GEA Bock HGZ Series User manual

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engineering for a better world GEA Refrigeration Technologies
Bock Compressor HGZ7
Assembly instructions
HGZX7/1620-4 R404A/R507 HGZX7/1620-4 R410A
HGZX7/1860-4 R404A/R507 HGZX7/1860-4 R410A
HGZX7/2110-4 R404A/R507 HGZX7/2110-4 R410A
HGZ7/1620-4 R22
HGZ7/1860-4 R22
HGZ7/2110-4 R22

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1 Safety 3
 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standarddesign
 2.2 Mainandfunctionalparts
2.3 Shortdescriptionoptionaldesign
2.4 Nameplate
2.5 Typekey
3 Areas of application 9
3.1 Refrigerants
3.2 Oilcharge
3.3 Limitsofapplication
3.4 Subcoolingtemperature
4Description of functions 12
4.1 Two-stagerefrigerationcircuitwithliquidsubcooler
5 Compressor assembly 14
5.1 Settingup
 5.2 Installationoftheliquidsubcoolersystem(standarddesign)
5.3 Installationexample,liquidsubcoolerwithaccessories
 5.4 Factory-installedliquidsubcoolersystem(optionaldesign)
5.5 Pipeconnections
5.6 Pipes
5.7 Layingsuctionandpressurelines
5.8 Operatingtheshut-offvalves
5.9 Operatingmodeofthelockableserviceconnections
6 Electrical connection 21
6.1 Informationforcontactorandmotorcontactorselection
6.2 Circuitdiagramforpart-windingstart
6.3 Standardmotor,designfordirectorpartialwindingstart
6.4 ElectronictriggerunitMP10
6.5 ConnectingofthetriggerunitMP10
6.6 FunctiontestofthetriggerunitMP10
6.7 Oilsumpheater(accessories)
7 Commissioning 28
 7.1 Preparationsforstart-up
 7.2 Pressurestrengthtest
 7.3 Leaktest
 7.4 Evacuation
 7.5 Refrigerantcharge
 7.6 Start-up
 7.7 Avoidingliquitsluggings
8 Maintenance 31
8.1 Preparation
8.2 Worktobecarriedout
8.3 Sparepartrecommendation
 8.4 Replacingthevalveplates
8.5 Extractfromthelubricantstable
8.6 Decommissioning
8.7 Accessories
9 Technical data 34
10 Dimensions and connections 35
11 Declaration of conformity and installation 38
12 Service 40
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 3
 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standarddesign
 2.2 Mainandfunctionalparts
2.3 Shortdescriptionoptionaldesign
2.4 Nameplate
2.5 Typekey
3 Areas of application 9
3.1 Refrigerants
3.2 Oilcharge
3.3 Limitsofapplication
3.4 Subcoolingtemperature
4Description of functions 12
4.1 Two-stagerefrigerationcircuitwithliquidsubcooler
5 Compressor assembly 14
5.1 Settingup
 5.2 Installationoftheliquidsubcoolersystem(standarddesign)
5.3 Installationexample,liquidsubcoolerwithaccessories
 5.4 Factory-installedliquidsubcoolersystem(optionaldesign)
5.5 Pipeconnections
5.6 Pipes
5.7 Layingsuctionandpressurelines
5.8 Operatingtheshut-offvalves
5.9 Operatingmodeofthelockableserviceconnections
6 Electrical connection 21
6.1 Informationforcontactorandmotorcontactorselection
6.2 Circuitdiagramforpart-windingstart
6.3 Standardmotor,designfordirectorpartialwindingstart
6.4 ElectronictriggerunitMP10
6.5 ConnectingofthetriggerunitMP10
6.6 FunctiontestofthetriggerunitMP10
6.7 Oilsumpheater(accessories)
7 Commissioning 28
 7.1 Preparationsforstart-up
 7.2 Pressurestrengthtest
 7.3 Leaktest
 7.4 Evacuation
 7.5 Refrigerantcharge
 7.6 Start-up
 7.7 Avoidingliquitsluggings
8 Maintenance 31
8.1 Preparation
8.2 Worktobecarriedout
8.3 Sparepartrecommendation
 8.4 Replacingthevalveplates
8.5 Extractfromthelubricantstable
8.6 Decommissioning
8.7 Accessories
9 Technical data 34
10 Dimensions and connections 35
11 Declaration of conformity and installation 38
12 Service 40

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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.

