GEA HGX34 CO2 T Series User manual

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engineering for a better world GEA Refrigeration Technologies
Bock Compressor HGX34 CO2 T
Assembly instructions
HGX34/110-4 ML CO2 T HGX34/110-4 S CO2 T HGX34/110-4 SH CO2 T
HGX34/130-4 ML CO2 T HGX34/130-4 S CO2 T HGX34/130-4 SH CO2 T
HGX34/150-4 ML CO2 T HGX34/150-4 S CO2 T HGX34/150-4 SH CO2 T
HGX34/170-4 ML CO2 T HGX34/170-4 S CO2 T HGX34/170-4 SH CO2 T
HGX34/190-4 ML CO2 T HGX34/190-4 S CO2 T HGX34/190-4 SH CO2 T
HGX34/210-4 ML CO2 T HGX34/210-4 S CO2 T HGX34/210-4 SH CO2 T
HGX34/230-4 ML CO2 T HGX34/230-4 S CO2 T HGX34/230-4 SH CO2 T
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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 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
4 Compressor assembly 12
4.1 Setting up
4.2 Pipes
4.3 Flange shut-off valves (HP/LP
4.4 Option: cutting ring screw joint (HP/LP)
4.5 Operating mode of the lockable service connections
4.6 Operating the shut-off valves
4.7 Connecting the pipelines - cut ring system
4.8 Connecting the pipelines - solder system
4.9 Laying suction and pressure lines
4.10 Oil return
5 Electrical connection 17
5.1 Information for contactor and motor contactor selection
5.2 Standard motor, designed for direct or part winding start
5.3 Basic circuit diagram for part winding start
5.4 Special motor: design for direct or star-delta start
5.5 Star-delta start with special motor
5.6 Electronic trigger unit MP 10
5.7 Connection of the electronic trigger unit MP 10
5.8 Functional test of the electronic trigger unit MP 10
5.9 Oil sump heater
6 Commissioning 28
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 Pressure switch
6.8 Decompression valves
6.9 Avoiding slugging
7 Maintenance 32
7.1 Preparation
7.2 Work to be carried out
7.3 Accessories
7.4 Spare parts recommendation
7.5 Decommissioning
8 Technical data 34
9 Dimensions and connections 36
10 Declaration of conformity and installation 38
11 Service 39

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1|Safety
1.1 Identicationofsafetyinstructions:
1.2 Qualicationsrequiredofpersonnel
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cationslistedbelow:
•For example, a refrigeration technician, refrigeration mechatronics
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
the work to be carried out and recognising any potential dangers.
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
immediately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 compressors named in the title
manufactured by Bock. Bock refrigerating compressors are 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).
Commissioning is only permissible if the compressors have been installed in accordance with these
assembly instructions and the entire system into which they are integrated has been inspected and
approved in accordance with legal regulations.
The compressors are intended for use with CO2in transcritical and/or subcritical 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accident.
Refrigerating compressors are pressurised machines and
thereforerequireparticular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 pressure side or below 0 °C on the suction side
can be reached.
- Avoid the contact with refrigerant under any circumstances.
Thecontactwithrefrigerantcanleadtosevereburnsandskin
irritations.
Danger of suffocation.
NeverreleasesignicantvolumesofCO2or the entire contents of
the system into closed rooms!
•TranscriticalCO2applications are still in the development phase.
•Theyrequireacompletelynewkindofsystemandcontrol.
•TheyarenotageneralsolutionforthesubstitutionofF-gases.
•Therefore,weexpresslypointoutthatallinformationinthis
assembly instruction has been provided according to our current
levelofknowledgeandmaychangeduetofurtherdevelopment.
Legal claims based on the correctness of the information cannot
be made at any time and are hereby expressly excluded.
WARNING The compressor may not be used in potentially explosive
environments!

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2|Product description
• Semi-hemeticfour-cylinderreciprocatingcompressorwithsuctiongascooleddrivingmotor.
• Theflowofrefrigerantsuckedinfromtheevaporatorisledovertheengineandprovidesfor
a particularly intensive cooling. Thus the engine can be kept special during high load on a
relatively low temperature level.
• Onedecompressionvalveeachonthelowandhighpressureside,whichventintothe
amosphere when these inadmissibly high printing pressures are reached.
Fig. 1
2.1 Short description
Fig. 2
Oil sight glass
Valve plate
Cylinder cover
Motor section
Dimension and connection values can be found in Chapter 9
Transport eyelet
Oil pump
Drive section
Discharge
shut-off valve
Name plate
Suction
shut-off valve
Terminal box

