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Related Manuals for GEA Bock HGZ Series
Summary of Contents for GEA Bock HGZ Series
- Page 1 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 engineering for a better world GEA Refrigeration Technologies...
- Page 2 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. Manufacturer GEA Bock GmbH 72636 Frickenhausen Contact GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone +49 7022 9454 0 Fax +49 7022 9454 137 bock@gea.com www.bock.de...
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Page 3: Table Of Contents
Contents Page Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use Product description 2.1 Short description standard design 2.2 Main and functional parts 2.3 Short description optional design 2.4 Name plate 2.5 Type key Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application 3.4 Subcooling temperature Description of functions 4.1 Two-stage refrigeration circuit with liquid subcooler Compressor assembly 5.1 Setting up 5.2 Installation of the liquid subcooler system (standard design) 5.3 Installation example, liquid subcooler with accessories... -
Page 4: Safety
1| Safety 1.1 Identification of safety instructions: Indicates a dangerous situation which, if not DANGER! avoided, will cause immediate fatal or serious injury. Indicates a dangerous situation which, if not WARNING! avoided, may cause fatal or serious injury. Indicates a dangerous situation which, if not CAUTION! avoided, may cause fairly severe or minor injury. Indicates a situation which, if not ATTENTION! avoided, may cause property damage. INFO! Important information or tips on simplifying work. 1.2 Qualifications required of personnel WARNING! I nadequately qualified 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 qualifica- tions listed below: • F or example, a refrigeration technician, refrigeration mechatron-... -
Page 5: Intended Use
1| Safety 1.4 Intended use These assembly instructions describe the standard version of the HGZ7 manufactured by Bock. The compressor is intended for use in refrigeration systems in compliance with the limits of application. Only the refrigerant specified in these instructions may be used. Any other use of the compressor is prohibited! 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 a ssembly instructions and the entire system into which it is integrated has been inspected and a pproved in accordance with legal regulations. -
Page 6: Product Description
2 | Product description 2.1 Short description standard version Semi-hermetic, two-stage, six cylinder reciprocating compressor with suction-gascooled drive motor. Stages divided into LP / HP at the ratio of 2 : 1 Two-stage operation with liquid subcooler Expansion valve for subcooling adjusted for refrigerant and application range Terminal box Intermediate pressure chamber Notice CE certification for piping (only for Oil pump HGZ7/2110-4) Name plate Oil sump heater Oil sight glasses Fig. 1 Oil drain plug Charge plug Suction shut-off valve Valve plate Discharge shut-off valve Intermediate pressure line Fig. 2 Dimension and connection values can be found in Chapter 9... -
Page 7: Main And Functional Parts
2 | Product description 2.2 Main and functional parts 1. Standard version: Compressor with intermediate-pressure line mounted and insulated. Fig. 3: Liquid subcooler, expansion valve, solenoid valve, filter drier and two sight glasses enclosed separately, for individual, external mounting. Fig. 3 2. Optional version: Liquid subcooler, expansion valve, solenoid valve, filter drier and two sight glasses mounted directly to the compressor, piped and insulated. 2.3 Short description optional version L iquid subcooler, expansion valve, solenoid valve, filter drier and two sight glasses mounted directly to the compressor, piped and insulated. Expansion valve Liquid subcooler Filter drier 2 sight glasses Solenoid valve Fig. 4 Dimension and connection values can be found in Chapter 9... -
Page 8: Name Plate
2 | Product description 2.4 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany Fig. 5 Type designation Voltage, circuit, frequency Machine number Nominal rotation speed 50 Hz maximum operating current Displacement Starting current (rotor blocked) low pressure stage ND = ∆: Partial winding 1 High pressure stage HD = YYY: Partial windings 1 and 2 Voltage, circuit, frequency ND (LP): max. admissible operating pressure 10 Nominal rotation speed Low pressure side 11 Displacement 60 Hz HD (HP): max. admissible operating pressure low pressure stage... -
Page 9: Areas Of Application
3 | Areas of application 3.1 Refrigerants • HFC : R404A/R507, R410A • (H)CFC: 3.2 Oil charge The compressors are filled at the factory with the following oil type: - for R404A/R507, R410A FUCHS Reniso Triton SE 55 - for R22 FUCHS Reniso SP 46 Compressors with ester oil filling (FUCHS Reniso Triton SE 55) are marked with an X in the type designation (e.g. HGZX7/2110-4 R404A). INFO! For refilling, we recommend the above oil types. Alternatives: see lubricants table, Chapter 8.5. ATTENTION! The oil level must be in the visible part of the sight glass; damage max. oil level to the compressor is possible if min. oil level... - Page 10 3 | Areas of application R404A/R507 Fig. 7 R410A Fig. 8 Unlimited application range Evaporation temperature (°C) Condensing temperature (°C) ∆t suction gas superheat (K) Design for other areas on request Fig. 9 Max. permissible operating pressure (LP/MP/HP) : 19/19/28 bar 1) LP = low pressure MP = intermediate pressure HP = high pressure...
