BOCK HGX12e CO2 LT Series User manual

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colour the world
of tomorrow
BOCK®
Assembly instructions
96571-08.2022-Gb
Translation of the original instructions
BOCK HGX12e CO2LT
HGX12e/20-4 ML CO2 LT HGX12e/20-4 S CO2 LT
HGX12e/30-4 ML CO2 LT HGX12e/30-4 S CO2 LT
HGX12e/40-4 ML CO2 LT HGX12e/40-4 S CO2 LT

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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
Contents Page
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.
Bock GmbH
72636 Frickenhausen
Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Phone [phone]
Fax [phone]
www.bock.de
[email protected]
Manufacturer
Contact

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Contents Page
3 Areas of application 8
3.1 Refrigerants
3.2 Oil charge
3.3 Limits of application
4 Compressor assembly 10
4.1 Storage and transportation
4.2 Setting up
4.3 Pipe connections
4.4 Pipes
4.5 Flange shut-off valves (HP/LP)
4.6 Laying suction and pressure lines
4.7 Operating the shut-off valves
4.8 Operating mode of the lockable service connections
4.9 Oil return
4.10 Suction pipe lter
5 Electrical connection 14
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 Δ / 400 V Y
5.4 Electronic trigger unit INT69 G
5.5 Connection of the electronic trigger unit INT69 G
5.6 Functional test of the electronic trigger unit INT69 G
5.7 Oil sump heater
5.8 Selection and operation of compressors with frequency converters
6 Commissioning 20
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
6.10 Filter dryer
7 Maintenance 24
7.1 Preparation
7.2 Work to be carried out
7.3 Spare parts recommendation / accessories
7.4 Lubricants
7.5 Decommissioning
8 Technical data 26
9 Dimensions and connections 28
10 Declaration of incorporation 30
11 Service 31

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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 imme-
diately 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
1|Safety
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 appropriate
expert knowledge and 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.

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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 and
2014/68/EU 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 CO2 in 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
b elow 0°C u p to 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.
CO2 is a nonammable, acidic, colourless and odourless gas and
heavier than air.
Never release signicant volumes of CO2or the entire contents of
the system into closed rooms!
Safety installations are designed or adjusted in accordance with EN
378-2 or appropriate safety standards.
• 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!
1|Safety

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• Semi-hermetic two-cylinder reciprocating compressor with suction gas cooled driving motor.
• The 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 on a relatively low temperature level
specially during high load.
• Oil pump independent of direction of rotation for reliable and safe oil supply.
• One decompression valve each on the low and high pressure side, which vent into the atmos-
phere when inadmissibly high pressure levels are reached.
Fig. 1
2.1 Short description
Fig. 2
Dimension and connection values can be found in chapter 9
Oil pump
2|Product description
Transport eyelet
Oil sight glass
Valve plate
Name plate
Discharge
shut-off valve
Suction
shut-off valve
Terminal box
Cylinder cover

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2.3 Type key (example)
1 Type designation
2 Machine number
3 maximum operating current
4 Starting current (rotor blocked)
5 ND (LP): max. admissible operating
pressure (g) Low pressure side
HD (HP): max. admissible 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!
}
}
2.2 Name plate (example)
Fig. 3
2|Product description
1
2
3
4
5
13
12
7
11
6
10
8
9
SE 55
27,3
32,8
HGX12e/40-4 S CO2LT
10,7/6,2A
111A 64A
BC12345A001
Bock GmbH, Benzstr. 7
72636 Frickenhausen, Germany
C85E
3,5
4,2
IP66
100/100 bar
BOCK
/
HG 12 e 40- 4CO2 X
¹) HG - Hermetic Gas-Cooled (sauggasgekühlt)
²) X - Esterölfüllung
³) ML - Deep freezing at low and medium evaporation temperatures
S - For frequency regulation and extended limits of application
Low Temperature
CO2version
Compressor version ³)
Number of poles
Swept volume
e-series
Number of cylinders
Size
Oil charge ²)
Series ¹)
LT
S
Öl: BOCKlub E85

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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!
Fig. 4
max.
min.
0,6 Ltr.
Oil level ~
~
3|Areas of application
3.1 Refrigerants
• R744: CO2 (required CO2 quality 4.5 (< 5 ppm H2O))
The compressors are lled at the factory with the following oil type:
Compressor version ML and S: BOCKlub E85
3.2 Oil charge

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3|Areas of application
ATTENTION Compressor operation is possible within the operating limits.
These can be found in Bock compressor selection tool (VAP)
under vap.bock.de. Observe the information given there.
- Permissible ambient temperature (-20 °C) - (+60 °C).
- Max. permissible discharge end temperature 160 °C.
- Min. discharge end temperature ≥50 °C.
- Min. oil temperature ≥ 30 °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 30 - 70 Hz.
(For more on the frequency converter, see chapter 5.8, p. 19)
3.3 Limits of application
Max. permissible operating
pressure (LP/HP)1): 100/100 bar
1) LP = Low pressure
HP = High pressure