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1 Type designation
2 Machine number
3 maximum operating current
4 Starting current (rotor blocked)
Y: Part winding 1
YY: Part winding 1 and 2
5 ND (LP): max. permissible operating
pressure (g) Low pressure side
HD (HP):
max. permissible 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!
}
}
Fig. 3
/
HG 34230- 4CO2 X
2.3 Typekey (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X - Ester oil charge
³)ML - Normal cooling and deep freezing at low and medium evaporation temperatures
S - Forfrequencyregulationandextendedlimitsofapplication
SH - For high evaporating temperatures eg. heat pumps, different oil charge
transcritical
CO2version
Compressor version ³)
Number of poles
Swept volume
Numbers of cylinders
Size
Oil charge ²)
Series ¹)
T
S
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AS12345-001
59,3 A
231 A 283 A
20,1
24,1
CO2,C 85 E
HGX34/230-4 S CO2T
100/150 bar
GEA Bock GmbH
72636 Frickenhausen, Germany
2|Product description
2.2 Name plate (example)

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3|Areas of application
 Thecompressorsarelledatthefactorywiththefollowingoiltype:
Compressor version ML andS: BockC85E
Compressor versionSH: BockC150E
(only this oils may be used)
3.1 Refrigerants
• CO2: R744(RecommendationCO2quality4.5(<5ppmH2O))
3.2 Oil charge
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.
- Min. oil temperature ≥ 30°C
- Max. permissible ambient temperature -30°C - +60°C
-Max.permissibleswitchingfrequency12x/h.
- A minimum running time of 3 min. steady-state condition
(continuous operation) must be achieved.
Avoid continuous operation in limit range.
Foroperationwithfrequencyconverter:
-Frequencyrange25-70Hz
- 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.
3.3 Limits of application
max. oil level
min. oil level
Fig. 4
ATTENTION Property damage possible.
The oil level must be in the
visible part of the sight glass;
damage to the compressor
is possible if overfilled or
underfilled!

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3|Areas of application
toEvaporation temperature (°C)
∆toh Suction gas superheat (K)
po Suction pressure (bar)
pv2Discharge end pressure (bar)
Unlimited
application range
Fig. 5
Max. permissible operating
pressure (LP/HP)1):100/150bar
1) LP = Low pressure
HP = High pressure
10 20 30 50
50
40
90
80
120
Einsatzgrenzen HGX34 CO
2 T
100
70
60
40 po (bar)
p
V2
(bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
Compressor version ML

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toEvaporation temperature (°C)
∆toh Suction gas superheat (K)
po Suction pressure (bar)
pv2Discharge end pressure (bar)
Unlimited
application range
Fig. 6
Max. permissible operating
pressure (LP/HP)1):100/150bar
1) LP = Low pressure
HP = High pressure
10 20 30 50
50
40
90
80
120
Einsatzgrenzen HGX34 CO
2 T
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
p
V2
(bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
Compressor version S
3|Areas of application

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toEvaporation temperature (°C)
∆toh Suction gas superheat (K)
po Suction pressure (bar)
pv2Discharge end pressure (bar)
Unlimited
application range
Fig. 7
Max. permissible operating
pressure (LP/HP)1):100/150bar
1) LP = Low pressure
HP = High pressure
10 20 30 50
50
40
90
80
120
Einsatzgrenzen HGX34 CO
2 T
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
pV2 (bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
10 20 30 50
50
40
90
80
120
100
70
60
40 po (bar)
p
V2
(bar)
110
130
140
60
0-10-20-30
-40
10
to (°C)
20
64,3 70
25
?t = 10 K
Oh
Compressor version SH
3|Areas of application

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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.
Compound connection basically 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. 8
Fig. 9
Fig. 10
Fig. 11
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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
4.2 Pipes
Pipes and system components must be clean and dry inside and free of scale, swarf and layers of
rust and phosphate. Only use hermetically sealed 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.
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.
Immediately after coolingtechnical connection of the compressor
ofshutoffdevicesinsuction-,discharge-,oilreturnlineetc.close
and compressors evacuate.
Checkthecompressorfortransportdamagebeforestartingany
work.