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1|Safety
TheseassemblyinstructionsdescribethestandardversionoftheHGZ7manufacturedbyBock.The
compressorisintendedforuseinrefrigeration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!
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.
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-stage,sixcylinderreciprocatingcompressorwithsuction-gascooled
drivemotor.
 StagesdividedintoLP/HPattheratioof2:1
 Two-stageoperationwithliquidsubcooler
 Expansionvalveforsubcoolingadjustedforrefrigerantandapplicationrange
2.1 Short description standardversion
Intermediate
pressure
chamber
Terminalbox
DimensionandconnectionvaluescanbefoundinChapter9
Oilpump
Suction
shut-offvalve
Nameplate
NoticeCEcertication
forpiping(onlyfor
HGZ7/2110-4)
Oilsightglasses
Oildrainplug Chargeplug
Valveplate
Discharge
shut-offvalve
Intermediate
pressureline
Fig.1
Fig.2
Oilsumpheater

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 Liquidsubcooler,expansionvalve,solenoidvalve,lterdrierandtwosightglassesmounted
directlytothecompressor,pipedandinsulated.
2.3 Short description optionalversion
DimensionandconnectionvaluescanbefoundinChapter9
2|Product description
2sightglasses
1. Standard version:Compressorwithintermediate-pressurelinemountedandinsulated.
Fig.3:Liquidsubcooler,expansionvalve,solenoidvalve,lterdrierandtwosightglasses
enclosedseparately,forindividual,externalmounting.
2. Optional version:Liquidsubcooler,expansionvalve,solenoidvalve,lterdrierandtwosight
glassesmounteddirectlytothecompressor,pipedandinsulated.
2.2 Main and functional parts
Fig.3
Expansion
valve
Liquid
subcooler
Filterdrier
Solenoidvalve
Fig.4

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GEA Bock GmbH
72636 Frickenhausen, Germany
2|Product description
/
HGZ 72110-4 X
Fig.5
2.4 Name plate(example)
2.5 Typekey (example)
1)HGZ=Hermeticgascooled(suctiongascooled),two-stage
2)X=Esteroilfilling(HFCrefrigerant R404A/R507,R410A)
3)PossiblealternativerefrigerantsR404A/R507,R410A,R22
R404A
1 Typedesignation 6 Voltage,circuit,frequency
2 Machinenumber 7 Nominalrotationspeed
3 maximumoperatingcurrent 8 Displacement
4 Startingcurrent(rotorblocked)  VND=lowpressurestage
∆:Partialwinding1  VHD=Highpressurestage
 YYY:Partialwindings1and2 9 Voltage,circuit,frequency
5 ND(LP): max.admissibleoperatingpressur e 10 Nominalrotationspeed
Lowpressureside 11 Displacement
 HD(HP): max.admissibleoperatingpressur eVND=lowpressurestage
Highpressureside VHD=Highpressurestage
12 Oiltypelledatthefactory
Observe the limits of 13 Terminalboxprotectiontype
application diagrams! Electrical accessories can change
the IP protection class!
50 Hz
}
60 Hz
}
.
.
.
.
Refrigerants3)
Numberofpoles
Sweptvolume
Size
oilcharge²)
Series ¹)

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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 operation points.
- Max. permissible discharge end temperature 140 °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.
With enterprise with output regulator:
- in the frontier sometimes reduction and/or individual attitude
of the suction gas overheating necessarily.
Foroperationwithfrequencyconverter:
- 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.
When operating in the vacuum range, there is a danger of air
entering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atthefactorywiththefollowingoiltype:
-forR404A/R507,R410A FUCHSRenisoTritonSE55
 -forR22 FUCHSRenisoSP46
Compressorswithesteroillling(FUCHSRenisoTritonSE55)aremarkedwithanXinthetype
designation(e.g.HGZX7/2110-4R404A).
3.1 Refrigerants
• HFC:    R404A/R507,R410A
• (H)CFC:   R22
3.2 Oil charge
3.3 Limits of application
INFO! Forrefilling,werecommendtheaboveoiltypes.
Alternatives: seelubricantstable,Chapter8.5.
The oil level must be in the visible
part of the sight glass; damage
to the compressor is possible if
overfilled or underfilled!
ATTENTION!
Fig.6
max.oillevel
min.oillevel