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INFO New compressors are factory-lled with inert gas. Leave this
service charge in the compressor for as long as possible and prevent
the ingress of air.
Immediately after refrigeration technological connection of
the compressor close the shut-off devices in suction-, dis-
charge-, oil return line etc. and evacuate the compressor.
Check the compressor for transport damage before starting any
work.
4.2 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.
Provide adequate clearance for maintenance work.
Ensure adequate compressor ventilation.
Do not use in a corrosive, dusty, damp atmosphere or a com-
bustible environment.
F
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B
A
1 2
3
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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
?
4.1 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.
ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
4|Compressor assembly

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B1
A1
Material soldering / welding connection: S235JR
The pipe connections have graduated inside diameters so that pipes with
standard 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. 5: graduated
internal diameter
4.3 Pipe connections
ATTENTION Damage possible.
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).
4|Compressor assembly
4.5 Flange shut-off valves (HP/LP)
CAUTION Risk of injury.
The compressor must be depressurized through connections A1
and B1 before commencing any work and prior to connecting to
the refrigerant system.
4.4 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.
Fig. 7 Fig. 8

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4|Compressor assembly
Fig. 9
Rigid fixed
point
As short as possible
Fig. 10 Fig. 11
Valve spindle seal
Release
Tighten
4.6 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.
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.
4.7 Operating the shut-off valves (example)
Before opening or closing the shut-off valve, release the valve spindle seal by approx. 1/4 of a turn
counter-clockwise.
After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise.

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4|Compressor assembly
4.8 Operating mode of the lockable service connections (example)
After activating the spindle, generally t the spindle protection cap again and tighten with 40 - 50 Nm.
This serves as a second sealing feature during operation.
Pipe connection
Pipe connection
Fig. 12
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. 13
Opening the service connection
Spindle: Turn 1/2 - 1 turn to the right clockwise.
—> Service connection opened / shut-off valve opened.
Connection
blocked
Spindle
Spindle Connection
open
Compressor
Compressor
Service connec-
tion closed
Service connec-
tion opened
To ensure the oil return function will work reliably no matter what kind of system conguration you
are using, Bock recommends incorporating oil separators or oil level monitoring equipment. The "O"
connection is already available from the factory for the purpose of installing 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.
4.9 Oil return
For systems with long pipes and higher degree of contamination, a lter on the
suction-side is recommended. The lter has to be be renewed depending on the degree of contamina-
tion (reduced pressure loss).
4.10 Suction pipe lter

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5 Electrical connection
INFO Connect the compressor motor in accordance with the circuit diagram
(see inside of terminal box).
Use suitable cable glands 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!
ATTENTION When attaching accessories with an electrical cable, a minimum
bending radius of 3 x the cable diameter must be maintained for
laying the cable.
5.1 Information for contactor and motor contactor selection
All protection equipment, switching and monitoring devices must comply with the local safety reg-
ulations and established specications (e.g. VDE) as well as the manufacturer’s specications.
Motor protection switches are required! Motor contactors, feed lines, fuses and motor protec-
tion switches must be rated according to the maximum operating current (see name plate). For
motor protection, use a current-dependent, time-delayed overload protection device for monitoring
all three phases. Adjust the overload protection device so that it must be actuated within 2 hours at
1.2 times the maximum working current.
5|Electrical connection

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Star-delta start-up is only possible on 230 V voltage supply. Example:
230 V ∆
Direct start Star-delta start
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 stand-
ard version. In the
case of special volt-
ages, the instruc-
tions afxed to the
terminal box apply.
5.2 Connection of the driving motor
The compressor is designed with a motor for star-delta circuits.
Designation on the name plate ∆/ Y
5|Electrical connection

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Anschlußkasten Verdichter
BT1
INT69G
QA1
L1 L2 L3 N PE PE
FC1.1
FC2
SF1
BP1
P>
QA2
BP2
P
QA2
L1.1
L2.1
L3.1
L1.2
N
PE
BT3
1112 14
L N B1 B2
12
11
10
9
8
7
6
5
4
3
2
1
BT2
Θ
BT2
Θ
FC1.1
I> I> I>
1
2
QA2
3
4
5
6
-EC1 3~
M
Θ
EB1
5.3 Circuit diagramm for direct start 230 V ∆/ 400 V Y
Fig. 14
Compressor terminal box
BT1 Cold conductor (PTC sensor) motor winding
BT2 Thermal protection thermostat (PTC sensor)
FC1 Load circuit safety switches
FC2 Control power circuit fuse
BP1 High pressure safety monitor
BP2 Safety chain (high/low pressure monitoring)
BT3 Release switch (thermostat/pressostat)

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Anschlußkasten Verdichter
BT1
INT69G
QA1
L1 L2 L3 N PE PE
FC1.1
FC2
SF1
BP1
P>
QA2
BP2
P
QA2
L1.1
L2.1
L3.1
L1.2
N
PE
BT3
1112 14
L N B1 B2
12
11
10
9
8
7
6
5
4
3
2
1
BT2
Θ
BT2
Θ
FC1.1
I> I> I>
1
2
QA2
3
4
5
6
-EC1 3~
M
Θ
EB1
QA1 Main switch
SF1 Control voltage switch
EC1 Compressor motor
QA2 Compressor contactor
INT69 G Electronic trigger unit INT69 G
EB1 Oil sump heater

