gea compressor hgx22p co 2 assembly instructions

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engineering for a better world

GEA Compressor HGX22P CO2

Assembly instructions

HGX22P/110-4 CO2HGX22P/125-4 CO2HGX22P/160-4 CO2HGX22P/190-4 CO2

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About these instructionsRead these instructions before assembly and before using the compressor. This will avoid misunder-standings 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 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

[email protected]

www.gea.com

Manufacturer

Contact

1 Safety 4 1.1 Identificationofsafetyinstructions 1.2 Qualificationsrequiredofpersonnel 1.3 General safety instructions 1.4 Intended use 2 Product description 6 2.1 Short description 2.2 Name plate 2.3 Type key

Contents Page

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Contents Page

3 Areas of application 8 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application 4 Compressor assembly 9 4.1 Storage and transport 4.2 Setting up 4.3 Pipe connections 4.4 Pipes 4.5 Laying suction and pressure lines 4.6 Operating the shut-off valves 4.7 Operating mode of the lockable service connections 5 Electrical connection 12 5.1 Information for contactor and motor contactor selection 5.2 Connection of the driving motor 5.3 Circuit diagram for direct start 230 V Δ / 400 V Y --> with MP10 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 Circuit diagram for direct start 230 V Δ / 400 V Y --> with INT69 G 5.8 Electronic trigger unit INT69 G 5.9 Connection of the electronic trigger unit INT69 G 5.10 Functional test of the electronic trigger unit INT69 G 5.11 Oil sump heater (accessories) 6 Commissioning 22 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 Decompression valves 6.8 Avoiding slugging 6.9 Connection of oil level regulator 7 Maintenance 26 7.1 Preparation 7.2 Work to be carried out 7.3 Spare parts recommendation 7.4 Accessories 7.5 Lubricants 7.6 Decommissioning 8 Technical data 28 9 Dimensions and connections 29 10 Declaration of installation 30 11 Service 31

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1| Safety

1.2 Qualificationsrequiredofpersonnel

1.3 General safety instructions

WARNING! Inadequately qualified personnel poses the risk of accidents, theconsequence being serious or fatal injury. Work on compressorsmustthereforeonlybeperformedbypersonnelwiththequalifica-tions listed below:

• For example, a refrigeration technician, refrigeration mechatron-ics engineer. As well as professions with comparable training, which enable personnel to assemble, install, maintain and repair refrigeration and air-conditioning systems. Personnel must be capable of assessing thework to be carried out and recognising any potential dangers.

WARNING! • Refrigerating compressors are pressurised machines and thereforerequireparticularcautionandcareinhandling.

• Risk of burns! Depending on the operating conditions, surfacetemperatures of over 60 °C on the pressure side or below 0 °C on the suction side can be reached.

• Themaximumpermissible overpressuremustnotbe exceeded, even for testing purposes.

1.1 Identificationofsafetyinstructions:

DANGER! Indicatesadangeroussituationwhich,ifnot

avoided,willcauseimmediatefatalorseriousinjury.

WARNING! Indicatesadangeroussituationwhich,ifnot

avoided,maycausefatalorseriousinjury.

CAUTION! Indicatesadangeroussituationwhich,ifnot

avoided,maycausefairlysevereorminorinjury.

ATTENTION! Indicatesasituationwhich,ifnot

avoided,maycausepropertydamage.

INFO! Importantinformationortipsonsimplifyingwork.

WARNING! DANGER OF SUFFOCATION! NeverreleasesignificantvolumesofCO2 or the entire contents of the system into closed rooms!

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1| Safety

These assembly instructions describe the standard version of the HGX22P -CO2 manufactured by GEA.

The compressor is intended for use with CO2 in sub-critical systems in compliance with the limits of application.

Onlytherefrigerantspecifiedintheseinstructionsmaybeused.

Any other use of the compressor is prohibited!

1.4 Intended use

WARNING! The compressor may not be used in potentially explosive environments!

The GEA refrigerating compressor named in the title is intended for installing in a machine (within the EUaccording to theEUDirectives2006/42/ECMachineryDirective,97/23/ECPressureEquipmentDirective and 2006/95/EC – Low Voltage Directive).Commissioning is only permissible if the compressor has been installed in accordance with these assembly instructions and the entire system into which it is integrated has been inspected and approved in accordance with legal regulations.