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Page 11: Subcooling Temperature
3 | Areas of application 3.4 Subcooling temperature The design of the expansion valve on the compressor can be defined with the help of the diagram by approximately calculating the subcooling temperature arising in the relevant operating conditions (t Diagrams for determining the subcooling temperature at the output of the liquid subcooler. Fig. 10 Fig. 11 = S ubcooling temperature at the subcooler outlet (FUA) = Evaporating temperature Fig. 12... -
Page 12: Description Of Functions
4| Description of functions The refrigerant suctioned out of the evaporator (21) is compressed by the 4 cylinders of the LP stage (2) to intermediate pressure MP. After that, the superheated refrigerant flows through the intermediate pressure chamber (3), where it is cooled by the liquid subcooler system to reduce the discharge end temperature. The refrigerant then flows 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 final pressure. Liquid subcooler system The liquid subcooler system consists of the components - liquid subcooler (plate heat exchanger) (6) - expansion valve (7) - sight glasses (8, 9) - solenoid valve (10) - filter drier (11) After the refrigerant reciever (16), the liquid line will be splitted into two lines: Line A leads through the liquid subcooler (6) and the subcooled refrigerant flows to the evaporator (21). 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... - Page 13 4| Description of functions 4.1 Two-stage refrigeration cycle with liquid subcooler Line A Line B Scope of supply Fig. 13 Explanations 1 Compressor 16 Refrigerant receiver 2 Cylinder LP-stage 17 Filter drier 3 Intermediate pressure chamber MP 18 Solenoid valve 4 Intermediate pressure line MP 19 Sight glass 5 Cylinder HP-stage 20 Expansion valve (evaporator) 6 Liquid subcooler 21 Evaporator 7 Reinjection valve 22 Liquid separator 8 Sight glass 23 Damper, suction line 9 Sight glass...
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Page 14: Compressor Assembly
5| Compressor assembly INFO! New compressors are factory-filled 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 Setting up Use transport eyelet. Do not lift manually! Use lifting gear! Fig. 14 Provide adequate clearance for maintenance work. -
Page 15: Installation Of The Liquid Subcooler System (Standard Design)
5| Compressor assembly 5.2 Installation of the liquid subcooler system (standard version) Separately enclosed components: Liquid subcooler Reinjection valve Solenoid valve Filter drier 2 sight glasses Screw-in sleeve, solder adapter and seals Please check for completeness of parts before beginning installation. Fig. 18 INFO! Observe manufacturer‘s instructions! 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! Assembly: INFO! - Page 16 5| Compressor assembly Intermediate pressure chamber Intermediate pressure line (Shown without Fig. 19 insulation) Connection of pressure compensation line for expansion valve 16 " UNF Refrigerant injection connection M22 x 1,5 Schrader connection for intermedie-pressure gauge 16 " UNF Position of temperature sensor / unpainted...
