GEA HGX22P CO2 Series User manual

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engineering for a better world GEA Refrigeration Technologies
Bock Compressor HGX22P CO2
Assembly instructions
HGX22P/110-4 CO2
HGX22P/125-4 CO2
HGX22P/160-4 CO2
HGX22P/190-4 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 10
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
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 20
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
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.
WARNING! DANGER OF SUFFOCATION!
 NeverreleasesignicantvolumesofCO2or the entire contents of
the system into closed rooms!

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1|Safety
These assembly instructions describe the standard version of the HGX22P -CO2manufactured by
Bock.
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
WARNING! The compressor may not be used in potentially explosive
environments!
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.

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Name plate
Fig. 1
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
2|Product description
• Semi-hermetictwo-cylinderreciprocatingcompressorwithoilpumplubrication.
• Suction gas cooled drive motor.
2.1 Short description

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2|Product description
2.2 Name plate (example)
2.3 Typekey (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X - Ester oil charge
³) Additional declaration for Pluscom compressors
Fig. 3
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. permissible operating 10 Nominal rotation speed
pressure (g) Low pressure side 11 Displacement
HD (HP): max. permissible 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
}
/
HG 22 P 125- 4CO2 X
CO2Version
Number of poles
Swept volume
³)
Numbers of cylinders
Size
Oil charge ²)
Series ¹)
1
2
3
4
513
12
7
11
6
10
8
9
40/55
AS33567A001
C85E
20,9/12,1A
Δ: 121A Y: 70A
GEA Bock GmbH
72636 Frickenhausen, Germany

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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8x/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.
 Thecompressorsarelledatthefactorywiththefollowingoiltype:
BockC85E(onlythisoilmaybeused)
3.1 Refrigerants
• CO2: R744
3.2 Oil charge
3.3 Limits of application
R744
Max. permissible operating
pressure (LP/HP)1): 40/55 bar
Unlimited application range
1) LP = Low pressure
HP = High pressure
Fig. 4
Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Suction gas temperature (°C)

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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. 5
Fig. 6
Fig. 7
Fig. 8
4.2 Pipe connections
The pipe connections have graduated inside diameters so that pipes with
standart millimetre and inch dimansions 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. 9: graduated
internal diameter
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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-
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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4.4 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.
4|Compressor assembly
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.
Fig. 10
Rigid
fixed point
As short as
possible

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Valve spindle seal
Release
Tighten
Fig. 11 Fig. 12
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.
4.5 Operating the shut-off valves
Pipe connection
Pipe connection
4.6 Operatingmodeofthelockableserviceconnections
Fig. 13
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. 14
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

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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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). Set the short
circuit trigger current at max. 7 times the permissible operating current according to the compressor
name plate.

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5|Electrical connection
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! The connection examples shown refer to the standard
 version.Inthecaseofspecialvoltages,theinstructionsafxedtothe
terminal box apply.

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         

  





















 


         
  
      



 







 

 


  

 







 










5.3 Circuit diagramm for direct start 230 V ∆/ 400 V Y
Fig. 15
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. 16
Temperature monitoring connections:
Motor winding: Terminals 1 - 2
Thermal protection thermostat: Terminals 3 - 4
Restart prevention: Terminals 5 - 6
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.
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
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.
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.

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5.7 Oil sump heater
ATTENTION! The oil sump heater must generally be connected and operated.
Inordertoavoiddamagetothecompressor,thecompressorisequippedwithanoilsumpheateras
a standart feature.
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.
5|Electrical connection
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
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
 compressor.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).
6.1 Preparations for start-up
INFO! In order to protect the compressor against inadmissible operating
conditions,high-pressureandlow-pressurepressostats controls 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
WARNING! The compressor must never be pressurised using oxygen or other
technical gases!
The maximum permissible overpressure of the compressor must not
be exceeded at any time during the testing process (see name plate
data)!
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.
The pressure strength test is best carried out using dry nitrogen (N2).
Do not mix any refrigerant with the testing medium (N2) as this could cause the ignition limit to
shift into the critical range.
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.
6.4 Evacuation
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.

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6|Commissioning
Make sure that the suction and pressure line shut-off valves are open.
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!
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.
CAUTION! Wear personal protective clothing such as goggles and protective
gloves!
6.5 Refrigerant charge
Fillingtheliquid refrigerant: Itisrecommend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by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.
• One after start-up necessarily becoming refrigerant addition can be lled
gaseously into the suction face.
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.
WARNING! Max.permissiblepressureatllingunderanycircumstancesdo 
not exceed. In time suitable measures meet (e.g. Printing retaining
refrigerant plant or high pressure stage of the cascade operate).

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6|Commissioning
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conditionscanoccure,which
mayresultinapermanentleak.Alwayschecksystemforrefrigerantlossafter
activation of decompression valve!
The decompression valves do not replace any pressure switches and the
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appro-
priate safety standards.
FailuretoobservecanresultinriskofinjuryfromCO2streaming out of the two
decompression valves!
6.7 Decompression valves
6.6 Start-up
WARNING! Ensure that both shut-off valves are open before starting the
compressor!
 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. 17
ATTENTION! Iflargerquantitiesofoilhavetobetoppedup,thereisariskofoil
impacteffects.Ifthisisthecase,checktheoilreturn!