Danfoss BOCK HGX34e A 2 Pole Hg Compressors Installation Guide

: June 13, 2024
: Danfoss

Table of Contents

BOCK HGX34e A 2 Pole Hg Compressors
Product Information
Product Usage Instructions
Safety Instructions
Qualifications Required of Personnel
General Safety Instructions
Intended Use

BOCK HGX34e A 2 Pole Hg Compressors

Product Information

Product Name: HGX34e/380-4 S A

Model Number: AQ464037893946en-IN0201

About these instructions:

Read these instructions before assembly and before using the
compressor. This will avoid misunderstandings and prevent
damage.
Improper assembly and use of the compressor can lead to 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 compressor is installed.

Product Usage Instructions

Safety Instructions

Instruction Type	Description
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.

Qualifications Required of Personnel

WARNING! Inadequately qualified 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
qualifications listed below:

Qualified refrigeration engineers or mechanics.
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.

General Safety Instructions

WARNING! 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.

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 Pressure Equipment Directive).
Commissioning is permissible only if the compressor has been
installed in accordance with these assembly 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 specified in these
instructions may be used. Any other use of the compressor is
prohibited!

Product Description

The compressor includes the following components:

Transport eyelet
Discharge shut-off valve
Oil pump
Name plate
Oil sightglass
Terminal box
Suction shut-off valve
Cylinder cover
Valve plate
Drive motor
Motor part

Dimension and connection values can be found in Chapter 9 of the
user manual.

BOCK® HGX34e A
Operating guide
HGX34e/380-4 S A

Translation of the original instructions

AQ464037893946en-IN0201

About these instructions
Read these instructions before assembly and before using the compressor. This will avoid misunderstandings and prevent damage. Improper assembly and use of the compressor can lead to 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 compressor is installed.
D GB F E

2 | AQ464037893946en-IN0201

Contents
1 Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use 2 Product description 2.1 Short description 2.2 Name plate 2.3 Type key 3 Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Operating limits 4 Compressor assembly 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 filter and filter drier 5 Electrical connection 5.1 Information for contactor and motor contactor selection 5.2 Connecting the drive 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 of the INT69 G 5.7 Function test of the trigger unit INT69 G 6 Commissioning 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 liquid sluggings 7 Maintenance 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 9 Dimensions and connections 10 Declaration of incorporation
© Danfoss | Climate Solutions | 2023.09

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AQ464037893946en-IN0201 | 3

1| Safety
1.1 Identification 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 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.

D

GB

1.2 Qualifications required of personnel

F

WARNING! Inadequately qualified personnel poses the risk of accidents, the

E

consequence being serious or fatal injury. Work on compressors

must therefore only be performed by personnel with the qualifica-

tions listed below:

· For example, a refrigeration technician, refrigeration mechatron-

ics 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

thework to be carried out and recognising any potential dangers.

4 | AQ464037893946en-IN0201

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

D

environments!

GB

These assembly instructions describe the standard version of the compressor named in the title

F

manufactured by Bock. Bock refrigerating compressors are intended for installation in a machine

E

(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 specified in these instructions may be used.

Any other use of the compressor is prohibited!

AQ464037893946en-IN0201 | 5

2 |Product description
2.1 Short description · Semi-hermetic four-cylinder reciprocating compressor with oil pump lubrication. · Lightweight aluminum design · Suction gas-cooled drive motor

Transport eyelet Discharge shut-off valve
Oil pump D GB F E

Fig. 1

Name plate Oil sightglass

Terminal box
Suction shut-off valve

Fig. 2

Cylinder cover Valve plate Drive motor Motor part

Dimension and connection values can be found in Chapter 9

6 | AQ464037893946en-IN0201

2 |Product description
2.2 Name plate (example)

BOCK

1

HGX34e/380-4 SA

2

AT38125A028

3

31,2/18,0A

4

132A 76A

5

19/28

Fig. 3

IP66

6

3237,,13

7 8

9

3392,,78

10 11

SBSEOEC555K5 lub E55 12

13

1 Type designation 2 Machine number

6 Voltage, circuit, frequency

} 7 Nominal rotation speed

50 Hz

3 maximum operating current

8 Displacement

4 Starting current (rotor blocked)

9 Voltage, circuit, frequency

} 5 ND LP: max. admissible operating pressure 10 Nominal rotation speed

60 Hz

Low pressure side HD (HP): max. admissible operating

11 Displacement 12 Oil type filled at the factory

pressure. High pressure side

13 Protection system terminal box

D

Observe the limits of application diagrams!

