BOCK HGX22e S CO2 Series User manual

 
  
 
BOCK HGX 22 e A





BOCK®

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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.
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
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 Storage and transport
4.2 Setting up
4.3 Maximum permissible inclination
4.4 Pipe connections
4.5 Pipes
4.6 Laying suction and discharge lines
4.7 Operating the shut-off valves
4.8 Operating mode of the lockable service connections
4.9 Suctionpipelterandlterdrier
5 Electrical connection 14
5.1 Information for contactor and motor contactor selection
5.2 Connection of the driving motor
5.3 Circuit diagram
5.4 Electronic trigger unit INT69 G
5.5 Connection of the trigger unit INT69 G
5.6 External connection INT69 G
5.7 Function test of the trigger unit INT69 G
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 Avoiding slugging
7 Maintenance 22
7.1 Preparation
7.2 Work to be carried out
7.3 Spare parts recommendation/accessories
7.4 Extract from the lubricants table
7.5 Decommissioning
8 Technical data 24
9 Dimensions and connections 25
10 Declaration of installation 26
11 Service 27

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1|Safety
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:

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1|Safety
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.
1.4 Intended use
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 Bock. Bock refrigerating compressors are intended for installation in a machine
(within the EU according to the EU Directives 2006/42/EC Machinery Directive and 2014/68/EU Pres-
sure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!

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2|Product description
• Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication.
• Lightweight aluminum design
• Suction gas cooled drive motor
Name plate
Fig. 1
2.1 Short description
Fig. 2
Oil sight glass
Valve plate
Cylinder cover
Discharge shut-
off valve
Oil pump
Terminal box
Suction
shut-off valve
Drive section
Motor section
Dimension and connection values can be found in Chapter 9
Transport eyelet

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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
}
2|Product description
/
HG 22 e 190-4 S AX
2.3 Type key (example)
¹)HG - HermeticGas-cooled(suctiongas-cooled)
²)X - Esteroilcharge(HFCrefrigerant,e.g.R134a,R404A/R507,R407C)
³)S - More powerful motor, e.g. for air-conditioning applications
Lightweight aluminum design
Motor variant ³)
Number of poles
Swept volume
e-series
Numbers of cylinders
Size
Oil charge ²)
Series ¹)
2.2 Name plate(example)
Fig. 3
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 S A
SE 55
AS35830A001
16,2/9,4A
87A 50A
66
Bock GmbH, Benzstr. 7
72636 Frickenhausen, Germany
BOCK

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3|Areas of application
 Thecompressorsarelledatthefactorywiththefollowingoiltype:
- for R134a, R404A/R507, R407C FUCHS Reniso Triton SE 55
Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXinthetype
designation (e.g. HGX22e/190-4A).
3.1 Refrigerants
• HFKW/HFC:  R134a, R404A/R507, R407C
3.2 Oil charge
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!
ATTENTION!max.
min.
0,8 Ltr.
oil level
Fig. 4
~
~
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 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 supplementary cooling:
- Use only oils with high thermal stability.
- Avoid continuous operation near the limits.
 Foroperationwithfrequencyconverter:
- The potential control range of the compressor is 30-70 Hz.
- Max. permissible current consumption must not be exceeded.
At max. rotation speed therefore, the application limit can
be reduced.
- Use a thermal protection thermostat.
- Do not operate an additional capacity controller.
-Oilreturnatlowfrequencymustbeguaranteed.
- Consultation with Bock.
3.3 Limits of application

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ATTENTION! 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!
Max. permissible operating pressure (LP/HP)1):
19/28 bar
1) LP = Low pressure
HP = High pressure

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4|Compressor assembly
 Setuponanevensurfaceorframewithsufcientload-
bearing capacity.
 Provideadequateclearanceformaintenancework.
 Ensureadequatecompressorventilation.
Do not use in a dusty, damp atmosphere or a combustible
environment.
Fig. 7
Fig. 8
Fig. 9
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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
4.2 Setting up
?
4.1 Storage and transport
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. 6
Fig. 5
ATTENTION! Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
INFO Newcompressorsarefactory-lledwithinertgas.Leavethisser-
vice 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.

