GEA HGZ7 Series User manual

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engineering for a better world
GEA Bock Compressor HGZ7
Assembly instructions
HGZX7/1620-4 R404A/R507 HGZX7/1620-4 R410A
HGZX7/1860-4 R404A/R507 HGZX7/1860-4 R410A
HGZX7/2110-4 R404A/R507 HGZX7/2110-4 R410A
HGZ7/1620-4 R22
HGZ7/1860-4 R22
HGZ7/2110-4 R22

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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.gea.com
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 standard design
2.2 ain and functional parts
2.3 Short description optional design
2.4 Name plate
2.5 Type key
3 Areas of application 9
3.1 Refrigerants
3.2 Oil charge
3.3 Limits of application
3.4
Subcooling temperature
4Description of functions 12
4.1 Two-stagerefrigerationcircuitwithliquidsubcooler
5 Compressor assembly 14
5.1 Storage and transportation
5.2 Setting up
 5.3 Installationoftheliquidsubcoolersystem(optionaldesign)
5.4
Installationexample,liquidsubcoolerwithaccessories
 5.5 Factory-installedliquidsubcoolersystem(optionaldesign)
5.6 Pipe connections
5.7 Pipes
5.8 Laying suction ans pressure lines
5.9 Operating the shut-off valves
5.10 Operating mode of the lockable service connections
6 Electrical connection 21
6.1 Information for contactor and motor contactor selection
6.2 Circuit diagram for part-winding start
6.3 Standard motor, design for direct or partial winding start
6.4 Electronic trigger unit MP10
6.5 Connecting the trigger unit MP10
6.6 Functional test of the trigger unit MP10
 6.7 Oilsumpheater(accessories)
7 Commissioning 28
7.1 Preparations for start-up
7.2 Pressure strengh test
7.3 Leak test
7.4 Evacuation
7.5 Refrigerant charge
7.6 Start-up
7.7 Avoid slugging
8 Maintenance 31
8.1 Preparation
8.2 Work to be carried out
8.3 Spare parts recommendation
8.4 Replacing the valve plates
8.5 Extract from the lubricants table
8.6 Decommissioning
8.7 Accessories
9 Technical data 34
10 Dimensions and connections 35
11 Declaration of conformity and installation 38
12 Service 40

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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:
1|Safety

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1.4 Intended use
1.3 General 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.
WARNING The compressor may not be used in potentially explosive
environments!
These assembly instructions describe the standard version of the compressor named in the title
manufactured by GEA Bock. GEA 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 compressors are 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!
1|Safety

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2|Product description
Oil drain plug
Semi-hermetic, two-stage, six cylinder reciprocating compressor with suction-gascooled
drive motor.
 StagesdividedintoLP/HPattheratioof2:1
Compressor with intermediate pressure shut-off mounted and insulated.
2.1 Short description standard version
Dimension and connection values can be found in Chapter 10
Oil pump
Suction shut-off valve
Name plate
Notice
CEcertication
forpiping(onlyfor
HGZ7/2110-4)
Oil sight glasses
Charge plug
Valve plate
Discharge
shut-off valve
Intermediate
pressure line
Fig. 1
Fig. 2
Terminal box
Intermediate
pressure
chamber

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2|Product description
 Liquidsubcooler,expansionvalve,solenoidvalve,lterdrierandasightglassenclosed
separately,forindividual,externalmounting(Fig.3).
 Liquidsubcooler,expansionvalve,solenoidvalve,lterdrierandasightglassmounted
directlytothecompressor,pipedandinsulated(Fig.4).
2.3 Short description optional version, mounted
Dimension and connection values can be found in Chapter 10
Sight glass
2.2 Short description optional version, enclosed
Fig. 3
Liquid
subcooler
Filter drierSolenoid valve
Fig. 4
Expansion
valve

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50 Hz
}
60 Hz
}
Observe the limits of application
diagrams!
1 Type designation
2 Machine number
3 Type code
4 Maximum operating current
5 Startingcurrent(rotorblocked)
Y: Partwinding1
 YY: Partwindings1and2
6 ND(LP): max. admissible operating
pressur e (g)Low pressure side
 HD(HP): max. admissible operating
pressur e(g)High pressure side
7 Voltage,circuit,frequency
8 Nominal rotation speed
9 Displacement
VND = low pressure stage
VHD = high pressure stage
10 Voltage,circuit,frequency
11 Nominal rotation speed
12 Displacement
VND = low pressure stage
VHD = high pressure stage
13 Oiltypelledatthefactory
14 Terminal box protection type
Electrical accessories can change
the IP protection class!
2|Product description
/
HGZ 72110-4 X
Fig. 5
2.4 Name plate (example)
2.5 Type key (example)
1)HGZ=Hermeticgascooled(suctiongascooled),two-stage
2)X=Esteroilfilling(HFCrefrigerant R404A/R507,R410A)
3)PossiblealternativerefrigerantsR404A/R507,R410A,R22
R404A
Refrigerants 3)
Number of poles
Swept volume
Size
Oil charge ²)
Series ¹)
1
2
4
5
6
14
13
8
12
7
11
9
10
GEA Bock GmbH
72636 Frickenhausen, Germany
3
.
.
.
.
Y/YY
Y/YY
AN35455A040