Electrical accessories can change

GB

the IP protection class!

F

2.3 Type key (example)

E

HG X 3 4 e / 380-4 S A

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)
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

AQ464037893946en-IN0201 | 7

3 |Areas of application

3.1 Refrigerants · HFKW / HFC: R134a, R404A, R507, R407C, R513A

3.2 Oil charge

The compressors are filled with the following oil type at the factory:

– 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. HGX34e/380-4 S A).

INFO!

For refilling, we recommend the above oil types. Alternatives: see chapter 7.4

ATTENTION!

The oil level must be in the visible part of the sight glass; damage to the compressor is possible if overfilled or underfilled!

max. oil level min.

~~ 0,7 Ltr. Fig. 4

D

3.3 Operating limits

GB

ATTENTION! Compressor operation is possible within the operating limits.

F

These can be found in Bock compressor selection tool (VAP)

under vap.bock.de. Observe the information given there.

E

– 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 threshold.
For operation with frequency converter: – The potential control range of the compressor is 25-70 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.

8 | AQ464037893946en-IN0201

3 |Areas of application

ATTENTION!

For operation with capacity regulator: – Continuous operation, when the capacity regulator is activated,
is not permissible and can cause damage to the compressor. – The suction gas superheat temperature may need to be reduced
or set individually when operating near to the threshold. – When the capacity regulator is activated, the gas velocity in
the system can not under certain circumstances ensure that sufficient oil is transported back to the compressor.
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

LP = Low pressure HP = High pressure

D GB F E

AQ464037893946en-IN0201 | 9

4 |Compressor assembly

INFO

New compressors are factory-filled 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.

4.1 Storage and transport

?Fig. 5

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 combustible environment.

Fig. 6

Use transport eyelet. Do not lift manually! Use lifting gear!

4.2 Setting up

ATTENTION! Attachments (e.g. pipe holders, additional units, fastening parts, etc.) directly to the compressor are not permissible!
D

GB

F

Provide adequate clearance for maintenance work.

Ensure adequate compressor ventilation.

E

Fig. 7

Do not use in a dusty, damp atmosphere or a combustible environment.

Fig. 8 Fig. 9

Set up on an even surface or frame with sufficient loadbearing capacity.

10 | AQ464037893946en-IN0201

4 |Compressor assembly

4.3 Maximum permissible inclination
ATTENTION! Poor lubrication can damage the compressor. Respect the stated values.

A

aa

A

aa

Fig. 10

A max. 30°, max. 2 minutes

GEA Bock GmbH 72636 Frickenhausen, Germany

a max. 15°, continuous operation

4.4 Pipe connections
Fig. 11: Stepped internal diameters

The discharge and suction line valves have stepped internal

diameters so that pipes with standard millimetre and inch

dimensions can be used. The depth of pipe insertion will

D

depend on the dimension.

The connection diameters of the shut-off valves are rated for GB

maximum compressor output. The required pipe cross-section must be

F

matched to the output. The same applies for non-return valves. E

ATTENTION! Overheating can damage the valve.
Remove the pipe supports from the valve for soldering. Solder them with protective gas to prevent oxidation products (scale).

AQ464037893946en-IN0201 | 11

4 |Compressor assembly
4.5 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. 4.6 Laying suction and pressure lines
ATTENTION Improperly installed pipes can cause cracks and tears, the result being a loss of refrigerant.

INFO

Proper layout of the suction and discharge lines directly after

the compressor is integral to the system’s smooth running and

vibration behaviour.

A rule of thumb: Always lay the first pipe section starting from the shut-off valve downwards and parallel to the drive shaft.

D

GB

F

E

As short as possible

Rigid fixed point

Fig. 12

4.7 Operating the shut-off valves
Before opening or closing the shut-off valve, release the adjustable 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.

Valve spindle seal

Fig. 13

Fig. similar

12 | AQ464037893946en-IN0201

Release Tighten

Fig. 14

Fig. similar

4 |Compressor assembly
4.8 Operating mode of the lockable service connections
Service connection closed

Connection blocked
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.
Service connection opened

Pipe connection
Compressor Fig. 15

D

Connection Spindle open

Pipe connection

GB

F

Opening the service connectionSpindle Spindle: Turn ½ – 1 turn to the right clockwise. –> Service connection opened / shut-off valve opened.

