GEA HGX46/280-4 ML CO2T Assembly Instructions Manual Download

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GB
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96259-03.2016-DGb

engineering for a better world

GEA Compressor HGX46 CO

Assembly instructions

HGX46/250-4 ML CO

HGX46/250-4 S CO

HGX46/250-4 SH CO

HGX46/280-4 ML CO

HGX46/280-4 S CO

HGX46/280-4 SH CO

HGX46/310-4 ML CO

HGX46/310-4 S CO

HGX46/310-4 SH CO

HGX46/345-4 ML CO

HGX46/345-4 S CO

HGX46/345-4 SH CO

HGX46/440-4 ML CO

Summary of Contents for HGX46/280-4 ML CO2T

Page 1: ...ssembly instructions HGX46 250 4 ML CO2 T HGX46 250 4 S CO2 T HGX46 250 4 SH CO2 T HGX46 280 4 ML CO2 T HGX46 280 4 S CO2 T HGX46 280 4 SH CO2 T HGX46 310 4 ML CO2 T HGX46 310 4 S CO2 T HGX46 310 4 SH CO2 T HGX46 345 4 ML CO2 T HGX46 345 4 S CO2 T HGX46 345 4 SH CO2 T HGX46 440 4 ML CO2 T ...

Page 2: ...e 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 Manufacturer Contact 1 Safety 4 1 1 Identification of safety instructions 1 2 Qualifications required of personnel 1 3 Safety instructions 1 4 Intended use 2 ...

Page 3: ... delta start 5 6 Basic circuit diagram for star delta start with special motor with MP10 5 7 Electronic trigger unit MP10 5 8 Connection of the electronic trigger unit MP10 5 9 Functional test of the electronic trigger unit MP10 5 10 Basic circuit diagram for star delta start with special motor with INT69 G 5 11 Electronic trigger unit INT69 G 5 12 Connection of the electronic trigger unit INT69 G...

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: ... 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 refrigerant can lead to severe burns and skin irritations Danger of suffocation CO2 ...

Page 6: ... relatively 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 amosphere when these inadmissibly high printing pressures are reached Fig 1 Fig 2 Dimension and connection values can be found in Chapter 9 2 1 Short description Oil sight glass Valve plate Cylinder cover...

Page 7: ...uency 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 Product description Fig 3 2 2 Name plate example HG 4 6 345 4 CO2 X 2 3 Type key example HG Hermetic Gas Cooled suction gas cooled X Ester oil charge ML Norma...

Page 8: ...eration 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 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 12x h A minimum runni...

Page 9: ...missible operating pressure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure 10 20 30 50 50 40 90 80 120 Einsatzgrenzen HGX34 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 t 10 K Oh 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 t 10 K Oh 90 120 100 pV2 bar 110 130 140 t 10 K Oh Compressor vers...

Page 10: ...essure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure 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 t 10 K Oh 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 t 10 K Oh Compressor version S 3 Areas of appli...

Page 11: ...Fig 7 Max permissible operating pressure LP HP 1 100 150 bar 1 LP Low pressure HP High pressure 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 t 10 K Oh Compressor version SH 3 Areas of application Evaporation temperatures 5 C 40 bar on request ...

Page 12: ...cient 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 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...

Page 13: ...e with a spanner wrench This should cause the cutting ring with its cutting edges to cut into the pipe resulting in a visible collar In order to stick to the turns we recommend using marking lines on union nut and pipe After assembly it is necessary to check the collar The gasket must not be damaged At least 80 of the cutting face has to be covered After check up screw on and tighten again as desc...

Page 14: ...ively for changing with inert gas in the factory and under no circum stances may they be connected to the refrigeration circuit the Schrader valves are approved for overpressure up to 28 bar only INFO Optionally to the flange shut off valves cutting ring screw joints Fig 17 and 18 HP LP are also available Fig 15 Fig 16 Pipes and system components must be clean and dry inside and free of scale swar...

Page 15: ...le seal release tighten Fig 19 Rigid fixed point 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 As short as possible 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 an...

Page 16: ...rvice connections Fig 22 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 23 Opening the service connection Spindle Turn 1 turn to the right clockwise Service connection opened shut off valve opened The connection which cann...

Page 17: ...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 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 66 and part winding 2 33 This winding devision reduces the start up current during a part winding start to approx 65 of the value for a direct start 5 Electrical connection ...

Page 19: ...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 66 1U1 1V1 1W1 and via K2 to winding 2 33 2U1 2V1 2W1 The mo...

Page 20: ...1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 5 3 Basic circuit diagram for part winding start compressor with MP10 Fig 24 5 Electrical connection Compressor terminal box BP1 Oil pressure safety switch BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat BT3 Release switch thermostat EB1 Oil sump he...

Page 21: ... 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT3 T2 N L M S QA2 PE FC1 1 Motor protection switch part winding 1 FC1 2 Motor protection switch part winding 2 FC2 Control power circuit fuse KF1 Delay relay max 1s QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch ...

Page 22: ... 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 EB1 11 12 14 L N B1 B2 BT2 Θ BT2 Θ Fig 25 5 Electrical connection Compressor terminal box BP1 Oil pressure safety switch BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat BT3 Release switch thermostat EB1 Oil...

Page 23: ...F1 KF1 6 8 6 2 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT3 T2 N L M S QA2 PE FC1 1 Motor protection switch part winding 1 FC1 2 Motor protection switch part winding 2 FC2 Control power circuit fuse KF1 Delay relay max 1s QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch ...