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3|Areas of application
 Thecompressorsarelledatthefactorywiththefollowingoiltype:
-fürR404A/R507,R410A FUCHSRenisoTritonSE55
 -fürR22 FUCHSRenisoSP46
Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXin the type
designation(e.g.HGZX7/2110-4R404A).
3.1 Refrigerants
• HFKW:   R404A/R507,R410A
• (H)FCKW:   R22
3.2 Oil charge
INFO For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 8.5.
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.
- Permissible ambient temperature (-20°C) - (+60°C)
- 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 supplementary cooling:
- Use only oils with high thermal stability.
- Avoid continuous operation near the threshold.
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!
3.3 Limits of application
ATTENTION The oil level must be in the
visible part of the sight glass;
damage to the compressor is
possible if overfilled or under-
filled!
max.
min.
2,3 Ltr.
oil level
Fig. 6
~
~

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Max. permissible operating pressure (LP/MP/HP)1): 19/19/28 bar
Design for other areas
onrequest
Fig. 7
Fig. 8
Fig. 9
3|Areas of application
R404A/R507
R410A
R22
1)LP = low pressure MP = intermediate pressure HP = high pressure
tOEvaporation temperature(°C)
tCCondensing temperature(°C)
∆tOhsuctiongassuperheat(K)
Unlimitedapplicationrange

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3|Areas of application
Thedesignoftheexpansionvalveonthecompressorcanbedenedwiththehelpofthediagramby
approximately calculating the subcooling temperature arising in the relevant operating
conditions(t0/tc).
Diagramsfordeterminingthesubcoolingtemperatureattheoutputoftheliquidsubcooler.
3.4 Subcooling temperature
tU= Subcooling temperature at the
subcooleroutlet(FUA)
tO= Evaporating temperature
Fig. 10
Fig. 11
Fig. 12

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Therefrigerantsuctionedoutoftheevaporator(20)iscompressedbythe4cylindersoftheLPstage
(2)tointermediatepressureMP.Afterthat,thesuperheatedrefrigerantowsthroughtheintermediate
pressurechamber(3),whereitiscooledbytheliquidsubcoolersystemtoreducethedischargeend
temperature.The refrigerant then ows through the intermediate pressure line (4) to the electric
motor of the compressor for to cool the motor. After this, the refrigerant is suctioned in by the two HP
cylinders(5)andcompressedtothenalpressure.
Liquidsubcoolersystem
Theliquidsubcoolersystemconsistsofthecomponents
-liquidsubcooler(plateheatexchanger)(6)
-expansionvalve(7)
-sightglass(8)
-solenoidvalve(9)
-lterdrier(10)
Aftertherefrigerantreciever(15),theliquidlinewillbesplittedintotwolines:
Line A leads through the liquid subcooler (6) and the subcooled refrigerant ows to the
evaporator (20).ThroughLine B refrigerantis expanding through the expansionvalve (7)into the
liquidsubcooler(6)inordertosubcooltherefrigerantoflineAandthroughtheintermediatepressure
line(MP)tocoolthesuperheatedrefrigerant,whichiscompressedfromlowpressuretointermediate
pressurechamber(3).
4|Description of functions

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4|Description of functions
Explanations
1 Compressor
2 Cylinder LP-stage
3 Intermediate pressure chamber MP
4 Intermediate pressure line MP
5 Cylinder HP-stage
6 Liquidsubcooler
7 Reinjection valve
8 Sight glass
9 Solenoid valve
10 Filter drier
11 Damper, pressure line
12 Oil separator
13 Non-return valve
14 Condenser
15 Refrigerant receiver
16 Filter drier
17 Solenoid valve
18 Sight glass
19 Expansionvalve(evaporator)
20 Evaporator
21 Liquidseparator
22 Damper, suction line
23 Filter suction line
LP = Low pressure
MP = Intermediate pressure
HP = High pressure
FUE=Liquidsubcooler,inlet
FUA=Liquidsubcooler,outlet
4.1 Two-stagerefrigerationcyclewithliquidsubcooler
Scope of supply
Line A
Line B
Fig. 13

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5|Compressor assembly
 Setuponanevensurfaceorframewithsufcientload-
bearing capacity.
Compressor in principle rigidly install.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
Do not use in a corrosive, dusty, damp atmosphere or a
combustible environment.
Fig. 16
Fig. 17
Fig. 18
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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
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.
?
5.1 Storage and transportation
 Usetransporteyelet.
Do not lift manually!
 Useliftinggear!
 Storageat(-30°C)-(+70°C),maximumpermissiblerelativehumidity
10% -95 %, no condensation.
Do not store in a corrosive, dusty, vaporous atmosphere or in a com-
bustible environment.
Fig. 15
Fig. 14
5.2 Setting up
ATTENTION Fittings (e.g. pipe holders, additional units, mounting parts etc.) on
the compressor are not permissible!