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AB
4.3 Flange shut-off valves (HP/LP)
4|Compressor assembly
4.4 Option:cuttingringscrewjoint(HP/LP)
Remove
Schrader
connection HP Remove
Schrader
connection LP
Fig. 14 Fig. 15
CAUTION Riskofinjury.
The compressor must be depressurised through connections A
andBbeforecommencinganyworkandpriortoconnectingtothe
refrigerant system.
ATTENTION Property damage possible.
ThecompressorasdeliveredisequippedwithSchradervalveson
the high and low pressure connections. These are used exclusively
forchangingwithinertgasinthefactory,andundernocircum-
stances may they be connected to the refrigeration circuit (the
Schrader valves are approved for overpressure up to 28 bar only)!
INFO Optionallyto theflangeshut-off valves,cuttingringscrewjoints
(Fig.14 and 15) (HG/LP) are also available.
Fig. 12 Fig. 13

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4|Compressor assembly
4.6 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. 18 Fig. 19
Valve spindle seal
release tighten
Pipe connection
Pipe connection
4.5 Operatingmodeofthelockableserviceconnections
Fig. 16
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. 17
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

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4|Compressor assembly
•On its high-pressure side, the compressor has a shut-off valve with multi-sided cutting ring for safe
installation of the discharge line.
Cutting ring function before tightening the union nut
4.7 Connecting the pipelines - cut ring system
Fig. 20
Tubepreparation:
The tube has to be sawn in a right angle. An angular tolerance of ±1° is permissible.
Slightly trim the pipe ends inside and outside. For thin walled steel pipes or soft pipes made of
nonferrous metal, reinforcing sleeves have to be used.
Pipeassembly:
Push Union Nut (5) and Cut Ring (3) onto Pipe (2). Insert pipe into Socket (6) as far as it will go and
firmly press against pipe stop, otherwise incorrect assembly. Hand tighten union nut until socket,
cutting ring and union nut are locked. Tighten union nut 1 ½ turns using a spanner wrench. The
cutting ring is noticeably locked to the socket face (for assembly inside pipe connection, hold up
valve with a spanner wrench). This should cause the cutting ring with its cutting edges to cut into
the pipe resulting in a visible collar. In order to stick to the turns we recommend using marking lines
on union nut and pipe. After assembly, it is necessary to check the collar. The gasket must not be
damaged. At least 80% of the cutting face has to be covered. After check-up, screw on and tighten
again as described above.
. . . . . .
Collar

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Fig. 22
Rigid
fixed point
As short as
possible
4.9 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.
4|Compressor assembly
ATTENTION Property damage possible.
Improperlyinstalledpipescancausecracksandtearswhichcan
result in a loss of refrigerant.
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.
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. 21: graduated
internal diameter
4.8 Connecting the pipelines - solder system
ATTENTION Property damage possible.
Remove the valve from the compressor for soldering. Superhea-
ting can damage the valve. Cool the valve body during soldering.
Only solder using inert gas to inhibit oxidation products (scale).

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5|Electrical connection
5 Electrical connection
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!
5.1 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.
4|Compressor assembly
Toensuretheoilreturnfunctionwillworkreliablynomatterwhatkindofsystemcongura-
tion you are using, GEA Bock recommends incorporating oil separators or oil level monitoring
equipment.The"O"connectionisalreadyavailablefromthefactoryforthepurposeofinstal-
ling the additional oil level monitoring component. Oil should be returned from the oil separator to
thecompressorviathe"D1"connectionprovidedforthispurposeonthecompressor.
4.10 Oil return

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5.2 Standardmotor,designedfordirectorpartwindingstart
Designation on the name plate Sticker on the terminal box
Y/YY
Compressors marked in this way are suitable for direct or part winding start. The motor winding is
divided into two parts: part winding 1 = 66% and part winding 2 = 33%. This winding devision reduces
the start-up current during a part winding start to approx. 65% of the value for a direct start.
5|Electrical connection

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In the factory, the motor is switched for direct starting (YY). For part winding start (Y/YY), remove the
bridges and connect the motor feed cable according to the circuit diagram:
400 V
Direct start YY Part winding start Y/YY
L1
L2
L3
L1
L2
L3
L1 L3
L2
PTC
PW II
PW I
PTC
ATTENTION Property damage possible.
Failure to comply results in reversed elds of rotation and can
cause motor damage. After the motor has started up with part win-
ding1,partwinding2 must beswitchedonafter max.1second
delay. Failure to comply can be detrimental to the service life of
the motor.
Ensure that power is supplied via K1 to winding 1 (66%) (1U1 /
1V1 / 1W1) and via K2 to winding 2 (33%) (2U1 / 2V1 / 2W1). The
motor contactors (K1/K2) are each to be rated for approx. 70% of
the max. operating current.
5|Electrical connection

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5.3 Basiccircuitdiagramforpartwindingstart
R1 Cold conductor (PTC sensor) motor winding
R2 Thermal protection thermostat (PTC sensor)
F1.1 / 1.2 2 motor protection switches (66% / 33% of I Atotal)
F2 Control power circuit fuse
F3 High pressure safety monitor
F4 Safety chain (high/low pressure monitoring)
B1 Release switch (thermostat)
Fig. 23
5|Electrical connection
Compressor terminal box