GEA Bock HGX2/70-4 CO2 T User manual

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engineering for a better world GEA Refrigeration Technologies
GEA Bock Compressor HGX2 CO2 T
Assembly instructions
HGX2/70-4 CO2 T
HGX2/90-4 CO2 T
HGX2/110-4 CO2 T
HGX2/130-4 CO2 T
GEABock GmbH
72636Frickenhausen, Germany

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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

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Contents Page
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
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
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 MP10
5.5 Connection of the electronic trigger unit MP10
5.6 Functional test of the electronic trigger unit MP10
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 conformity and installation 30
11 Service 31

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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 Bock. GEA Bock refrigerating compressors are 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 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 2110- 4 CO2
XT
1
2
3
4
5
100/150 bar
HGX2/110-4 CO2T
AS30046A002
32,3 A
Y
Y: 110 A Y: 141 A
380-420V Y/YY
9,66
440-480V Y/YY
1740 11,66
65
13
12
7
11
6
10
8
9
CO2,C 85 E
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!
}
}
GEA Bock GmbH
72636 Frickenhausen, Germany

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3|Areas of application
 Thecompressorsarelledatthefactorywiththefollowingoiltype:
GEABock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. oil temperature ≥ 30°C.
- Min. pressure gas temperature ≥50°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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1
Max. permissible operating
pressure(LP/HP)1):100/150bar
1HGX2/130-4 CO2 T
Applications limit
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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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.
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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B
A
1 2
3
4
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4
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 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!

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Materialsoldering/weldingconnection:S235(JRG2C)
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
4.3 Connecting the pipelines - solder system
ATTENTION Damage possible.
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).
•On its high-pressure side, the compressor has a shut-off valve with multi-sided cutting ring for safe
installation of the discharge line.
Cutting ring function before tightening the union nut
4.4 Connecting the pipelines - cutting ring system
Tubepreparation:
The tube has to be sawn in a right angle. An angular tolerance of ±1° is permissible.
Slightly trim the pipe ends inside and outside. For thin walled steel pipes or soft pipes made of
nonferrous metal, reinforcing sleeves have to be used.
Pipeassembly:
Push Union Nut (5) and Cut Ring (3) onto Pipe (2). Insert pipe into Socket (6) as far as it will go and
firmly press against pipe stop, otherwise incorrect assembly. Hand tighten union nut until socket,
cutting ring and union nut are locked. Tighten union nut 1 ½ turns using a spanner wrench. The
cutting ring is noticeably locked to the socket face (for assembly inside pipe connection, hold up valve
with a spanner wrench). This should cause the cutting ring with its cutting edges to cut into the pipe
resulting in a visible collar. In order to stick to the turns we recommend using marking lines on union
nut and pipe. After assembly, it is necessary to check the collar. The gasket must not be damaged.
At least 80% of the cutting face has to be covered. After check-up, screw on and tighten again as
described above.
Fig. 12
Figure similar
. . . . .
Collar

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4|Compressor assembly
4.5 Pipes
4.6 Flangeshut-offvalves(HP/LP)
CAUTION Riskofinjury.
The compressor must be depressurised through connections A
andBbeforecommencinganyworkandpriortoconnectingtothe
refrigerant system.
Pipes and system components must be clean and dry inside and free of scale, swarf and layers of
rust and phosphate. Only use hermetically sealed 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.
AB
Fig. 13 Fig. 14
4.7 Option:cuttingringscrewjoint(HP/LP)
Remove
Schrader
connection HP
Remove
Schrader
connection LP
Abb. 15 Abb. 16
ATTENTION Property damage possible.
The compressor as delivered is equipped with Schrader valves on
the high and low pressure connections. These are used exclusively
for changing with inert gas in the factory, and under no circum-
stances may they be connected to the refrigeration circuit (the
Schradervalvesareapprovedforoverpressureupto28baronly)!

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4|Compressor assembly
Valve spindle seal
release
tighten
4.9 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.
Fig. 18 Fig. 19
4.8 Laying suction and pressure lines
Aruleofthumb:
Alwayslaytherstpipesectionstartingfromtheshut-offvalvedownwards and
parallel to the drive shaft.
ATTENTION Property damage possible.
Improperlyinstalledpipescancausecracksandtearswhichcan
result in a loss of refrigerant.
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.
Fig. 17
As short as
possible
Rigid fixed
point

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4.10Operatingmodeofthelockableserviceconnections
Pipe connection
Openingtheshut-offvalve:
Spindle: turn to the left (counter-clockwise) as far as it will go.
—> Shut-off valve completely opened / service connection closed.
The connection which cannot be shut off is intended for safety devices.
Opening the service connection
Spindle: Turn ½ - 1 turn to the right clockwise.
—> Service connection opened / shut-off valve opened.
The connection which cannot be shut off is intended for safety devices.
Spindle
Connection cannot
be shut offConnection
blocked
Service connec-
tion closed
Pipe connection
Spindle
Connection cannot
be shut offConnection
offen
Service connec-
tion opened
Fig. 13
Fig. 14
Afteractivatingthespindle,generallytthespindleprotectioncapagainandtightenwith14-16Nm.
This serves as a second sealing feature during operation.

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5|Electrical connection
5 Electrical connection
INFO 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.
Comparethevoltageandfrequencyvalueswiththedataforthe
mains power supply.
Only connect the motor if these values are the same.
DANGER Riskofelectricshock!Highvoltage!
Onlycarryoutworkwhentheelectricalsystemisdisconnected
from the power supply!
5.1 Information for contactor and motor contactor selection
All protection equipment, switching and monitoring devices must comply with the local safety
regulationsandestablishedspecications(e.g.VDE)aswellasthemanufacturer’sspecications.
Motorprotectionswitchesarerequired! Motor contactors, feed lines, fuses and motor protection
switches must be rated according to the maximum operating current (see name plate). For motor
protection, use a current-independent, time-delayed overload protection device for monitoring all
three phases. Adjust the overload protection device so that it must be actuated within 2 hours at 1.2
times the maximum working current.

