GEA Bock HGX2 CO2 T Series Assembly Instructions Manual

Bock HGX2 CO2 T Series
GEA
Brand
GEA
Model
Bock HGX2 CO2 T Series
Type
Assembly Instructions Manual

This manual is also suitable for

GEA Bock HGX2 CO2 T Series is a semi-hermetic two-cylinder reciprocating compressor designed for use with CO2 in transcritical and/or subcritical systems. It features a suction gas-cooled drive motor for intensive cooling and low motor temperature, cylindrical roller bearing support for the crankshaft, a double slide bearing on the motor flange, and a bi-directional oil pump with oil pressure relief valve.

GEA Bock HGX2 CO2 T Series is a semi-hermetic two-cylinder reciprocating compressor designed for use with CO2 in transcritical and/or subcritical systems. It features a suction gas-cooled drive motor for intensive cooling and low motor temperature, cylindrical roller bearing support for the crankshaft, a double slide bearing on the motor flange, and a bi-directional oil pump with oil pressure relief valve.

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engineering for a better world GEA Refrigeration Technologies
Bock Compressor HGX2 CO
2
T
Assembly instructions
HGX2/70-4 CO
2
T
HGX2/90-4 CO
2
T
HGX2/110-4 CO
2
T
HGX2/130-4 CO
2
T
2
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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 5
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 9
4.1 Settingup
4.2 Pipes
4.3 Flangeshut-offvalves(HP/LP)
4.4 Operatingmodeofthelockableserviceconnections
4.5 Operatingtheshut-offvalves
4.6 Pipeconnections
4.7 Layingsuctionandpressurelines
5 Electrical connection 12
5.1 Informationforcontactorandmotorcontactorselection
5.2 Standadmotor,designedfordirectorpartwindingstart
5.3 Mainelinewiringdiagramforpartwinding
5.4 ElectronictriggerunitMP10
5.5 ConnectionoftheelectronictriggerunitMP10
5.6 FunctionaltestoftheelectronictriggerunitMP10
5.7 Oilsumpheater(accessories)
6 Commissioning 18
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
7 Maintenance 22
7.1 Preparation
7.2 Worktobecarriedout
7.3 Sparepartsrecommendation
7.4 Accessories
7.5 Decommissioning
8 Technical data 24
9 Dimensions and connections 25
10 Declaration of conformity and installation 26
11 Service 27
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+4970229454-0
Fax +4970229454-137
[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 Generalsafetyinstructions
1.4 Intendeduse
2 Product description 5
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 9
4.1 Settingup
4.2 Pipes
4.3 Flangeshut-offvalves(HP/LP)
4.4 Operatingmodeofthelockableserviceconnections
4.5 Operatingtheshut-offvalves
4.6 Pipeconnections
4.7 Layingsuctionandpressurelines
5 Electrical connection 12
5.1 Informationforcontactorandmotorcontactorselection
5.2 Standadmotor,designedfordirectorpartwindingstart
5.3 Mainelinewiringdiagramforpartwinding
5.4 ElectronictriggerunitMP10
5.5 ConnectionoftheelectronictriggerunitMP10
5.6 FunctionaltestoftheelectronictriggerunitMP10
5.7 Oilsumpheater(accessories)
6 Commissioning 18
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
7 Maintenance 22
7.1 Preparation
7.2 Worktobecarriedout
7.3 Sparepartsrecommendation
7.4 Accessories
7.5 Decommissioning
8 Technical data 24
9 Dimensions and connections 25
10 Declaration of conformity and installation 26
11 Service 27
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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.
WARNING! DANGER OF SUFFOCATION!
NeverreleasesignicantvolumesofCO
2
or the entire contents of
the system into closed rooms!
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1| Safety
TheseassemblyinstructionsdescribethestandardversionoftheHGX2CO
2
T manufacturedbyBock.
Thecompressorisintendedforusewith CO
2
in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!
The Bock 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.
2 | Product description
2.1 Short description
Important information
•TranscriticalCO
2
applications 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operatingmanual
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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100/150 bar
HAX2/110-4 CO
2
T
AS30046A002
26,7 A
380-420V Y/YY
9,66
440-480V Y/YY
1750
11,66
65
CO2,C 85 E
Y: 110 A Y: 141 A
GEA Bock GmbH
72636 Frickenhausen, 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.
