GEA Bock HG22P A User manual

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engineering for a better world GEA Refrigeration Technologies
GEA Bock Compressor HG22P A
Assembly instructions
HG22P/125-4 A HG22P/125-4 S A HGX22P/125-4 A HGX22P/125-4 S A
HG22P/160-4 A HG22P/160-4 S A HGX22P/160-4 A HGX22P/160-4 S A
HG22P/190-4 A HG22P/190-4 S A HGX22P/190-4 A HGX22P/190-4 S A
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About these instructions
Read these instructions before assembly and before using the compressor. This will avoid
misunderstandings and prevent damage. Improper assembly and use of the compressor can lead to
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
compressor 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

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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 6
2.1 Short description
2.2 Name plate
2.3 Type code
3 Areas of application 8
3.1 Refrigerants
3.2 Oil charge
3.3 Operating limits
4Compressor assembly 10
4.1 Storage and transport
4.2 Setting up
4.3 Maximum permissible inclination
4.4 Pipe connections
4.5 Pipes
4.6 Laying suction and discharge lines
4.7 Operating the shut-off valves
4.8 Operating mode of the lockable service connections
5 Electrical connection 14
5.1 Information for contactor and motor contactor selection
5.2 Connecting the drive motor
5.3 Circuit diagram
5.4 Electronic trigger unit MP 10
5.5 Connecting the trigger unit MP 10
5.6 External connection of the MP 10 for terminal boxes at reduced height
5.7 Functional test of the trigger unit MP 10
6 Commissioning 20
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 Avoidingliquidshocks
7 Maintenance 22
7.1 Preparation
7.2 Work to be carried out
7.3 Spare parts recommendation
7.4 Accessories
7.5 Extract from the lubricants table
7.6 Decommissioning
8 Technical data 24
9 Dimensions and connections 25
10 Declaration of conformity and installation 26
11 Service 27

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1.1 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.
1|Safety
1.2 Qualicationsrequiredofpersonnel
WARNING! Inadequatelyqualiedpersonnelposetheriskof
 accidents,theconsequencebeingseriousorfatalinjury.
Work on compressors is therefore reserved for personnel
 withthequalicationslistedbelow:
• For example, a refrigeration technician, refrigeration mechatronic
engineer.
As well as professions with comparable training, which enables
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.
1.3 General safety instructions
DANGER! • Refrigerating compressors are pressurised machines and as such
call for heightened caution and care in handling.
The maximum permissible overpressure must not be exceeded,
even for testing purposes.
WARNING! • Risk of burns! Depending on the operating conditions, surface
temperatures of over 60°C on the discharge side or below 0°C on
the suction side can be reached.

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1|Safety
These assembly instructions describe the standard version of the HG22P A manufactured by
GEA Bock. The compressor is intended for mobile applications in cooling systems in compli-
ance with the operating limits. Only the refrigerant specied in these instructions may be used.
Any other use of the compressor is prohibited!
The GEA 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 permissible only 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.
1.4 Intended use
WARNING! The compressor may not be used in potentially
explosive environments!

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2|Product description
• Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication.
• Lightweight aluminum design
• Suction gas-cooled drive motor
2.1 Brief description
Motor part
Dimension and connection values can be found in Chapter 9
Transport
eyelet
Fig. 1
Fig. 2
Name plate
Oil sightglass
Discharge
shut-off
valve
Oil pump
Terminal box
Suction
shut-off valve
Cylinder cover
Valveplate
Drive motor

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2|Product description
/
HG 22 P 190- 4 S AX
1 Type designation
2 Machine number
3 Maximum operating current
4 Start-upcurrent(rotorblocked)
5 ND(LP):Maximumadmissibleoperating
  pressure(g)Lowpressure
 HD(HP):Maximumadmissibleoperating
  pressure(g)Highpressure
Observe the
limit of application diagrams!
50 Hz
60 Hz
6 Voltage,switching,frequency
7 Nominal rotation speed
8 Displacement
9 Voltage,switching,frequency
10 Rated speed
11 Displacement
12 Oiltypelledatfactory
13 Protection system terminal box
Electrical accessories can change
the IP protection class!
}
}
2.2 Name plate(example)
2.3 Type code(example)
¹)HG-HermeticGas-cooled(suctiongas-cooled)
²)X- Esteroilcharge(HFCrefrigerant,e.g.R134a,R404A,R507,R407C)
³) AdditionalspecicationforPluscomcompressors
4)S - More powerful motor, e.g. for air-conditioning applications
Lightweight aluminum design
Motor version 4)
Number of poles
Swept volume
³)
Number of cylinders
Size
Oil charge ²)
Series ¹)
1
2
3
4
5
13
12
7
11
6
10
8
9
19/28 SE 55
16,5
19,8
HGX22P/190-4 S A
16,1/9,3 A
67A 40A
IP66
GEA Bock GmbH
72636 Frickenhausen, Germany
Fig. 3

