GEA HG22e/160-4 User manual

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GEA Bock HG22e/HG34e
Assembly instructions
96415-04.2017-Gb
Translation of the original instructions
HG22e/125-4 HG22e/125-4 S
HG22e/160-4 HG22e/160-4 S
HG22e/190-4 HG22e/190-4 S
HG34e/215-4 HG34e/215-4 S
HG34e/255-4 HG34e/255-4 S
HG34e/315-4 HG34e/315-4 S
HG34e/380-4 HG34e/380-4 S
HGX34e/215-4 S R407C
HGX34e/255-4 S R407C
HGX22e/125-4 HGX22e/125-4 S
HGX22e/160-4 HGX22e/160-4 S
HGX22e/190-4 HGX22e/190-4 S
HG34e/215-4 HGX34e/215-4 S
HG34e/255-4 HGX34e/255-4 S
HG34e/315-4 HGX34e/315-4 S
HG34e/380-4 HGX34e/380-4 S
HGX34e/315-4 S R407C
HGX34e/380-4 S R407C

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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 [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 key
3 Areas of application 8
3.1 Refrigerants
3.2 Oil charge
3.3 Limits of application
3.4 Refrigerants - design for R407C, 35 bar
3.5 Oil charge for R407C, 35 bar
3.6 Limits of application for R407C, 35 bar
4Compressor assembly 12
4.1 Storage and transport
4.2 Setting up
4.3 Pipe connections
4.4 Pipes
4.5 Laying suction and pressure lines
4.6 Operating the shut-off valves
4.7 Operating mode of the lockable service connections
5 Electrical connection 15
5.1 Information for contactor and motor contactor selection
5.2 Connection of the driving motor
5.3 Circuit diagram for direct start 230 V Δ/ 400 V Y
5.4 Electronic trigger unit INT69 G
5.5 Connection of the electronic trigger unit INT69 G
5.6 Functional test of the electronic trigger unit INT69 G
5.7 Start unloader
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 slugging
6.8 Connection of oil level regulator
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 27
10 Declaration of installation 30
11 Service 31

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1|Safety
1.2 Qualicationsrequiredofpersonnel
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 Inadequatelyqualied personnelposesthe riskof accidents, the
consequencebeingseriousorfatalinjury.Workoncompressors
isthereforereservedforpersonnelwhichisqualiedtoworkon
pressurized refrigerant systems:
• 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 the work to be carried out and recognising any potential
dangers.
1.1 Identicationofsafetyinstructions:

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1|Safety
1.4 Intended use
1.3 General safety instructions
WARNING Risk of accidents.
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.
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.
- Avoid contact with refrigerant necessarily.
Contact with refrigerant can cause severe burns and skin
damage.
WARNING The compressor may not be used in potentially explosive
environments!
These assembly instructions describe the standard version of the compressor named in the title man-
ufactured 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 and 2014/68/EU Pressure
EquipmentDirective).
Commissioning is permissible only if the compressor has been installed in accordance with these as-
sembly instructions and the entire system into which it is integrated has been inspected and approved
in accordance with legal regulations.
The compressors are 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!

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2|Product description
• HG22e: Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication.
• HG34e: Semi-hermetic four-cylinder reciprocating compressor with oil pump lubrication.
• Suction gas cooled drive motor.
2.1 Short description
Dimension and connection values can be found in Chapter 9
Fig. 1 HG22e
HG34e
Fig. 2
Oil pump
Valve plate
Discharge
shut-off valve
Name plate
Oil sight glass
Terminal box
Suction
shut-off
valve
Cylinder cover
Drive section
Motor section
Transport eyelet

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2|Product description
2.2 Name plate (example)
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) 9 Voltage,circuit,frequency
5 ND(LP):max.admissibleoperating 10 Nominalrotationspeed
pressure (g)Low pressure side 11 Displacement
 HD(HP): max. admissible operating  12 Oiltypelledatthefactory
pressur e(g)High pressure side 13 Terminal box protection type
Observe the limits of application Electrical accessories can change
diagrams! the IP protection class!
50 Hz
}
60 Hz
}
1
2
3
4
513
12
7
11
6
10
8
9
19/28 SE 55
27,3
32,8
HGX34e/315-4
21,1/12,2A
111A 64A
AS38125A001
GEA Bock GmbH
72636 Frickenhausen, Germany
SE 55
27,3
32,8
IP66
Fig. 3
/
HG 43 e 380-4 SX
2.3 Type key (example)
¹)HG-HermeticGas-cooled(suctiongas-cooled)
²)X
-Esteroilcharge(HFCrefrigerant,e.g.R134a,R404A/R507,R407C)
3)S - More powerful motor
R407C
Refrigerant
Motor variant 3)
Number of poles
Swept volume
e-series
Numbers of cylinders
Size
Oil charge ²)
Series ¹)