•Cylindricalrollerbearingsupportthecrankshaftontheoilpumpside.
•Doubleslidebearingonthemotorange.
•Bi-directionaloilpumpwithoilpressurereliefvalve.
•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
Connection
oilevelregulator
ConnectionHP
Oilsumpheater
Oilsightglass
ConnectionLP
Transporteyelet
Thermalprotection
thermostat
Valveplate
Oilllerplug
Oilpump
Oildrain,oillter
Terminalbox
Suction
shut-offvalve
Motorsection
Drivesection
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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)
Fig.3
/
Transcritical
CO
2
version
Numberofpoles
Sweptvolume
Size
Esteroilcharge
Series¹
)
HG 2 110- 4 CO
2
X
T
1
2
3
4
5
100/150 bar
HGX2/110-4 CO
2
T
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
ATTENTION! Compressor operation is possible within the operating limits
shown in the diagrams. Thresholds should not be selected as
design or continuous operation points.
- Max. permissible discharge end temperature 160°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.
Thecompressorsarelledatthefactorywiththefollowingoiltype:
BockC85E(onlythisoilmaybeused).
3.1 Refrigerants
• CO
2
: R744
3.2 Oil charge
3.3 Limits of application
Max. permissible operating
pressure (LP/HP)
1)
: 100/150 bar
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!
max.oillevel
min.oillevel
ATTENTION!
Fig.4
1
1
HGX2/130-4 CO
2
T
Applicationslimit
1)
LP=Lowpressure
HP=Highpressure
Fig.5
Unlimited
applicationrange
t
o
 Evaporationtemperature(°C)
∆t
oh
Suctiongassuperheat(K)
p
o
Suctionpressure(bar)
p
v2
Dischargeendpressure(bar)
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?
4 | Compressor assembly
4.1 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.
Usetransporteyelet.
Donotliftmanually!
Useliftinggear!
Provideadequateclearanceformaintenancework.
Ensureadequatecompressorventilation.
Donotuseinacorrosive,dusty,dampatmosphereora
combustibleenvironment.
Fig.6
Fig.7
Fig.8
Fig.9
F
E
D
C
B
A
1
2
3
4
F
E
D
C
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
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 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.
Ensureaproperoilreturn.
Keeppressurelossestoanabsoluteminimum.
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4 | Compressor assembly
4.3 Flange shut-off valves (HP/LP)
ATTENTION! The compressor must be depressurised through connections A
andBbeforecommencinganyworkandpriortoconnectingtothe
refrigerant system
A
B
Fig.10
Fig.11
4.4 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off
Connection
blocked
Serviceconnec-
tionclosed
Pipeconnection
Spindle
Connectioncannot
beshutoff
Connection
offen
Serviceconnec-
tionopened
Fig.12
Fig.13
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4 | Compressor assembly
•
Thecompressorhasashut-offvalvewithmulti-sidedcuttingringforthesafeinstallationofthe
suctionanddischargeline.
Cuttingringfunctionbeforetighteningtheunionnut
. . . . . .
4.6 Pipe connections
Fig.16
Valve spindle seal
release
tighten
4.5 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.14
Fig.15
4.7 Laying suction and discharge line
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.
Procedure:
Push Union Nut (5) and Cut Ring (3) onto Pipe (2).
HandtightenUnionNut(5)untillocked.
InsertPipe(2)firmlyintorebatelocatedinSocket(6)ensuringthepipefitssnugly.Tighten
UnionNut(5)1½turnsusingaspanner/wrench,whilegrippingconnectingSocket(6)with
another spanner/wrench. This should cause the Cutting Edge (1) of Cut Ring (3) to Cut into
Pipe (2) resulting in a visible collar.
12
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Fig.17
As short as
possible
Rigid fixed
point
4 | Compressor assembly
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.
5| Electrical connection
5 Electrical connection
DANGER! Highvoltage!Riskofelectricshock!Onlycarryoutworkwhenthe
electrical system is disconnected from the power supply!
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.
5.1 Information for contactor and motor contactor selection
Allprotectionequipment,switchingandmonitoringdevicesmustcomplywiththelocalsafetyregula-
tionsandestablishedspecications(e.g.VDE)andregulationsaswellasthemanufacturer’sspecica-
tions.Motorprotectionswitchisrequired!Motorcontactors,feedlines,fusesandmotorprotection
switchesmustberatedaccordingtothemaximumoperatingcurrent(seenameplate).
Usethefollowingoverloadprotectiondevice:
Acurrent-dependenttime-delayedoverloadprotectiondeviceformonitoringofallthreephases,not
sethigherthantheratedcurrentofthemachine,whichmustrespondat1.2timesthesetcurrent
within2hoursandmustnothaverespondedat1.05timesthesetcurrentwithin2hours,oranother
comparabledevice.
D
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INFO! Mechanicalstartunloaderwithbypasssolenoidisnotrequired.
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.
L1
L2
L3
L1
L2
L3
L1
L3
L2
PTC
PW II
PW I
PTC
400 V
Direct start YY Part winding start Y/YY
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.
ATTENTION! Failure to comply results in reversed fields 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.
ATTENTION! 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.
14
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nderung
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
20.Feb.2009
Kelich
09.M„r.2010
Urspr.
2
Ers..
3
Ers.d.
4
PWMP10
5 6 7
BKMPRESSRS
8
=
+
9
Bl.
1
Bl.
1
XSS
Q1
L1 L2 L3 N PE
Anschluasten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
L S M
X2 1 2 3 4 5 6
7
F1.1
F1.2
8
R2
4A
F2
S1
9 10
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.18
Compressorterminalbox
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
A
total)
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)
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nderung
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
20.Feb.2009
Kelich
09.M„r.2010
Urspr.
2
Ers..
3
Ers.d.
4
PWMP10
5 6 7
BKMPRESSRS
8
=
+
9
Bl.
1
Bl.
1
XSS
Q1
L1 L2 L3 N PE
Anschluasten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
L S M
X2 1 2 3 4 5 6
7
F1.1
F1.2
8
R2
4A
F2
S1
9 10
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
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5 | Electrical connection
5.4 Electronic trigger unit MP 10
The compressor motor is tted with cold conductor temperature sensors(PTC) connected to the
electronictriggerunitMP10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.
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.
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 MP 10 and terminals PTC 1
and PTC 2 on the compres-
sor 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.
5.5 Connection of the trigger unit MP 10
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board
Fig.19
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Operation mode:Theoilsumpheateroperateswhenthecompressorisshutdown.
Theoilsumpheaterisswitchedoffwhenthecompressorstarts.
Connexion: Theoilsumpheatermustbeconnectedviaanauxiliarycontact(orparallelwiredauxiliary
contact)ofthecompressorcontactortoaseperateelectriccircuit.
Electricaldata:110-240V-1-50/60Hz,50-120W,PTC-heateradjusting.
5 | Electrical connection
ThecompressorandthetriggerunitMP10areoperationalwhentheH3LED(green)lights.
5.6 Function test of the trigger unit MP 10
Pos
Procedure
LED H1 LED H2 LED H3
red red green
1
• Interrupt power supply (L1 or S1) OFF OFF OFF
•
Releasethemotortemperaturesensorconnection(1or2)
• Releasethehotgastemperaturesensor(ifinstalled)(3or4)
2
• Restore the power supply (L1 or S1) ON
•
Functioncheckofmotortemperaturesensor:operational ON
•
Functioncheckofhotgastemperaturesensor:operational ON
3
• Interrupt power supply again (L1 or S1) OFF OFF OFF
• Reconnectterminals1or2and/or3or4
4
• Restore the power supply (L1 or S1): OFF OFF ON
• MP10isoperationalagain
Beforestart-up,troubleshootingormakingchangestothecontrolpowercircuit,checkthefunctionality
ofthetriggerunit:
ATTENTION! The oil sump heater must generally be connected and operated.
5.7 Oil sump heater (accessories)
Inordertoavoiddamagetothecompressor,thecompressormustbeequippedwithanoilsump
heater.
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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.
Checkthecompressorfortransportdamage!
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;thiscanresultinwindingand
terminalboarddamage.
WARNING! Whenthecompressorisnotrunning,dependingonambient
temperatureandamountofrefrigerantcharge,itispossiblethat
the pressure may rise and exceed permitted levels for the
compressor.Adequateprecautionsmustbetakentoprevent
thishappening(e.g.usingacoldstoragemedium,areceivertank,
asecondaryrefrigerantsystem,orpressurereliefdevices).
6.2 Pressure strength test
DANGER! Bursting! The compressor must only be pressurised using nitrogen
(N
2
