GEA HGX4 CO2 Series Bedienungsanleitung

96020-09.2013-DGbFEI

engineering for a better world GEA Refrigeration Technologies

Bock Compressor HGX4 CO2

Assembly instructions

HGX4/310-4 CO2

HGX4/385-4 CO2

HGX4/465-4 CO2

HGX4/555-4 CO2

96020-09.2013-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.bock.de

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

3 Areas of application 8

3.1 Refrigerants

3.2 Oil charge

3.3 Limits of application

4Compressor assembly 9

4.1 Setting up

4.2 Pipe connections

4.3 Pipes

4.4 Laying suction and pressure lines

4.5 Operating the shut-off valves

4.6 Operating mode of the lockable service connections

5 Electrical connection 12

5.1 Information for contactor and motor contactor selection

5.2 Standard motor, design for direct or partial winding start

5.3 Basic circuit diagram for partial winding start with standard motor

5.4 Electronic trigger unit MP 10

5.5 Connection of the electronic trigger unit MP 10

5.6 Functional test of the electronic trigger unit MP 10

5.7 Oil sump heater (accessories)

6 Commissioning 18

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 22

7.1 Preparation

7.2 Work to be carried out

7.3 Spare parts recommendation

7.4 Accessories

7.5 Extract from the lubricants table

7.6 Decommissioning

8 Technical data 25

9 Dimensions and connections 26

10 Declaration of conformity and installation 28

11 Service 29

96020-09.2013-DGbFEI

Contents Page

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

3 Areas of application 8

3.1 Refrigerants

3.2 Oil charge

3.3 Limits of application

4Compressor assembly 9

4.1 Setting up

4.2 Pipe connections

4.3 Pipes

4.4 Laying suction and pressure lines

4.5 Operating the shut-off valves

4.6 Operating mode of the lockable service connections

5 Electrical connection 12

5.1 Information for contactor and motor contactor selection

5.2 Standard motor, design for direct or partial winding start

5.3 Basic circuit diagram for partial winding start with standard motor

5.4 Electronic trigger unit MP 10

5.5 Connection of the electronic trigger unit MP 10

5.6 Functional test of the electronic trigger unit MP 10

5.7 Oil sump heater (accessories)

6 Commissioning 18

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 22

7.1 Preparation

7.2 Work to be carried out

7.3 Spare parts recommendation

7.4 Accessories

7.5 Extract from the lubricants table

7.6 Decommissioning

8 Technical data 25

9 Dimensions and connections 26

10 Declaration of conformity and installation 28

11 Service 29

96020-09.2013-DGbFEI

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.

WARNING! DANGER OF SUFFOCATION!

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

the system into closed rooms!

96020-09.2013-DGbFEI

1|Safety

These assembly instructions describe the standard version of the HGX4 -CO2manufactured by Bock.

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 Bock 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.

96020-09.2013-DGbFEI

1 112

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four-cylinderreciprocatingcompressorwithsuction-gascooleddrivemotor.

• Flange-mounted drive motor on the compressor case.

• The stream of refrigerant sucked out of the evaporator flows over the motor and cools it

intensively. In this way, the motor can be kept at a relatively low temperature level, particularly

under high loads

2.1 Short description

96020-09.2013-DGbFEI

AS12345-001

27/55

C85E

2|Product description

2.2 Name plate (example)

2.3 Typekey (example)

¹) HG - Hermetic Gas-Cooled (suction gas-cooled) for deep-freezing

²) X - Ester oil charge

Fig. 3

HG 4310- 4CO2

CO2Version

Number of poles

Swept volume

Size

Oil charge ²)

Series ¹)

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

Y: Part winding 1 10 Nominal rotation speed

YY: Part windings 1 and 2 11 Displacement

5 ND (LP):

max. admissible operating

 12 Oiltypelledatthefactory

pressur

e (g) Low pressure side 13 Terminal box protection type

HD (HP):

max. admissible operating

Electrical accessories can change

pressur

e(g) High pressure side the IP protection class!

Observe the limits of application

diagrams!

50 Hz

}

60 Hz

}

GEA Bock GmbH

72636 Frickenhausen, Germany

96020-09.2013-DGbFEI

3|Areas of application

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.

- Max. permissible discharge end temperature 140 °C

    -Max.permissibleswitchingfrequency12x/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.

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

Bock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)

Fig. 5

R744

Max. permissible operating

pressure (LP/HP)1): 27/55 bar

1) LP = Low pressure

HP = High pressure

Unlimited

application range

1HGX4/385-4 CO2

Maximum condensing

temperature tc= 0°C

2HGX4/555-4 CO2

Maximum condensing

temperature tc= -7,5°C

The oil level must be in the visible

part of the sight glass; damage

to the compressor is possible if

overfilled or underfilled!

ATTENTION!

Fig. 4

max. oil level

min. oil level

96020-09.2013-DGbFEI

4|Compressor assembly

4.1 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.

Use transport eyelet.

Do not lift manually!

Use lifting gear!

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

 Ensureadequatecompressorventilation.

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

combustible environment.

Fig. 6

Fig. 7

Fig. 8

Fig. 9

4.2 Pipe connections

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. 10: graduated

internal diameter

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

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).

96020-09.2013-DGbFEI

4.4 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

4.3 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. 11

Rigid

fixed point

As short as

possible

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