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111213 Name plate

Fig. 1

Fig. 2

Oil sight glass

Valve plate

Cylinder cover

Discharge shut-off valve

Oil pump

Terminal box

Suction shut-off valve

Drive section

Motor section

Dimension and connection values can be found in Chapter 9

Transport eyelet

2| Product description

• Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication.• Suction gas cooled drive motor.

2.1 Short description

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2| Product description

2.2 Name plate (example)

2.3 Typekey (example)

¹) HG - Hermetic Gas-Cooled (suction gas-cooled)

²) X - Ester oil charge

³) Additional declaration for Pluscom compressors

Fig. 3

1 Typedesignation 6 Voltage,circuit,frequency2 Machine number 7 Nominal rotation speed3 maximum operating current 8 Displacement4 Startingcurrent(rotorblocked) 9 Voltage,circuit,frequency5 ND (LP): max. permissible operating 10 Nominal rotation speed pressure (g) Low pressure side 11 Displacement HD (HP): max. permissible operating 12 Oiltypefilledatthefactory pressure (g) High pressure side 13 Terminal box protection type Observe the limits of application Electrical accessories can change diagrams! the IP protection class!

50 Hz}

60 Hz}

/HG 22 P 125- 4 CO2X

CO2 Version

Number of poles

Swept volume

³)

Numbers of cylinders

Size

Oil charge ²)

Series ¹)

123

45

1312

7

11

6

10

89

40/55

AS33567A001

C85E

20,9/12,1AΔ: 121A Y: 70A

GEA Bock GmbH72636 Frickenhausen, Germany

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3| Areas of application

ATTENTION! Compressor operation 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 140 °C-Max.permissibleswitchingfrequency8x/h.

- A minimum running time of 3 min. steady-state condition (continuous operation) must be achieved.

Foroperationwithfrequencyconverter:- The maximum current and power consumption must not be exceeded. Inthecaseofoperationabovethemainsfrequency,the application limit can therefore be limited.

Thecompressorsarefilledatthefactorywiththefollowingoiltype: GEA 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)

Suction gas temperature (°C)

Fig. 5Max. permissible operating

pressure (LP/HP)1): 40/55 bar

1) LP = Low pressureHP = High pressure

R744

Unlimited application range

The oil level must be in the visible part of the sight glass; damage to the com-pressor is possible if over-filled or underfilled!

ATTENTION! max.

min.

0,6 Ltr. oil level

Fig. 4

~~

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4| Compressor assembly

4.3 Pipe connections

INFO! Newcompressorsarefactory-filledwithinertgas(3barnitrogen). 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.

ATTENTION! Do not solder as long as the compressor is under pressure. Superheating can damage the valve. Remove the pipe supports

therefore from the valve for soldering and accordingly cool the valve body during and after soldering.

Only solder using inert gas to inhibit oxidation products (scale).

?4.1 Storage and transport

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 com-bustible environment.

Fig. 7

Fig. 6

ATTENTION! Attachments(e.g.pipeholders,additionalunits,fasteningparts,etc.) directly to the compressor are not permissible!

4.2 Setting up

Setuponanevensurfaceorframewithsufficientload-bearing capacity.

Single compressor preferably on vibration damper. Duplex and parallel circuits always rigid.

Provideadequateclearanceformaintenancework. Ensureadequatecompressorventilation.

Do not use in a corrosive, dusty, damp atmosphere or a combustible environment.

Fig. 8

Fig. 9

Fig. 10

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BTol.-Ang. DIN ISO 2768-mK

Ra Rz

Maß Passung Freigabe

Alternativbezug:Baumustergeprüft

Teil inaktiv

Lieferantenzeichnung

--

K.-Auftrag:PL:

Zeichnung ungültig

Entwicklungsstand

Teil keine Serie

120400

±0.5

über 0.5bis 6

Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de

-

-Unbemaßte Radien:

-

Diese Zeichnung ist unser Eigentum!Sie darf ohne unsere Genehmigung weder nach-gebildet, vervielfältigt, oder Dritten Personen zu-gänglich gemacht werden. Der Nachbau nachdieser Zeichnung, oder an Hand der nach dieserZeichnung hergestellten Gegenstände durch denAbnehmer oder Dritte ist nicht gestattet.Wir behalten uns alle Rechte, gemäß DIN ISO 16016an dieser Zeichnung vor.

Bearb.DatumÄnderungs-Nr.

