Danfoss BOCK UL-HGX12P User manual

AQ450440479309en-US0201
Reciprocating Compressor
BOCK®UL-HGX 12 P
Operating guide
UL-HGX12P/60 S 0,7 UL-HGX12P/90 S 2
UL-HGX12P/75 ML 1 UL-HGX12P/110 ML 2
UL-HGX12P/75 S 2 UL-HGX12P/110 S 3
UL-HGX12P/90 ML 2
Translation of the original instructions

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Foreword
Contents Page
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!
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.
1 Safety ............................................................................................................................... 4
1.1 Identication of safety instructions .................................................................................... 4
1.2 General safety instructions ................................................................................................ 4
1.3 Intended use ...................................................................................................................... 5
1.4 Qualications required of personnel ................................................................................... 5
2 Product description......................................................................................................... 6
2.1 Short description ............................................................................................................... 6
2.2 Name plate (example) ........................................................................................................7
2.3 Type key (example) ............................................................................................................ 7
3 Areas of application ........................................................................................................ 8
3.1 Refrigerants ....................................................................................................................... 8
3.2 Oil charge .......................................................................................................................... 8
3.3 Limits of application ........................................................................................................... 8

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Contents Page
4 Compressor assembly..................................................................................................... 9
4.1 Storage and transport ........................................................................................................ 9
4.2 Setting up .......................................................................................................................... 9
4.3 Pipe connections .............................................................................................................. 10
4.4 Pipes ................................................................................................................................ 10
4.5 Laying suction and pressure lines .................................................................................... 10
4.6 Operating the shut-off valves ........................................................................................... 11
4.7 Operating Mode of the lockable service connections ....................................................... 11
4.8 Suction pipe lter and lter drier ...................................................................................... 12
5 Electrical connection .................................................................................................... 12
5.1 General safety .................................................................................................................. 12
5.2 Information for contactor and motor contactor selection .................................................. 12
5.3 Connection for the driving motor ...................................................................................... 13
5.4 Circuit diagramm for direct start 230 V ∆ / 400 V Y ....................................................... 14
5.5 Electronic trigger unit INT69 G ......................................................................................... 16
5.6 Connection of the trigger unit INT69 G ............................................................................. 16
5.7 Function test of the trigger unit INT69 G .......................................................................... 17
5.8 Oil sump heater (accessories) .......................................................................................... 17
6 Commissioning .............................................................................................................. 18
6.1 Preparations for start-up .................................................................................................. 18
6.2 Pressure integrity test ...................................................................................................... 18
6.3 Leak test .......................................................................................................................... 18
6.4 Evacuation ....................................................................................................................... 18
6.5 Refrigerant charge ........................................................................................................... 19
6.6 Start-up ........................................................................................................................... 19
6.7 Avoiding slugging ............................................................................................................. 19
7 Maintenance .................................................................................................................. 20
7.1 Preparation ...................................................................................................................... 20
7.2 Work to be carried out .....................................................................................................20
7.3 Spare parts recommendation/accessories .......................................................................20
7.4 Lubricants / oils ...............................................................................................................20
7.5 Decommissioning ............................................................................................................20
8 Technical data................................................................................................................ 21
9 Dimensions and connections ....................................................................................... 22
10 Declaration of incorporation......................................................................................... 23
11 UL-CerticateofCompliance........................................................................................ 25

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1| Safety
Indicates a dangerous situation which, if not avoided, will cause
immediate 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 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 accidents.
Refrigerating compressors are pressurized 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 (140°F) on the discharge side or below 0°C (32°F) on
the suction side
can be reached.
- Contact with refrigerant must be avoided.
Contact with refrigerant can cause severe burns and skin
damage.
1.1 Identicationofsafetyinstructions
1.2 General safety instructions