Page 24: ...24 D GB F E 96259 03 2016 DGb 5 Electrical connection 5 5 Special motor design for direct or star delta start Designation on the name plate Sticker on the terminal box Y ...

Page 25: ...lectrical connection Star delta start up is only possible for 230 V power supply Example 230 V Direct start Star delta start 400 V Y Direct start only L1 L3 L2 PTC L1 L2 L3 L1 L2 L3 L1 L3 L2 PTC PTC W2 U2 V2 W1 U1 V1 W2 U2 V2 W1 U1 V1 ...

Page 26: ...1 FC1 2 FC2 SF1 QA2 EB1 BT2 Θ BT2 Θ X1 L1 L1 N N 43 43 11 12 14 L S M X2 1 2 3 4 5 6 Fig 26 With several connect them in series 5 6 Basic circuit diagram for star delta start with special motor compressor with MP10 5 Electrical connection Compressor terminal box BP1 Oil pressure safety switch BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sens...

Page 27: ... 5 13 14 2 5 QA4 BP2 P KF1 QA4 QA3 2 8 2 1 8 KF1 QA3 QA4 2 8 2 1 8 KF1 P BP3 L1 1 L2 1 L3 1 L1 2 N PE BT3 T2 N L M S QA2 PE FC1 1 1 2 Motor protection switch FC2 Control power circuit fuse KF1 Delay relay for contactor changeover QA1 Main switch QA2 Mains contactor QA3 Δ contactor QA4 Y contactor SF1 Control voltage switch ...

Page 28: ...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 con...

Page 29: ...nection 1 or 2 Release the hot gas temperature sensor if installed 3 or 4 2 Restore the power supply L1 or SF1 ON Function check of motor temperature sensor operational ON Function check of hot gas temperature sensor operational ON 3 Interrupt power supply again L1 or SF1 OFF OFF OFF Reconnect terminals 1 or 2 and or 3 or 4 4 Restore the power supply L1 or SF OFF OFF ON MP10 is operational again B...

Page 30: ...B1 OG OG 11 12 14 L N B1 B2 BT2 Θ BT2 Θ 5 10 Basic circuit diagram for star delta start with special motor compressor with INT69 G Fig 28 With several connect them in series BP1 Oil pressure safety switch BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat BT3 Release switch thermostat EB1 Oil ...

Page 31: ...2 7 13 14 2 5 QA4 BP2 P KF1 QA4 QA3 2 8 2 2 8 KF1 QA3 QA4 2 8 2 2 8 KF1 P BP3 L1 1 L2 1 L3 1 L1 2 N PE BT3 T2 N L M S QA2 PE FC1 1 1 2 Motor protection switch FC2 Control power circuit fuse KF1 Delay relay for contactor changeover QA1 Main switch QA2 Mains contactor QA3 Δ contactor QA4 Y contactor SF1 Control voltage switch ...

Page 32: ... relay switching output is executed as a floating changeover contact This electrical circuit operates according to the quiescent current principle i e the relay drops into a the idle position and deactivates the motor contactor even in case of a sensor break or open circuit INFO Connect the trigger unit INT69 G in accordance with the circuit dia gram Protect the trigger unit with a delayed action ...

Page 33: ... connected and operated 5 14 Oil sump heater In order to avoid damage to the compressor the compressor is equipped with an oil sump heater as a standart feature Relay position INT69 G B2 12 14 11 Fig 30 5 13 Function test of the trigger unit INT69 G Before commissioning after troubleshooting or making changes to the control power circuit check the functionality of the trigger unit Perform this che...

Page 34: ...econdary 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 maximum ...

Page 35: ...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 36: ...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 37: ... 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 38: ...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 39: ...81176 81177 Set oil pump kit 80774 Set oil sump heater 230 V AC 80854 Available accessories can be found on the Internet at www gea com 7 4 Accessories 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 ...

Page 40: ... 38 5 253 330 247 HGX46 280 4 ML CO 2 T 24 40 29 30 59 3 35 5 231 283 247 HGX46 280 4 S CO 2 T 24 40 29 30 73 0 43 1 253 330 247 HGX46 280 4 SH CO 2 T 24 40 29 30 73 4 43 4 253 330 247 HGX46 310 4 ML CO 2 T 27 20 32 60 66 2 39 8 231 283 247 28 1 1 8 35 1 3 8 HGX46 310 4 S CO 2 T 27 20 32 60 81 4 48 4 253 330 265 HGX46 310 4 SH CO 2 T 27 20 32 60 82 0 48 8 253 330 265 HGX46 345 4 ML CO 2 T 30 20 36...

Page 41: ...ax power consumption apply for 50Hz operation For 60Hz operation the specifications have to be multiplied by the factor 1 2 The max working current remains unchanged Take account of the max operating current max power consumption for design of fuses supply lines and safety devices Fuse Consumption category AC3 All specifications are based on the average of the voltage range Cutting ring connector ...

Page 42: ... in for HGX46 440 4 ML CO2 T Änderungen vorbe Subject to change Anschlüsse Connections SV Saugabsperrventil Roh Suction line valve tube DV Druckabsperrventil Ro Discharge line valve tu A Anschluss Saugseite n Connection suction side A1 Anschluss Saugseite a Connection suction side A2 Anschluss Druckseite n Connection discharge s B Anschluss Druckseite n Connection discharge s B1 Anschluss Drucksei...

Page 43: ...ion discharge side 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 M26 x 1 5 H Oil charge plug M22 x 1 5 J1 Oil sump heater Ø 15 mm 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 ...

Page 44: ...ards 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 Th...

Page 45: ...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 46: ...37 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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GEA HGX46/280-4 ML CO2T, Assembly Instructions Manual

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