Werkstoff:

Ausgangsteil, bzw. Rohteil:-

-

Gepr.

NameDatum19.04.

WerkstückkantenDIN ISO 13715

Ersatz für:

Ersetzt durch:

Erstellt2010

Geprüft

-

Kurz

Zone

1/x

Oberflächenbehandlung / Härte:-

Blatt:Änderungsbeschreibung

400Benennung:

±0.8

1000 30 6

-

±0.3

12030

±0.2

Zeichn.-Nr. Teile-Nr.

Oberflächenangaben ISO 1302

x.xxxx-xxxxx.x

Zust.Gußtoleranzen:

Gewicht: (kg)

±0.1

Maßstab:

1:1

Wasserwaagefür Indesign

Der Lieferant muß sicherstellen, dass die Ware ineinwandfreiem Zustand angeliefert wird (Korrosions-schutz, Verpackung für sicheren Transport).

Rz 25Rz 160

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4.5 Laying suction and pressure lines

INFO! Proper layout of the suction and pressure lines directly after the compressor is integral to the smooth running and vibration behaviour of the system.

ATTENTION! Improperly installedpipescancausecracksand tearswhichcanresult in a loss of refrigerant.

A rule of thumb:Alwayslaythefirstpipesectionstartingfromtheshut-offvalvedownwards andparallel to the drive shaft.


4.4 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 broken by severe vibrations.

Ensure a proper oil return. Keep pressure losses to an absolute minimum.

Fig. 12

Rigid fixed point

As short as possible

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 requiredpipe cross sectionmust bematched to the output. The same applies for non-return valves.

Fig. 11: graduated internal diameter

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Valve spindle seal

Release

Tighten

Fig. 13 Fig. 14


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.

4.6 Operating the shut-off valves

Pipe connection

Pipe connection

4.7 Operatingmodeofthelockableserviceconnections

Fig. 15Opening 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.

Fig. 16Opening the service connectionSpindle: Turn ½ - 1 turn to the right clockwise. —> Service connection opened / shut-off valve opened.

Service connec-tion closed

Connectionblocked

Spindle

Service connec-tion opened

SpindleConnectionopen

Compressor

Compressor

Afteractivatingthespindle,generallyfitthespindleprotectioncapagainandtightenwith14-16Nm.This serves as a second sealing feature during operation.

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5| Electrical connection

5 Electrical connection

DANGER! Highvoltage!Riskofelectricshock!Onlycarryoutworkwhentheelectrical system is disconnected from the power supply!

INFO! Connect the compressor motor in accordance with the circuit diagram (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.

Comparethevoltageandfrequencyvalueswiththedataforthemainspower supply.

Only connect the motor if these values are the same.

5.1 Information for contactor and motor contactor selectionAllprotectiondevicesandswitchingormonitoringunitsmustbefittedinaccordancewiththelocalsafetyregulationsandestablishedspecifications(e.g.VDE)aswellaswiththemanufacturer’sinfor-mation. Motorprotection switchesare required! Motor contactors, feed lines, fuses and motor protection switches must be rated on the basis of the maximum working current (see name plate). For motor protection use a current-dependent and time-delayed overload protection device for moni-toring all three phases. Set the overload protection device so that it must be actuated within 2 hours, if there is 1.2 times the max. working current.

ATTENTION! Whenattachingaccessorieswithanelectricalcable,aminimumbending radius of 3 x the cable diameter must be maintained for laying the cable.

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5.2 Connection of the driving motor

The compressor is designed with a motor for star-delta circuits.

Designation on the name plate Sticker on the terminal box

∆ / Y

Star-delta start-up is only possible on 230 V voltage supply . Example:

230 V ∆

Direct start Star-delta start

400 V Y

Direct start only

Elektrischer A

nschlussE

lectrical connectionR

accordement électrique

∆ / Y

96027-11.06-DGbF

∆Niedere Spannung

Low voltageBas voltage

YHohe Spannung

High voltageHaut voltage

L3L1 L2

L3L1 L2

Elektrischer A

nschlussE

lectrical connectionR

accordement électrique

∆ / Y

96027-11.06-DGbF

∆Niedere Spannung

Low voltageBas voltage

YHohe Spannung

High voltageHaut voltage

L3L1 L2

L3L1 L2L1 L2 L3

L1 L2 L3

INFO! The connection examples shown refer to the standard version.Inthecaseofspecialvoltages,theinstructionsaffixedtothe terminal box apply.

