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Summary of Contents for GEA HGX22e/85-4 S CO2
- Page 1 GEA Bock HGX22e S CO /HGX34e S CO Assembly instructions 96422-07.2018-Gb Translation of the original instructions HGX22e/85-4 S CO HGX22e/105-4 S CO HGX22e/130-4 S CO HGX34e/145-4 S CO HGX34e/170-4 S CO HGX34e/210-4 S CO HGX34e/255-4 S CO...
- Page 2 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...
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Page 3: Table Of Contents
Contents Page Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use Product description 2.1 Short description 2.2 Name plate 2.3 Type key Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application Compressor assembly 4.1 Storage and transport 4.2 Setting up 4.3 Pipe connections 4.4 Pipes... -
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 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 1.2 Qualifications required of personnel WARNING Inadequately qualified 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 qualifications listed below: •... -
Page 5: Intended Use
These assembly instructions describe the standard version of the compressor named in the title manufactured by GEA. GEA refrigerating compressors are intended for installation in a machine (within the EU according to the EU Directives 2006/42/EC Machinery Directive, 2014/68/EU Pressure Equipment Directive). -
Page 6: Product Description
2 | Product description 2.1 Short description • HGX22e S CO : Semi-hermetic two-cylinder reciprocating compressor with suction gas cooled drive motor. • HGX34e S CO : Semi-hermetic four-cylinder reciprocating compressor with suction gas cooled drive 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 special during high load on a relatively low temperature level. -
Page 7: Type Key
2 | Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany HGX34e/255-4 S CO2 AX34567A045 22,3 44,8/25,9A Δ: 178A Y: 103A 26,8 40/55 IP66 C85E Fig. 3 Voltage, circuit, frequency Type designation 50 Hz Nominal rotation speed Machine number Displacement maximum operating current... -
Page 8: Areas Of Application
3.1 Refrigerants • CO : R744 (Recommendation CO2 quality 4.5 (< 5 ppm H 3.2 Oil charge The compressors are filled at the factory with the following oil type: GEA C 85 E (only this oils may be used) ATTENTION Property damage possible. The oil level must be in the max. HGX22e S CO visible part of the sight 0,5 Ltr. -
Page 9: 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 pre- vent the ingress of air. Check the compressor for transport damage before starting any work. 4.1 Storage and transportation Storage at (-30°C) - (+70°C), maximum permissible relative humidity 10% -95 %, no condensation. -
Page 10: Pipes
4| Compressor assembly 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. -
Page 11: Operating The Shut-Off Valves
4| Compressor assembly 4.6 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. Tighten Release Valve spindle seal Fig. -
Page 12: Electrical Connection 12 Dgb
4| Compressor assembly 4.8 Suction pipe filter For systems with long pipes and higher degree of contamination, a filter on the suction-side is recommended. The filter has to be be renewed depending on the degree of contamination (reduced pressure loss). 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 13: Connection Of The Driving Motor
5| Electrical connection 5.2 Connection of the driving motor The compressor is designed with a motor for star-delta circuits. Designation on the name plate Sticker on the terminal box ∆ / Y Star-delta start-up is only possible on 230 V voltage supply. Example: 230 V ∆... - Page 14 5.3 Circuit diagramm for direct start 230 V ∆ / 400 V Y FC1.1 I> I> I> FC1.1 L3 N PE -EC1 Θ B1 B2 INT69G Compressor terminal box Anschlußkasten Verdichter Fig. 12 High pressure safety controller Safety chain (high/low pressure monitoring) Thermal protection thermostat (PTC sensor) Release switch (thermostat/pressostat) Oil sump heater Compressor motor...
- Page 15 L1.1 L2.1 L3.1 L1.2 P> Θ Θ FC1.1 Motor protection switch Control power circuit fuse INT69 G Electronic trigger unit INT69 G Main switch Mains contactor Control voltage switch...
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Page 16: Electronic Trigger Unit Int69 G
5| Electrical connection 5.4 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 17: Oil Sump Heater (Accessories)
5| Electrical connection 5.6 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 Gauge state Relay position... -
Page 18: Commissioning
6| Commissioning 6.1 Preparations for start-up INFO To protect the compressor against inadmissible operating conditions, high pressure and low pressure pressostats 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. Check the compressor for transport damage! WARNING When the compressor is not running, depending on ambient... -
Page 19: 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 20: 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 21: Filter Dryer
6| Commissioning 6.8 Avoid slugging ATTENTION Slugging can result in damage to the compressor and cause refrigerant to leak. To prevent slugging: The complete refrigeration system must be properly designed. All components must be compatibly rated with each other with regard to output (particularly the evaporator and expansion valves). Suction gas superheat at the compressor input should be 15 K. -
Page 22: Maintenance
145-4 S CO 170-4 S CO 210-4 S CO 255-4 S CO Designation Item No. Item No. Item No. Item No. Set of gaskets 81580 Valve plate kit 81270 81269 Set piston/connecting rod 81073 81074 81075 81076 Set connecting rod 81268 Only use genuine GEA spare parts! -
Page 23: Accessories
7| Maintenance 7.4 Accessories Available accessories can be found on the Internet at www.gea.com. 7.5 Extract from the lubricants table For operation with CO the oil C 85 E is necessary! 7.6 Decommissioning Close the shut-off valves on the compressor. CO does not need to be recycled and can therefore be blown off into the environment. -
Page 24: Technical Data
8| Technical data Oil charge Weight 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz No. of cylinders... - Page 25 8| Technical data Oil charge Weight 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz No. of cylinders...
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Page 26: Dimensions And Connections
8 “ NPTF Erstellt / Drawn Buettner 18.05.16 Geprüft / Verified Zuder 18.05.16 GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de Freigabe / Approved Layh Layh Maß Dimension Passung / Clearance 18.05.16 b. / Edited Geprüft / Appr. - Page 27 Rechte für den Fall der Patent-, Gebrauchsmuster- Rechte für den Fall der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten. zu Schadenersatz. Alle GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de Freigabe / Approved 18.05.16 Layh Layh DIN ISO 1 / Mod-No.
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Page 28: 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 HGX22e -CO and HGX34e -CO complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. -
Page 29: Service
11 | Service Dear customer, GEA compressors are top-quality, reliable and service-friendly quality products. 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 Yours faithfully GEA Bock GmbH Benzstraße 7... - Page 30 • • 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 ®...
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