BOCK HGX44e CO2 User manual

BOCK HGX44e CO2(subcritical)
BOCK®colour the world
of tomorrow
Assembly instructions
96507-06.2021-Gb
Translation of the original instructions
HGX44e/320-4 S CO2
HGX44e/390-4 S CO2
HGX44e/475-4 S CO2
HGX44e/565-4 S CO2

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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
About these instructions
Manufacturer
Contact
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
Telephone [phone]
Fax [phone]
www.bock.de
[email protected]

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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 9
4.1 Storage and transport
4.2 Setting up
4.3 Pipe connections
4.4 Pipes
4.5 Laying suction and pressure lines
4.6 Operating the shut-off valves
4.7 Operating mode of the lockable service connections
4.8 Suction pipe lter
5 Electrical connection 13
5.1 Information for contactor and motor contactor selection
5.2 Standard motor, design for direct or partial winding start
5.3 Basic circuit diagram for partial winding start with standard motor
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 (accessories)
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 Decompression valves
6.8 Avoiding slugging
6.9 Filter dryer
6.10 Connection of oil level regulator
7 Maintenance 24
7.1 Preparation
7.2 Work to be carried out
7.3 Spare parts recommendation / accessories
7.4 Lubricants / oil
7.5 Decommissioning
8 Technical data 25
9 Dimensions and connections 26
10 Declaration of incorporation 28
11 Service 29

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1|Safety
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
immediately 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
1.2 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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1|Safety
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, 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 CO2in sub-critical 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 The compressor may not be used in potentially explosive
environments!
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.
Danger of suffocation.
CO2 is a non-ammable, acidic, colorless and odorless 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.

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2|Product description
Fig. 1
2.1 Short description
Dimension and connection values can be found in Chapter 10
Oil pump
Suction
shut-off
valve
Fig. 2
Terminal box
Cylinder cover
Decompres-
sion valve
(HP)
Valve plate
• Semi-hermetic four-cylinder reciprocating compressor with suction-gas cooled drive 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 special during high load on a relatively
low temperature level.
• 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
atmosphere when these inadmissibly high printing pressures are reached.
Transport eyelet
Name plate
Oil sight glass
Discharge shut-off valve
Decompression
valve (LP)

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2|Product description
Fig. 3
2.2 Name plate (example)
1
2
3
4
5
6
7
8
9
10
11
12
13
BC12345A001
35,0 A
101 A 174 A
67,0
80,4
30/55
C85E
HGX44e/565-4 S CO2
/
HG 44 e 565- 4 CO2 X
2.3 Type key (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X - Ester oil charge
³) S - More powerful motor
CO2 Version
Motor variant ³)
Number of poles
Swept volume
e-series
Number of cylinders
Size
Oil charge ²)
Series ¹)
S
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
Y: Part winding 1 10 Nominal rotation speed
YY: Part windings 1 and 2 11 Displacement
5 ND (LP): max. admissible operating 12 Oil type lled at the factory
pressur e (g) Low pressure side 13 Terminal box protection type
HD (HP): max. admissible operating Electrical accessories can change
pressur e (g) High pressure side the IP protection class!
Observe the limits of application
diagrams!
50 Hz
}
60 Hz
}
Bock GmbH, Benzstr. 7
72636 Frickenhausen, Germany
BOCK
BOCK lub E85

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3|Areas of application
ATTENTION Property damage possible.
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!
1) LP = Low pressure HP = High pressure
The compressors are lled at the factory with the following oil type:
BOCK lub E85 (only this oil may be used).
3.1 Refrigerants
• R744: CO2(Recommendation CO2quality4.5(<5ppmH2O))
3.2 Oil charge
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. oil temperature ≥ 30°C.
- Min. pressure gas temperature ≥50°C.
-Max.permissibleswitchingfrequency8x/h.
- A minimum running time of 3 min. steady-state condition
(continuous operation) must be achieved.
- Max. permissible operating pressure (LP/HP)1):30/55bar
Foroperationwithfrequencyconverter:
-Frequencyrange25-70Hz
- The maximum current and power consumption must not be
 exceeded.Inthecaseofoperationabovethemainsfrequency,
the application limit can therefore be limited.
3.3 Limits of application
max.
min.
oil level
Fig. 4
1,9 Ltr.
~
~
Maximum permissible operating
pressure (LP/HP)1):30/55bar