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5.3 Circuit diagramm for direct start 230 V ∆ / 400 V Y --> compressor with MP10

BT1 Cold conductor (PTC sensor) motor windingBT2 Thermal protection thermostat (PTC sensor)FC1 Load circuit safety switchesFC2 Control power circuit fuseBP1 Safety chain (high/low pressure monitoring)BP2 Release switch (thermostat/pressostat)

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Urspr.

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Ers.d.

Anlagenbezeichnung

Οnderung

Vorblatt:

Datum

1

Name

Bearb.

Gepr.

Norm

HG34P

R410A/Co2

200308Kommission:

Gesamtblatt:

Datum

27.05.2015

27.05.2015

11

Kelich

Name

Zeichnungsnummer:

Kundennummer:

Kunde:

Anlage

Bl. Gruppe:

=

2INT69_24V

Ort

Bl.

Fbl.

+

1 (ohne HA)

2HG34 FU+Box

27.0

5.20

15ES

SG_A

1_35

_01D

Klemmenkasten Verdichter

MP10

A1 Alarm Motorschutz

A2 Übertemperatur BT1, BT2

A3 Alarm Hochdruck

BT1

QA1

FC1

I> I>I>

QA2

PE

FC1

A1

X1 L1 L1 N N 43 43 11 12 14L S M

X2 1 2 3 4 5 6

FC2

SF1

BT2

A2

BP1

P

PE

A3

BP2

P<

PE

QA2

1 2

EB1

QA2

3 4

L1.1L2.1L3.1L1.2

NPE

-EC1 3~M

Θ

L1 L2 L3 N PE

Compressor terminal boxFig. 17

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QA1 Main switchSF1 Control voltage switchEC1 Compressor motorQA2 Compressor contactorMP10 Electronic trigger unit MP10EB1 Oil sump heater

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Οnderung

Vorblatt:

Datum

1

Name

Bearb.

Gepr.

Norm

HG34P

R410A/Co2

200308Kommission:

Gesamtblatt:

Datum

27.05.2015

27.05.2015

11

Kelich

Name

Zeichnungsnummer:

Kundennummer:

Kunde:

Anlage

Bl. Gruppe:

=

2INT69_24V

Ort

Bl.

Fbl.

+

1 (ohne HA)

2HG34 FU+Box

27.0

5.20

15ES

SG_A

1_35

_01D


MP10



A3 Alarm Hochdruck

BT1

QA1

FC1

I> I>I>

QA2

PE

FC1

A1

X1 L1 L1 N N 43 43 11 12 14L S M

X2 1 2 3 4 5 6

FC2

SF1

BT2

A2

BP1

P

PE

A3

BP2

P<

PE

QA2

1 2

EB1

QA2

3 4

L1.1L2.1L3.1L1.2

NPE

-EC1 3~M

Θ

L1 L2 L3 N PE

A1 Alarm motor protectionA2 Overheating BT1, BT2A3 Alarm high pressure

16

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PTC1 PTC2

Terminal boxFig. 18

Temperature monitoring connections: Motor winding: Terminals 1 - 2 Thermal protection thermostat: Terminals 3 - 4 Restart prevention: Terminals 5 - 6

ATTENTION!

Terminals 1 - 6 on the trigger unit MP 10 and terminals PTC 1 and PTC 2 on the compres-sor terminal board must not come into contact with mains voltage. This would destroy the trigger unit and PTC sensors.The supply voltage at L1-N (+/- for DC 24 V version) must be identical to the voltage at terminals11,12,14and43.

5.4 Electronic trigger unit MP 10

The compressormotor is fittedwith cold conductor temperature sensors (PTC) connected to theelectronic 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.

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 conditions occur. Find and remedy the cause.

5.5 Connection of the trigger unit MP 10

INFO! Connect the trigger unit MP10 in accordance with the circuit dia-gram. Protect the trigger unit with a delayed-action fuse (FC2) of max.4A.Inordertoguaranteetheprotectionfunction,installthetriggerunitasthefirstelementinthecontrolpowercircuit.

INFO! Theunithasarestartpreventiondevice.Afteryouhaverectifiedthefault,interruptthemainsvoltage.Thisunlockstherestartpreventiondevice and the LEDs H1 and H2 go out.

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The compressor and the trigger unit MP10 are operational when the H3 LED (green) lights.