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Max. permissible operating pressure (LP/MP/HP)1): 19/19/28 bar
Design for other areas
onrequest
Fig.7
Fig.8
Fig.9
3|Areas of application
R404A/R507
R410A
R22
1)LP=lowpressureMP=intermediatepressureHP=highpressure
tOEvaporationtemperature(°C)
tCCondensingtemperature(°C)
∆tOhsuctiongassuperheat(K)
Unlimitedapplicationrange

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3|Areas of application
Thedesignoftheexpansionvalveonthecompressorcanbedenedwiththehelpofthediagramby
approximatelycalculatingthesubcoolingtemperaturearisingintherelevantoperating
conditions(t0/tc).
Diagramsfordeterminingthesubcoolingtemperatureattheoutputoftheliquidsubcooler.
3.4 Subcooling temperature
tU=Subcoolingtemperatureatthe
subcooleroutlet(FUA)
tO=Evaporatingtemperature
Fig.10
Fig.11
Fig.12

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Therefrigerantsuctionedoutoftheevaporator(21)iscompressedbythe4cylindersoftheLPstage
(2)tointermediatepressureMP.Afterthat,thesuperheatedrefrigerantowsthroughtheintermediate
pressurechamber(3),whereitiscooledbytheliquidsubcoolersystemtoreducethedischargeend
temperature.The refrigerant then ows through the intermediate pressure line (4) to the electric
motorofthecompressorfortocoolthemotor.Afterthis,therefrigerantissuctionedinbythetwoHP
cylinders(5)andcompressedtothenalpressure.
Liquidsubcoolersystem
Theliquidsubcoolersystemconsistsofthecomponents
-liquidsubcooler(plateheatexchanger)(6)
-expansionvalve(7)
-sightglasses(8,9)
-solenoidvalve(10)
-lterdrier(11)
Aftertherefrigerantreciever(16),theliquidlinewillbesplittedintotwolines:
Line A leads through the liquid subcooler (6) and the subcooled refrigerant ows to the
evaporator (21).ThroughLine B refrigerantisexpanding through theexpansionvalve (7)intothe
liquidsubcooler(6)inordertosubcooltherefrigerantoflineAandthroughtheintermediatepressure
line(MP)tocoolthesuperheatedrefrigerant,whichiscompressedfromlowpressuretointermediate
pressurechamber(3).
4|Description of functions

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4|Description of functions
Explanations
1 Compressor
2 CylinderLP-stage
3 IntermediatepressurechamberMP
4 IntermediatepressurelineMP
5 CylinderHP-stage
6 Liquidsubcooler
7 Reinjectionvalve
8 Sightglass
9 Sightglass
10 Solenoidvalve
11 Filterdrier
12 Damper,pressureline
13 Oilseparator
14 Non-returnvalve
15 Condenser
16 Refrigerantreceiver
17 Filterdrier
18 Solenoidvalve
19 Sightglass
20 Expansionvalve(evaporator)
21 Evaporator
22 Liquidseparator
23 Damper,suctionline
24 Filtersuctionline
LP =Lowpressure
MP =Intermediatepressure
HP =Highpressure
FUE=Liquidsubcooler,inlet
FUA=Liquidsubcooler,outlet
Scopeofsupply
Line A
Line B
4.1 Two-stagerefrigerationcyclewithliquidsubcooler
Fig.13

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?
5|Compressor assembly
5.1 Setting up
Setuponanevensurfaceorframewithsufcientload-
bearingcapacity.
Compressorinprinciplerigidlyinstall.
 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.
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.14
Fig.15
Fig.16
Fig.17
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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-
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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

