 L N B1 B2 12 11 10 9 8 7 6 5 4 3 2 1 50 50 BP2 High pressure safety controller BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor BT3 Release switch Thermostat DELTA P II Oil differential pressure monitor DELTA P II ac...

Page 15: ...KF1 6 c 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT3 BT2 Θ Θ vio bn bu gr Θ EB1 pk og FC1 1 1 2 Motor protection switch FC2 Control power circuit fuse INT69 G Electronic trigger unit INT69 G KF1 Timer relay for contactor switch QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch ...

Page 16: ...direct start YY at the factory For part winding start Y YY the bridges must be removed and the motor feed line connected according to the circuit diagram 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 switched on after a maximum delay of one second Failure to comply can adver...

Page 17: ...r unit INT69 G and PTC sensors The compressor motor is fitted with cold conductor temperature sensors PTC connected to the electronic trigger unit INT69 G in the terminal box In case of excess temperature in the motor winding the INT 69 G deactivates the motor contactor Once cooled it can be restarted only if the electronic lock of the output relay terminals B1 B2 is released by interrupting the s...

Page 18: ...ng or making changes to the control power circuit check the functionality of the trigger unit Perform this check using a continuity tester or gauge Relay position INT69 G B2 12 14 11 Fig 13 Gauge state Relay position Deactivated state 11 12 INT69 G switch on 11 14 Remove PTC connector 11 12 Insert PTC connector 11 12 Reset after mains on 11 14 ...

Page 19: ...ion in pressure The consequences can be foaming and migration of the oil causing oil shocks under certain circumstances Operation The oil sump heater operates when the compressor is at a standstill When the compres sor starts up the oil sump heater switches off again automatically Connexion The oil sump heater must be connected via an auxiliary contact or parallel wired auxili ary contact of the c...

Page 20: ...efrigerant 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 refrige...

Page 21: ...ded 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 s...

Page 22: ...mer 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 23: ...rly 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 6 9 Filter dryer Gaseous CO2 has a significantly lower solubility in water than ot...

Page 24: ...e 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 mandatory for factory produced series systems for field installations or when operating near the application limit for the first time after 100 to 200 opera...

Page 25: ...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 compressor larger amounts of CO2 in the oil can be set free If the decompression of the compressor i...

Page 26: ...28 3 65 109 200 HGX44e 565 4 S CO 2 49 2 59 0 56 3 33 6 101 174 201 1 2 3 2 4 380 420 V Y YY 3 50 Hz PW 440 480 V Y YY 3 60 Hz PW PW Part Winding Winding ratio 50 50 1 2 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 to be mul...

Page 27: ...lsieb mm M12x1 5 Oil filter O Anschluss Ölspiegelregulator mm 3xM6 Connection oil level regulator Q Anschluss Öltemperatursensor Zoll inch 1 8 NPTF Connection oil temperature sensor SI1 Druckentlastungsventil HD Zoll inch 1 8 NPTF Decompression valve HP SI2 Druckentlastungsventil ND Zoll inch 1 8 NPTF Decompression valve LP L SW Löt Schweissanschluss solder welding connection 2 5 3 4 Y 366 F M C O...

Page 28: ... oil pressure switch 1 8 NPTF D Connection oil pressure switch LP 7 16 UNF D1 Connection oil return from oil separator 1 4 NPTF F Oil drain M12 x 1 5 H Oil charge plug 1 4 NPTF J Connection oil sump heater 3 8 NPTF K Sight glass 3 x M6 L Connection thermal protection thermostat 1 8 NPTF M Oil strainer M12 x 1 5 O Connection oil level regulator 3 x M6 Q Connection oil temperature sensor 1 8 NPTF SI...

Page 29: ... 1 5 1 3 2 1 3 3 1 3 7 1 5 1 1 5 2 1 5 13 and 1 7 1 to 1 7 4 excepted 1 7 4 f are fulfilled Applied harmonised standards in particular EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction EN 12693 2008 Refrigerating systems and heat pumps Safety and environmental requirements Positive displacement refrigerant compressors Remarks We also declare tha...

Page 30: ...ou have any 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 ...

Page 31: ...D GB F E 31 96507 11 2019 DGbFEI ...

Page 32: ...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 ...

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