5.6 Function test of the trigger unit MP 10

Pos ProcedureLED H1 LED H2 LED H3

red red green1 • Interrupt power supply (L1 or SF1) 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 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 SF1): OFF OFF ON• MP 10 is operational again

Before start-up, troubleshooting or making changes to the control power circuit, check the functionality of the trigger unit:

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Urspr.

Ers.f.

Ers.d.

Anlagenbezeichnung

Οnderung

Vorblatt:

Datum

2INT69

Name

Bearb.

Gepr.

Norm

HG34P

R410A/Co2

200308Kommission:

Gesamtblatt:

Datum

27.05.2015

27.05.2015

11

Kelich

Name

Zeichnungsnummer:

Kundennummer:

Kunde:

Anlage

Bl. Gruppe:

=

2INT69_24V

Ort

Bl.

Fbl.

+

2INT69 (Ohne HA)

2INT69HR60

27.0

5.20

15ES

SG_A

1_35

_01D




A3 Alarm Hochdruck

INT69 G

BT1

QA1

FC1

I> I>I>

QA2

PE

FC1

A1

FC2

SF1

A2

BP1

P

PE

A3

BP2

P<

PE

QA2

1 2

EB1

QA2

3 4

L1L2L3L1.1

NPE

1112 14L N B1 B2

-EC1 3~M

Θ

BT2

L1 L2 L3 N PE

5.7 Circuit diagramm for direct start 230 V ∆ / 400 V Y --> compressor with INT69 G

Fig. 19

BT1 Cold conductor (PTC sensor) motor windingBT2 Thermal protection thermostat (PTC sensor)FC1 Load circuit safety switchesFC2 Control power circuit fuseBP1 Safety chain (high/low pressure monitoring)BP2 Release switch (thermostat/pressostat)

Compressor terminal box

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0 1 2 3 4 5 6 7 8 9

Urspr.

Ers.f.

Ers.d.

Anlagenbezeichnung

Οnderung

Vorblatt:

Datum

2INT69

Name

Bearb.

Gepr.

Norm

HG34P

R410A/Co2

200308Kommission:

Gesamtblatt:

Datum

27.05.2015

27.05.2015

11

Kelich

Name

Zeichnungsnummer:

Kundennummer:

Kunde:

Anlage

Bl. Gruppe:

=

2INT69_24V

Ort

Bl.

Fbl.

+

2INT69 (Ohne HA)

2INT69HR60

27.0

5.20

15ES

SG_A

1_35

_01D




A3 Alarm Hochdruck

INT69 G

BT1

QA1

FC1

I> I>I>

QA2

PE

FC1

A1

FC2

SF1

A2

BP1

P

PE

A3

BP2

P<

PE

QA2

1 2

EB1

QA2

3 4

L1L2L3L1.1

NPE

1112 14L N B1 B2

-EC1 3~M

Θ

BT2

L1 L2 L3 N PE

QA1 Main switchSF1 Control voltage switchEC1 Compressor motorQA2 Compressor contactorINT69 G Electronic trigger unit INT69 GEB1 Oil sump heater

A1 Alarm motor protectionA2 Overheating BT1, BT2A3 Alarm high pressure

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5.8 Electronic trigger unit INT69 G

5.9 Connection of the trigger unit INT69 G

The compressormotor is fittedwith cold conductor temperature sensors (PTC) connected to theelectronic trigger unit INT69 G in the terminal box. In case of excess temperature in the motor winding, the INT69 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 supply voltage.

The hot gas side of the compressor can also be protected against overtemperature using thermal protection thermostats (accessory).

The unit trips when an overload or inadmissible operating conditions occur. Find and remedy the cause.

INFO The relayswitchingoutput isexecutedasafloatingchangeover contact.Thiselectricalcircuitoperatesaccordingtothequiescent currentprinciple, i.e. the relaydrops intoa the idlepositionand deactivatesthemotorcontactorevenincaseofasensorbreakor open circuit.

INFO Connect the trigger unit INT69 G in accordance with the circuit dia-gram. Protect the trigger unit with a delayed-action fuse (FC2) of max.4A.Inordertoguaranteetheprotectionfunction,installthetriggerunitasthefirstelementinthecontrolpowercircuit.

Οnderung

Klebeschilder

0

Datum Name

Datum

Bearb.

Gepr.

Norm

1

04.12.2009

Kelich

22.05.2015

Urspr.

2

Ers. f.

