D GB 6 7 8 9 10 11 12 13 1 2 3 4 F 5 E GEA Bock Compressor HGX4 CO2 96020-02.
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.
96020-02.2015-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 immediately cause fairly severe or minor injury.
1| Safety 1.3 Safety instructions WARNING Risk of accident. Refrigerating compressors are pressurised machines and therefore require particular caution and care in handling. The maximum permissible overpressure must not be exceeded, even for testing purposes. 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. - Avoid the contact with refrigerant under any circumstances.
2| Product description 2.1 Short 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.
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 AS12345-001 C85E 27/55 Fig. 3 1 2 3 4 5 Type designation Machine number maximum operating current Starting current (rotor blocked) Y: Part winding 1 YY: Part windings 1 and 2 ND (LP): max. admissible 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 correct oil level is shown in figure 4. Damage to the compressor is possible if overfilled or underfilled! max. ~ ~ 1,8 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 T he 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. Release Tighten Valve spindle seal Fig. 14 Fig. 13 4.
5| Electrical connection 5 Electrical connection DANGER INFO Risk of electric shock! High voltage! Only carry out work when the electrical system is disconnected from the power supply! 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.
5| Electrical connection 5.2 Standard motor, design for direct or partial winding start Designation on the name plate Sticker on the terminal box Y/YY Compressors with this marking are suitable for direct or partial winding start. The motor winding is subdivided into two parts: Partial winding 1 = 66% and part winding 2 = 33%. This winding division reduces the start-up current needed for a part winding start to approx. 65% of that for a direct start.
5.3 Basic circuit diagram for partial winding start with standard motor D GB F E Compressor terminal box 1-2 R1 R2 F1.1/F1.
D GB F E 96020-02.2015-DGbFEI S1 M1 K1 K2 K1T MP10 E1 XSS Control voltage switch Compressor motor Mains contactor (part winding 1) Mains contactor (part winding 2) Delay relay max.
5| Electrical connection 5.4 Electronic trigger unit MP10 The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the electronic trigger unit MP10 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 To protect the compressor against inadmissible operating conditions, high pressure and low pressure pressostats 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 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. First evacuate the system and then include the compressor in the evacuation process. Relieve the compressor pressure.
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 Avoiding slugging ATTENTION Slugging can damage the compressor and cause refrigerant to leak. To prevent slugging: The complete refrigeration system 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 superheat at the compressor input should be min. 15 - 25 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 lock. 7.
7| Maintenance 7.3 Spare parts recommendation HGX4 / ... 310-4 CO2 385-4 CO2 465-4 CO2 555-4 CO2 Designation Item No. Item No. Item No. Item No. Set of gaskets 80472 08913 Valve plate kit 80473 80438 80438 80439 Set piston/connecting rod 80399 80399 80433 80434 Set connecting rod 80424 Only use genuine GEA Bock spare parts! 7.4 Accessories Available accessories can be found on the Internet at www.gea.com. 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.
48,2 / 57,8 HGX4/555-4 CO2 1 Voltage 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW 38,3 38,3 31,6 28,2 A PW 1 + 2 Max. Operating current 2 3 kg 152 151 154 157 A 82 / 107 82 / 107 107 / 140 107 / 140 PW 1 / PW 1 + 2 (rotor locked) Starting current Weight 28 (1 1/8) 22 (7/8) mm (inch) Discharge line DV 35 (1 3 /8) 28 (1 1/8) mm (inch) Suction line SV Connections 4 2,7 Ltr.
6 7 9| Dimensions and connections DV L1 A* ca.360 306 Centre of gravity B 1) ca.180 A1 Q 6 7436 535 ca.690 75 DV L1 A* 64 DV L1 A* ca.360 306 DV L1 A* F E ca.180 A1 SI1 D P ca.235 73 Q F73112 ca.
9| Dimensions and connections SV DV Suction line Discharge line A* Connection suction side, not lockable A1 Connection suction side, lockable B Connection discharge side, not lockable B1 Connection discharge side, lockable C Connectoin oil pressure switch OIL D Connection oil pressure switch LP D1 Connection oil return from oil separator E Connection oil pressure gauge 1/ “ NPTF 8 7/ “ UNF 16 1/ “ NPTF 8 7/ “ UNF 16 7/ “ UNF 16 7/ “ UNF 16 1/ “ NPTF 4 1/ “ NPTF 8 F Oil drain M22 x 1,5
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: HGX4 -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 96020-02.
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.
