GEA HGX12P CO2 User manual

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engineering for a better world
GEA Compressor HGX12P CO2
Assembly instructions
HGX12P/30-4 CO2
HGX12P/40-4 CO2
HGX12P/50-4 CO2
HGX12P/75-4 CO2

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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 General 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 9
4.1 Storage and transport
4.2 Setting up
4.3 Pipe connections
4.4 Pipes
4.5 Laying suction and pressure lines
4.6 Operating the shut-off valves
4.7 Operating mode of the lockable service connections
5 Electrical connection 12
5.1 Information for contactor and motor contactor selection
5.2 Connection of the driving motor
5.3 Circuit diagram for direct start 230 V Δ/ 400 V Y --> with MP10
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 Circuit diagram for direct start 230 V Δ/ 400 V Y --> with INT69 G
5.8 Electronic trigger unit INT69 G
5.9 Connection of the electronic trigger unit INT69 G
5.10 Functional test of the electronic trigger unit INT69 G
5.11 Oil sump heater (accessories)
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 Decompression valves
6.8 Avoiding slugging
6.9 Connection of oil level regulator
7 Maintenance 26
7.1 Preparation
7.2 Work to be carried out
7.3 Spare parts recommendation
7.4 Accessories
7.5 Lubricants
7.6 Decommissioning
8 Technical data 28
9 Dimensions and connections 29
10 Declaration of installation 30
11 Service 31

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WARNING! DANGER OF SUFFOCATION!
 NeverreleasesignicantvolumesofCO2or the entire contents of
the system into closed rooms!
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.

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1|Safety
These assembly instructions describe the standard version of the HGX12P -CO2manufactured by GEA.
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 GEA 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.

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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 two-cylinder reciprocating compressor with oil pump lubrication.
• Suction gas cooled drive motor.
2.1 Short description

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2|Product description
/
HG 21 P 75- 4CO2 X
2.2 Name plate (example)
2.3 Typekey (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X - Ester oil charge
³) Additional declaration for Pluscom compressors
CO2Version
Number of poles
Swept volume
³)
Numbers of cylinders
Size
Oil charge ²)
Series ¹)
Fig. 3
1
2
3
4
5
7
6
10
8
9
13
12
11
C85E
40/55
AS33567A001
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
5 ND (LP): max. permissible operating 10 Nominal rotation speed
pressure (g) Low pressure side 11 Displacement
HD (HP): max. permissible operating  12 Oiltypelledatthefactory
pressur e(g) High pressure side 13 Terminal box protection type
Observe the limits of application Electrical accessories can change
diagrams! the IP protection class!
50 Hz
}
60 Hz
}
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 C 85 E (only this oil may be used)
3.1 Refrigerants
• CO2: R744
3.2 Oil charge
Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Suction gas temperature (°C)
R744
1
Fig. 5 Max. permissible operating
pressure (LP/HP)1): 40/55 bar
1) LP = Low pressure
HP = High pressure
Unlimited
application range
1HGX12P/75-4 CO2
Maximum condensing
temperature tc= 0°C
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 140 °C
    -Max.permissibleswitchingfrequency8x/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.
3.3 Limits of application
The oil level must be in the
visible part of the sight
glass; damage to the com-
pressor is possible if over-
filled or underfilled!
ATTENTION!max.
min.
0,5 Ltr.
oil level
Fig. 4
~
~

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4|Compressor assembly
4.3 Pipe connections
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).
?
4.1 Storage and transport
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!
4.2 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.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
Do not use in a corrosive, dusty, damp atmosphere or a
combustible environment.
Fig. 8
Fig. 9
Fig. 10
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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

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Fig. 12
Rigid
fixed point
As short as
possible
4.5 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
4.4 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.
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