Compressor Fig. 16

E

After activating the spindle, generally fit the spindle protection cap again and tighten with 14-16 Nm. This serves as a second sealing feature during operation.
4.9 Suction pipe filter and filter drier
For systems with long pipes and higher degree of contamination, a filter on the suction-side is recommended. The filter has to be 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 filter drier and a sight glass with a moisture indicator.

AQ464037893946en-IN0201 | 13

5| Electrical connection

5 Electrical connection
DANGER! High voltage! Risk of electric shock! Only carry out work when the electrical system is disconnected from the power supply!
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.

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.

5.1 Information for contactor and motor contactor selection

All protection devices and switching or monitoring units must be fitted in accordance with the local

safety regulations and established specifications (e.g. VDE) as well as with the manufacturer’s infor-

mation. Motor protection switches are required! Motor contactors, feed lines, fuses and motor

D

protection switches must be rated on the basis of the maximum working current (see name plate).

GB 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,

F

if there is 1.2 times the max. working current.

E

14 | AQ464037893946en-IN0201

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

/ Y

Star-delta start-up is only possible in the voltage range. Example:

230 V

Direct start

Star-delta start

L1 L2 L3

400 V Y Direct start only

L1 L2 L3

D
L1 L2 L3
GB

INFO!

The connection examples shown refer to the standard

version. In the case of special voltages, the instructions affixed to the

F

terminal box apply.

E

AQ464037893946en-IN0201 | 15

5.3 Circuit diagram for direct start 230 V / 400 V Y

QA1

FC1.1

I> I> I>

1

3

5

QA2

2

4

6

FC2

SF1

QA2

FC1.1

L1 L2 L3 N PE

PE

D

GB

1

2

F

3

4

E

5

6

7

M

8

-EC1 3~

9

10

BT1

11

12

12 14 11 L N B1 B2

INT69G
CAonmspcrhelussßokratsetremninVael rbdoixchter
Fig. 17

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)

16 | AQ464037893946en-IN0201

L1.1 L2.1 L3.1 L1.2

EB1 P>
BP1
BT2
BT2

QA2

P

BP2

BT3

N PE
D GB F E

QA1 SF1 EC1 QA2 INT69 G EB1

Main switch Control voltage switch Compressor motor Compressor contactor Electronic trigger unit INT69 G Oil sump heater

AQ464037893946en-IN0201 | 17

5| Electrical connection

5.4 Electronic trigger unit INT69 G
The compressor motor is fitted 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.

INFO

The relay switching output is executed as a floating 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.

D

5.5 Connection of the trigger unit INT69 G

GB 1 F E

INFO 2

Connect the trigger unit INT69 G in accordance with the circuit diagram. Protect the 3trigger unit with a delay4 ed-action fuse (FC2) o5f max. 4 A. In order to guarantee the protection function, install the trigger unit as the first element in the control power circuit.

or Protection MP10

L

S

M

1 N N 43 43 11 12 14

ATTENTION Measure circuit BT1 and BT2 (PTC sensor) must not come Ri1nto conRt2act with ex ternal voltage. This would destroy the trigger X2un1it2IN3T649 G5 a6nd PTC sensors.

INT69 G

OG OG

LN

Steuerstrom- BT1
–
kreis
BT2
–
BT1
BT2
–

B1 B2

12 14 11

N L
Steuerstromkreis
Fig. 18 Terminal box

18 | AQ464037893946en-IN0201

1

2

3

4

5

6

5 |Electrical connection

1

2

3

4

5

6

5.6 External connection of the INT69 G
Schaltschrank Schaltschrank

INT69G INT69G

1 2 3 4 5 6 7 8 09 10 11 12

BT1

Cold conductor (PTC

sensor) motor winding

1 2 3 4 5 6 7 8 09 10 11 12

BT2

Heat protection thermo-

stat (PTC sensor)

EB1

BT1 BT2 BT2

EB1

Oil sump heater

Fig. 19 EB1 Terminal BBTo1x BT2 BT2

D

GB

5.7 Function test of the trigger unit INT69 G

F

Before commissioning, after troubleshooting or making changes to the control power circuit, check

E

the functionality of the trigger unit. Perform this check using a continuity tester or gauge.