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1) LP = Low pressure HP = High pressure
4|Compressor assembly
Setup on an even surface or frame with sufcient load-
bearing capacity.
Single compressor preferably and parallel circuits screwing
always rigid.
Decouple the system accordingly to avoid structure-borne
noise.
F
E
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B
A
1 2
3
4
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C
4
3
2
1
A
B
Tol.-Ang. DIN ISO 2768-mK
Ra Rz
Maß Passung
Freigabe
Alternativbezug:
Baumustergeprüft
Teil inaktiv
Lieferantenzeichnung
-
-
K.-Auftrag:
PL:
Zeichnung ungültig
Entwicklungsstand
Teil keine Serie
120
400
±0.5
über 0.5
bis 6
Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
Unbemaßte Radien:
-
Diese Zeichnung ist unser Eigentum!
Sie darf ohne unsere Genehmigung weder nach-
gebildet, vervielfältigt, oder Dritten Personen zu-
gänglich gemacht werden. Der Nachbau nach
dieser Zeichnung, oder an Hand der nach dieser
Zeichnung hergestellten Gegenstände durch den
Abnehmer oder Dritte ist nicht gestattet.
Wir behalten uns alle Rechte, gemäß DIN ISO 16016
an dieser Zeichnung vor.
Bearb.
Datum
Änderungs-Nr.
Werkstoff:
Ausgangsteil, bzw. Rohteil:
--
Gepr.
Name Datum
19.04.
Werkstückkanten
DIN ISO 13715
Ersatz für:
Ersetzt durch:
Erstellt
2010
Geprüft
-
Kurz
Zone
1/x
Oberflächenbehandlung / Härte:
-
Blatt:
Änderungsbeschreibung
400
Benennung:
±0.8
1000
30 6
-
±0.3
120
30
±0.2
Zeichn.-Nr. Teile-Nr.
Oberflächenangaben ISO 1302
x.xxxx-xxxxx.x
Zust.
Gußtoleranzen:
Gewicht: (kg)
±0.1
Maßstab:
1:1
Wasserwaage
für Indesign
Der Lieferant muß sicherstellen, dass die Ware in
einwandfreiem Zustand angeliefert wird (Korrosions-
schutz, Verpackung für sicheren Transport).
Rz 25
Rz 160
s
25
z y x w u t
0,05
Rz 1,6
0,3
0,7
1,6
2
Rz 16
6,3
Rz 63
Rz 6,3
Rz 12,5
F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage
Sun protection: If the compressor is set up outdoors, it has to be
protected from direct sunlight.
INFO New compressors are factory-lled with inert gas. Leave this
service charge in the compressor for as long as possible and pre-
vent the ingress of air. Check the compressor for transport damage
before starting any work.
?
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.
Provide adequate clearance for maintenance work.
Ensure adequate compressor ventilation.
Do not use in a corrosive, dusty, damp atmosphere or a
combustible environment.
4.2 Setting up
ATTENTION Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!

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4.5 Laying suction and pressure lines
4|Compressor assembly
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 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.
The pipe connections have graduated inside diameters so that pipes with
standart millimetre and inch dimensions can be used. The pipe connections
are suitable for soldering and welding.
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.
Abb. 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/
welding. Only soldering/welding using inert gas to inhibit oxida-
tion products (scale).
ATTENTION Property damage possible.
Improperly installed pipes can cause cracks and tears, the result
being a loss of refrigerant.
Lay Discharge and suction gas line stress-free and professional.
INFO Proper layout of the suction and discharge lines directly after
the compressor is integral to the system’s smooth running and
vibration behaviour.

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4|Compressor assembly
Fig. 6
As short as
possible
Rigid
fixed point
4.6 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. 7 Fig. 8
Valve spindle seal
Release Tighten
Aruleofthumb: Always lay the rst pipe section starting from the shut-off valve downwards
and parallel to the drive shaft.

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4|Compressor assembly
4.7 Operating mode of the lockable service connections
Pipe connection
Pipe connection
Fig. 9
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. 10
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 connec-
tion closed
Connection
blocked
Spindle
Connection cannot be
shut off
Connection cannot be
shut off
Service connec-
tion opened
Spindle Connection
open
Compressor
Compressor
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).
4.8Suctionpipelter

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5|Electrical connection
5.1 Information for contactor and motor contactor selection
All protection equipment, switching and monitoring devices must comply with the local safety
regulations 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 protection
switches must be rated according to the maximum operating current (see name plate). For motor
protection, use a current-independent, 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.
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.
DANGER Risk of electric shock! High voltage!
Only carry out work when the electrical system is disconnected
from the power supply!
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.
5.2 Standard motor, design for direct or partial winding start
Designation on the name plate
Y/YY
Compressors with this marking are suitable for direct or partial winding start. The motor winding is
subdivided into two parts: Partial winding 1 = 50% and part winding 2 = 50%. This winding division
reduces the start-up current needed for a part winding start to approx. 50% of that for a direct start.
INFO A mechanical unloaded start with bypass solenoid valve is
notrequired