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1.4 Qualicationsrequiredofpersonnel
Inadequatelyqualiedpersonnelposestheriskofaccidents,the
consequence being serious or fatal injury. Work on compressors
isthereforereservedforpersonnelwhoarequaliedtoworkon
pressurized refrigerant systems:
• For example, a refrigeration technician, refrigeration mechatronic
engineer. As well as professions with comparable training that 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 recognizing any potential dangers.
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 ma-
chine (within the EU according to the EU Directives 2006/42/EC Machinery Directive, 2014/68/
EU Pressure Equipment Directive, outside the EU according to the respective national regulations
and guidelines).
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!
1| Safety
1.3 Intended use

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2| Product description
2.1 Short description
• Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication.
• Suction gas cooled drive motor. The stream of refrigerant sucked out of the evaporator flows
over the motor and cools it intensively. In this way, the motor can be kept at a relatively low
temperature level, particularly under high loads.
Fig. 2
Dimension and connection values can be found in Chapter 9
Fig. 1
Transport eyelet
Valve plate
Oil pump Name plate
Oil sight glass
Cylinder cover
Discharge
shut-off valve
Drive section
Terminal box
Suction
shut-off valve Motor section

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2| Product description
2.3 Type key (example)
BOCK lub E55
IP 65
180,0
217,2
380-420 Y/YY
440-480 Y/YY
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 LP: Max. admissible operating pressur e 12 Oil type lled at the factory
(g) Low pressure side 13 Terminal box protection type
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
}
Fig. 3
Bock GmbH, Benzstr. 7
72636 Frickenhausen, Germany
BOCK
2.2 Name plate (example)
/
HGUL- 1 P 110 S 3X
Engine performance in HP
Motor variant 4)
Swept volume
³)
Numbers of cylinders
Size
Oil lling ²)
Series ¹)
Identication UL compressor
2
thermally protected system
¹) HG - Hermetic Gas-cooled (suction gas-cooled) for the normal- / air conditioning applications
²) X - Ester oil charge (HFC refrigerant, e.g. R134a, R404A/R507, R407C)
³) Additional declaration for Pluscom compressors
4) S - More powerful motor, e.g. for air-conditioning applications
10,6 / 6,1A
:HGX12P/110 S 3
: AS35830A001
45A Y: 26A
332 cfh
399 cfh
LP/HP = 276/406 psig
Type
No
: UL-HGX12P/110 S 3

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3| Areas of application
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 (-4°F...140°F)
- Max. permissible discharge end temperature 140°C (284°F).
- Max. permissible switching frequency 12x /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 threshold.
- The suction gas superheat temperature may need to be reduced
or set individually when operating near to the threshold.
For operation with frequency converter:
- 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.
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!
3.3 Limits of application
The compressors are lled at the factory with the following oil type: BOCK lub E55
3.2 Oil charge
For refilling, we recommend the above oil types.
See also section 7.4.
The oil level must be in the
visible part of the sight glass;
damage to the compressor is
possible if overfilled or under-
filled!
Max.
Min.
0,5 Ltr./
18 fl.oz
Oil level
Fig. 4
~
~
3.1 Refrigerants
Maximum admissible operating pressure (LP/HP)1):
19/28 bar (276/406 psig)
1) LP = Low pressure
HP = High pressure
HFC + blends R134a, R404A/R507
HFC/HFO blends R448A, R449A, R450A, R513A
More informations about approved refrigerants on Bock compressor selection tool VAP (vap.bock.de).

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4| Compressor assembly
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
?
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.
Attachments (e.g. pipe holders, additional units, fastening parts,
etc.) directly to the compressor are not permissible!
Setup on an even surface or frame with sufcient load-
bearing capacity.
Single compressor preferably on vibration damper.
Duplex and parallel circuits always rigid.
Provide adequate clearance for maintenance work.
Ensure adequate compressor ventilation.
Do not use in a corrosive, dusty, damp atmosphere or a
combustible environment.
4.1 Storage and transport
4.2 Setting up
Use transport eyelet.
Do not lift manually!
Use lifting gear!
Storage at -30°C...+70°C (-22°F...+158°F), maximum permissible
relative humidity 10% - 95%, no condensation
Do not store in a corrosive, dusty, vaporous atmosphere or in a com-
bustible environment.
Sun protection: If the compressor is set up outdoors, it has
to be protected from direct sunlight.