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Page 17: Installation Example, Liquid Subcooler With Accessories
5| Compressor assembly 5.3 Installation example, liquid subcooler with accessories Dia. 16 mm Ø 16 mm Ø 16 mm Dia. 16 mm Heat Wärme- insulation dämmung Line A Line B Dia. 16 mm Ø 16 mm from the receiver Dia.12 mm Ø 12 mm to the evaporator Dia.12 mm Ø 12 mm Dia.12 mm Ø 12 mm Dia.6 mm Ø 6 mm Dia.16 mm Ø 16 mm Intermediate pressure Mitteldruckkammer MP Line B chamber MP Fig. 20 1 Liquid subcooler 5 Expansion valve liquid subcooler, 2 Filter drier 6 temp. sensor expansion valve... -
Page 18: Factory-Installed Liquid Subcooler System (Optional Design)
5| Compressor assembly 5.4 Factory-installed liquid subcooler system (optional design) Liquid subcooler, expansion valve, solenoid valve and two sight glasses are mounted directly at the compressor, piped and insulated. Fig. 21 FUE: Liquid subcooler inlet FUA: Liquid subcooler outlet 5.5 Pipe connections ATTENTION! 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). The pipe connections have graduated inside diameters so that pipes with standart millimetre and inch dimensions can be used. -
Page 19: Pipes
5| Compressor assembly 5.6 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. 5.7 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. -
Page 20: Operating The Shut-Off Valves
5| Compressor assembly 5.8 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. tighten release Valve spindle seal Fig. 24 Fig. 25 5.9 Operating mode of the lockable service connections Connection cannot Service connection be shut off closed Pipe connection Connection Spindle blocked Opening the shut-off valve: Compressor Fig. 26 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. Connection cannot Service connection be shut off opened Pipe connection Connection Spindle open... -
Page 21: Electrical Connection 21 E
6| Electrical connection Electrical connection DANGER! H igh voltage! Risk of electric shock! Only carry out work when the electrical system is disconnected from the power supply! INFO! C onnect the compressor motor in accordance with the circuit diagram (see inside of terminal box). U se suitable cable entry point of the correct protection type (see name plate) for routing cables into the terminal box. I nsert the strain reliefs and prevent chafe marks on the cables. -
Page 22: Circuit Diagram For Part-Winding Start
6.2 Circuit diagram for part-winding start F1.2 F1.1 I=40% I=60% F1.1 F1.2 X SS X1 L1 L1 N N 43 43 11 /YYY X2 1 MP10 R2 R2 R2 Compressor terminal box Anschluákasten Verdichter Fig. 28 Main switch F1.1 Motor protection switch part winding 1 F1.2 Motor protection switch part winding 2 Fuse control current circuit High pressure safety monitor Safety chain (high/low pressure monitoring ) - Page 23 L1.1 L2.1 L3.1 L1.2 K2T K3T Y1 P> P< Pl K1T Delay relay max. 1 s (slow release), part winding 2 K2T D elay relay max. 20 s (slow release), Open solenoid Y1 (subcooler) K3T D elay relay max. 20 s (slow release), compresssor switch-off (suction subcooler) Solenoid valve intermediate cooler Compressor motor Cold conductor (PTC sensor) Thermal protection thermostat (PTC sensor) Oil temperature (NTC sensor) PW MP10 BOCK COMPRESSORS...
