GEA HAX2 CO2 T Assembly Instructions Manual Download

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GB
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96031-03.2016-DGbF

engineering for a better world

GEA Compressor HAX2 CO

Assembly instructions

HAX2/70-4 CO

HAX2/90-4 CO

HAX2/110-4 CO

HAX2/130-4 CO

GEA Bock GmbH
72636 Frickenhausen, Germany

Summary of Contents for HAX2 CO2 T

Page 1: ...1 96031 03 2016 DGbF engineering for a better world GEA Compressor HAX2 CO2 T Assembly instructions HAX2 70 4 CO2 T HAX2 90 4 CO2 T HAX2 110 4 CO2 T HAX2 130 4 CO2 T GEA Bock GmbH 72636 Fricke nhaus en Germa ny ...

Page 2: ...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 refrigeration gea com www gea com Manu...

Page 3: ...e of the lockable service connections 5 Electrical connection 15 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 Electronic trigger unit MP10 5 5 Connection of the electronic trigger unit MP10 5 6 Functional test of the electronic trigger unit MP10 5 7 Oil sump heater 5 8 F...

Page 4: ...ing which 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 s...

Page 5: ...surised machines and therefore require particular 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 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 refrig...

Page 6: ... One decompression valve each on the low and high pressure side which vent into the atmosphere when these inadmissibly high printing pressures are reached 2 1 Short description Discharge shut off valve Dimension and connection values can be found in Chapter 9 Cylinder cover Transport eyelet Valve plate Oil pump Terminal box Suction shut off valve Drive section Name plate Oil sight glass Air deflec...

Page 7: ...e 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 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 ...

Page 8: ...erating 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 ambient temperature 45 C Max permissible discharge end temperature 160 C Min oil temperature 30 C Min pressure gas temperature 50 C Max permissible switching frequency 12x h A minimum running time of 3 min steady state cond...

Page 9: ...e LP HP 1 100 150 bar 1 HAX2 130 4 CO2 T Applications limit 1 LP Low pressure HP High pressure Fig 5 Unlimited application range 3 Areas of application to Evaporation temperature C toh Suction gas superheat K po Suction pressure bar pv2 Discharge end pressure bar 1 ...

Page 10: ...ficient load bearing capacity 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 8 Fig 9 Fig 10 F E D 1 2 3 4 1 Storage and transportation Use transport eyelet Do not lift manually Use lifting gear...

Page 11: ...nut 4 4 Connecting the pipelines cutting ring system 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 Cut Ring 3 onto Pipe 2 Insert pipe into Socket 6 as far as it w...

Page 12: ...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 13 Fig 14 4 7 Option cutting ring screw joint HP LP Remove Schrader connection HP Remove Schrader connection LP Abb 15 Abb 16 ATTENTION Property damage possible The compressor as delivered is equipped with Schrader valves on the hig...

Page 13: ...clockwise Fig 18 Fig 19 4 8 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...

Page 14: ...Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cannot be shut off is intended for safety devices Spindle Connection cannot be shut off Connection blocked Service connec tion closed Pipe connection Spindle Connection cannot be shut off Connection offen Service connec tion opened Fig 20 Fig 21 After activ...

Page 15: ...ply 5 1 Information for contactor and motor contactor selection All protection equipment switching and monitoring devices must comply with the local safety regulations 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 protection switches must be rated according to the maximum operat...

Page 16: ...inal 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 70 and part winding 2 30 This winding devision redu ces the start up current during a part winding start to approx 65 of the value for a direct start INFO Mechanical start unloader with bypass solenoid is not required ...

Page 17: ...roperty damage possible Failure to comply results in reversed fields of rotation and can cause motor damage After the motor has started up with part win ding 1 part winding 2 must be switched on after max 1 second delay Failure to comply can be detrimental to the service life of the motor Ensure that power is supplied via K1 to winding 1 70 1U1 1V1 1W1 and via K2 to winding 2 30 2U1 2V1 2W1 The mo...