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4.4 Pipes
4| Compressor assembly
Fig. 6
Damage possible.
Do not solder as long as the compressor is under pressure.
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).
Fig. 5: graduated internal diameter
The pipe connections have graduated inside diameters so that pipes
with standart millimetre and inch 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.
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.
4.5 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.
Improperly installed pipes can cause cracks and tears, the result
being a loss of refrigerant.
Proper layout of the suction and discharge lines directly after
the compressor is integral to the system’s smooth running and
vibration behavior.
Rigid
fixed point
As short as
possible
4.3 Pipe connections

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4| Compressor assembly
After activating the spindle, generally t the spindle protection cap again and tighten with 14-16 Nm
(10.3-11.8 lb-ft). This serves as a second sealing feature during operation.
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.
4.6 Operating the shut-off valves
Fig. 7 Fig. 8
Valve spindle seal
Release
Tighten
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.
Fig. 10
Opening the service connection
Spindle: Turn 1/2 - 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
4.7 Operating mode of the lockable service connections

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4| Compressor assembly
5| Electrical connection
All protection devices and switching or monitoring units must be tted in accordance with the local
safety regulations and established specications (e.g. OSHA, UL/CSA) as well as with the manufac-
turer’s information. 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.
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
relieves 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!
5.1 General safety
When attaching accessories with an electrical cable, a minimum
bending radius of 3 x the cable diameter must be maintained for
laying the cable.
For systems with long pipes and higher degree of contamination, a lter on the suction-side is
recommended. The lter has to 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.
4.8 Suctionpipelterandlterdrier
5.2 Information for contactor and motor contactor selection

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5.3 Connection for the driving motor
5| Electrical connection
The compressor is designed with a motor for star-delta circuits.
Designation on the name plate
∆/ Y
Star-delta start-up is only possible on 230 V voltage supply. Example:
The connection examples shown refer to the standard version. In
thecaseofspecialvoltages,theinstructionsafxedtotheterminal
box apply.
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

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5.4 Circuit diagramm for direct start 230 V ∆/ 400 V Y
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)
Fig. 11
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

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5| Electrical connection
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. 12
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.
5.5 Electronic trigger unit INT69 G
5.6 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.
Control circuit

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5| Electrical connection
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 gage.
Gage 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
Relay position INT69 G
B2 12 14 11
Fig. 13
5.8 Oil sump heater (accessories)
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.
Connection: The oil sump heater must be connected via an auxiliary contact (or parallel wired auxil-
iary contact) of the compressor contactor to a separate electric circuit.
El. data: 115 V - 1 - 60 Hz, 65 - 135 W
Connection to the current path of the safety control chain is not
permitted.

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6| Commissioning
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!
6.3 Leak test
Carry out the leak test on the refrigerating plant in accordance with UL 207 or a corresponding
safety standard, while always observing the maximum permissible overpressure for the compressor.
To protect the compressor against inadmissible operating conditions,
high pressure and low pressure pressostats are mandatory on the
installation side.
Risk of bursting!
The compressor must only be pressurized using nitrogen (N2).
Never pressurize 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.
6.2 Pressure integrity 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 UL 207 or a
corresponding safety standard without the inclusion of the compressor.
6.4 Evacuation
First evacuate the system and then include the compressor in the evacuation process.
Relieve the compressor pressure.
Open the suction and pressure line shut-off valves.
Evacuate the suction and discharge pressure sides using the vacuum pump.
At the end of the evacuation process, the vacuum should be < 1.5 mbar (0.02 psig) when the pump
is switched off.
Repeat this process as often as is required.
Do not start the compressor if it is under vacuum. Do not apply
any voltage - even for test purposes (must only be operated with
refrigerant).
Under vacuum, the spark-over and creepage current distances of the
terminal board connection bolts shorten; this can result in winding and
terminal board damage.