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3|Areas of application
 Thecompressorsarelledatthefactorywiththefollowingoiltype:
- 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. HGX34e/380-4).
3.1 Refrigerants
• HFKW / HFC: R134a, R404A/R507, R407C
• (H)FCKW/(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 7.5
ATTENTION 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! Fig. 4
max.
min.
HG22e =
0,7 Ltr.
HG34e =
0,8 Ltr.
oil level
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.
- 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 capacity regulator:
- Continuous operation, when the capacity regulator is activated,
is not permissible and can cause damage to the compressor.
- The suction gas superheat temperature may need to be reduced
or set individually when operating near to the threshold.
- When the capacity regulator is activated, the gas velocity in the
systemcannotundercertaincircumstancesensurethatsuf-
cient oil is transported back to the compressor.
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.

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

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2|Produktbeschreibung
1
2
3
4
513
12
7
11
6
10
8
9
/
HG 43 e 315- R407C 4 SX
19/35 SE 55
27,3
32,8
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Überdruck
Niederdruckseite
HD (HP): max. zulässiger Überdruck
Hochdruckseite
Beachten Sie hierzu die
Einsatzgrenzendiagramme!
50 Hz
60 Hz
6 Spannung, Schaltung, Frequenz
7 Nenndrehzahl
8 Hubvolumen
9 Spannung, Schaltung, Frequenz
10 Nenndrehzahl
11 Hubvolumen
12 Werkseitig eingefüllte Ölsorte
13 Schutzart Klemmenkasten
Elektrisches Zubehör kann die IP-
Schutzklasse verändern!
HGX34e/315-4 S R407C
28,1/16,2A
134A 77A
}
}
Abb. 3
2.2 Typschild (Beispiel)
2.3 Typschlüssel (Beispiel)
¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)
²) X
- Esterölfüllung
3) S - Stärkerer Motor
Kältemittel
Motorvariante 3)
Polzahl
Hubraum
e-Serie
Zylinderzahl
Baugröße
Ölfüllung ²)
Baureihe ¹)
AS38125A001
 Thecompressorsarelledatthefactorywiththefollowingoiltype:FUCHSRenisoTritonSE55
Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXinthetype
designation (e.g. HGX34e/380-4R407C).
3.4 Refrigerant - Design for R407C, 35 bar
• HFKW / HFC: R407C
3.5 Oil charge for R407C, 35 bar
Only compressors with the additional designation
R407C (see name plate, Fig. 3 and 9)
Fig. 9
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2|Produktbeschreibung
1
2
3
4
513
12
7
11
6
10
8
9
/
HG 43 e 315- R407C 4 SX
19/35 SE 55
27,3
32,8
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Überdruck
Niederdruckseite
HD (HP): max. zulässiger Überdruck
Hochdruckseite
Beachten Sie hierzu die
Einsatzgrenzendiagramme!
50 Hz
60 Hz
6 Spannung, Schaltung, Frequenz
7 Nenndrehzahl
8 Hubvolumen
9 Spannung, Schaltung, Frequenz
10 Nenndrehzahl
11 Hubvolumen
12 Werkseitig eingefüllte Ölsorte
13 Schutzart Klemmenkasten
Elektrisches Zubehör kann die IP-
Schutzklasse verändern!
HGX34e/315-4 S R407C
28,1/16,2A
134A 77A
}
}
Abb. 3
2.2 Typschild (Beispiel)
2.3 Typschlüssel (Beispiel)
¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)
²) X
- Esterölfüllung
3) S - Stärkerer Motor
Kältemittel
Motorvariante 3)
Polzahl
Hubraum
e-Serie
Zylinderzahl
Baugröße
Ölfüllung ²)
Baureihe ¹)
AS38125A001
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2|Produktbeschreibung
1
2
3
4
513
12
7
11
6
10
8
9
/
HG 43 e 315- R407C 4 SX
19/35 SE 55
27,3
32,8
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Überdruck
Niederdruckseite
HD (HP): max. zulässiger Überdruck
Hochdruckseite
Beachten Sie hierzu die
Einsatzgrenzendiagramme!
50 Hz
60 Hz
6 Spannung, Schaltung, Frequenz
7 Nenndrehzahl
8 Hubvolumen
9 Spannung, Schaltung, Frequenz
10 Nenndrehzahl
11 Hubvolumen
12 Werkseitig eingefüllte Ölsorte
13 Schutzart Klemmenkasten
Elektrisches Zubehör kann die IP-
Schutzklasse verändern!
HGX34e/315-4 S R407C
28,1/16,2A
134A 77A
}
}
Abb. 3
2.2 Typschild (Beispiel)
2.3 Typschlüssel (Beispiel)
¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)
²) X
- Esterölfüllung
3) S - Stärkerer Motor
Kältemittel
Motorvariante 3)
Polzahl
Hubraum
e-Serie
Zylinderzahl
Baugröße
Ölfüllung ²)
Baureihe ¹)
AS38125A001
3|Areas of application
INFO For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.5
R22
Fig. 8
Evaporationtemperature(°C)
Condensingtemperature(°C)
Suctiongassuperheat(K)
Suctiongastemperature(°C)
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)
Max. permissible operating
pressure (LP/HP)1): 19/28 bar
1) LP = Low pressure
HP = High pressure

