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