GEA HGX4 CO2 Series User manual

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engineering for a better world GEA Refrigeration Technologies
Bock Compressor HGX4 CO2
Assembly instructions
HGX4/310-4 CO2
HGX4/385-4 CO2
HGX4/465-4 CO2
HGX4/555-4 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
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 Standard motor, design for direct or partial winding start
5.3 Basic circuit diagram for partial winding start with standard motor
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 25
9 Dimensions and connections 26
10 Declaration of conformity and installation 28
11 Service 29

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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 Standard motor, design for direct or partial winding start
5.3 Basic circuit diagram for partial winding start with standard motor
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 25
9 Dimensions and connections 26
10 Declaration of conformity and installation 28
11 Service 29

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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 HGX4 -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four-cylinderreciprocatingcompressorwithsuction-gascooleddrivemotor.
• Flange-mounted drive motor on the compressor case.
• The stream of refrigerant sucked out of the evaporator flows over the motor and cools it
intensively. In this way, the motor can be kept at a relatively low temperature level, particularly
under high loads
2.1 Short description

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AS12345-001
27/55
C85E
2|Product description
2.2 Name plate (example)
2.3 Typekey (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled) for deep-freezing
²) X - Ester oil charge
Fig. 3
/
HG 4310- 4CO2 X
CO2Version
Number of poles
Swept volume
Size
Oil charge ²)
Series ¹)
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
Y: Part winding 1 10 Nominal rotation speed
YY: Part windings 1 and 2 11 Displacement
5 ND (LP): max. admissible operating  12 Oiltypelledatthefactory
pressur e (g) Low pressure side 13 Terminal box protection type
HD (HP): max. admissible operating Electrical accessories can change
pressur e(g) High pressure side the IP protection class!
Observe the limits of application
diagrams!
50 Hz
}
60 Hz
}
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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.
 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
Evaporation temperature (°C)
Condensing temperature (°C)
Suction gas superheat (K)
Fig. 5
R744
1
2
Max. permissible operating
pressure (LP/HP)1): 27/55 bar
1) LP = Low pressure
HP = High pressure
Unlimited
application range
1HGX4/385-4 CO2
Maximum condensing
temperature tc= 0°C
2HGX4/555-4 CO2
Maximum condensing
temperature tc= -7,5°C
The oil level must be in the visible
part of the sight glass; damage
to the compressor is possible if
overfilled or underfilled!
ATTENTION!
Fig. 4
max. oil level
min. oil level

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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
4.2 Pipe connections
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
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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. 11
Rigid
fixed point
As short as
possible