GEA HGX34 CO2 T Series User manual

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engineering for a better world GEA Refrigeration Technologies
Bock Compressor HGX34 CO2 T
Assembly instructions
HGX34/110-4 ML CO2 T HGX34/110-4 S CO2 T HGX34/110-4 SH CO2 T
HGX34/130-4 ML CO2 T HGX34/130-4 S CO2 T HGX34/130-4 SH CO2 T
HGX34/150-4 ML CO2 T HGX34/150-4 S CO2 T HGX34/150-4 SH CO2 T
HGX34/170-4 ML CO2 T HGX34/170-4 S CO2 T HGX34/170-4 SH CO2 T
HGX34/190-4 ML CO2 T HGX34/190-4 S CO2 T HGX34/190-4 SH CO2 T
HGX34/210-4 ML CO2 T HGX34/210-4 S CO2 T HGX34/210-4 SH CO2 T
HGX34/230-4 ML CO2 T HGX34/230-4 S CO2 T HGX34/230-4 SH 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.bock.de
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 12
4.1 Setting up
4.2 Pipes
4.3 Flange shut-off valves (HP/LP
4.4 Option: cutting ring screw joint (HP/LP)
4.5 Operating mode of the lockable service connections
4.6 Operating the shut-off valves
4.7 Connecting the pipelines - cut ring system
4.8 Connecting the pipelines - solder system
4.9 Laying suction and pressure lines
4.10 Oil return
5 Electrical connection 17
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 Special motor: design for direct or star-delta start
5.5 Star-delta start with special motor
5.6 Electronic trigger unit MP 10
5.7 Connection of the electronic trigger unit MP 10
5.8 Functional test of the electronic trigger unit MP 10
5.9 Oil sump heater
6 Commissioning 28
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
7 Maintenance 32
7.1 Preparation
7.2 Work to be carried out
7.3 Accessories
7.4 Spare parts recommendation
7.5 Decommissioning
8 Technical data 34
9 Dimensions and connections 36
10 Declaration of conformity and installation 38
11 Service 39

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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 Bock. 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).
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
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.
NeverreleasesignicantvolumesofCO2or the entire contents of
the system into closed rooms!
•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.
WARNING The compressor may not be used in potentially explosive
environments!

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2|Product description
• Semi-hemeticfour-cylinderreciprocatingcompressorwithsuctiongascooleddrivingmotor.
• Theflowofrefrigerantsuckedinfromtheevaporatorisledovertheengineandprovidesfor
a particularly intensive cooling. Thus the engine can be kept special during high load on a
relatively low temperature level.
• Onedecompressionvalveeachonthelowandhighpressureside,whichventintothe
amosphere when these inadmissibly high printing pressures are reached.
Fig. 1
2.1 Short description
Fig. 2
Oil sight glass
Valve plate
Cylinder cover
Motor section
Dimension and connection values can be found in Chapter 9
Transport eyelet
Oil pump
Drive section
Discharge
shut-off valve
Name plate
Suction
shut-off valve
Terminal box

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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!
}
}
Fig. 3
/
HG 34230- 4CO2 X
2.3 Typekey (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X - Ester oil charge
³)ML - Normal cooling and deep freezing at low and medium evaporation temperatures
S - Forfrequencyregulationandextendedlimitsofapplication
SH - For high evaporating temperatures eg. heat pumps, different oil charge
transcritical
CO2version
Compressor version ³)
Number of poles
Swept volume
Numbers of cylinders
Size
Oil charge ²)
Series ¹)
T
S
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AS12345-001
59,3 A
231 A 283 A
20,1
24,1
CO2,C 85 E
HGX34/230-4 S CO2T
100/150 bar
GEA Bock GmbH
72636 Frickenhausen, Germany
2|Product description
2.2 Name plate (example)

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3|Areas of application
 Thecompressorsarelledatthefactorywiththefollowingoiltype:
Compressor version ML andS: BockC85E
Compressor versionSH: BockC150E
(only this oils may be used)
3.1 Refrigerants
• CO2: R744(RecommendationCO2quality4.5(<5ppmH2O))
3.2 Oil charge
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.
- Max. permissible discharge end temperature 160°C.
- Min. oil temperature ≥ 30°C
- Max. permissible ambient temperature -30°C - +60°C
-Max.permissibleswitchingfrequency12x/h.
- A minimum running time of 3 min. steady-state condition
(continuous operation) must be achieved.
Avoid continuous operation in limit range.
Foroperationwithfrequencyconverter:
-Frequencyrange25-70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
max. oil level
min. oil level
Fig. 4
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!

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3|Areas of application
toEvaporation temperature (°C)
∆toh Suction gas superheat (K)
po Suction pressure (bar)
pv2Discharge end pressure (bar)
Unlimited
application range
Fig. 5
Max. permissible operating
pressure (LP/HP)1):100/150bar
1) LP = Low pressure
HP = High pressure
10 20 30 50
50
40
90
80
120
Einsatzgrenzen HGX34 CO
2 T
100
70
60
40 po (bar)
p
V2
(bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
Compressor version ML

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toEvaporation temperature (°C)
∆toh Suction gas superheat (K)
po Suction pressure (bar)
pv2Discharge end pressure (bar)
Unlimited
application range
Fig. 6
Max. permissible operating
pressure (LP/HP)1):100/150bar
1) LP = Low pressure
HP = High pressure
10 20 30 50
50
40
90
80
120
Einsatzgrenzen HGX34 CO
2 T
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
p
V2
(bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
Compressor version S
3|Areas of application