GEA Bock HGX2 CO2 T Series User manual

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GEA Bock HGX2 CO2T
Assembly instructions
96458-03.2019-Gb
Translation of the original instructions
GEABock GmbH
72636Frickenhausen, Germany
HGX2/70-4 CO2 T
HGX2/90-4 CO2 T

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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 [phone]
Fax [phone]
[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 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 10
4.1 Storage and transportation
4.2 Setting up
4.3 Connecting the pipelines - solder system
4.4 Connecting the pipelines - cutting ring system
4.5 Pipes
4.6 Flange shut-off valves (HP/LP)
4.7 Option: cutting ring screw joint (HP/LP)
4.8 Laying suction and pressure lines
4.9 Operating the shut-off valves
4.10 Operating mode of the lockable service connections
 4.11 Suctionpipelter
5 Electrical connection 15
5.1 Information for contactor and motor contactor selection
5.2 Standard motor, designed for direct or part winding start
5.3 Basic circuit diagram for part winding start
5.4 Electronic trigger unit INT69 G
5.5 Connection of the electronic trigger unit INT69 G
5.6 Functional test of the electronic trigger unit INT69 G
5.7 Oil sump heater
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 Pressure switch
6.8 Decompression valves
6.9 Avoiding slugging
6.10 Filter dryer
7 Maintenance 26
7.1 Preparation
7.2 Work to be carried out
7.3 Accessories
7.4 Spare parts recommendation
7.5 Lubricants
7.6 Decommissioning
8 Technical data 28
9 Dimensions and connections 29
10 Declaration of installation 31
11 Service 32

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1|Safety
1.1 Identicationofsafetyinstructions:
1.2 Qualicationsrequiredofpersonnel
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cationslistedbelow:
• For example, a refrigeration technician, refrigeration mechatronics
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
the work to be carried out and recognising any potential dangers.
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.
ATTENTION Indicatesasituationwhich,ifnotavoided,maycause
property damage
INFO Importantinformationortipsonsimplifyingwork

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1|Safety
These assembly instructions describe the standard version of the compressors named in the
title manufactured by GEA. GEA refrigerating compressors are intended for installing in a
machine (within the EU according to the EU Directives 2006/42/EC Machinery Directive and
2014/68/EUPressureEquipmentDirective).
Commissioning is only permissible if the compressors have been installed in accordance with these
assembly instructions and the entire system into which they are integrated has been inspected and
approved in accordance with legal regulations.
The compressors are intended for use with CO2in transcritical and/or subcritical 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!
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.
The contactwithrefrigerantcanleadtosevere burnsandskin
irritations.
Danger of suffocation.
CO2 is a nonammable, acidic, colorless and odorless gas and
heavier than air.
NeverreleasesignicantvolumesofCO2or the entire contents of
the system into closed rooms!
Safetyinstallationsaredesignedoradjustedinaccordancewith
EN 378-2 or appropriate safety standards.
• Transcritical CO2applications are still in the development phase.
•Theyrequireacompletelynewkindofsystemandcontrol.
• They are not a general solution for the substitution of F-gases.
•Therefore, we expressly point out that all information in this
assembly instruction has been provided according to our current
 levelofknowledgeandmaychangeduetofurtherdevelopment.
Legal claims based on the correctness of the information cannot
be made at any time and are hereby expressly excluded.

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100/150bar
HAX2/110-4CO
2
T
AS30046A002
26,7A
380-420VY/YY
9,66
440-480VY/YY
1750 11,66
65
CO2,C85 E
Y:110 A Y: 141 A
GEAGEA Bock GmbH
72636Frickenhausen, Germany
2| Product description
•Semi-hermetic two-cylinder reciprocating compressor with suction gas-cooled drive motor.
•The refrigerant coming from the evaporator is entering the compressor and owing over
the motor. This ensures an especially intensive cooling of the motor. Therefore the motor
temperature remains on a relatively low level - especially at high load.
• Oil pump independent of direction of rotation for reliable and safe oil supply.
•One decompression valve each on the low and high pressure side, which vent into the
atmosphere when these inadmissibly high printing pressures are reached.
2.1 Short description
Discharge
shut-off valve
Dimension and connection values can be found in Chapter 9
Fig. 1
Fig. 2
Cylinder cover
Transport eyelet
Valve plate
Oil pump
Terminal box
Suction
shut-off valve Motor section
Drive section
Name plate
Oil sight glass

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2| Product description
2.2 Name plate (example)
2.3 Typekey (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X - Ester oil charge
Fig. 3
/
Transcritical
CO2version
Number of poles
Swept volume
Size
Oil charge ²)
Series¹)
HG 2 4 CO2
XT
1 Type designation
2 Machine number
3 maximum operating current
4 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. permissible operating
pressur e(g) High pressure side
Observe the limits of
application diagrams!
50 Hz
60 Hz
6 Voltage,circuit,frequency
7 Nominal rotation speed
8 Displacement
9 Voltage,circuit,frequency
10 Nominal rotation speed
11 Displacement
12 Oiltypelledatthefactory
13 Terminal box protection type
Electrical accessories can change
the IP protection class!
}
}
1
2
3
4
5
100/150 bar
HGX2/90-4 CO2T
AZ30046A002
23,8 A
Y
Y: 87 A Y: 149 A
380-420V Y/YY
7,70
440-480V Y/YY
1740 9,30
65
13
12
7
11
6
10
8
9
CO2,C 85 E
GEA Bock GmbH
72636 Frickenhausen, Germany
90-

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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(RecommendationCO2quality4.5(<5ppmH2O))
3.2 Oil charge
ATTENTION Property damage possible.
The oil level must be in the
visible part of the sight glass;
damage to the compressor
is possible if overfilled or
underfilled! Fig. 4
max.
min.
2,0 Ltr.
oil level ~
~
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 160 °C.
- Min. discharge end temperature ≥50 °C.
- Min. oil temperature ≥ 30 °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 supplementary cooling:
- Use only oils with high thermal stability.
- Avoid continuous operation near the threshold.
Foroperationwithfrequencyconverter:
-Frequencyrange30-60Hz.
- 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

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Max. permissible operating
pressure (LP/HP)1):100/150bar
1) LP = Low pressure
HP = High pressure
Fig. 5
Unlimited
application range
3|Areas of application
toEvaporation temperature (°C)
∆toh Suction gas superheat (K)
po Suction pressure (bar)
pv2Discharge end pressure (bar)

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4|Compressor assembly
INFO New compressors are factory-lled with inert gas. 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.
4.2 Setting up
 Setuponanevensurfaceorframewithsufcientload-bearing
capacity.
Single compressor preferably on vibration damper.
Compound connection basically rigid.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
Do not use in a corrosive, dusty, damp atmosphere or a com-
bustible environment.
Fig. 8
Fig. 9
Fig. 10
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A
1 2
3
4
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3
2
1
A
B
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
30 6
-
±0.3
120
30
±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
s
25
z y x w u t
0,05
Rz 1,6
0,3
0,7
1,6
2
Rz 16
6,3
Rz 63
Rz 6,3
Rz 12,5
F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage
?
4.1 Storage and transportation
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
combustible environment.
Fig. 7
Fig. 6
ATTENTION Attachments(e.g.pipeholders,additionalunits,fasteningparts,
etc.) directly to the compressor are not permissible!