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GEA Bock HGX46 CO
Assembly instructions
96460-08.2018-Gb
Translation of the original instructions
HGX46/280-4 ML CO
2
HGX46/310-4 ML CO
2
HGX46/345-4 ML CO
2
HGX46/440-4 ML CO
2
T
HGX46/280-4 S CO
T
HGX46/310-4 S CO
T
HGX46/345-4 S CO
T
T
2
T
HGX46/280-4 SH CO
2
T
HGX46/310-4 SH CO
2
T
HGX46/345-4 SH CO
2
T
2
T
2
T
2
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Table of Contents
Related Manuals for GEA Bock HGX46 CO2 T Series
Summary of Contents for GEA Bock HGX46 CO2 T Series
- Page 1 GEA Bock HGX46 CO Assembly instructions 96460-08.2018-Gb Translation of the original instructions HGX46/280-4 ML CO HGX46/280-4 S CO HGX46/280-4 SH CO HGX46/310-4 ML CO HGX46/310-4 S CO HGX46/310-4 SH CO HGX46/345-4 ML CO HGX46/345-4 S CO HGX46/345-4 SH CO HGX46/440-4 ML CO...
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Page 2: Table Of Contents
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. Manufacturer GEA Bock GmbH 72636 Frickenhausen Contact GEA Bock GmbH Benzstraße 7... - Page 3 Contents Page Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application Compressor assembly 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 Laying suction and pressure lines 4.8 Operating the shut-off valves...
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Page 4: Safety
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 imme- diately cause fairly severe or minor injury. -
Page 5: Safety Instructions
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). -
Page 6: Product Description
2 | Product description 2.1 Short description • Semi-hermetic six-cylinder reciprocating compressor with suction gas cooled driving motor. • The flow 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 on a relatively low temperature level specially during high load. -
Page 7: Type Key
2 | Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany HGX46/345-4 S CO 30,2 AV12345-001 90,9 A 36,2 221 A 361 A CO2,C 85 E 100/150 bar Fig. 3 Type designation Voltage, circuit, frequency 50 Hz... -
Page 8: Areas Of Application
R744 (Recommendation CO quality 4.5 (< 5 ppm H 3.2 Oil charge The compressors are filled at the factory with the following oil type: Compressor version ML and S: GEA C85E Compressor version SH: GEA C150E (only this oils may be used) ATTENTION Property damage possible. - Page 9 3 | Areas of application Einsatzgrenzen HGX34+46 CO Compressor version ML (bar) ?t = 10 K (bar) 64,3 (°C) Unlimited Fig. 5 application range Max. permissible operating (bar) pressure (LP/HP) : 100/150 bar Evaporation temperature (°C) ∆t Suction gas superheat (K) LP = Low pressure Suction pressure (bar) HP = High pressure...
- Page 10 (bar) 64,3 3 | Areas of application (°C) Compressor version S (bar) ?t = 10 K (bar) 64,3 (°C) Unlimited Fig. 6 application range Max. permissible operating (bar) pressure (LP/HP) : 100/150 bar Evaporation temperature (°C) ∆t Suction gas superheat (K) LP = Low pressure Suction pressure (bar) HP = High pressure...
- Page 11 (bar) 64,3 3 | Areas of application (°C) Compressor version SH (bar) ?t = 10 K (bar) 64,3 (°C) Unlimited Fig. 7 application range Max. permissible operating pressure (LP/HP) : 100/150 bar Evaporation temperature (°C) ∆t Suction gas superheat (K) LP = Low pressure Suction pressure (bar) HP = High pressure...
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Page 12: Compressor Assembly
4 | Compressor assembly INFO New compressors are factory-filled with inert gas. Leave this service charge in the compressor for as long as possible and prevent the ingress of air. Immediately after refrigeration technological connection of the compressor close the shut-off devices in suction-, dis- charge-, oil return line etc. -
Page 13: Connecting The Pipelines - Solder System
4 | Compressor assembly 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). Material soldering / welding connection: S235 (JRG2C) The pipe connections have graduated inside diameters so that pipes with standard millimetre and inch dimensions can be used. -
Page 14: Pipes
4 | Compressor assembly 4.5 Pipes 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. -
Page 15: Laying Suction And Pressure Lines
4 | Compressor assembly 4.7 Laying suction and pressure lines 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. -
Page 16: Operating Mode Of The Lockable Service Connections
To ensure the oil return function will work reliably no matter what kind of system configuration you are using, GEA recommends incorporating oil separators or oil level monitoring equipment. The "O" connection is already available from the factory for the purpose of installing the additional oil level monitoring component. -
Page 17: Electrical Connection
5 | Electrical connection Electrical connection DANGER Risk of electric shock! High voltage! Only carry out work when the electrical system is disconnected from the power supply! ATTENTION When attaching accessories with an electrical cable, a minimum bending radius of 3 x the cable diameter must be maintained for laying the cable. -
Page 18: Standard Motor, Designed For Direct Or Part Winding Start
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 = 50 % and part winding 2 = 50 %. - Page 19 5 | Electrical connection 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 PW II PW I ATTENTION Property damage possible.