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Page 24: Standard Motor, Design For Direct Or Partial Winding Start
6| Electrical connection 6.3 Standard motor, design for direct or partial winding start Designation on the name plate Sticker on the terminal box ∆ / YYY Compressors with this marking are suitable for direct or partial winding start. The motor winding is subdivided into two parts: Partial winding 1 = 60% and part winding 2 = 40%. This winding d ivision reduces the start-up current needed for a part winding start to approx. 65% of that for a direct start. INFO! A mechanical unloaded start with bypass solenoid valve is not required. In the factory, the motor is switched for direct starting (YYY). For part winding start ∆ / YYY, remove the bridges and connect the motor feed cable according to the circuit diagram: 400 V Direktstart YY Teilwicklungsstart Y/YY Direct start YYY Part winding start ∆/YYY INFO! W hen testing the winding with resistance meter, please note that part winding 1 and part winding 2 are internally connected. -
Page 25: Electronic Trigger Unit Mp
6| Electrical connection 6.4 Electronic trigger unit MP 10 The compressor motor is fitted 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. -
Page 26: Function Test Of The Trigger Unit Mp
6| Electrical connection 6.6 Function test of the trigger unit MP 10 Before start-up, troubleshooting or making changes to the control power circuit, check the functionality of the trigger unit: LED H1 LED H2 LED H3 Procedure green • Interrupt power supply (L1 or S1) • Release the motor temperature sensor connection (1 or 2) • Release the hot gas temperature sensor (if installed) (3 or 4) • Restore the power supply (L1 or S1) •... -
Page 27: Oil Sump Heater (Accessories)
6| Electrical connection 6.7 Oil sump heater (accessories) When the compressor is at a standstill, refrigerant diffuses into the lubrication oil of the compressor housing, depending on pressure and ambient temperature. This reduces the lubrication capacity of the oil. When the compressor starts up, the refrigerant contained in the oil evaporates out through the reduction in pressure. The consepuences can be foaming and migration of the oil, causing oil shocks under certain circumstances. Operation: The oil sump heater operates when the compressor is at a standstill. When the compressor starts up, the oil sump heating switches off. Connection: The oil sump heater must be connected via an auxiliary contact (or parallel wired Anschlussschema für Ölsumpfheizung auxiliary contact) of the compressor contactor to a separate electric circuit. Connection diagramm for oil sump heater Electrical data: 230 V - 1 - 50/60 Hz, 140 W. Plan de raccordement pour résistance de carter d‘huile Fig. 30 ATTENTION! The oil sump heater must not be connected to the electrical circuit of the safety control chain... -
Page 28: Commissioning
7| Commissioning 7.1 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! 7.2 Pressure strength test DANGER! Bursting! The compressor must only be pressurised using nitrogen ). -
Page 29: Refrigerant Charge
7| Commissioning 7.5 Refrigerant charge 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. Pay attention to adequate refrigerant fill before starting up the compressor. During operation, refrigerant must be free of bubbles in sight glasses 1 and 2 of the liquid subcooler. 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 overfilling the system with refrigerant! I n order to prevent shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always only be added to the refrigerating system in liquid form. -
Page 30: Avoiding Liquit Sluggings
7| Commissioning 7.7 Avoiding liquid sluggings 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. When selecting the evaporator expansion valve, pay attention to correction factors for liquid subcooling. Avoid transfer of refrigerant into the compressor when the system is at a standstill. -
Page 31: Maintenance
8| Maintenance 8.1 Preparation 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 infiltrating the system! After maintenance has been performed: Connect safety switch. Evacuate compressor. Release switch-on lock. 8.2 Work to be carried out 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. -
Page 32: Replacing The Valve Plates
8| Maintenance 8.4 Replacing the valve plates The compressors are divided into an LP and an HP compressor stage. Different valve plate designs are required because of the different ducts in the individual compressor stages. The valve plates have been fitted with safety bolts to prevent any confusion. The safety bolts engage in the corresponding bores on the cylinder heads, the safety bolts must not be removed! Installation of the valve plates:: Safety bolt Safety valve Safety bolt Safety valve Ventilplatte LP-Stufe Valve plate LP stage Valve plate HP stage Ventilplatte HP-Stufe... -
Page 33: Extract From The Lubricants Table
8| Maintenance 8.5 Extract from the lubricants table The oil type filled as standard in the factory is marked on the name plate. This oil type should be used as a preference. Alternatives are stated in the extract from our lubricants table below. Refrigerants Bock standard oil types Recommended alternatives Fuchs Reniso Triton SEZ 32 HFKW Esso/Mobil EAL Arctic 46 Fuchs Reniso Triton SE 55 (e.g. R134a, R404A, Sunoco Suniso SL 46 R407C) Texaco Capella HFC 55 Fuchs Reniso SP 32 BP Energol LPT 46 HFCKW (e.g. R22) Fuchs Reniso SP 46 Sunoco Suniso 3,5 GS Texaco Capella WF 46 8.6 Decommissioning... -
Page 34: Technical Data
9| Technical data... -
Page 35: Dimensions And Connections
10| Dimensions and connections 10.1 Compressor in standard design Intermediate pressure mixed line mounted and insulated. (Liquid subcooler with accessories as an extra item) Centre of gravity View X: Connection possibility for oil level regulator Three-hold connector for oil level regulator Products ESK, AC+R, CARLY (3x M6, 10 deep) Fig. 32 Dimensions in mm... - Page 36 10| Dimensions and connections 10.2 Compressor in optional design (Liquid subcooler with accessories attached directly to the compressor) View X: Connection possibility for oil level regulator Three-hold connector for oil level regulator Products ESK, AC+R, CARLY (3x M6, 10 deep) Fig. 33 Dimensions in mm...