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Amax. 30°,
max. 2 minutes
amax. 15°,
continuous
operation
Fig. 10
A
a
A
aa
A
a
A
4.3 Maximum permissible inclination
ATTENTION! Poor lubrication can damage the compressor.
Respect the stated values.
4|Compressor assembly
The discharge and suction line valves have stepped internal
diameters so that pipes with standard millimetre and inch
dimensions can be used. The depth of pipe insertion will
depend on the dimension.
The connection diameters of the shut-off valves are rated for
maximum compressor output.Therequiredpipecross-sectionmustbe
matched to the output. The same applies for non-return valves.
Fig.11:Stepped
internal diameters
4.4 Pipe connections
ATTENTION! Overheating can damage the valve.
Remove the pipe supports from the valve for soldering. Solder
them with protective gas to prevent oxidation products (scale).

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4|Compressor assembly
4.5 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. 13 Fig. 14
Valve spindle seal
Release
Tighten
4.7 Operating the shut-off valves
Before opening or closing the shut-off valve, release the adjustable 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. 12
Rigid fixed
point As short
as possible
6.5 Laying suction and discharge 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 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.
Fig. similar Fig. similar

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Pipe connection
Pipe connection
4.8 Operating mode of the lockable service connections
Fig. 15
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. 16
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
4|Compressor assembly
Afteractivatingthespindle,generallytthespindleprotectioncapagainandtightenwith14-16Nm.
This serves as a second sealing feature during operation.
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contamination(reduced
pressureloss).
Moisture in the refrigeration circuit can lead to crystal and hydrate formation. For this reason, we
recommendusingalterdrierandasightglasswithamoistureindicator.
4.9Suctionpipelterandlterdrier

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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devicesandswitchingormonitoringunitsmustbettedinaccordancewiththelocal
safetyregulationsandestablishedspecications(e.g.VDE)aswellaswiththemanufacturer’sinfor-
mation. Motor protection switches are required! Motor contactors, feed lines, fuses and motor
protection switches must be rated on the basis of the maximum working current (see name plate).
For motor protection use a current-dependent and time-delayed overload protection device for moni-
toring all three phases. Set the overload protection device so that it must be actuated within 2 hours,
if there is 1.2 times the max. working current.
5|Electrical connection
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.

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5|Electrical connection
5.2 Connection of the driving motor
The compressor is designed with a motor for star-delta circuits.
Designation on the name plate
∆/ Y
Star-delta start-up is only possible in the ∆voltage range. 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.

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5.3 Circuit diagram for direct start 230 V ∆/ 400 V Y
Fig. 17
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)
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
Compressor terminal box

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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

18
D
GB
F
E
96192-01.2021-DGbFE
5|Electrical connection
PTC1 PTC2
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
Terminal box
Fig. 18
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.
Control circuit

D
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F
E
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96192-01.2021-DGbFE
5|Electrical connection
Relay position INT69 G
B2 12 14 11
5.7 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.
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
5.6 External connection INT69 G
BT1 Cold conductor (PTC
sensor)motorwinding
BT2 Heat protection thermo-
stat(PTCsensor)
EB1 Oil sump heater
Οnderung
1
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
04.12.2009
bauknecht
08.05.2020
Urspr.
2
Ers. f.
3
Ers. d.
4
HG22e/34e HC
567
BOCK COMPRESSORS
8
=
+
9
Bl.
5Bl.
3
2
Schaltschrank
EB1 BT2
BT2
BT1
1 2 3 4 5 6 7 8 09 10 11 12
INT69G
Οnderung
1
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
04.12.2009
bauknecht
08.05.2020
Urspr.
2
Ers. f.
3
Ers. d.
4
HG22e/34e HC
567
BOCK COMPRESSORS
8
=
+
9
Bl.
5Bl.
3
2
Schaltschrank
EB1 BT2
BT2
BT1
1 2 3 4 5 6 7 8 09 10 11 12
INT69G
Switch cabinet
Fig. 19
Fig. 20
Terminal box

20
D
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6|Commissioning
6.1 Preparations for start-up
6.4 Evacuation
First evacuate the system and then includethe compressor in the evacuation process.
Relieve the compressor pressure.
Open the suction and discharge line valves.
Evacuate the suction and high 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the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 (may be operated only with refrigerant).
Under vacuum, the spark-over and creepage current distances of the
terminal board connection bolts shorten; this can lead to winding and
terminal board damage.
INFO! To protect the compressor against inadmissible operating conditions,
high pressure and low pressure pressostats 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!
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.
6.3 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.
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.