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3.6 Limits of application for R407C, 35 bar
R407C
Fig. 10
Verdampfungstemperatur(°C)
Verüssigungstemperatur(°C)
Sauggastemperatur(°C)
3|Areas of application
Unlimited application range
Evaporationtemperature(°C)
Condensingtemperature(°C)
Suctiongastemperature(°C)
Design for other
areasonrequest
Max. permissible operating
pressure (LP/HP)1): 19/35 bar
1) LP = low pressure
HP = high pressure
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.
- 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 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!

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4|Compressor assembly
?
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.
4.2 Setting up
 Setuponanevensurfaceorframewithsufcientload-
bearing capacity.
Single compressor preferably on vibration damper.
Duplex and parallel circuits always rigid.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
Do not use in a corrosive, dusty, damp atmosphere or a
combustible environment.
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
4.3 Pipe connections
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.
ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
ATTENTION Damage possible.
Do not solder as long as the compressor is under pressure.
Superheating can damage the valve. Remove the pipe supports
therefore from the valve for soldering and accordingly cool the
valve body during and after soldering.
Only solder using inert gas to inhibit oxidation products (scale).
Sun protection: If the compressor is set up outdoors, it has
to be protected from direct sunlight.

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4|Compressor assembly
4.4 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.
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. 11: graduated
internal diameter
As short as
possible
Rigid
fixed point
4.5 Laying suction and pressure lines
A rule of thumb:Alwayslaytherstpipesectionstartingfromtheshut-offvalvedownwards and
parallel to the drive shaft.
ATTENTION Improperly installed pipes can cause cracks and tears, the result
being a loss of refrigerant.
INFO Proper layout of the suction and discharge lines directly after
the compressor is integral to the system’s smooth running and
vibration behaviour.
Fig. 12
1
2
3
4
5
6
7
8
9
10
11
12
13

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4|Compressor assembly
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. 13 Fig. 14
4.6 Operating the shut-off valves
Valve spindle seal
Release
Tighten
Pipe connection
Pipe connection
4.7 Operating mode of the lockable service connections
Fig. 15
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. 16
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
Afteractivatingthespindle,generallytthespindleprotectioncapagainandtightenwith14-16Nm.
This serves as a second sealing feature during operation.

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5|Electrical connection
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.
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 ∆
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 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.
DANGER Risk of electric shock! High voltage!
Only carry out work when the electrical system is disconnected
from the power supply!
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.
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.