3

Ers. d.

4

Schaltplan

5 6 7

BOCK COMPRESSORS

8

=

+

9

Bl.

MP10 INt69 Bl.

MP10 INt69

INT69 G Motor Protection MP10

Steuerstrom-

kreis

LN

Steuerstrom-

kreis

L N1112 14

B1 B2OG OG

+

-BT1

Θ

X1 L1 L1 N N 43 43 11 12 14L S M

X2 1 2 3 4 5 6

R1 R2

+

-BT1

Θ

+

-BT2

Θ

+

-BT2

ΘLN


Terminal boxFig. 20

ATTENTION Measure circuit BT1 and BT2 (PTC sensor) must not come into contact with external voltage. This would destroy the trigger unit INT69 G and PTC sensors.

Control circuit

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5.11 Oil sump heater (accessories)

Inordertoavoiddamagetothecompressor,thecompressormustbeequippedwithanoilsumpheater.

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: 110 - 240 V - 1 - 50/60 Hz, 50 - 120 W, PTC-heater adjusting.

ATTENTION The oil sump heater must generally be connected and operated!

Relay position INT69 G

B2 12 14 11

Fig. 21

5.10 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 check using a continuity tester or gauge.


Gauge state Relay position

1. Deactivated state 11-12

2. INT69 G switch-on 11-14

3. Remove PTC connector 11-12

4. Insert PTC connector 11-12

5. Reset after mains on 11-14

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6| Commissioning

WARNING! Whenthecompressorisnotrunning,dependingonambient temperatureandamountofrefrigerantcharge,itispossiblethat the pressure may rise and exceed permitted levels for the compressor.Adequateprecautionsmustbetakentoprevent thishappening(e.g.usingacoldstoragemedium,areceivertank, asecondaryrefrigerantsystem,orpressurereliefdevices).

6.1 Preparations for start-up

INFO! In order to protect the compressor against inadmissible operating conditions,high-pressureandlow-pressurepressostatscontrolsaremandatory 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.

Checkthecompressorfortransportdamage!

6.4 Evacuation

ATTENTION! Do not start the compressor if it is under vacuum. Do not apply any voltage - even for test purposes (must only be operated with refrigerant).

Under vacuum, the spark-over and creepage current distances of the terminal board connection bolts shorten; this can result in winding and terminal board damage.

DANGER! Riskofbursting! 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 into the critical range.

6.3 Leaktest

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.

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.

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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. Repeatthisprocessasoftenasisrequired.

Make sure that the suction and pressure line shut-off valves are open.

Fillingtheliquidrefrigerant:Itisrecommendedthatthesystemfirstbefilledat standstill with gas on the high-pressure side up to a system pressure of at least5.2bar(ifitisfilledbelow5.2barwithliquid,thereisariskofdryiceformation).Furtherfillingaccordingtosystem.

To eliminate the possibility of dry ice formation when the system is operating (duringandafter thefillingprocess), theshut-offpointof the low-pressureswitch should be set to a value of at least 5.2 bar.

•Arefrigerantsupplement,whichmaybecomenecessaryafterstart-up,canbetopped up in vapour form on the suction side.

INFO! Depending upon design of the CO2refrigerantfillingbottle (with/without tubing) CO2canbefilledinliquidafterweightor gaseously. Use only high-dried CO2quality!

ATTENTION! Avoid overfilling the machine with refrigerant! Donotchargeliquidrefrigerantintothesuction-sideonthe compressor. Do not mix additives with the oil and refrigerant.

WARNING! Never exceed the max. permissible pressures while charging. Precautionsmustbetakenintime(eg.operatingauxiliaryconden-sing unit for standstill pressure control or high pressure stage of the cascade).

CAUTION! Wear personal protective clothing such as goggles and protective gloves!

6.5 Refrigerant charge

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6| Commissioning

Thecompressorisfittedwithtwodecompressionvalves.Onevalveeachonthesuctionanddischargeside.Ifexcessivepressuresarereached,thevalvesopenand prevent further pressure increase.Thereby CO2 is blown off to the ambient! (see also Chapter 7.6)!Intheeventthatapressurereliefvalveactivatesrepeatedly,checkvalveandreplaceifnecessaryasduringblow-offextremeconditionscanoccure,whichmayresultinapermanentleak.Alwayschecksystemforrefrigerantlossafteractivation 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 inthesystemanddesignedoradjustedinaccordancewithEN378-2orappro-priate safety standards.FailuretoobservecanresultinriskofinjuryfromCO2 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 properly.

