Danfoss BOCK HGX22e/125-4 A User manual

AQ452755960718en-000201
BOCK®HGX 22 (P)(e) A
Operating guide
HGX22e/125-4 A HGX22e/125-4 S A
HGX22e/160-4 A HGX22e/160-4 S A
HGX22e/190-4 A HGX22e/190-4 S A
HGX22P/125-4 A HGX22P/125-4 S A
HGX22P/160-4 A HGX22P/160-4 S A
HGX22P/190-4 A HGX22P/190-4 S A
Translation of the original instructions

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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.

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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 Lubricants / oil
7.5 Decommissioning
8 Technical data 24
9 Dimensions and connections 25
10 Declaration of incorporation 26

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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 = e-series / P = Pluscom
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
BOCK lub E55

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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, R513A BOCK lub E55
Compressors with ester oil charge (BOCK lub E55)aremarkedwithanXinthetype
designation (e.g. HGX22e/190-4A).
3.1 Refrigerants
• HFKW/HFC:  R134a, R404A/R507, R407C, R513A
3.2 Oil charge
INFO! For refilling, we recommend the above oil types.
Alternatives: see chapter 7.4
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.
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.