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3|Areas of application
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 operating 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supplementarycooling:
- Use only oils with high thermal stability.
- Avoid continuous operation near the threshold.
Foroperationwithfrequencyconverter:
- The potential control range of the compressor is 30-70 Hz.
- Max. permissible current consumption must not be exceeded.
At max. rotation speed therefore, the application limit can
be reduced.
- Use a thermal protection thermostat.
- Do not operate an additional capacity controller.
    -Oilreturnatlowfrequencymustbeguaranteed.
- Consultation with GEA Bock.
Foroperationwithcapacityregulator:
- The suction gas superheat temperature may need to be
reduced or set individuallywhen operating near to the threshold
When operating in the vacuum range, there is a danger of air en-
tering on the suction side. This can cause chemical reactions, a
pressure rise in the condenser and an elevated compressed-gas
temperature. Prevent the ingress of air at all costs!
 Thecompressorsarelledwiththefollowingoiltypeatthefactory:
- for R134a, R404A/R507, R407C FUCHS Reniso Triton SE 55
- for R22 FUCHS Reniso SP 46
Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXinthetype
designation (e.g. HGX22P/190-4A).
3.1 Refrigerants
• HFKW/HFC:  R134a,R404A/R507,R407C
• (H)FCKW/(H)CFC: R22
3.2 Oil charge
3.3 Operating limits
INFO! For refilling, we recommend the above oil types.
Alternatives:see lubricants table, Chapter 7.5.
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.
0,7 Ltr.
oil level
Fig. 4
~
~

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Design for other
areasonrequest
Unlimited
application range
Supplementary cooling or
reduced suction gas temperature
Supplementary cooling and
reduced suction gas temperature
Motor version S
(morepowerfulmotor)
Evaporatingtemperature(°C)
Condensingtemperature(°C)
Suctiongassuperheat(K)
Suctiongastemperature(°C)
R134a
R407C
R404A/R507
R22
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Max. permissible operating
pressure (LP/HP)1):19/28bar
1) LP = Low pressure
HP = High pressure

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4|Compressor assembly
 Setuponanevensurfaceorframewithsufcientload-
bearing capacity.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
Do not use in a dusty, damp atmosphere or a combustible
environment.
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.
Fig. 11
Fig. 12
Fig. 13
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3
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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
?
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. 10
Fig. 9
ATTENTION! Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
4.2 Setting up

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4|Compressor assembly
ATTENTION! Overheating can damage the valve.
Remove the pipe supports from the valve for soldering. Solder
them with protective gas to prevent oxidation products (scale).
The discharge and suction line valves have stepped internal
diameters so that pipes with standard millimetre and inch
dimensions can be used. The depth of pipe insertion will
depend on the dimension.
The connection diameters of the shut-off valves are rated for
maximum compressor output.Therequiredpipecross-sectionmustbe
matched to the output. The same applies for non-return valves.
Fig.15:Stepped
internal diameters
4.4 Pipe connections
4.3 Maximum permissible inclination
Amax. 30°,
max. 2 minutes
amax. 15°,
continuous
operation
ATTENTION! Poor lubrication can damage the compressor.
Respect the stated values.
Fig. 14
A
a
A
aa
A
a
A

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4.6 Laying suction and discharge lines
INFO! Proper layout of the suction and discharge lines directly after
the compressor is integral to the system’s smooth running and
vibration behaviour.
ATTENTION! Improperly installed pipes can cause cracks and tears, the result
being 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.
4.5 Pipes
Pipes and system components must be clean and dry inside and free of scale, swarf and layers of
rust and phosphate. Only use 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.
Rigid
Fixed point
As short as
possible Fig. 16
4|Compressor assembly

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4|Compressor assembly
4.7 Operating the shut-off valves
Before opening or closing the shut-off valve, release the adjustable 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. 17 Fig. 18
Pipe connection
Pipe connection
4.8 Operating mode of the lockable service connections
Fig. 19
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.
Fig. 20
Opening the service connection
Spindle:Turn½-1turntotherightclockwise.
—> Service connection opened / shut-off valve opened.
Service connec-
tion closed
Connection
blocked
Spindle
Service connec-
tion opened
Spindle Connection
open
Compressor
Compressor
Valve spindle seal
Release
Tighten

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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devicesandswitchingormonitoringunitsmustbettedinaccordancewiththelocal
safetyregulationsandestablishedspecications(e.g.VDE)aswellaswiththemanufacturer’sinfor-
mation. Motor protection switches are required! Motor contactors, feed lines, fuses and motor
protection switches must be rated on the basis of the maximum working current (see name plate).
For motor protection use a current-dependent and time-delayed overload protection device for moni-
toring all three phases. Set the overload protection device so that it must be actuated within 2 hours,
if there is 1.2 times the max. working current.