Gauge state

Relay position

Relay position INT69 G

1. Deactivated state

11-12

2. INT69 G switch-on

11-14

Datum 3. 04.12.2009 Remove PTC connector

11-12

Bearb.

bauknecht

4. Insert PTC connector GDeapturm.

0084..0152..22002009

11-12

tum

Name NBeoarmrb.

bauknecht

Urspr.

Ers. f.

Gepr. 5. 08.05.2020 Reset after mains on

11-14

tum

Name Norm

Urspr.

Ers. f.

B2 12 14 11 HG22e/34e HC

Ers. d.

HG22e/34e HCFig. 20

Ers. d.

AQ464037893946en-IN0201 | 19

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!

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

DANGER! Risk of bursting!

The compressor must only be pressurised using nitrogen (N2). Never pressurise with oxygen or other gases!

D

The maximum permissible overpressure of the compressor must not

be exceeded at any time during the testing process (see name plate

GB

data)! Do not mix any refrigerant with the nitrogen as this could

F

cause the ignition limit to shift into the critical range.

E

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.

6.4 Evacuation
ATTENTION! Do not start the compressor if it is under vacuum.Do not apply any voltage even for test purposes (may be operated only with refrigerant). Under vacuum, the spark-over and creepage current distances of the terminal board connection bolts shorten; this can lead to winding and terminal board damage.

First evacuate the system and then includethe compressor in the evacuation process. Relieve the compressor pressure. Open the suction and discharge line valves. Evacuate the suction and high pressure sides using the vacuum pump. At the end of the evacuation process, the vacuum should be < 1.5 mbar when the pump is switched off. Repeat the process as often as is required.

20 | AQ464037893946en-IN0201

6 |Commissioning

6.5 Refrigerant charge

CAUTION! Wear personal protective clothing such as goggles and protective gloves!

Make sure that the suction and discharge line 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 vapour form on the suction side, or, taking suitable precautions, also in liquid form at the inlet to the evaporator.

INFO!

Avoid overfilling the system with refrigerant!
To avoid shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always only be filled 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.

6.6 Start-up

D

WARNING! Ensure that both shut-off valves are open before starting

GB

the compressor!

F

Check that the safety and protection devices (pressure switch, motor protection, electrical

E

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 sightglass.

ATTENTION! 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!

6.7 Avoiding liquid sluggings

ATTENTION! Slugging can damage the compressor and cause coolant to leak.

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 refrigerant in the compressor while the system is at a
standstill.

AQ464037893946en-IN0201 | 21

7 |Maintenance

7.1 Preparation
WARNING! 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 infiltrating the system!
After maintenance has been performed: Connect safety switch. Evacuate compressor. Release switch lock.

7.2 Work to be carried out

Oil change: In principle, an oil change is not mandatory if the system is correctly manufactured
and operated.
However, based on decades of experience we recommend that the following oil change/service
work is carried out: – First oil change during the first maintenance system. – Then after every 10,000 12,000 operating hours, though no more than
3 years, cleaning oil and suction filter at the same time.

D

Annual checks: Oil level, tightness, running noise, pressures, temperatures, function of auxiliary

devices such as a oil sump heater, pressure switch.

GB

F

7.3 Spare parts recommendation/ accessories

Available spare parts and accessories can be found on our compressor selection tool under

E

vap.bock.de as well as at bockshop.bock.de.

Only use genuine Bock spare parts!

22 | AQ464037893946en-IN0201

7 |Maintenance

7.4 Lubricants / oil

The oil type filled 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 significantly 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.

Refrigerants

Bock standard oil types

HFKW (z.B. R134a, R407, R 404A, R513A)

BOCK lub E55

7.5 Decommissioning Close the shut-off valve on the compressor. Drain the refrigerant (it must not be discharged directly into the environment) and dispose of it according to the regulations. When the compressor is depressurised, 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 valid national regulations.
D GB
F E

AQ464037893946en-IN0201 | 23

8 |Technical data
Oil charge

D GB F E
Voltage

24 | AQ464037893946en-IN0201

Type

Displacement

Electrical data 3

Connections 4

No. of cylinders

50 / 60 Hz
(1450 / 1740 rpm)

Max. Working
current

Max. power consump-

Starting current
(rotor

Weight

Discharge
line DV

Suction
line SV

2

tion

locked)

1

/ Y

2

/ Y

m3/h

A

kW

A

kg mm (inch) mm (inch)

Ltr.