- Page 37 10| Dimensions and connections Suction line see technical data, Chapter 9 Discharge line Liquid subcooler IN " Ø 16 mm - " Liquid subcooler OUT Ø 16 mm - Connection suction side, not lockable 8 “ NPTF Connection suction side, lockable 16 “ UNF Connection intermediate pressure, not lockable 8 “ NPTF Connection intermediate pressure, not lockable 4 “ NPTF Connection discharge side, not lockable 8 “ NPTF Connection discharge side, lockable 16 “ UNF Connectoin oil pressure safety switch OIL 16 “ UNF Connection oil pressure safety switch LP 16 “...
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Page 38: Declaration Of Conformity And Installation
11| Declaration of conformity and installation DECLARATION OF CONFORMITY CE 01 for using the compressors within the European Union (in accordance with Low Voltage Directive 2006/95/EC) We hereby declare that the following refrigerating compressors Product designation: HGZ7 comply with the Low Voltage Directive 2006/95/EC. Applied harmonised standard: EN 60034-1:2010 EN 60204-1:2006 DECLARATION OF INSTALLATION for using the compressors within the European Union (in accordance with Machinery Directive 2006/42/EC) The manufacturer: GEA Bock GmbH, Benzstraße 7 72636 Frickenhausen, Tel.: 07022/9454-0 hereby declares that the refrigerating compressor HGZ7 complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. Applied harmonised standard: EN 12693:2008 and the corresponding standards referenced A partly completed machine may only be put into operation when it has been established that the machine, into which the partly completed machine is to be installed, conforms to the r egulations of the Machinery Directive (2006/42/EC). The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery on request. The special technical documentation required for partly completed machinery has been created in accordance with Appendix VII Part B. - Page 39 11| Declaration of conformity PED - CLASSIFICATION (as per EU Pressure Equipment Directive 97/23/EC) DECLARATION OF CONFORMITY for use of the compressors within the European Union (as per EU Pressure Equipment Directive 97/23/EC) We hereby declare that piping of the refrigerant compressors HGZX7/2110-4 R404A, HGZX7/2110-4 R410A und HGZ7/2110-4 R22 agrees with the Pressure Equipment Directive 97/23/EG dated 29 May 1997. Valid for Category I piping Evaluation procedure module A The other parts of the piping fall under article 3§3 of the Guideline and correspond to good engineering practice Frickenhausen, 01.11.2011 ppa. Wolfgang Sandkötter, Chief Development Officer...
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Page 40: Service
11| Service Dear customer, Bock compressors are top-quality, reliable and service-friendly quality products. If you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The Bock service team can be contacted by phone with a toll-free hotline 00 800 / 800 000 88 or via e-mail: bock@gea.com. Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany We also provide information on the Internet at www.bock.de. For example, under the "Documentation" link you will find: - Technical information - Product information - Product brochures - and much more... - Page 42 • • GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 index.
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