GEA HGX12e S CO2 User manual

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engineering for a better world GEA Refrigeration Technologies
Bock Compressor HGX12e S CO2
Assembly instructions
HGX12e/20-4 S CO2
HGX12e/30-4 S CO2
HGX12e/40-4 S CO2
HGX12e/50-4 S CO2
HGX12e/60-4 S CO2
HGX12e/75-4 S CO2

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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.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 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
4Compressor assembly 9
4.1 Setting up
4.2 Pipe connections
4.3 Pipes
4.4 Laying suction and pressure lines
4.5 Operating the shut-off valves
4.6 Operating mode of the lockable service connections
5 Electrical connection 12
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 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
6.9 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 25
10 Declaration of conformity and installation 26
11 Service 27

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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
These assembly instructions describe the standard version of the compressor named in the title
manufactured by Bock. Bock refrigerating compressors are intended for installation in a machine
(within the EU according to the EU Directives 2006/42/EC Machinery Directive, 97/23/EC 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 compressor is intended for use with CO2in sub-critical 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
1.3 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.
Danger of suffocation.
NeverreleasesignicantvolumesofCO2or the entire contents of
the system into closed rooms!
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
• Suction gas cooled drive motor
Name plate
Fig. 1
2.1 Short description
Fig. 2
Oil sight glass
Valve plate
Cylinder cover
Discharge
shut-off valve
Oil pump
Terminal box
Suction
shut-off valve
Drive section
Motor section
Dimension and connection values can be found in Chapter 9
Transport eyelet

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2|Product description
1 Type designation
2 Machine number
3 maximum operating current
4 Starting current (rotor blocked)
5 ND (LP): max. admissible operating pressur e
(g) Low pressure side
HD (HP): max. admissible 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!
}
}
2.2 Name plate (example)
Fig. 3
1
2
3
4
5
7
6
10
8
9
13
12
11
/
HG 21 e 75- 4CO2 X
2.3 Type key (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X - Ester oil charge
3)S - More powerful motor
S
CO2version
Motor variant 3)
Number of poles
Swept volume
e-series
Numbers of cylinders
Size
Oil charge ²)
Series ¹)

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Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
R744
3|Areas of application
The compressors are lled at the factory with the following oil type:
Bock C 85 E (only this oils may be used)
3.1 Refrigerants
• CO2: R744
3.2 Oil charge
Fig. 5
Maximum admissible
operating pressure (g)
(LP/HP)1): 40/55 bar
1) LP = Low pressure
HP = High pressure
Unlimited
application range
max. oil level
min. oil level
Fig. 4
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!
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 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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.
∆t0h = 10 K

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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.
Duplex and parallel circuits always 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
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. 10: graduated
internal diameter
4.2 Pipe connections
F
E
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C
B
A
1 2
3
4
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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. Check the compressor for transport
damage before starting any work.
ATTENTION 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).

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4|Compressor assembly
Fig. 11
As short as
possible
Rigid
fixed point
4.4 Laying suction and pressure lines
4.3 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.
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.

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Valve spindle seal
Release
Tighten
4|Compressor assembly
Fig. 12 Fig. 13
Pipe connection
Pipe connection
4.6 Operating mode of the lockable service connections
Fig. 14
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. 15
Opening the service connection
Spindle: Turn ½ - 1 turn clockwise.
—> Service connection opened / shut-off valve opened.
Connection
blocked
Spindle
Spindle Connection
open
Compressor
Compressor
Service connection
closed
Service connection
opened
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.

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5|Electrical connection
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.
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!
5 Electrical connection

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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 on 230 V voltage supply. Example:
230 V ∆
Direct star 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
5|Electrical connection
INFO The connection examples shown refer to the standard version.
In the case of special voltages, the instructions afxe to the
terminal box apply.

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         

  





















 


         
  
      



 







 

 


  

 







 










5.3 Circuit diagramm for direct start 230 V ∆/ 400 V Y
Fig. 16
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
Compressor terminal box

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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
Fig. 17
Temperature monitoring connections:
Motor winding: Terminals 1 - 2
Thermal protection thermostat: Terminals 3 - 4
Restart prevention: Terminals 5 - 6
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 (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.
5.5 Connection of the trigger unit MP 10
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.
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.
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.

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5|Electrical connection
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.
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.
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:

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6|Commissioning
6.4 Evacuation
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 compres-
sor.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).
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.
6.1 Preparations for start-up
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.
6.2 Pressure strength test
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
Carry out the leak test of the refrigerating system in accordance with EN 378-2 or a corresponding
safety standard without including 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.
DANGER Risk of bursting!
Do not mix any refrigerant with the nitrogen (N2) as this could cau-
se the ignition limit to shift into the critical range.

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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.
6|Commissioning
Make sure that the suction and pressure line shut-off valves are open.
6.5 Kältemittelfüllung
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.
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.
CAUTION Wear personal protective clothing such as goggles and protective
gloves!
WARNING Never exceed the max. permissible pressures while charging.
Precautions must be taken in time.
INFO Depending upon design of the CO2refrigerantllingbottle
(with/without tubing) CO2canbelledinliquidafterweightor
gaseously.
Use only high-dried CO2quality!

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6.7 Decompression valves
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).
CO2 streaming out
Fig. 18
WARNING Ensure that both shut-off valves are open before starting the
compressor!
6.6 Start-up
ATTENTION Iflargerquantitiesofoilhavetobetoppedup,thereisariskof
oil hammer effects.
If this is the case check the oil return!
ATTENTION 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 CO2is 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 condi-
tions can occure, which may result in a permanent leak. Always
check system for refrigerant loss after activation of pressure relief
valve!
Thedecompressionvalvesdonotreplaceanypressureswitchesandthe
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 appropriate safety standards.
Failure to observe can result in risk of injury from CO2streaming
out of the two decompression valves!