Danfoss BOCK UL-HGX12e CO2 LT User manual

AQ450435606290en-US0201
Operating guide
Reciprocating Compressor
BOCK
®
UL-HGX 12 e CO2LT
UL-HGX12e/20 ML 0,7 CO2 LT U L-HGX12e/20 S 1 CO2 LT
UL-HGX12e/30 ML 1 CO2 LT UL-HGX12e/30 S 2 CO2 LT
UL-HGX12e/40 ML 2 CO2 LT UL- HGX12e/40 S 3 CO2 LT
Translation of the original instructions

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1 Safety.............................................................................................................................4
 1.1 Identicationofsafetyinstructions.......................................................................................4
 1.2 Qualicationsrequiredofpersonnel......................................................................................4
 1.3 Safetyinstructions.................................................................................................................5
 1.4 Intendeduse..........................................................................................................................5
2 Product description....................................................................................................... 6
 2.1 Shortdescription...................................................................................................................6
 2.2 Nameplate............................................................................................................................7
 2.3 Typekey.................................................................................................................................7
Contents Page
Foreword
Risk of accidents.
Refrigerating compressors are pressurized machines and, as such, call for heightened caution
and care in handling.
Improper assembly and use of the compressor can result in serious or fatal injury!
• To avoid serious injury or death, observe all safety instructions contained in these
instructions before assembly and before using the compressor! This will avoid
misunderstandings and prevent serious or fatal injury and damage!
• Never use the product improperly but only as recommended by this manual!
• Observe all product safety labels!
• Refer to local building codes for installation requirements!
CO2applications require a completely new kind of system and control. They are not a general
solution for the substitution of F-gases. Therefore, we expressly point out that all information
in these assembly instructions 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.
Unauthorizedchangesandmodicationstotheproductnotcoveredbythismanualareprohibitedand
willvoidthewarranty!
Thisinstructionmanualisamandatorypartoftheproduct.Itmustbeavailabletothepersonnelwho
operateandmaintainthisproduct.Itmustbepassedontotheendcustomeralongwiththeunitin
whichthecompressorisinstalled.
ThisdocumentissubjecttothecopyrightofBockGmbH,Germany.Theinformationprovidedinthis
manualissubjecttochangeandimprovementswithoutnotice.

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Contents Page
3 Areas of application.......................................................................................................8
 3.1 Refrigerants...........................................................................................................................8
 3.2 Oilcharge..............................................................................................................................8
 3.3 Limitsofapplication..............................................................................................................9
4 Compressor assembly................................................................................................... 10
 4.1 Storageandtransportation....................................................................................................10
 4.2 Settingup..............................................................................................................................10
 4.3 Pipeconnections...................................................................................................................11
 4.4 Pipes......................................................................................................................................11
 4.5 Flangeshut-offvalves(HP/LP)..............................................................................................11
 4.6 Layingsuctionandpressurelines.........................................................................................12
 4.7 Operatingtheshut-offvalves................................................................................................12
 4.8 Operatingmodeofthelockableserviceconnections............................................................13
 4.9 Oilreturn................................................................................................................................14
 4.10 Suctionpipelter...................................................................................................................14
5 Electrical connection.....................................................................................................15
 5.1 Informationforcontactorandmotorcontactorselection.......................................................15
 5.2 Connectionofthedrivingmotor.............................................................................................16
 5.3 Circuitdiagramfordirectstart280VΔ /460VY.................................................................18
 5.4 ElectronictriggerunitINT69G..............................................................................................20
 5.5 ConnectionoftheelectronictriggerunitINT69G..................................................................20
 5.6 FunctionaltestoftheelectronictriggerunitINT69G............................................................21
 5.7 Oilsumpheater......................................................................................................................21
 5.8 Selectionandoperationoffrequencyconverters..................................................................21
6 Commissioning.............................................................................................................. 22
 6.1 Preparationsforstart-up.......................................................................................................22
 6.2 Pressurestrengthtest...........................................................................................................22
 6.3 Leaktest...............................................................................................................................22
 6.4 Evacuation.............................................................................................................................23
 6.5 Refrigerantcharge.................................................................................................................23
 6.6 Start-up.................................................................................................................................24
 6.7 Pressureswitch.....................................................................................................................24
 6.8 Pressurereliefvalves.............................................................................................................25
 6.9 Avoidingslugging...................................................................................................................26
 6.10 Filterdryer.............................................................................................................................26
7 Maintenance.................................................................................................................. 26
 7.1 Preparation............................................................................................................................26
 7.2 Worktobecarriedout...........................................................................................................27
 7.3 Sparepartsrecommendation/accessories..........................................................................27
 7.4 Lubricants..............................................................................................................................27
 7.5 Decommissioning..................................................................................................................27
8 Technical data............................................................................................................... 28
9 Dimensions and connections........................................................................................ 30
10 Declaration of incorporation......................................................................................... 32
 11 UL-CerticateofCompliance........................................................................................34

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1|Safety
1.1 Identicationofsafetyinstructions:
1.2 General safety instructions
Indicates a dangerous situation which, if not avoided, will cause imme-
diate fatal or serious injury
Indicates a dangerous situation which, if not avoided, may cause fatal
or serious injury
Indicates a dangerous situation which, if not avoided, may immediately
cause fairly severe or minor injury.
Indicates a situation which, if not avoided, may cause property damage
Important information or tips on simplifying work
Risk of accident.
Refrigerating compressors are pressurized machines and therefore
require particular caution and care in handling.
The maximum permissible overpressure must not be exceeded, even for
testing purposes.
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 national safety standards.
Risk of burns!
• Depending on the operating conditions, surface temperatures of over
140°F (60°C) on the pressure side or below 32°F (0°C) on the suction
side can be reached.
• Avoid contact with refrigerant under any circumstances. Contact
with refrigerant can lead to severe burns and skin irritations.