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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 in the ∆voltage range. Example:
230 V ∆
Direct start Star-delta start
400 V Y
Direct start only
Elektrischer Anschluss Electrical connection Raccordement électrique ∆/ Y
96027-11.06-DGbF
∆
Niedere Spannung
Low voltage
Bas voltage
Y
Hohe Spannung
High voltage
Haut voltage
L3
L1 L2
L3
L1 L2
Elektrischer Anschluss Electrical connection Raccordement électrique ∆/ Y
96027-11.06-DGbF
∆
Niedere Spannung
Low voltage
Bas voltage
Y
Hohe Spannung
High voltage
Haut voltage
L3
L1 L2
L3
L1 L2
L1 L2 L3
L1 L2 L3
INFO! The connection examples shown refer to the standard
 version.Inthecaseofspecialvoltages,theinstructionsafxedtothe
terminal box apply.
5|Electrical connection

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R1 Cold conductor PTC sensor motor winding
R2  Thermalprotectionthermostat(PTCsensor)
F1 Load circuit safety switches
F2 Control power circuit fuse
F3  Safetychain(high/lowpressuremonitoring)
B1  Releaseswitch(thermostat/pressostat)
Q1 Main switch
5.3 Circuit diagram for direct start 230 V ∆/ 400 V Y
Fig. 21 Terminal box compressor
         

  
























         





 







 




  

 







 











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S1 Control voltage switch
M1 Compressor motor
K1 Compressor contactor
MP10 Electronic trigger unit MP 10
E Oil sump heater
X3 Terminal strip in terminal box
XSS Terminal strip in the external switch cabinet
         

  
























         





 







 




  

 







 










A1 Alarm Motor protection
A2 Overheating R1, R2
A3 Alarm high pressure
XSS Terminal strip in the external
switch cabinet

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5|Electrical connection
PTC1 PTC2
Terminal box
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 signaled by the H3 LED
(green)afterthepowersupplyisapplied.Incaseofexcesstemperatureinthemotorwinding,theunit
switches off the compressor and the H1 LED illuminates red.
The hot gas side of the compressor can also be protected against overtemperature using a thermal
protectionthermostat(accessory).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 the fault has been
remedied, either interrupt the mains voltage or acknowledge with
the external alarm reset switch S1 (see circuit diagram, Chapter 5.3).
This unlocks the restart prevention device and the LEDs H1
and/or H2 extinguish.
Fig. 22
INFO! Connect the trigger unit MP10 in accordance with the circuit diagram.
Protect the trigger unit with a delayed-action fuse (F) of max. 4 A.
To guarantee the protection function, install the trigger unit
  astherstelementinthecontrolcircuit.
5.5 Connecting the trigger unit MP 10
Temperaturemonitoringconnections:
Motorwinding: Terminals1-2
Hot-gasside: Terminals3-4
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.

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5|Electrical connection
5.6 External connection of the MP 10 for terminal boxes at reduced height (Accessories)
Terminal box
PTC1
PTC2
1234
34
PE
R2
ThecompressorandthetriggerunitMP10areoperationalwhentheH3LED(green)illuminates.
X3:
5.7 Function test of the trigger unit MP 10
Item Procedure LED H1 LED H2 LED H3
Red Red Green
1•Power supply interrupted (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•Power supply interrupted 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:
Fig. 23
0.5 mm²

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6|Commissioning
6.1 Preparations for start-up
6.4 Evacuation
First evacuate the system and then includethe compressor in the evacuation process.
Relieve the compressor pressure.
Open the suction and discharge line valves.
Evacuate the suction and high 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theprocessasoftenasisrequired.
ATTENTION! Do not start the compressor if it is under vacuum.Do not apply any voltage
even for test purposes (may be operated only with refrigerant).
Under vacuum, the spark-over and creepage current distances of the
terminal board connection bolts shorten; this can lead to winding and
terminal board damage.
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!
6.2 Pressure strength test
DANGER! Bursting! The compressor must only be pressurised using nitrogen
(N2). 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 (N2)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.