Page 18: ...Ers d 4 X SS Q1 L1 L2 L3 N PE Anschluákasten Verdichter I 66 F1 1 K1 1 2 1 3 4 2 5 6 3 1U1 1V1 1W1 M Y YY M1 R1 2U1 2V1 2W1 I 33 F1 2 K2 1 2 4 3 4 5 5 6 6 PE X1 L1 L1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 R2 F1 1 F1 2 4A F2 S1 7 MP10 8 5 3 Basic circuit diagram for part winding start Compressor terminal box R1 Cold conductor PTC sensor motor winding R2 Thermal protection thermostat PTC sensor F1...

Page 19: ...W MP10 5 6 7 BOCK COMPRESSORS 8 9 Bl 1 Bl 1 M 1 M1 1 K1 9 X3 1 10 2 C1 3 F5 4 T2 N P l L P F3 M S 11 12 13 K1 P F4 14 K1 K1T K2 15 16 K1T P B1 17 18 K1 19 E1 20 L1 1 L2 1 L3 1 L1 2 N PE Q1 Main switch M1 Compressor motor M1 1 Fan motor K1 Mains contactor part winding 1 K2 Mains contactor part winding 2 K1T Delay relay max 1s S1 Control voltage switch E1 Oil sump heater XSS Terminal strip in the ex...

Page 20: ...e H3 LED green 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 The H2 LED red is provided for the protection function The unit trips when an overload or inadmissible operating c...

Page 21: ... to the control power circuit check the functionality of the trigger unit Operation The oil sump heater operates when the compressor is at a standstill When the compressor starts up the oil sump heating switches off Connexion The oil sump heater must be connected via an auxiliary contact or parallel wired auxiliary contact of the compressor contactor to a seperate electric circuit Electrical data ...

Page 22: ... secondary refrigerant system or pressure relief devices 6 3 Leak test 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 DANGER Risk of bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximu...

Page 23: ...ility 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 side ATTENTION Do not start the compressor if it is under vacuum Do not apply any voltage even for tes...

Page 24: ...ed off danger of oil liquid shocks reduced capacity of the refrigerating system Suitably adjusted pressure switches that switch off the compressor before reaching the maximum permissible operating pressure must be installed in the system The pressure reduction for the pressure switches can occur either at the suction and pressure lines between the shut off valve and compressor or at the non lockab...

Page 25: ... activates repeatedly check valve and replace if necessary as during blow off extreme condi tions can occure 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 d...

Page 26: ...ant in the compressor while the system is at a standstill ATTENTION Slugging can result in damage to the compressor and cause refrigerant to leak WARNING Before starting any work on the compressor Switch off the compressor and secure it to prevent a restart Relieve compressor of system pressure Prevent air from infiltrating the system After maintenance has been performed Connect safety switch Evac...

Page 27: ...d to intolerable excessive pressure For this reason the suction side LP and the high pressure side HP of the compressor have to be secured by decompression valves 7 5 Lubricants For operation with CO2 the GEA oil C 85 E is necessary 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 ...

Page 28: ...4 CO 2 T 11 50 13 80 31 8 18 5 127 161 160 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 70 30 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 multiplied by the factor 1 2 The...

Page 29: ...lve tub A Anschluss Saugseite ni Connection suction side A1 Anschluss Saugseite ab Connection suction side A2 Anschluss Saugseite ni Connection suction side B Anschluss Druckseite n Connection discharge si B1 Anschluss Druckseite a Connection discharge si B2 Anschluss Druckseite n Connection discharge si E Anschluss Öldruckmano Connection oil pressure F Ölablass Oil drain H Stopfen Ölfüllung Oil c...

Page 30: ...dards 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 Directive 2006 42 EC The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery on request T...

Page 31: ...ions 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 refrigeration gea com Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 11 Service ...

Page 32: ...137 refrigeration gea com www gea com 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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