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Page 20: Basic Circuit Diagram For Part Winding Start
5 | Electrical connection 5.3 Basic circuit diagram for part winding start FC1.2 FC1.1 FC1.2 FC1.1 I> I> I> I> I> I> I> I> I> I> I> I> FC1.1 FC1.1 FC1.2 FC1.2 L3 N PE L3 N PE Y/YY Y/YY B1 B2 B1 B2 INT69... - Page 21 L1.1 L1.1 L2.1 L2.1 L3.1 L3.1 L1.2 L1.2 P> P> Θ Θ Θ Θ Θ Θ DELTA- P II DELTA- P II 6.c.8 FC1.1/1.2 Motor protection switch 6.c.8 Control power circuit fuse INT69 G Electronic trigger unit INT69 G Delay relay for contactor switch over Main switch Mains contactor (part winding 1) PW INT69 HGX34 46 CO2T...
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Page 22: Special Motor: Design For Direct Or Star-Delta Start
5 | Electrical connection 5.4 Special motor: design for direct or star-delta start Designation on the name plate Sticker on the terminal box Δ / Y... - Page 23 5 | Electrical connection Star-delta start-up is only possible for 230 V power supply. Example: 230 V Δ 400 V Y Direct start Star-delta start Direct start only...
- Page 24 5 | Electrical connection 5.5 Basic circuit diagram for star-delta start with special motor FC1.1 FC1.1 I> I> I> FC1.1 I> I> I> I> I> I> FC1.1 FC1.1 FC1.1 FC1.2 FC1.2 FC1.2 FC1.2 I> I> I> FC1.2 FC1.2 I> I> I>...
- Page 25 L1.1 L2.1 L1.1 L3.1 L2.1 L1.1 L1.2 L3.1 L2.1 L1.2 L3.1 L1.2 P> P> P> Θ Θ Θ Θ Θ Θ Θ Θ Θ DELTA- P II DELTA- P II 6.a.7 6.a.8 6.a.8 DELTA- P II 6.a.7 6.a.8 6.a.8 6.b.7 6.b.8 6.b.8 FC1.1/1.2 Motor protection switch...
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Page 26: Electronic Trigger Unit Int69 G
5 | Electrical connection 5.6 Electronic trigger unit INT69 G The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the electronic trigger unit INT69 G in the terminal box. In case of excess temperature in the motor winding, the INT69 G deactivates the motor contactor. -
Page 27: Oil Sump Heater
5 | Electrical connection 5.8 Function test of the trigger unit INT69 G Before commissioning, after troubleshooting or making changes to the control power circuit, check the functionality of the trigger unit. Perform this check using a continuity tester or gauge. Relay position INT69 G Trigger unit state Relay position... -
Page 28: Commissioning
6 | Commissioning 6.1 Preparations for start-up INFO In order to protect the compressor against inadmissible operating conditions, high-pressure and low-pressure pressostats controls 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. -
Page 29: Evacuation
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;... -
Page 30: Start-Up
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. -
Page 31: Decompression Valves
6 | Commissioning 6.8 Decompression valves ATTENTION The compressor is fitted with two decompression valves. One valve each on the suction and discharge side. If excessive pressures are reached, the valves open and prevent further pressure increase. Thereby CO is blown off to the ambient! In the event that a pressure relief valve activates repeatedly, check valve and replace if necessary as during blow-off extreme con- ditions can occur, which may result in a permanent leak. -
Page 32: Avoiding Slugging
6 | Commissioning 6.9 Avoiding slugging ATTENTION Slugging can result in damage to the compressor and cause refrigerant to leak. To prevent slugging: The complete refrigeration plant must be properly designed. All components must be compatibly rated with each other with regard to output (particularly the evaporator and expansion valves). -
Page 33: Work To Be Carried Out
Set oil sump heater , 230 V AC 80854 Only use genuine GEA spare parts! 7.4 Accessories Available accessories can be found on the Internet at www.gea.com. 7.5 Lubricants For operation with CO the following oil types are necessary: compressor version ML and S: GEA C85E... -
Page 34: Technical Data
8 | Technical data Oil charge (sight glass centre) Oil charge (ex works) Suction line Discharge line Weight Starting current (rotor locked) Max. power consumption Max. operating current 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW Voltage PW = Part Winding Winding ratio : 50 % / 50 %... - Page 35 8 | Technical data...
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Page 36: Dimensions And Connections
Offenders will be held liable for the prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event payment of damages. All rights reserved in the event GEA Bo Maß / Dimension Maß / Dimension Passung / Clearance Passung / Clearance Zust. - Page 37 9 | Dimensions and connections Suction line see technical data, chapter 8 Discharge line Connection suction side, not lockable 16 “ UNF Connection suction side, lockable 16 “ UNF Connection suction side, not lockable 8 “ NPTF Connection discharge side, not lockable 16 “...
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Page 38: Declaration Of Installation
DECLARATION OF INSTALLATION for using the compressors within the European Union (in accordance with Machinery Directive 2006/42/EC) The manufacturer: GEA Bock GmbH, Benzstraße 7 72636 Frickenhausen, Tel.: 07022/9454-0 hereby declares that the refrigerating compressor HGX46 CO T complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. -
Page 39: Service
If you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The GEA service team can be contacted by phone with a toll-free hotline 00 800 / 800 000 88 or via e-mail: info@gea.com. - Page 40 • • 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 ®...