GEA HG22e Series User manual

D
GB
F
E
1
96188-09.2013-DGbFEI
engineering for a better world GEA Refrigeration Technologies
Bock Compressor HG22e
Assembly instructions
HG22e/125-4 HG22e/125-4 S HGX22e/125-4 HGX22e/125-4 S
HG22e/160-4 HG22e/160-4 S HGX22e/160-4 HGX22e/160-4 S
HG22e/190-4 HG22e/190-4 S HGX22e/190-4 HGX22e/190-4 S
1
2
3
4
5
6
7
8
9
10
1 1
12
13

2
D
GB
F
E
96188-09.2013-DGbFEI
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 13
 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 ∆/ 400 V Y
 5.4 Startunloader
 5.5 ElectronictriggerunitMP10
 5.6 ConnectionoftheelectronictriggerunitMP10
 5.7 FunctionaltestoftheelectronictriggerunitMP10
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 Avoidingslugging
 6.8 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 22
9 Dimensions and connections 23
10 Declaration of conformity and installation 24
11 Service 25
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+49702294540
Fax +4970229454137
[email protected]
www.bock.de
Manufacturer
Contact

D
GB
F
E
3
96188-09.2013-DGbFEI
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 13
 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 ∆/ 400 V Y
 5.4 Startunloader
 5.5 ElectronictriggerunitMP10
 5.6 ConnectionoftheelectronictriggerunitMP10
 5.7 FunctionaltestoftheelectronictriggerunitMP10
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 Avoidingslugging
 6.8 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 22
9 Dimensions and connections 23
10 Declaration of conformity and installation 24
11 Service 25

4
D
GB
F
E
96188-09.2013-DGbFEI
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.

D
GB
F
E
5
96188-09.2013-DGbFEI
1|Safety
TheseassemblyinstructionsdescribethestandardversionoftheHG22emanufacturedbyBock.The
compressoris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!
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.
1.4 Intended use
WARNING! The compressor may not be used in potentially
explosive environments!

6
D
GB
F
E
96188-09.2013-DGbFEI
1
2
3
4
5
6
7
8
9
10
1 1
12
13
2|Product description
• Semi-hermetictwo-cylinderreciprocatingcompressorwithoilpumplubrication.
• Suctiongascooleddrivemotor.
2.1 Short description
Nameplate
Fig.1
Fig.2
Oilsightglass
Cylindercover
Oilpump
Terminalbox
Suction
shut-offvalve
Drivesection
Motorsection
DimensionandconnectionvaluescanbefoundinChapter9
Transporteyelet
Valveplate
Discharge
shut-offvalve

D
GB
F
E
7
96188-09.2013-DGbFEI
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
}
/
HG 22 e 190-4 SX
2.3 Typekey (example)
¹)HG-HermeticGas-cooled(suctiongas-cooled)forthenormal-/airconditioningapplications
²)X - Esteroilcharge(HFCrefrigerant,e.g.R134a,R404A/R507,R407C)
³)S - Morepowerfulmotor,e.g.forair-conditioningapplications
Motorvariant³)
Numberofpoles
Sweptvolume
e-series
Numbersofcylinders
Size
Oilcharge²)
Series¹)
Typschild (Beispiel)
1
2
3
4
513
12
7
11
6
10
8
9
1 Typbezeichnung
2 Maschinennummer
3 maximaler Betriebsstrom
4 Anlaufstrom (Rotor blockiert)
5 ND (LP): max. zulässiger Stillstandsdruck
Saugseite
HD (HP): max. zulässiger Betriebsdruck
Hochdruckseite
Einsatzgrenzendiagramme beachten!
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
HGX22e/190-4
SE 55
AS35830A001
13,8/8,0A
69A 40A
66
GEA Bock GmbH
72636 Frickenhausen, Germany
Fig.3

8
D
GB
F
E
96188-09.2013-DGbFEI
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 additional cooling:
- Use only oils that are highly thermally stable.
- Avoid continuous operation near the limits.
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!
 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.HGX22e/190-4).
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.
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!
max.oillevel
min.oillevel
ATTENTION!
Fig.4

D
GB
F
E
9
96188-09.2013-DGbFEI
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
R22
Fig.5
Fig.6
Fig.7
Fig.8
Unlimitedapplicationrange
Supplementarycoolingor
reducedsuctiongastemperature
Supplementarycoolingand
reducedsuctiongastemperature
MotorversionS
(morepowerfulmotor)
1) LP=Lowpressure
HP=Highpressure
Max. permissible operating
pressure (LP/HP)1): 19/28 bar

10
D
GB
F
E
96188-09.2013-DGbFEI
?
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.9
Fig.10
Fig.11
Fig.12
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.13:graduated
internaldiameter
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
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).

D
GB
F
E
11
96188-09.2013-DGbFEI
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.14
As short as
possible
Rigid
fixed point

12
D
GB
F
E
96188-09.2013-DGbFEI
4|Compressor assembly
Pipeconnection
Pipeconnection
4.6 Operatingmodeofthelockableserviceconnections
Fig.17
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.18
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
Valve spindle seal
Release
Tighten
 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.15 Fig.16
4.5 Operating the shut-off valves

D
GB
F
E
13
96188-09.2013-DGbFEI
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).
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.
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.