220-240 V / 380-420 V Y – 3 – 50 Hz 265-290 V / 440-480 V Y – 3 – 60 Hz

HG34e/380-4 S A

4

33,1 / 39,7

31,2 / 18,0 11,1

132 / 76 59

22 (7/8) 28 (11/8)

1,3

1 Tolerance (± 10%) relative to the mean value of the voltage range. Other voltages and types of current on request.
2 – The specifications for max. power consumption apply for 50Hz operation. For 60Hz operation, the specifications have to be multiplied by the factor
1.2. The max. working current remains unchanged.
– Take account of the max. operating current / max. power consumption for
design of fuses, supply lines and safety devices.
Fuse: Consumption category AC3

3 All specifications are based on the average of the voltage range 4 For solder connections

7

6

5

9 |Dimensions and connections

135 321 +2 273
115

Centre of gravity

46 78

J
190 310
416 534 +2

A

X

B,L

C F

X

4

286 +2
DV B1
4x 12 230 272

H,D1 O,K

Anschlüsse / Connections Saugabsperrventil, Ro SV Suction line valve, tub Druckabsperrventil, R DV Discharge line valve, t Anschluss Saugseite, A Connection suction sid Anschluss Saugseite, A1 Connection suction sid Anschluss Druckseite, B Connection discharge Anschluss Druckseite, B1 Connection discharge Anschluss Öldrucksich C Connection oil pressu Anschluss Ölrückführu D1 Connection oil return f Ölablass F Oil drain Stopfen Ölfüllung H Oil charge plug Anschluss Ölsumpfhe J Connection oil sump h Schauglas K Sight glass Anschluss Wärmesch L Connection thermal pr Anschluss Ölspiegelre O Connection oil level re (L)* = Lötanschluss / b

SV A1 A

D

GB

¹) SV 90° rotating

Dimensions in mm

*) approx. 310 mm with teHrmalbinhaelrmbeotxisecsheartVreerddiuchcteerdHhGei/gShetm(ia-hcecremsestiocrcyo)mpressor HG

Fig. 21

Änderungen vorbehalten
F Subject to change without notic

Typ /

Teile-Nr. /

E

type

part-no.

HGX34e/380-4 S A 41297

SV Suction line DV Discharge line

see technical data, Chapter 8

A

Connection suction side, not lockable

A1 Connection suction side, lockable

B

Connection discharge side, not lockable

B1 Connection discharge side, lockable

C

Connection oil pressure safety switch

Der Lieferant muss sicherstellen, dass die Ware in einwandfreiem Zustand angeliefert wird
D1 (Korrosionsschutz, Verpackung für sicheren
Transport).

Connection oil return from oil separator

The supplier has to ensure the delivery of parts

in proper conditions (corrosion prevention,

packaging for safe transportation).

F Weitergabe sowie Vervielfältigung dieses Dokuments,
Verwertung und Mitteilung seines Inhalts sind ver-

Oil drain

boten, soweit nicht ausdrücklich gestattet. Zuwider-

handlungen verpflichten zu Schadenersatz. Alle

Rechte für den Fall der Patent-, Gebrauchsmuster-

H oder Geschmacksmustereintragung vorbehalten.
The reproduction, distribution and utilization of this

Oil charge plug

document as well as the communication of its

contents to others without express authorization is

prohibited. Offenders will be held liable for the

Zust.

/

Rev.

7

6

K

Sight glass

L

Connection thermal protection thermostat

O

Connection oil level regulator

1/8″ NPTF Gußtoleranzen / General casting tolerances:
–

Zeichnu Drawin

Baumustergeprüft / Type examination:
7Nein / No /16″ UNF Gewicht / Weight: (kg) –

7. 0

Allgemeintoleranzen / General tolerances
1DIN ISO 2768-mK-E

Benen

/8″ NPTF über / above 0.5 6 30 120 400

bis / up to 6 30 120 400 1000
7/16″ UNF ±0.1 ±0.2 ±0.3 ±0.5 ±0.8

Unbemaßte Radien / Undimensioned radii: –
1/8″ NPTF

Oberflä Indicat DIN EN

1/4″ NPTF

M10

1/4″ NPTF

5 1 1/38/”8-4″ N18PTUFNEF Änd.-Nr. / Mod-No. Datum / Date Bearb. / Edited Geprüft / Appr. Maß / Dimension

