GEA HGX12P CO2 Bedienungsanleitung

09917-11.2015-DGbFEI

engineering for a better world

GEA Compressor HGX12P CO2

Assembly instructions

HGX12P/30-4 CO2

HGX12P/40-4 CO2

HGX12P/50-4 CO2

HGX12P/75-4 CO2

09917-11.2015-DGbFEI

About these instructions

Read 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 Identicationofsafetyinstructions

 1.2 Qualicationsrequiredofpersonnel

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

09917-11.2015-DGbFEI

WARNING! DANGER OF SUFFOCATION!

 NeverreleasesignicantvolumesofCO2or the entire contents of

the system into closed rooms!

1|Safety

1.2 Qualicationsrequiredofpersonnel

1.3 General safety instructions

WARNING! Inadequately qualied 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qualica-

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

thereforerequireparticularcautionandcareinhandling.

• 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.

• The maximum permissible overpressure must not be exceeded,

even for testing purposes.

1.1 Identication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.

INFO! Importantinformationortipsonsimplifyingwork.

09917-11.2015-DGbFEI

1|Safety

These assembly instructions describe the standard version of the HGX12P -CO2manufactured by GEA.

The compressor is intended for use with CO2in sub-critical systems in compliance with the limits of

application.

Onlytherefrigerantspeciedintheseinstructionsmaybeused.

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EUaccordingtotheEUDirectives2006/42/ECMachineryDirective,97/23/ECPressureEquipment

Directive 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.

09917-11.2015-DGbFEI

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

HG 21 P 75- 4CO2

2.2 Name plate (example)

2.3 Typekey (example)

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

²) X - Ester oil charge

³) Additional declaration for Pluscom compressors

CO2Version

Number of poles

Swept volume

³)

Numbers of cylinders

Size

Oil charge ²)

Series ¹)

Fig. 3

C85E

40/55

AS33567A001

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

5 ND (LP): max. permissible operating 10 Nominal rotation speed

pressure (g) Low pressure side 11 Displacement

HD (HP):

max. permissible operating

 12 Oiltypelledatthefactory

pressur

e(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

}

GEA Bock GmbH

72636 Frickenhausen, Germany

09917-11.2015-DGbFEI

3|Areas of application

 Thecompressorsarelledatthefactorywiththefollowingoiltype:

GEA C 85 E (only this oil may be used)

3.1 Refrigerants

• CO2: R744

3.2 Oil charge

Evaporation temperature (°C)

Condensing temperature (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

R744

Fig. 5 Max. permissible operating

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

1) LP = Low pressure

HP = High pressure

Unlimited

application range

1HGX12P/75-4 CO2

Maximum condensing

temperature tc= 0°C

ATTENTION! Compressor operation is possible within the operating limits

shown in the diagrams. Please note the signicance

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.permissibleswitchingfrequency8x/h.

- A minimum running time of 3 min. steady-state condition

(continuous operation) must be achieved.

Foroperationwithfrequencyconverter:

- The maximum current and power consumption must not be

exceeded.Inthecaseofoperation abovethemainsfrequency,

the application limit can therefore be limited.

3.3 Limits of application

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.

0,5 Ltr.

oil level

Fig. 4

09917-11.2015-DGbFEI

4|Compressor assembly

4.3 Pipe connections

INFO! Newcompressorsarefactory-lled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.

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.pipeholders,additionalunits,fasteningparts,

etc.) directly to the compressor are not permissible!

4.2 Setting up

 Setuponanevensurfaceorframewithsufcientload-

bearing capacity.

Single compressor preferably on vibration damper.

Duplex and parallel circuits always rigid.

 Provideadequateclearanceformaintenancework.

 Ensureadequatecompressorventilation.

Do not use in a corrosive, dusty, damp atmosphere or a

combustible environment.

Fig. 8

Fig. 9

Fig. 10

Tol.-Ang. DIN ISO 2768-mK

Ra Rz

Maß

Passung

Freigabe

Alternativbezug:

Baumustergeprüft

Teil inaktiv

Lieferantenzeichnung

K.-Auftrag:

PL:

Zeichnung ungültig

Entwicklungsstand

Teil keine Serie

120

400

±0.5

über 0.5

bis 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 nach

dieser Zeichnung, oder an Hand der nach dieser

Zeichnung hergestellten Gegenstände durch den

Abnehmer oder Dritte ist nicht gestattet.

Wir behalten uns alle Rechte, gemäß DIN ISO 16016

an dieser Zeichnung vor.

Bearb.

Datum

Änderungs-Nr.

Werkstoff:

Ausgangsteil, bzw. Rohteil:

Gepr.

Name

Datum

19.04.

Werkstückkanten

DIN ISO 13715

Ersatz für:

Ersetzt durch:

Erstellt

2010

Geprüft

Kurz

Zone

1/x

Oberflächenbehandlung / Härte:

Blatt:

Änderungsbeschreibung

400

Benennung:

±0.8

1000

±0.3

120

±0.2

Zeichn.-Nr. Teile-Nr.

Oberflächenangaben ISO 1302

x.xxxx-xxxxx.x

Zust.

Gußtoleranzen:

Gewicht: (kg)

±0.1

Maßstab:

1:1

Wasserwaage

für Indesign

Der Lieferant muß sicherstellen, dass die Ware in

einwandfreiem Zustand angeliefert wird (Korrosions-

schutz, Verpackung für sicheren Transport).

Rz 25

Rz 160

0,05

Rz 1,6

0,3

0,7

1,6

Rz 16

6,3

Rz 63

Rz 6,3

Rz 12,5

F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage

09917-11.2015-DGbFEI

Fig. 12

Rigid

fixed point

As short as

possible

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installedpipes can cause cracks andtearswhich can

result in a loss of refrigerant.

A rule of thumb:

Alwayslaytherstpipesectionstartingfromtheshut-offvalvedownwards and

parallel to the drive shaft.

4|Compressor assembly

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.

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

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