BOCK HGX44e CO2 Manuel utilisateur

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

96507-06.2021-DGbFEI

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 +49 7022 9454-0

Fax +49 7022 9454-137

www.bock.de

[email protected]

96507-06.2021-DGbFEI

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

96507-06.2021-DGbFEI

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.

96507-06.2021-DGbFEI

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.

96507-06.2021-DGbFEI

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)

96507-06.2021-DGbFEI

2|Product description

Fig. 3

2.2 Name plate (example)

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

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)

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

96507-06.2021-DGbFEI

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

96507-06.2021-DGbFEI

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.

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

±0.3

120

±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

0,05

Rz 1,6

0,3

0,7

1,6

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!

96507-06.2021-DGbFEI

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.

Ce manuel convient aux modèles suivants

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