D GB F E GEA Bock Compressor HAX2 CO2 T 96031-02.
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.
96031-02.2015-DGbF 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 4.8 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 7 7.1 7.2 7.3 7.4 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 HAX2 CO2 T manufactured by GEA Bock. The compressor is intended for use with CO2 in transcritical and/or subcritical 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 air-cooled drive motor. • Air flow is directed over motor by means of a fan and an air guide hood, which also serves to reduce the surface temperature at the compressor housing. • Cylindrical roller bearing support the crankshaft on the oilpumpside. • Double slide bearing on the motor flange. • Bi-directional oil pump with oil pressure relief valve.
2| Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany HAX2/110-4 CO2 T AS30046A002 26,7 A Y: 110 A Y: 141 A 1 2 3 4 5 380-420V Y/YY 9,66 440-480V Y/YY 1750 100/150 bar 65 11,66 CO2,C 85 E 6 7 8 9 10 11 12 13 Fig. 3 1 2 3 4 Type designation Machine number maximum operating current Starting current (rotor blocked) Y: Part winding 1 YY: Part winding 1 and 2 5 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. oil level min. oil level 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. Immediately after coolingtechnical connection of the compressor of shutoff devices in suction-, discharge-, oil return line etc. close and compressors evacuate. Check the compressor for transport damage before starting any work. 4.1 Storage and transport Fig.
4| Compressor assembly 4.4 Flange shut-off valves (HP/LP) ATTENTION! The compressor must be depressurised through connections A and B before commencing any work and prior to connecting to the refrigerant system. B A Fig. 11 Fig. 12 4.5 Operating mode of the lockable service connections D GB Spindle F Connection blocked Connection cannot be shut off E Service connection closed Pipe connection Fig.
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. 16 Fig. 15 4.7 Pipe connections • The compressor has a shut-off valve with multi-sided cutting ring for the safe installation of the D suction and discharge line.
4| Compressor assembly ATTENTION! Improperly installed pipes can cause cracks and tears which can result in a loss of refrigerant. 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 Rigid fixed point D Fig.
5| Electrical connection 5.2 Standard motor, designed for direct or part winding start Designation on the name plate Sticker on 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 = 70% and part winding 2 = 30%. This winding devision reduces the start-up current during a part winding start to approx. 65% of the value for a direct start.
5.3 Basic circuit diagram for part winding start 0 1 2 3 4 F2 F1.2 30% I=33% F1.1 I=66% 70% 4A S1 Q1 1 3 5 2 4 6 K1 1 3 5 2 4 6 F1.1 K2 F1.2 XSS L1 L2 L3 N PE 1 2 3 4 5 6 PE 7 8 D GB F E M1 1U1 1V1 1W1 M Y/YY 2U1 2V1 2W1 X1 L1 L1 N L N 43 43 11 X2 1 4 S 12 M 14 R1 2 3 5 MP10 6 R2 Compressor terminal box AnschluákastenVerdichter R1 Cold conductor (PTC sensor) motor winding Datum 02.Feb.
5 6 7 8 9 L1.1 L2.1 L3.1 L1.2 K1 K1 K1 K1T K1 9 10 11 12 13 K2 14 P> P F3 F4 K1T 15 16 N PE 17 18 19 20 P< D B1 GB F E X3 1 2 3 4 E1 F5 C1 T2 N L M S M 1 ~ 96031-02.2015-DGbF M1.1 PWMP10 P™l Q1 M1 M1.1 K1 K2 K1T S1 E1 XSS Main switch = Compressor motor + Fan motor BOCKCOMPRESSORS Mains contactor (part winding 1) Mains contactor (part winding 2) Delay relay max.
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 > 10 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. Close all shut-off valves. Relieve compressor of system pressure. Prevent air from infiltrating the system! After maintenance has been performed: Connect safety switch. Evacuate compressor. Open all shut-off valves. Function of the safety devices guarantee. Release switch-on lock..
7| Maintenance 7.5 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.
11,50 / 13,80 HAX2/130-4 CO2 T 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW PW=Part Winding Winding ratio: 70% / 30% 31,8 26,7 18,5 15,7 12,0 9,3 15,1 20,5 kW 2 Max. power consumption A Max. Operating current 2 ∆/Y 3 127 / 161 110 / 141 82 / 107 57 / 75 A ∆/ Y (rotor locked) Starting current 160 163 160 149 kg Weight Suction line SV 18 22 mm (inch) mm (inch) Discharge line DV Connections 4 2,5 Ltr. Oil charge 96031-02.
9| Dimensions and connections 5 6 7 4 3 320 Centre of gravity H E F,M 4x 210 260 ca.300 SV DV A Anschlüsse Sauganschluss, Rohr mit Schneidring Druckanschluss, Rohr mit Schneidring Anschluss Saugseite, nicht absperrbar 11 210 260 ca.340 ca.
10| Declaration of conformity and installation DECLARATION OF CONFORMITY CE 07 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: HAX2 CO2 T 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 96031-02.
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.