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1|Safety
1.3 Intended use
1.4 Qualicationsrequiredofpersonel
• Theseassemblyinstructionsdescribethestandardversionofthecompressors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PressureEquipmentDirective,outsidetheEUaccordingtotherespectivenational
regulationsandguidelines).
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transcriticaland/orsubcriticalsystemsincompli-
ancewiththelimitsofapplication.
Onlytherefrigerantspeciedintheseinstructionsmaybeused!
Any other use of the compressor is prohibited!
The compressor may not be used in potentially explosive
environments!
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thequalicationslisted
below:
• e.g.,arefrigerationtechnicianor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
recognizinganypotentialdangers.

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2|Product description
• 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
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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1 Typedesignation
2 Machinenumber
3 maximumoperatingcurrent
4 Startingcurrent(rotorblocked)
5 LP:max.admissibleoperating
   pressure(g)Lowpressureside
 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)
2|Product description
1
2
3
4
5
13
12
7
11
6
10
8
9
SE 55
27,3
32,8
: UL-HGX12e/40 S 3 CO2LT
10,7/6,2A
111A 64A
: BC12345A001
Bock GmbH, Benzstr. 7
72636 Frickenhausen, Germany
C85E
6,0
7,2
IP66
100/100 bar
BOCK
/
HG 12 e 40 SCO2 X
¹)HG - HermeticGas-Cooled(suctiongas-cooled)
²)X - Esteroilcharge
³) ML - Deepfreezingatlowandmediumevaporationtemperatures
S - Forfrequencyregulationandextendedlimitsofapplication
LowTemperature
CO2version
HPcodeformotorsize
Compressorversion3)
Sweptvolume
e-series
Numberofcylinders
Size
Oilcharge²)
Series¹)
Identication
ULcompressor
LT
3
Öl: BOCKlub E85
123 cfh
148 cfh
LP/HP = 1450/1450 psig
Type
No
Oil: BOCKlub E85
thermally protected system
UL -
2.3 Type key (example)
Fig.3

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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.
21fl.oz
0,6Ltr.
Oillevel ~
~
3|Areas of application
3.1 Refrigerants
• R744: CO2(required CO2quality 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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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 -4°F ... 140°F (-20 °C) - (+60 °C).
- Max. permissible discharge end temperature 320°F (160 °C).
- Min. discharge end temperature ≥122°F (50 °C).
- Min. oil temperature ≥ 86°F (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.
3.3 Limits of application
3|Areas of application
Max. permissible operating pressure (LP/HP)1):1450/1450psig,100/100bar
1) LP=Lowpressure
HP=Highpressure

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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
E
D
C
B
A
1 2
3
4
F
E
D
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
?
4.1 Storage and transportation
 Usetransporteyelet.
 Donotliftmanually!
 Useliftinggear!
 Storageat-22°F...158°F(-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.
Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
4|Compressor assembly
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.

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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
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
B1
A1
4.5 Flange shut-off valves (HP/LP)
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.6 Fig.7
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.

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Fig.8
Fig.9 Fig.10
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.
Property damage possible.
Improperly installed pipes can cause cracks and tears, which can
result in a loss of refrigerant.
Proper layout of the suction and pressure lines directly after
the compressor is integral to the smooth running and vibration
behavior of the system.
4|Compressor assembly
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.
Rigid fixed
point
As short as possible

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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.11
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.12
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
4|Compressor assembly

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4|Compressor assembly
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
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.
Risk of electric shock! High voltage!
Only carry out work when the electrical system is disconnected
from the power supply!
When attaching accessories with an electrical cable, a minimum
bending radius of 3x the cable diameter must be maintained for
laying the cable.
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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.

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5| Electrical connection
Designationonthenameplate
∆/ Y
5.2 Connection of the driving motor
Thecompressorisdesignedwithamotorforstar-deltacircuits.

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5| Electrical connection
Star-delta start-up is only possible for ∆(e.g. 280 V) power supply. Example:
280 V ∆
Direct start Star-delta start
460 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
Insulator
Insulators
L2 L3
INFO The supplied insulators must be mounted according to the illustrations
as shown.
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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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 280 V ∆/ 460 V Y
Fig.13
Compressorterminalbox
BP1 Highpressuresafetymonitor
BP2 Safetychain(high/lowpressuremonitoring)
BT1 Coldconductor(PTCsensor)motorwinding
BT2 Thermalprotectionthermostat(PTCsensor)
BT3 Releaseswitch(thermostat)
EB1 Oilsumpheater
EC1 Compressormotor
∆/ Y

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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
FC1.1 Motorprotectionswitch
FC2 Controlpowercircuitfuse
INT69G ElectronictriggerunitINT69G
QA1 Mainswitch
QA2 Netswitch
SF1 Controlvoltageswitch

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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.
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.
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.14
Controlcircuit
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.