Switch on the compressor and let it run for at least 10 minutes. Themachineshouldreachastateofequilibrium. Check the oil level: The oil level must be visible in the sight glass. After a compressor is replaced, the oil level must be checked again. If the level is too high, oil mustbedrainedoff(dangerofoilliquidshocks;reducedcapacityoftherefrigeratingsystem).

CO2 streaming out

Fig. 22

ATTENTION! Iflargerquantitiesofoilhavetobetoppedup,thereisariskofoilimpacteffects.Ifthisisthecase,checktheoilreturn!

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6.9 Connection of oil level regulatorThe connection "O" is provided for installing an oil level regulator. A corresponding adapter must be obtained from the trade.

6.8 Avoid slugging

ATTENTION! Slugging can result in damage to the compressor and cause refrigeranttoleak.

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). Thesystemmustreachastateofequilibrium. Particularlyincriticalsystems(e.g.severalevaporatorpoints),measuressuchastheuseofliquidtraps,solenoidvalveintheliquidline,etc.arerecommended. There should be no movement of refrigerant in the compressor while the system is at a standstill.

6| Commissioning

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7| Maintenance

7.5 Extract from the lubricants table

HGX22P / ... 110-4 CO2 125-4 CO2 160-4 CO2 190-4 CO2

Designation Item No. Item No. Item No. Item No.

Set of gaskets 80395

Valve plate kit 80305 80305 80306 80306

Set piston/connecting rod 80366 80468 80469 80471

Set connecting rod 80368

Only use genuine GEA spare parts!

7.3 Spare parts recommendation

For operation with CO2 the oil GEA C 85 E is necessary!

7.1 Preparation

7.2 Worktobecarriedout

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. - forfieldinstallationsorwhenoperatingneartheapplicationlimit:forthefirsttimeafter100

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! Beforestartinganyworkonthecompressor: Switch off the compressor and secure it to prevent a restart. Relieve compressor of system pressure. Preventairfrominfiltratingthesystem! After maintenance has been performed: Connect safety switch. Evacuate compressor. Releaseswitch-onlock.

Available accessories can be found on the Internet at www.gea.com

7.4 Accessories

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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 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 CO2intheoilcanbesetfree.Ifthedecompressionofthecompressorisnotsufficientenough, closed shut-off valves may lead 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| Maintenance

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8| Technical dataTy

pe

No. of cylinders

Disp

lace

men

t50

/ 60

Hz

(145

0 / 1

740

rp

m)

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ax.

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atin

gcu

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or

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e DV

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line

SV

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hA

kWA

kgm

m (i

nch)

mm

(inc

h)Lt

r.

HGX2

2P/1

10-4

CO

2

2

9,4

/ 11,

318

,9 /

10,9

6,0

121

/ 70

83

16 (5

/ 8)

22 (7

/ 8)

1,0

HGX2

2P/1

25-4

CO

211

,1 /

13,3

20,9

/ 12

,17,

212

1 / 7

078

HGX2

2P/1

60-4

CO

213

,7 /

16,4

25,6

/ 14

,88,

812

1 / 7

082

HGX2

2P/1

90-4

CO

216

,5 /

19,8

29,9

/ 17

,39,

913

4 / 7

784

12

3

2

4

220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz

Tole

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9| Dimensions and connections

SVDV

Suction lineDischarge line see technical data, Chapter 8

A* Connection suction side, not lockable 1/8“ NPTF

A1 Connection suction side, lockable 7/16“ UNF

B Connection discharge side, not lockable 1/8“ NPTF

B1 Connection discharge side, lockable 7/16“ UNF

D1 Connection oil return from oil separator 1/4“ NPTF

E Connection oil pressure gauge 1/8“ NPTF

F Oil drain M10

H Oil charge plug 1/4“ NPTF

J Oil sump heater (accessories) Ø 15 mm

K Sight glass 1 1/8“- 18 UNEF

L1 Thermal protection thermostat 1/8“ NPTF

O Connection oil level regulator 1 1/8“- 18 UNEF

SI1 Decompression valve HD 1/8“ NPTF

SI2 Decompression valve ND 1/8“ NPTF

* = only with additional adapter possible

Dimensions in mmFig. 231) SV 90° rotatable

Centre of gravity *

ca.135

ca.1

35 E

DV

FO,K

L1

J

B188

264

115

198ca.250

4x 12

ca.3

10 BSI1

SI2,A

Schwingungsdämpfer30

40M10

1.0850-10757.0 0h

Massenschwerpunkt 1) SV 90° drehbarMaße in mm

1)

Rz 12,5

Abnehmer oder Dritte ist nicht gestattet.