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Οnderung
2
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
20.02.2009
bauknecht
26.11.2020
Urspr.
2
Ers. f.
3
Ers. d.
4
PW INT69 HG44/66
567
BOCK COMPRESSORS
8
=
+
9
Bl.
6.d Bl.
5.a
2.a
Anschlußkasten Verdichter
BT1
INT69
DELTA- P II
QA1
L1 L2 L3 N PE
FC1.1
I> I> I>
QA2
1U1
1V1
1W1
PE
EC1
M
Y/YY
2U1
2V1
2W1
FC1.2
I> I> I>
QA3
FC1.1
FC1.2
FC2
SF1
BP2
P>
QA2
BP3
P
QA2
KF1
KF1
QA2
L1.1
L2.1
L3.1
L1.2
N
PE
QA3
BT4
BT2
Θ
1112 14
L N B1 B2
12
11
10
9
8
7
6
5
4
3
2
1
Θ
vio bn bu gr
Θ
EB1
pk og
21
20
BT3
Θ
50% 50%
5.3 Basic circuit diagram for partial winding start with standard motor
Fig. 11
BP2 High pressure safety controller
BP3 Safety chain (high/low pressure monitoring)
BT1 Cold conductor PTC sensor motor winding
BT2 Thermal protection thermostat (PTC sensor)
BT3 Oil temperature sensor
BT4 Release switch (Thermostat)
DELTA-P II Oil differential pressure monitor DELTA-P II (accessories)
EB1 Oil sump heater
EC1 Compressor motor
Compressor terminal box

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Οnderung
2
0
Datum Name
Datum
Bearb.
Gepr.
Norm
1
20.02.2009
bauknecht
26.11.2020
Urspr.
2
Ers. f.
3
Ers. d.
4
PW INT69 HG44/66
567
BOCK COMPRESSORS
8
=
+
9
Bl.
6.d Bl.
5.a
2.a
Anschlußkasten Verdichter
BT1
INT69
DELTA- P II
QA1
L1 L2 L3 N PE
FC1.1
I> I> I>
QA2
1U1
1V1
1W1
PE
EC1
M
Y/YY
2U1
2V1
2W1
FC1.2
I> I> I>
QA3
FC1.1
FC1.2
FC2
SF1
BP2
P>
QA2
BP3
P
QA2
KF1
KF1
QA2
L1.1
L2.1
L3.1
L1.2
N
PE
QA3
BT4
BT2
Θ
1112 14
L N B1 B2
12
11
10
9
8
7
6
5
4
3
2
1
Θ
vio bn bu gr
Θ
EB1
pk og
21
20
BT3
Θ
FC1.1/1.2 Motor protection switch
FC2 Control power circuit fuse
INT69 G Electronic trigger unit INT69 G
KF1 Timer relay for contactor switch
QA1 Main switch
QA2 Mains contactor (part winding 1)
QA3 Mains contactor (part winding 2)
SF1 Control voltage switch

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5|Electrical connection
400 V
Direktstart YY Teilwicklungsstart Y/YY
1V1 1W11U1
2W12V12U1
L3L2L1 L3L2L1
L3L2L1
1V1 1W11U1
2W12V12U1
Direct start YY Part winding start Y/YY
The motor is wired for direct start (YY) at the factory. For part winding start (Y/YY) the bridges must be
removed and the motor feed line connected according to the circuit diagram:
ATTENTION Failure to do this results in opposed rotary elds and results in
damage to the motor. After the motor starts up via partial winding
1, partial winding 2 must be switched on after a maximum delay
of one second . Failure to comply can adversely affect the service
life of the motor.

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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
5.4 Electronic trigger unit INT69 G
5.5 Connection of the trigger unit INT69 G
Terminal box
Fig. 12
INFO Connect the trigger unit INT69 G in accordance with the circuit dia-
gram. Protect the trigger unit with a delayed-action fuse (F) of max.
4 A. In order to guarantee the protection function, install the trigger
unitastherstelementinthecontrolpowercircuit.
ATTENTION
Measuring 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.
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 INT 69 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.

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5|Electrical connection
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.
Relay position INT69 G
B2 12 14 11
Fig. 13
Gauge state Relay position
Deactivated state 11-12
INT69 G switch-on 11-14
Remove PTC connector 11-12
Insert PTC connector 11-12
Reset after mains on 11-14

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5|Electrical connection
5.7 Oil sump heater (accessories)
Anschlussschema für Ölsumpfheizung
Connection diagramm for oil sump heater
Plan de raccordement pour résistance de carter d‘huile
09983- 10.01-DGBF
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When the compressor is at a standstill, refrigerant diffuses into the lubricating oil of the compressors
housing, depending on pressure and ambient temperature. This reduces the lubricating capacity of
the oil. When the compressor starts up, the refrigerant contained in the oil evaporates out through the
reduction in pressure. The consequences 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 compres-
sor starts up, the oil sump heater switches off again automatically.
Connexion:The oil sump heater must be connected via an auxiliary contact (or parallel wired auxili-
ary contact) of the compressor contactor to a seperate electric circuit.
Electrical data: 230 V - 1 - 50/60 Hz, 160 W.
Fig. 14
ATTENTION Connection to the current path of the safety control chain is not
permitted.
ATTENTION The oil sump heater must generally be connected and operated.
In order to avoid damage to the compressor, the compressor must be equipped with an oil sump heater.

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96507-06.2021-DGbFEI
6|Commissioning
6.1 Preparations for start-up
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!
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.
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.