Passung / Clearance

1/8″ NPTF

1 1/8″- 18 UNEF

BOCK G

AQ464037893946en-IN0201 | 25

10| Declaration of incorporation

Declaration of incorporation for incomplete machinery in accordance with EC Machinery Directive 2006/42/EC, Annex II 1. B

Manufacturer:

Bock Compressor India Pvt Ltd #3A1, Bommasandra Industrial Area, Hebbagodi, Hosur Road, Bangalore 560099

We, as manufacturer, declare in sole responsibility that the incomplete machinery

Name: Types:

Semi-hermetic compressor HG(X)22e/125-4 (S)(A)……… HG(X)66e/2070-4(S)(A)

Name: Types:

Open type compressor FKX40/470 K…………………….FKX40/655 K

Serial number:

BB00000A001 BN99999Z999

complies with the following provisions of the above-mentioned Directive:
According to Annex I, points 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.3, 1.3.7, 1.5.1, 1.5.2, 1.5.13 and 1.7.1 to 1.7.4 (excepted 1.7.4 f) are fulfilled.

D

Applied harmonised standards, in particular:

EN ISO 12100 :2010 Safety of machinery — General principles for design — Risk

GB

assessment and risk reduction

EN 12693

:2008 Refrigerating systems and heat pumps — Safety and environmental

F

requirements — Positive displacement refrigerant compressors

E

Remarks:

We also declare that the special technical documentation for this incomplete machine has been created in accordance with Annex VII, Part B and we obligate to provide these upon reasoned request from the individual national authorities by data transfer.

Commissioning is prohibited until it has been confirmed that the machinery into which the incomplete machine above is to be incorporated complies with the EC Machinery Directive and
an EC Declaration of Conformity, Annex II. 1. A exists.

Authorized person for compiling and handing over technical documentation:
Bock GmbH Alexander Layh Benzstraße 7 72636 Frickenhausen, Germany

Bock Compressor India Pvt Ltd Prasad Sannagowder #3A1, Bommasandra Industrial Area, Hebbagodi, Hosur Road, Bangalore 560099
Prasad Sannagowder, Managing Director Frickenhausen, 02nd of March 2021

26 | AQ464037893946en-IN0201

10| Declaration of incorporation

Declaration of incorporation of partly completed machinery in accordance with UK Statutory Instrument Supply of Machinery (Safety) Regulations 2008, Annex II 1. B

Manufacturer:

Bock Compressor India Pvt Ltd #3A1, Bommasandra Industrial Area, Hebbagodi, Hosur Road, Bangalore 560099

We, as manufacturer, declare in sole responsibility that the partly completed machinery

Name: Types:

Semi-hermetic compressor HG(X)22e/125-4 (S)(A)……… HG(X)66e/2070-4(S)(A)

Name: Types:
Serial number:

Open type compressor FKX40/470 K…………………….FKX40/655 K
BC00000A001 BN99999Z999

complies with the following provisions of the above-mentioned Statutory instrument:
According to Schedule 2, part1, points 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.3, 1.3.7, 1.5.1, 1.5.2, 1.5.13 and 1.7.1 to 1.7.4 (excepted 1.7.4 f) are fulfilled.

Designated standards: EN ISO 12100 :2010 Safety of machinery — General principles for design — Risk

assessment and risk reduction

EN 12693

:2008 Refrigerating systems and heat pumps — Safety and environmental requirements — Positive displacement refrigerant compressors

D

Remarks:

GB
We also declare that the special technical documentation for this partly completed machine

has been created in accordance with Annex II, 1. B and we obligate to provide these upon

F

reasoned request from the individual national authorities by data transfer.

E
Commissioning is prohibited until it has been confirmed that the machinery into which the partly completed machine above is to be incorporated complies with the UK Statutory Instrument Supply machinery (Safety) regulations 2008 and an EC Declaration of Conformity, Annex II, 1. A exists.

Authorized representative for compiling and handing over technical documentation:
UKCA Experts Ltd. Dept 302, 43 Owston Road Carcroft, Doncaster, DN6 8DA, United Kingdom

Bock Compressor India Pvt Ltd Prasad Sannagowder #3A1, Bommasandra Industrial Area, Hebbagodi, Hosur Road, Bangalore 560099
Prasad Sannagowder, Managing Director Frickenhausen, 14th of October 2022

AQ464037893946en-IN0201 | 27

D GB F E

28 | AQ464037893946en-IN0201

D GB F E

AQ464037893946en-IN0201 | 29

30 | AQ464037893946en-IN0201