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Wir behalten uns alle Rechte, gemäß DIN ISO 16016

Tol.-Ang. DIN ISO 2768-mK Lieferantenzeichnung

-K.-Auftrag:PL:

Zeichnung ungültig

Entwicklungsstand

Teil keine Serie

120400

±0.5Baumustergeprüft

Teil inaktiv

-

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-

78

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Bearb.Datum

bis 6


Unbemaßte Radien:

Ausgangsteil, bzw. Rohteil:

-

Änderungs-Nr.

Werkstoff:-

Datum

08.07.


Gepr.

Ersetzt durch:

Name

Ersatz für:

08.07.Geprüft

2010FrankeErstellt

1/1

Zone

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Änderungsbeschreibung

400Benennung:

±0.8

-

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Oberflächenbehandlung / Härte:

-

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12030

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1.0850-10757.0

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Gußtoleranzen:

1000

±0.2


Maßstab:

HGX22P/190-4 CO2

Rz 25Rz 160

s

25

zyxwut

0,05 Rz 1,60,3

Diese Zeichnung ist unser Eigentum!Sie darf ohne unsere Genehmigung weder nach-gebildet, vervielfältigt, oder Dritten Personen zu-gänglich gemacht werden. Der Nachbau nachdieser Zeichnung, oder an Hand der nach dieserZeichnung hergestellten Gegenstände durch den

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-K.-Auftrag:PL:

Zeichnung ungültig

Entwicklungsstand

Teil keine Serie

120400


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über 0.5

-

78

Rz 636,3 Rz 162 1,6 0,7

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Werkstoff:-

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08.07.


Gepr.

Ersetzt durch:

Name

Ersatz für:

08.07.Geprüft

2010FrankeErstellt

1/1

Zone

-

Blatt:


400Benennung:

±0.8

-

30


-

±0.3

12030

Widmaier


6

1.0850-10757.0

Zust.

Gußtoleranzen:

1000

±0.2


Maßstab:

HGX22P/190-4 CO2

Rz 25Rz 160

s

25

zyxwut

0,05 Rz 1,60,3



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08.07.Geprüft

2010FrankeErstellt

1/1

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-

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±0.3

12030

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1.0850-10757.0

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Gußtoleranzen:

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Maßstab:

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Rz 25Rz 160

s

25

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F

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10| Declaration of installation

DECLARATION OF INSTALLATION

for using the compressors within the European Union(in accordance with Machinery Directive 2006/42/EC)

The manufacturer: GEA Bock GmbH, Benzstraße 7 72636 Frickenhausen, Tel.: 07022/9454-0

hereby declares that the refrigerating compressor HGX22P -CO2 complies with the basic requirementsofAppendixII1BoftheMachineryDirective2006/42/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 Directive (2006/42/EC).

Themanufacturerundertakestotransmitelectronicallythespecialdocumentationrequiredbyindividualstatesforpartlycompletedmachineryonrequest.

Thespecialtechnicaldocumentationrequiredforpartlycompletedmachineryhasbeencreatedin accordance with Appendix VII Part B.

Person responsible for documentation is: Wolfgang Sandkötter, Benzstraße 7, 72636 Frickenhausen.

Frickenhausen, 01.11.2011 ppa. Wolfgang Sandkötter, ChiefDevelopmentOfficer

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Dear customer,

GEAcompressorsaretop-quality,reliableandservice-friendlyqualityproducts. Ifyouhaveanyquestionsaboutinstallation,operationandaccessories,pleasecontactourtechnicalservice 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: [email protected]

Yours faithfully

GEABockGmbH

Benzstraße 7

72636Frickenhausen

Germany

11| Service

32

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9601

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GbF

EI ©

GEA

Gro

up A

G. A

ll rig

hts

rese

rved

.

GEA Bock GmbH

Benzstraße 7, 72636 Frickenhausen, GermanyTelephone: +49 7022 9454-0, Fax: +49 7022 [email protected], 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.

gea compressor hgx22p co 2 assembly instructions

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