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5.2 Installationoftheliquidsubcoolersystem (standardversion)
Separatelyenclosedcomponents:
Liquidsubcooler
Reinjectionvalve
Solenoidvalve
Filterdrier
2 sightglasses
Screw-insleeve,solderadapterandseals
Pleasecheckforcompletenessofpartsbeforebeginninginstallation.
INFO! Observe manufacturer‘s instructions!
Assembly:
INFO! The points listed here represent general guidelines and information
onhowtopipeandconnectthesubcoolerunit.Toperformthiswork
technicalknowledgeandskillaswellasproofofahard-soldering
testcerticateinaccordancewithDINEN13133isrequired.
Pipe connections:
Forconnections,seedimensiondiagram Chapter 10.
Systemdesign,pipingandnecessarysupportpointsfortheindividualcomponents
mustbecarefullyplannedandcarriedout.
Properlyinsulateliquidsubcooleragainstcondensationandheatingandtherelated
lossofperformance.
Forrigidityreasons,theuseofstainlesssteelpipeswithawallof1mmispreferred.
Thepipesmustbefreeoftensionduringandaftersolderingtopreventpossible
breakslateron.
INFO! Useonly suitable hard solderandux.Solderunder an inertgas
atmosphere when copper components are to be soldered! The
accompanying expansion valve is designed and adjusted for the
compressor and the listed refrigerant (sensor charge, nozzle).
OnlyuseexpansionvalvesapprovedandsuppliedbyBock!
INFO! The intermediate pressure line and intermediate pressure chamber
are fully insulated at the factory. To mount the expansion valve,
cuttheinsulationasshowninthemarkedareainFig.17,page16.
Correctsensor placementismarkedbyanunpaintedarea onthe
pipe.
1
2
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5
6
1
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ATTENTION! To avoidvibrationcracksinthesubcoolersystem,the individual
components must be mounted directly to the compressor or
installed as a decoupled unit!
5|Compressor assembly
Fig.18

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Intermediate
pressure
chamber
Fig.19
X
W
Intermediate
pressureline
(Shownwithout
insulation)
RY
5|Compressor assembly
RConnectionofpressurecompensationlineforexpansionvalve 7/16" UNF
WRefrigerantinjectionconnection M22x1,5
XSchraderconnectionforintermedie-pressuregauge 7/16" UNF
YPositionoftemperaturesensor/unpainted

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1 Liquidsubcooler 5 Expansionvalve FUA liquidsubcooler,
2 Filterdrier 6 temp.sensorexpansionvalve Outlet
3 Solenoidvalve 7 Pressurecompensationconnection FUE liquidsubcooler,
4 sightglasses Inlet
INFO! General notes:
Sensorlines,wires,etc.shouldnotbeattachedwithcablebinders
directlytopipesorframes;otherwise,thethinpipesmaybeworn
through. It is better to run them through spiral protective tubes.
Ifthecompressorwillbesetupoutside,UV-resistantmaterials
should be used.
Ø16mm Ø16mm
Ø16mm
Ø16mm Ø6mm
Ø12mm
Ø12mm Ø12mm
FUE
MitteldruckkammerMP
Wärme-
dämmung
Fig.20
5|Compressor assembly
5.3 Installationexample,liquidsubcoolerwithaccessories
Dia.16mm
Dia.12mm
Heat
insulation
fromthereceiver
totheevaporator
Line A
Line B
Line B
Dia.16mm
Dia.16mm
Dia.6mm Dia.12mm Dia.12mm
Dia.16mm
Intermediatepressure
chamberMP

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INFO! A soldering suppot for tube diameter 54 mm is mounted to the
suction shut-off valve of the compressor.
A soldering support for tube diameter 2 1/8'' accompanies the
compressor.
Liquidsubcooler,expansionvalve,solenoidvalveandtwosightglassesaremounteddirectlyatthe
compressor,pipedandinsulated.
FUE
FUA
FUE:Liquidsubcoolerinlet
FUA:Liquidsubcooleroutlet
ATTENTION! Superheating can damage the valve.
Remove the pipe supports therefore from the valve for soldering.
Only solder using inert gas to inhibit oxidation products (scale).
5.5 Pipe connections
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.22:graduated
internaldiameter
5.4 Factory-installedliquidsubcoolersystem(optionaldesign)
Fig.21
5|Compressor assembly

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Rigid
fixed point
As short
as possible Fig.23
5|Compressor assembly
5.6 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.
5.7 Laying suction and pressure lines
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.
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.

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5|Compressor assembly
5.8 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.24 Fig.25
Valvespindleseal
release
tighten
Pipeconnection
Pipeconnection
5.9 Operatingmodeofthelockableserviceconnections
Fig.26
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.
Fig.27
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.
Serviceconnection
closed
Connection
blocked
Spindle
Connectioncannot
beshutoff
Connectioncannot
beshutoff
Serviceconnection
opened
Spindle Connection
open
Compressor
Compressor