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5.4 Electronic trigger unit INT69 G
5.5 Connection of the trigger unit INT69 G
The compressor motor is tted with cold conductor temperature sensors (PTC) connected to the
electronic trigger unit INT69 G in the terminal box. In case of excess temperature in the motor
winding, the INT69 G deactivates the motor contactor. Once cooled, it can be restarted only if the
electronic lock of the output relay (terminals B1+B2) is released by interrupting the supply voltage.
The hot gas side of the compressor can also be protected against overtemperature using thermal
protection thermostats (accessory).
The unit trips when an overload or inadmissible operating conditions occur. Find and remedy
the cause.
INFO The relay switching output is executed as a oating changeover
contact. This electrical circuit operates according to the quiescent
current principle, i.e. the relay drops into a the idle position and
deactivates the motor contactor even in case of a sensor break or
open circuit.
INFO Connect the trigger unit INT69 G in accordance with the circuit dia-
gram. Protect the trigger unit with a delayed-action fuse (FC2) of
max. 4 A. In order to guarantee the protection function, install the
trigger unit as the rst element in the control power circuit.
Οnderung
Klebeschilder
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
04.12.2009
Kelich
22.05.2015
Urspr.
2
Ers. f.
3
Ers. d.
4
Schaltplan
567
BOCK COMPRESSORS
8
=
+
9
Bl.
MP10 INt69 Bl.
MP10 INt69
INT69 G
Motor Protection MP10
Steuerstrom-
kreis
L
N
Steuerstrom-
kreis
L N
1112 14
B1 B2OG OG
+
-
BT1
Θ
X1 L1 L1 N N 43 43 11 12 14
L S M
X2123456
R1 R2
+
-
BT1
Θ
+
-
BT2
Θ
+
-
BT2
Θ
L
N
5|Electrical connection
Terminal box
Fig. 15
Control circuit
5.6 Function test of the trigger unit INT69 G
Before commissioning, after troubleshooting or making changes to the control power circuit, check
the functionality of the trigger unit. Perform this check using a continuity tester or gauge.
ATTENTION Measure circuit
BT1 and BT2 (PTC
sensor) must not
come into contact
with external
voltage.
This would destroy
the trigger unit
INT69 G and PTC
sensors.

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Relay position INT69 G
B2 12 14 11
Fig. 16
5|Electrical connection
Gauge state Relay position
1. Deactivated state 11-12
2. INT69 G switch-on 11-14
3. Remove PTC connector 11-12
4. Insert PTC connector 11-12
5. Reset after mains on 11-14
5.7 Oil sump heater
In order to avoid damage to the compressor, the compressor has to be equipped with an oil sump heater.
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 auxiliary
contact) of the compressor contactor to a separate electric circuit.
Electrical data: 220 - 240 V - 1 - 50/60 Hz, 80 W.
ATTENTION The oil sump heater must generally be connected and operated!
For safe operation of the compressor, the frequency converter must be able to apply an overload of
at least 160% of the compressor's maximum current (I-max.) for at least 3 seconds.
When using frequency converters, the following things must also be observed:
1. The maximum permissible operating current of the compressor (I-max) (see type plate or
technical data) must not be exceeded.
2. If abnormal vibrations occur in the system, the affected frequency ranges in the frequency
converter must be blanked out accordingly.
3. The maximum output current of the frequency converter must be greater than the maximum
current of the compressor (I-max).
4. Carry out all designs and installations in accordance with the local safety regulations and
common rules (e.g. VDE) and regulations as well as in accordance with the specications of the
frequency converter manufacturer
The permissible frequency range can be found in the technical data chapter 8, p. 26.
5.8 Selection and operation of compressors with frequency converters
f-min/f-max see chapter 8: Technical data: permissible frequency range.
Rotational speed
range 0 - f-min f-min - f-max
Start-up time < 1 s ca. 4 s
Switch-off time immediately

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6.1 Preparations for start-up
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!
INFO In order to protect the compressor against inadmissible operating
conditions, high-pressure and low-pressure pressostats controls
are mandatory on the installation side.
WARNING When the compressor is not running, depending on ambient
temperature and amount of refrigerant charge, it is possible
that the pressure may rise and exceed permitted levels for the
compressor. Adequate precautions must be taken to prevent this
happening (e.g. using a cold storage medium, a receiver tank, a
secondary refrigerant system, or pressure relief devices).
6.2 Pressure strength test
The compressor has been tested in the factory for pressure integrity. If however the entire system is
to be subjected to a pressure integrity test, this should be carried out in accordance with EN 378-2
or a corresponding safety standard without the inclusion of the compressor.
6.3 Leak test
Carry out the leak test on the refrigerating plant in accordance with EN 378-2 or a corresponding
safety standard, while always observing the maximum permissible overpressure for the compressor.
Only dry test gases may be used for the leak test, e.g. nitrogen N2 min. 4.6 (= purity 99.996 % or
higher).
DANGER Risk of 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.
6|Commissioning