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BT1 Coldconductor(PTCsensor)motorwinding
BT2 Thermalprotectionthermostat(PTCsensor)
FC1 Load circuit safety switches
FC2 Control power circuit fuse
BP1 High pressure safety monitor
BP2 Safety chain (high/low pressure monitoring)
BT3 Release switch (thermostat)
5.3 Circuit diagramm for direct start 230 V ∆/ 400 V Y
Fig. 17
Anschlußkasten Verdichter
BT1
INT69G
QA1
L1 L2 L3 N PE PE
FC1.1
FC2
SF1
BP1
P>
QA2
BP2
P
QA2
L1.1
L2.1
L3.1
L1.2
N
PE
BT3
1112 14
L N B1 B2
12
11
10
9
8
7
6
5
4
3
2
1
BT2
Θ
BT2
Θ
FC1.1
I> I> I>
1
2
QA2
3
4
5
6
-EC1 3~
M
Θ
EB1
Compressor terminal box

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QA1 Main switch
SF1 Control voltage switch
EC1 Compressor motor
QA2 Compressor contactor
INT69 G Electronic trigger unit INT69 G
EB1 Oil sump heater
Anschlußkasten Verdichter
BT1
INT69G
QA1
L1 L2 L3 N PE PE
FC1.1
FC2
SF1
BP1
P>
QA2
BP2
P
QA2
L1.1
L2.1
L3.1
L1.2
N
PE
BT3
1112 14
L N B1 B2
12
11
10
9
8
7
6
5
4
3
2
1
BT2
Θ
BT2
Θ
FC1.1
I> I> I>
1
2
QA2
3
4
5
6
-EC1 3~
M
Θ
EB1

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5.4 Electronic trigger unit INT69 G
5.5 Connection of the trigger unit INT69 G
The compressor motor is tted 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. Once cooled, it can be restarted only if the
electroniclockoftheoutputrelay(terminalsB1+B2)isreleasedbyinterruptingthesupplyvoltage.
The hot gas side of the compressor can also be protected against overtemperature using thermal
protectionthermostats(accessory).
The unit trips when an overload or inadmissible operating conditions occur. Find and remedy
the cause.
INFO Therelay switchingoutput isexecuted as a oating changeover
contact.Thiselectricalcircuitoperatesaccordingtothequiescent
current principle, i.e. the relay drops into a the idle position and
deactivates the motor contactor even in case of a sensor break or
open circuit.
INFO Connect the trigger unit INT69 G in accordance with the circuit dia-
gram. Protect the trigger unit with a delayed-action fuse (FC2) of
max. 4 A. In order to guarantee the protection function, install the
triggerunitastherstelementinthecontrolpowercircuit.
Οnderung
Klebeschilder
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
04.12.2009
Kelich
22.05.2015
Urspr.
2
Ers. f.
3
Ers. d.
4
Schaltplan
567
BOCK COMPRESSORS
8
=
+
9
Bl.
MP10 INt69 Bl.
MP10 INt69
INT69 G
Motor Protection MP10
Steuerstrom-
kreis
L
N
Steuerstrom-
kreis
L N
1112 14
B1 B2OG OG
+
-
BT1
Θ
X1 L1 L1 N N 43 43 11 12 14
L S M
X2123456
R1 R2
+
-
BT1
Θ
+
-
BT2
Θ
+
-
BT2
Θ
L
N
5|Electrical connection
Terminal box
Fig. 18
ATTENTION
Measure circuit BT1 and BT2
(PTC sensor) must not come
into contact with external
voltage.
This would destroy the trigger
unit INT69 G and PTC sensors.
Control circuit

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Relay position INT69 G
B2 12 14 11
Fig. 19
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.
5|Electrical connection
Gauge state Relay position
1. Deactivated state 11-12
2. INT69 G switch-on 11-14
3. Remove PTC connector 11-12
4. Insert PTC connector 11-12
5. Reset after mains on 11-14
5.7 Start unloader
To avoid current peaks during the starting phase we recommend using the GEA Bock-ESS soft
startingdevice(ElectronicSoftStart).Referto"Accessories"forfurtherinformation.

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6|Commissioning
6.1 Preparations for start-up
6.4 Evacuation
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.
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!
INFO To protect the compressor against inadmissible operating conditions,
high pressure and low pressure pressostats are mandatory on the
installation side.
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.
6.5 Refrigerant charge
CAUTION Wear personal protective clothing such as goggles and protective
gloves!
6.3 Leak test
Carry out the leak test on the refrigerating plant in accordance with EN 378-2 or a corresponding
safety standard, while always observing the maximum permissible overpressure for the compressor.
DANGER Risk of 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.
6.2 Pressure strength test
The compressor has been tested in the factory for pressure integrity. If however the entire system is
to be subjected to a pressure integrity test, this should be carried out in accordance with EN 378-2
or a corresponding safety standard without the inclusion of the compressor.