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5.3 Installationoftheliquidsubcoolersystem (optional version)
Separatelyenclosedcomponents:
Liquidsubcooler
Reinjection valve
Solenoid valve
Filter drier
Sight glass
Screw-in sleeve, solder adapter and seals
Please check for completeness of parts before beginning installation.
Assembly:
Pipe connections:
For connections, see dimension diagram Chapter 10.
System design, piping and necessary support points for the individual components must be
carefully planned and carried out.
Properlyinsulateliquidsubcooleragainstcondensationandheatingandtherelatedlossof
performance.
For rigidity reasons, the use of stainless steel pipes with a wall of 1 mm is preferred. The pipes
must be free of tension during and after soldering to prevent possible breaks lateron.
1
2
3
4
5
6
5|Compressor assembly
Fig. 19
INFO Observe manufacturer‘s instructions!
INFO The points listed here represent general guidelines and information
on how to pipe and connect the subcooler unit. To perform this work
technical knowledge and skill as well as proof of a hard-soldering
testcerticateinaccordancewithDINEN13133isrequired.
INFO Useonlysuitablehardsolderandux.Solderunderaninertgas
atmosphere when copper components are to be soldered! The
accompanying expansion valve is designed and adjusted for the
compressor and the listed refrigerant (sensor charge, nozzle).
Only use expansion valves approved and supplied by GEA Bock!
INFO The intermediate pressure line and intermediate pressure chamber
are fully insulated at the factory. To mount the expansion valve,
cut the insulation as shown in the marked area in Fig. 20, page 16.
Correct sensor placement is marked by an unpainted area on the
pipe.
ATTENTION To avoid vibration cracks in the subcooler system, the individual
components must be mounted directly to the compressor or
installed as a decoupled unit!
1
2
3
4
5
6

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5|Compressor assembly
RConnection of pressure compensation line for expansion valve 7/16"UNF
W Refrigerant injection connection M22 x 1,5
X Schrader connection for intermedie-pressure gauge 7/16"UNF
YPositionoftemperaturesensor/unpainted
Fig. 20
Intermediate
pressure line
(Shownwithout
insulation)
Y
R
X
W
Intermediate
pressure chamber

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5|Compressor assembly
1 Liquidsubcooler 5 Expansion valve FUA Liquidsubcooler,
2 Filter drier 6 Temp. sensor expansion valve Outlet
3 Solenoid valve 7 Pressure compensation connection FUE Liquidsubcooler,
4 Sight glass Inlet
Dia.16 mm Dia.6 mm
Dia.12 mm
Dia.12 mm Dia.12 mm
FUE
Fig.21
5.4 Installationexample,liquidsubcoolerwithaccessories
GB
INFO General notes:
Sensor lines, wires, etc. should not be attached with cable
binders directly to pipes or frames; otherwise, the thin pipes
may be worn through. It is better to run them through spiral
protective tubes.
If the compressor will be set up outside, UV-resistant materials
should be used.
X
Y
Line A
to the evaporator
Dia. 16 mm
Heat
insulation
Line B
Dia. 16 mm
Dia. 16 mm
from the receiver
Line B
Intermediate pressure
chamber MP

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5.6 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.23:graduated
internal diameter
5|Compressor assembly
ATTENTION Damage possible.
Superheating can damage the valve.
Remove the pipe supports therefore from the valve for soldering.
Only solder using inert gas to inhibit oxidation products (scale)
INFO A soldering suppot for tube diameter 54 mm is mounted to the
suction shut-off valve of the compressor.
A soldering support for tube diameter 2 1/8'' accompanies the
compressor.
Liquidsubcooler,expansionvalve,solenoidvalveandthesightglassaremounteddirectlyatthe
compressor, piped and insulated.
5.5 Factory-installedliquidsubcoolersystem(optionaldesign)
FUE
FUA
FUE:Liquidsubcoolerinlet
FUA:Liquidsubcooleroutlet
Fig.22

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5|Compressor assembly
5.8 Laying suction and pressure lines
5.7 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.
Rigid
fixed point
As short
as possible
Fig. 24

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5|Compressor assembly
5.9 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. 25 Fig. 26
Valve spindle seal
release
tighten
Pipe connection
Pipe connection
5.10 Operating mode of the lockable service connections
Fig. 27
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. 28
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