). Never pressurise with oxygen or other gases!
The maximum permissible overpressure of the compressor must not
be exceeded at any time during the testing process (see name plate
data)! Do not mix any refrigerant with the nitrogen as this could
cause the ignition limit to shift into the critical range.
Thecompressorhasbeenfactory-testedforpressureresistance.Thefollowingmustbeobservedif
theentireplantissubjectedtoanadditionalpressurestrengthtest:
TesttherefrigerationcircuitaccordingtoEN378-2oracorrespondingsafetystandard.
6.3 Leaktest
DANGER! Bursting!
Do not mix any refrigerant with the nitrogen (N
2
) as this could cause
the ignition limit to shift into the critical range.
CarryouttheleaktestoftherefrigeratingsysteminaccordancewithEN378-2oracorresponding
safetystandardwithout including the compressor.
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6 | Commissioning
Firstevacuatethesystemandthenincludethe compressor in the evacuation process.
Relievethecompressorpressure.
Openthesuctionandpressurelineshut-offvalves.
Evacuatethesuctionanddischargepressuresidesusingthevacuumpump.
Attheendoftheevacuationprocess,thevacuumshouldbe<1.5mbarwhenthepumpisswitchedoff.
Repeatthisprocessasoftenasisrequired.
Makesurethatthesuctionandpressurelineshut-offvalvesareopen.
Fillingtheliquidrefrigerant:Itisrecommendedthatthesystemrstbelled
at standstill with gas on the high-pressure side up to a system pressure of at
least5.2bar(ifitislledbelow5.2barwithliquid,thereisariskofdryice
formation).Furtherllingaccordingtosystem.
To eliminate the possibility of dry ice formation when the system is operating
(duringandafter the llingprocess),theshut-offpointof thelow-pressure
switch should be set to a value of at least 5.2 bar.
•Arefrigerantsupplement,whichmaybecomenecessaryafterstart-up,canbe
topped up in vapour form on the suction side.
INFO! Depending upon design of the CO
2
refrigerantllingbottle
(with/without tubing) CO
2
canbelledinliquidafterweightor
gaseously.
Use only high-dried CO
2
quality!
ATTENTION! Avoid overfilling the machine with refrigerant!
Donotchargeliquidrefrigerantintothesuction-sideonthe
compressor.
Do not mix additives with the oil and refrigerant.
WARNING! Never exceed the max. permissible pressures while charging.
Precautionsmustbetakenintime(eg.operatingauxiliaryconden-
sing unit for standstill pressure control or high pressure stage of
the cascade).
CAUTION! Wear personal protective clothing such as goggles and protective
gloves!
6.5 Refrigerant charge
20
D
GB
F
E
96032-04.2013-DGbF
6 | Commissioning
Thecompressoristted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
2
is blown off to the ambient (see also Chapter 7.6)!
Intheeventthatapressurereliefvalveactivatesrepeatedly,checkvalveand
replaceifnecessaryasduringblow-offextremeconditionscanoccure,which
mayresultinapermanentleak.Alwayschecksystemforrefrigerantlossafter
activation of pressure relief valve!
6.7 Decompression valve
CO
2
streaming
out
Fig.20
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.
Checktheoil level:Theoillevelmustbevisibleinthesightglass.
Afteracompressorisreplaced,theoillevelmustbecheckedagain.Ifthelevelistoohigh,oil
mustbedrainedoff(dangerofoilliquidshocks;reducedcapacityoftherefrigeratingsystem).
ATTENTION! Iflargerquantitiesofoilhavetobetoppedup,thereisariskofoil
impacteffects.Ifthisisthecase,checktheoilreturn!
The decompression valves do not replace any pressure switches and the
additional safety valves in the system. Pressure switches must always be installed
inthesystemanddesignedoradjustedinaccordancewithEN378-2orappro-
priate safety standards.
FailuretoobservecanresultinriskofinjuryfromCO
2
streaming out of the two
decompression valves!
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GEA Bock HGX2 CO2 T Series Assembly Instructions Manual

Bock HGX2 CO2 T Series
GEA
Brand
GEA
Model
Bock HGX2 CO2 T Series
Type
Assembly Instructions Manual
This manual is also suitable for

GEA Bock HGX2 CO2 T Series is a semi-hermetic two-cylinder reciprocating compressor designed for use with CO2 in transcritical and/or subcritical systems. It features a suction gas-cooled drive motor for intensive cooling and low motor temperature, cylindrical roller bearing support for the crankshaft, a double slide bearing on the motor flange, and a bi-directional oil pump with oil pressure relief valve.

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