D GB F E GEA Bock Compressor HGX12P CO2 09917-02.
About these instructions Read these instructions before assembly and before using the compressor. This will avoid misunderstandings 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 compressor is installed.
09917-02.2015-DGbFEI Contents 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 7 7.1 7.2 7.3 7.4 7.5 7.
1| Safety 1.1 Identification of safety instructions: 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 injury. CAUTION! Indicates a dangerous situation which, if not avoided, may cause fairly severe or minor injury. ATTENTION! Indicates a situation which, if not avoided, may cause property damage.
1| Safety 1.4 Intended use These assembly instructions describe the standard version of the HGX12P -CO2 manufactured by GEA Bock. The compressor is intended for use with CO2 in sub-critical systems in compliance with the limits of application. Only the refrigerant specified in these instructions may be used.
2| Product description 2.1 Short description • Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication. • Suction gas cooled drive motor. Transport eyelet Valve plate Name plate Oil pump D GB Oil sight glass F Fig. 1 E Cylinder cover Terminal box Discharge shut-off valve Drive section Fig. 2 Dimension and connection values can be found in Chapter 9 6 09917-02.
2| Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany 1 2 3 4 5 6 7 8 9 10 11 12 13 AS33567A001 40/55 C85E Fig. 3 1 2 3 4 5 Type designation Machine number maximum operating current Starting current (rotor blocked) ND (LP): max. permissible operating pressure (g) Low pressure side HD (HP): max.
3| Areas of application 3.1 Refrigerants • CO2: R744 3.2 Oil charge The compressors are filled at the factory with the following oil type: GEA Bock C 85 E (only this oil may be used) ATTENTION! The oil level must be in the visible part of the sight glass; damage to the compressor is possible if overfilled or underfilled! max. ~ ~ 0,5 Ltr. oil level min. Fig. 4 3.3 Limits of application ATTENTION! Compressor operation is possible within the operating limits shown in the diagrams.
4| Compressor assembly INFO! New compressors are factory-filled with inert gas (3 bar nitrogen). Leave this service charge in the compressor for as long as possible and prevent the ingress of air. Check the compressor for transport damage before starting any work. 4.1 Storage and transport Fig. 6 ? 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 combustible environment. Use transport eyelet.
4| Compressor assembly The pipe connections have graduated inside diameters so that pipes with standart millimetre and inch dimensions can be used. 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. Fig. 11: graduated internal diameter 4.4 Pipes Pipes and system components must be clean and dry inside and free of scale, swarf and layers of rust and phosphate.
4| Compressor assembly 4.6 Operating the shut-off valves Before opening or closing the shut-off valve, release the valve spindle seal by approx. ¼ of a turn counter-clockwise. After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise. Tighten Release Valve spindle seal Fig. 14 Fig. 13 4.
5| Electrical connection 5 Electrical connection DANGER! High voltage! Risk of electric shock! Only carry out work when the electrical system is disconnected from the power supply! INFO! onnect the compressor motor in accordance with the circuit diagram C (see inside of terminal box). Use suitable cable entry point of the correct protection type (see name plate) for routing cables into the terminal box. Insert the strain reliefs and prevent chafe marks on the cables.
5| Electrical connection The compressor is designed with a motor for star-delta circuits. Designation on the name plate Sticker on the terminal box Niedere Spannung Low voltage Bas voltage ∆ ∆/Y Star-delta start-up is only possible on 230 V voltage supply.
5.
D A1 Alarm Motor protection A2 Overheating R1, R2 A3 Alarm high pressure XSS Terminal strip in the external switch cabinet GB F E 09917-02.
5| Electrical connection 5.4 Electronic trigger unit MP 10 The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the electronic trigger unit MP 10 in the terminal box. Readiness to operate is signalled by the 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.
5| Electrical connection 5.
6| Commissioning 6.1 Preparations for start-up INFO! In order to protect the compressor against inadmissible operating conditions, high-pressure and low-pressure pressostats controls are mandatory on the installation side. The compressor has undergone trials in the factory and all functions have been tested. There are therefore no special running-in instructions.
6| Commissioning First evacuate the system and then include the compressor in the evacuation process. Relieve the compressor pressure. Open the suction and pressure line shut-off valves. Evacuate the suction and discharge pressure sides using the vacuum pump. At the end of the evacuation process, the vacuum should be < 1.5 mbar when the pump is switched off. Repeat this process as often as is required. 6.
6| Commissioning 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 properly. Switch on the compressor and let it run for at least 10 minutes. The machine should reach a state of equilibrium. Check the oil level: The oil level must be visible in the sight glass.
6| Commissioning 6.8 Avoid slugging ATTENTION! Slugging can result in damage to the compressor and cause refrigerant to leak. To prevent slugging: The complete refrigeration plant must be properly designed. All components must be compatibly rated with each other with regard to output (particularly the evaporator and expansion valves). Suction gas superheating at the compressor input should be min. 15 - 20 K (check the setting of the expansion valve). The system must reach a state of equilibrium.
7| Maintenance 7.1 Preparation 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. Evacuate compressor. Release switch-on lock. 7.
7| Maintenance 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 prevent oil from exiting with it. If the compressor is unpressurized, remove the piping on the pressureand suction-side (e.g. dismantling of the shut-off valve, etc.
220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz 10,6 / 6,1 9,5 / 5,5 8,7 / 5,0 7,3 / 4,2 5,9 / 3,4 A Max. Operating current 2 ∆/Y 09917-02.2015-DGbFEI 1 Tolerance (± 10%) relative to the mean value of the voltage range. Other voltages and types of current on request. 2 - 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 max. working current remains unchanged.
5 6 7 9| Dimensions and connections 5 6 7 5 6 7 B1 DV DV B1 A1 E E F F ca.135 JJ ca.135 ca.135 208 208 66 208 318 318 318 ca.415 ca.415 ca.415 66 66 ca.30 SI2,A E H,D1 H,D1 F O,K O,K 4x 4x SI1 Schwingungsdämpfer Schwingungsdämpfer Schwingungsdämpfer 4x H,D1 O,K 10 162 192 30 Vibration damper 10 10 162 162 192 192 30 30 SI1 SI1 SI2,A * SI2,A 3 3 L1 J ca.30 ca.30 B B1 DV B B 98 SV 1) A1 A1 ca.240 ca.240100 ca.240 100 100 L1 L1 98 98 ca.115 ca.115 ca.
10| Declaration of conformity and installation DECLARATION OF CONFORMITY CE 06 for using the compressors within the European Union (in accordance with Low Voltage Directive 2006/95/EC) We hereby declare that the following refrigerating compressors Product designation: HGX12P -CO2 comply with the Low Voltage Directive 2006/95/EC.
11| Service Dear customer, GEA Bock compressors are top-quality, reliable and service-friendly quality products. If you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The GEA Bock 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 D GB F 09917-02.
We live our values. Excellence • Passion • Integrity • Responsibility • GEA-versity D 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. GB F GEA Bock GmbH Benzstraße 7, 72636 Frickenhausen, Germany Telephone: +49 7022 9454-0, Fax: +49 7022 9454-137 refrigeration@gea.com, www.gea.