14
D
GB
F
E
96188-09.2013-DGbFEI
         

  





















 


         
  
      



 







 

 


  

 







 










5.3 Circuit diagramm for direct start 230 V ∆/ 400 V Y
Fig.19 Compressorterminalbox
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

D
GB
F
E
15
96188-09.2013-DGbFEI
         

  





















 


         
  
      



 







 

 


  

 







 










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

16
D
GB
F
E
96188-09.2013-DGbFEI
5|Electrical connection
PTC1 PTC2
Terminalbox
Fig.20
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.
5.5 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.
5.6 Connection of the trigger unit MP10
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.
Temperaturemonitoringconnections:
Motorwinding:   Terminals1-2
Thermalprotectionthermostat: Terminals3-4
Restartprevention:   Terminals5-6
5.4 Start unloader
ToavoidcurrentpeaksduringthestartingphasewerecommendusingtheBock-ESSsoftstarting
device(ElectronicSoftStart).Referto"Accessories"forfurtherinformation.
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.

D
GB
F
E
17
96188-09.2013-DGbFEI
5|Electrical connection
ThecompressorandthetriggerunitMP10areoperationalwhentheH3LED(green)lights.
5.7 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:

18
D
GB
F
E
96188-09.2013-DGbFEI
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.
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.
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
DANGER! 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.
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
DANGER! Bursting!
Do not mix any refrigerant with the nitrogen (N2) as this could cause
the ignition limit to shift into the critical range.
CarryouttheleaktestoftherefrigeratingsysteminaccordancewithEN378-2oracorresponding
 safetystandardwithout including the compressor.

D
GB
F
E
19
96188-09.2013-DGbFEI
6|Commissioning
CAUTION! Wear personal protective clothing such as goggles and protective
gloves!
Makesurethatthesuctionandpressurelineshut-offvalvesareopen.
 Withthecompressorswitchedoff,addtheliquidrefrigerantdirectlytothecondenserorreceiver,
breakingthevacuum.
 Iftherefrigerantneedstoppingupafterstartingthecompressor,itcanbetoppedupinvapour
formonthesuctionside,or,takingsuitableprecautions,alsoinliquidformattheinlettothe
evaporator.
INFO! Avoidoverllingthesystemwithrefrigerant!
 In order to prevent shifts in concentration, zeotropic refrigerant
blends (e.g. R407C) must always only be added to the refrigerating
systeminliquidform.
Do not pour liquid refrigerant through the suction line shut-off
valve on the compressor.
It is not permissible to mix additives with the oil and refrigerant.
6.5 Refrigerant charge
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con-
tactprotectionmeasures,etc.)arefunctioningproperly.
 Switchonthecompressorandletitrunforatleast10minutes.
 Checktheoil level:Theoilmustbevisibleinthesightglass.
 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!
6.7 Avoid slugging
ATTENTION! Slugging can result in damage to the compressor and cause
  refrigeranttoleak.
To prevent slugging:
 Thecompleterefrigerationplantmustbeproperlydesigned.
 Allcomponentsmustbecompatiblyratedwitheachotherwithregardtooutput(particularlythe
evaporatorandexpansionvalves).
 Suctiongassuperheatingatthecompressorinputshould be min. 7 - 10K(checkthesettingof
theexpansionvalve).
 Thesystemmustreachastateofequilibrium.
 Particularlyincriticalsystems(e.g.severalevaporatorpoints),measuressuchastheuseofliquid
traps,solenoidvalveintheliquidline,etc.arerecommended.
There should be no movement of refrigerant in the compressor while the system is at a
standstill.

20
D
GB
F
E
96188-09.2013-DGbFEI
7.1 Preparation
7.2 Worktobecarriedout
7|Maintenance
Inordertoguaranteeoptimumoperationalreliabilityandservicelifeofthecompressor,we recommend
carryingoutservicingandinspectionworkatregularintervals:
Oil change:
 - notmandatoryforfactory-producedseriessystems.
 - foreldinstallationsorwhenoperatingneartheapplicationlimit:forthersttimeafter100
to 200 operating hours, then approx. every 3 years or 10,000 - 12,000 operating hours.
Disposeofusedoilaccordingtotheregulations;observenationalregulations.
Annual checks: Oil level, leak tightness, running noises, pressures, temperatures, function of
auxiliarydevicessuchasoilsumpheater,pressureswitch.
WARNING! Beforestartinganyworkonthecompressor:
Switch off the compressor and secure it to prevent a restart.
Relieve compressor of system pressure.
Preventairfrominltratingthesystem!
After maintenance has been performed:
Connect safety switch.
Evacuate compressor.
Releaseswitch-onlock.
6.8 Connection of oil level regulator
Theconnection"O"isprovidedforinstallinganoillevelregulator.Acorrespondingadaptermustbe
obtainedfromthetrade.
6|Commissioning
OnlyusegenuineBockspareparts!
7.3 Spare parts recommendation
HG22e / ... 125-4(S) 160-4(S) 190-4(S)
Designation Ref. No. Ref. No. Ref. No.
Setofgaskets 80313
Valveplatekit 80305 80306
Oilpumpkit 08324