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Make sure that the suction and pressure line shut-off valves are open.
With the compressor switched off, add the liquid refrigerant directly to the condenser or receiver,
breaking the vacuum.
If the refrigerant needs topping up after starting the compressor, it can be topped up in vapor form
on the suction side, or, taking suitable precautions, also in liquid form at the inlet to the evapora-
tor.
6.5 Refrigerant charge
Wear personal protective clothing such as goggles and protective
gloves!
Avoidoverllingthesystemwithrefrigerant!
To avoid shifts in concentration, zeotropic refrigerant blends must
alwaysonlybelledinto the refrigerating plant in liquid form.
Do not pour liquid coolant through the suction line valve on
the compressor.
It is not permissible to mix additives with the oil and
refrigerant.
Check that the safety and protection devices (pressure switch, motor protection, electrical
contact protection measures, etc.) are all functioning properly.
Switch on the compressor and allow to run for a minimum of 10 min.
Check the oil level by: The oil must be visible in the sight glass.
Ensure that both shut-off valves are open before starting the
compressor!
If larger quantities of oil have to be topped up, there is a risk of
oil hammer effects.
If this is the case check the oil return!
6| Commissioning
6.6 Start-up
To prevent slugging:
The complete refrigeration system must be properly designed.
All components must be compatibly rated with each other with regard to output
(particularly the evaporator and expansion valves).
Suction gas superheat at the compressor input should be min. 7 - 10 K. (check the setting
of the expansion valve).
The system must reach a state of equilibrium.
Particularly in critical systems (e.g. several evaporator points), measures are recommended such
as replacement of liquid traps, solenoid valve in the liquid line, etc.
There should be no movement of coolant whatsoever while the compressor is at a
standstill.
Slugging can damage the compressor and cause refrigerant to
leak.
6.7 Avoiding slugging

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7.1 Preparation
7| Maintenance
7.2 Work to be carried out
In order to guarantee optimum operational reliability and service life of the compressor, we recom-
mend carrying out servicing and inspection work at regular intervals:
Oil change:
- not mandatory for factory-produced series systems.
- for eld installations or when operating near the application limit: for the rst time after 100
to 200 operating hours, then approx. every 3 years or 10,000 - 12,000 operating hours.
Dispose of used oil according to the regulations; observe national regulations.
Annual checks: Oil level, leak tightness, running noises, pressures, temperatures, function of aux-
iliary devices such as oil sump heater, pressure switch.
Before starting any work on the compressor:
Switch off the compressor and secure it to prevent a restart.
Relieve compressor of system pressure.
Preventairfrominltratingthesystem!
After maintenance has been performed:
Connect safety switch.
Evacuate compressor.
Release switch lock.
Available spare parts and accessories can be found on our compressor selection tool under
vap.bock.de as well as at bockshop.bock.de.
Only use genuine Bock spare parts!
7.3 Spare parts recommendation/accessories
7.5 Decommissioning
Close the shut-off valves on the compressor. Drain the refrigerant (it must not be discharged into the
environment) and dispose of it according to the regulations. When the compressor is depressurized,
undo the fastening screws of the shut-off valves. Remove the compressor using an appropriate hoist.
Dispose of the oil inside in accordance with the applicable national regulations.
7.4 Lubricants / oils
The oil type lled as standard in the factory is marked on the name plate, and this should always be
used, even in the case of maintenance units. Alternative oil types can vary signicantly in quality
due to additives or inferior raw materials by the manufacturer. Validation within the compressors entire
operating limits can not be guaranteed, if such alternative oil types are used. It is for this reason,
that we only recommend the use of oil from Bock! Bock assumes no liability for any damage arising
from alternative oil types.
Bock standard oil type: BOCK lub E55