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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 redu-
ces the start-up current during a part winding start to approx. 65% of the value for a direct start.
INFO Mechanicalstartunloaderwithbypasssolenoidisnotrequired.

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In the factory, the motor is switched for direct starting (YY). For part winding start (Y/YY), remove the
bridges and connect the motor feed cable according to the circuit diagram:
400 V
Direct start YY Part winding start Y/YY
L1
L2
L3
L1
L2
L3
L1 L3
L2
PTC
PW II
PW I
PTC
ATTENTION Property damage possible.
Failure to comply results in reversed elds of rotation and can
cause motor damage. After the motor has started up with part win-
ding1, partwinding2mustbeswitchedon aftermax.1second
delay. Failure to comply can be detrimental to the service life of
the motor.
Ensure that power is supplied via K1 to winding 1 (70%) (1U1 /
1V1/1W1)andviaK2towinding2(30%)(2U1/2V1/2W1).The
motorcontactors(K1/K2)areeachtoberatedforapprox.70%of
the max. operating current.
5|Electrical connection

18
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F
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nderung
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
20.Feb.2009
Kelich
09.M„r.2010
Urspr.
2
Ers.f.
3
Ers.d.
4
PWMP10
5 6 7
BOCKCOMPRESSORS
8
=
+
9
Bl.
1
Bl.
1
XSS
Q1
L1 L2 L3 NPE
AnschluákastenVerdichter
I=66%
F1.1
K1
1
2
1
3
4
2
5
6
3
1U1
1V1
1W1
PE
M
Y/YY
M1
R1
2U1
2V1
2W1
I=33%
F1.2
K2
1
2
4
3
4
5
5
6
6
X1 L1 L1 N N 43 43 11 12 14
LSM
X2123456
7
F1.1
F1.2
8
R2
4A
F2
S1
910
MP10
11
F5
K1
12
T2
13
N
P™l
14
L
15
M
16
S
P>
F3
17 18 19
K1
P
F4
20
K1
K1T
K2
21 22
K1T
P<
B1
23 24
K1
25
E1
26
L1.1
L2.1
L3.1
L1.2
N
PE
70% 30%
5.3 Basic circuit diagram for part winding start
Fig. 22
R1 Cold conductor (PTC sensor) motor winding
R2 Thermal protection thermostat (PTC sensor)
F1.1 /1.2 2 motor protection switches (70% / 30% of I Atotal)
F2 Control power circuit fuse
F3 High pressure safety monitor
F4 Safety chain (high/low pressure monitoring)
F5 Oil differential pressure monitor
B1 Release switch (thermostat)
Compressor terminal box

D
GB
F
E
19
96032-04.2015-DGbF
nderung
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
20.Feb.2009
Kelich
09.M„r.2010
Urspr.
2
Ers.f.
3
Ers.d.
4
PWMP10
5 6 7
BOCKCOMPRESSORS
8
=
+
9
Bl.
1
Bl.
1
XSS
Q1
L1 L2 L3 NPE
AnschluákastenVerdichter
I=66%
F1.1
K1
1
2
1
3
4
2
5
6
3
1U1
1V1
1W1
PE
M
Y/YY
M1
R1
2U1
2V1
2W1
I=33%
F1.2
K2
1
2
4
3
4
5
5
6
6
X1 L1 L1 N N 43 43 11 12 14
LSM
X2123456
7
F1.1
F1.2
8
R2
4A
F2
S1
910
MP10
11
F5
K1
12
T2
13
N
P™l
14
L
15
M
16
S
P>
F3
17 18 19
K1
P
F4
20
K1
K1T
K2
21 22
K1T
P<
B1
23 24
K1
25
E1
26
L1.1
L2.1
L3.1
L1.2
N
PE
Q1 Main switch
M1 Compressor motor
K1 Mains contactor (part winding 1)
K2 Mains contactor (part winding 2)
K1T Delay relay max. 1s
S1 Control voltage switch
E1 Oil sump heater
XSS Terminal strip in the external switch cabinet

20
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5|Electrical connection
Fig. 23
Temperature monitoring connections:
Motor winding: Terminals 1 - 2
Thermal protection thermostat: Terminals 3 - 4
Restart prevention: Terminals 5 - 6
ATTENTION
Terminals 1 - 6 on the trigger
unit MP10 and terminals PTC 1
and PTC 2 on the compressor
terminal board must not come
into contact with mains voltage.
This would destroy the trigger
unit and PTC sensors.
The supply voltage at L1-N
(+/-forDC24Vversion)must
be identical to the voltage at
terminals11,12,14and43.
5.6 Electronic trigger unit MP10
Thecompressormotoristtedwithcoldconductortemperaturesensors(PTC)connectedtotheelec-
tronic 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.
The hot gas side of the compressor can also be protected against overtemperature using a thermal
protection thermostat. The H2 LED (red) is provided for the protection function.
The unit trips when an overload or inadmissible operating conditions occur. Find and remedy
the cause.
5.7 Connection of the trigger unit MP10
INFO Theunithasarestartpreventiondevice.Afteryouhaverectiedthe
fault,interruptthemainsvoltage.Thisunlockstherestartprevention
device and the LEDs H1 and H2 go out.
INFO Connect the trigger unit MP10 in accordance with the circuit dia-
gram. Protect the trigger unit with a delayed-action fuse (F) of
max.4A.Inordertoguaranteetheprotectionfunction,installthe
triggerunitastherstelementinthecontrolpowercircuit.
Terminal box