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1 BOCK HGX12e S CO2 GEA Semi Hermetic Compressor

2.1 About these instructions

2.2 Contents

2.3 Safety

2.3.1 Identification of safety instructions:

2.3.2 Qualifications required of personnel

3 Product Usage Instructions

3.1 Commissioning

3.2 Maintenance

3.2.1 Documents / Resources

3.2.1.1 References

BOCK HGX12e S CO2 GEA Semi Hermetic Compressor

Product Information

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 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 compressor is
installed.

Safety
- Identification of safety instructions
- Qualifications required of personnel
- General safety instructions
- Intended use
Product description
- Short description
- Name plate
- Type key
Areas of application
- Refrigerants
- Oil charge
- Limits of application
Compressor assembly
- Storage and transport
- Setting up
- Pipe connections
- Pipes
- Laying suction and pressure lines
- Operating the shut-off valves
- Operating mode of the lockable service connections
- Suction pipe filter
Electrical connection
- Information for contactor and motor contactor selection
- Connection of the driving motor
- Circuit diagram for direct start 230 V / 400 V Y
- Electronic trigger unit INT69 G
- Connection of the electronic trigger unit INT69 G
- Functional test of the electronic trigger unit INT69 G
- Oil sump heater (accessories)
- Selection and operation of compressors with frequency
  converters
Commissioning
- Preparations for start-up
- Pressure strength test
- Leak test
- Evacuation
- Refrigerant charge
- Start-up
- Decompression valves
- Avoiding slugging
- Filter dryer
- Connection of oil level regulator
Maintenance
- Preparation
- Work to be carried out
- Spare parts recommendation/accessories
- Lubricants / oil
- Decommissioning
Technical data
Dimensions and connections
Declaration of incorporation

Safety

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.

Qualifications required of personnel

WARNING: Inadequately qualified personnel poses
the risk of accidents, the consequence being serious or fatal
injury. Work on compressors is therefore reserved for personnel
which is qualified to work on pressurized refrigerant systems:
engineer. As well as professions with comparable training, which
enables personnel to assemble, install, maintain and repair
refrigeration and air-conditioning systems. Personnel must be
capable of assessing

Product Usage Instructions

Commissioning

Preparations for start-up
Pressure strength test
Leak test
Evacuation
Refrigerant charge
Start-up
Decompression valves
Avoiding slugging
Filter dryer
Connection of oil level regulator

Maintenance

Preparation
Work to be carried out
Spare parts recommendation/accessories
Lubricants / oil
Decommissioning

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BOCK® HGX12e S CO2
Operating guide HGX12e/20-4 S CO2 HGX12e/30-4 S CO2 HGX12e/40-4 S CO2 HGX12e/50-4 S CO2 HGX12e/60-4 S CO2 HGX12e/75-4 S CO2

Translation of the original instructions

AQ451930031820en-000201

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 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 compressor is installed.
D GB F E

2 | AQ451930031820en-000201

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 Limits of application
4 Compressor assembly 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 filter
5 Electrical connection 5.1 Information for contactor and motor contactor selection 5.2 Connection of the driving motor 5.3 Circuit diagram for direct start 230 V / 400 V Y 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) 5.8 Selection and operation of compressors with frequency converters
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 Decompression valves 6.8 Avoiding slugging 6.9 Filter dryer 6.10 Connection of oil level regulator
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

Page 4
6 8 9
D 12 GB
F E
18
22
24 25 26

AQ451930031820en-000201 | 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.

1.2 Qualifications required of personnel

WARNING Inadequately qualified personnel poses the risk of accidents, the

consequence being serious or fatal injury. Work on compressors

is therefore reserved for personnel which is qualified to work on

pressurized refrigerant systems:

· For example, a refrigeration technician, refrigeration mechatronic

engineer. As well as professions with comparable training, which

enables personnel to assemble, install, maintain and repair refrigeration

and air-conditioning systems. Personnel must be capable of assessing

the work to be carried out and recognising any potential dangers.

4 | AQ451930031820en-000201

1| Safety

1.3 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.

1.4 Intended use

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-flammable, acidic, colorless and odorless gas and

heavier than air.

Never release significant volumes of CO2 or the entire contents of

the system into closed rooms!

GB Safety installations are designed or adjusted in accordance with

EN 378-2 or appropriate safety standards.

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, 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 compressor is intended for use with CO2 in sub-critical 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!

AQ451930031820en-000201 | 5

2| Product description
2.1 Short description
· Semi-hermetic two-cylinder reciprocating compressor with suction gas cooled drive motor. · The flow 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

Valve plate

Oil pump

Terminal box

Fig. 1

Name plate
Oil sight glass
Cylinder cover Discharge
shut-off valve

Suction shut-off valve

Drive section Motor section

Fig. 2 Dimension and connection values can be found in Chapter 9

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2| Product description
2.2 Name plate (example)

BOCK Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany

6 7

9 10

BOCK lub E85

Fig. 3

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

(g) Low pressure side

11 Displacement

HD (HP): max. admissible operating

12 Oil type filled at the factory

pressure (g) High pressure side 13 Terminal box protection type

Observe the limits of application

Electrical accessories can change

diagrams!

the IP protection class!

E 2.3 Type key (example)

HG X 1 2 e / 75- 4 S CO2

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 Numbers of cylinders Size Oil charge ²) Series ¹)

AQ451930031820en-000201 | 7

3| Areas of application

3.1 Refrigerants · CO2: R744 (Recommendation CO2 quality 4.5 (< 5 ppm H2O))

3.2 Oil charge The compressors are filled at the factory with the following oil type: BOCK lub E85 (only this oils may be used)

ATTENTION 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!

max.
oil level min.

~~ 0,5 Ltr. Fig. 4

3.3 Limits of application

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.

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. (For more on the frequency converter, see chapter 5.8, p. 17)

R744
t0h = 10 K
Fig. 5
8 | AQ451930031820en-000201

Unlimited application range
Evaporation temperature (°C) Condensing temperature (°C) Suction gas superheat (K)
Max. permissible operating pressure (LP/HP)1): 40/55 bar 1) LP = Low pressure
HP = High pressure
© Danfoss | Climate Solutions | 2023.07

4| Compressor assembly

INFO

New compressors are factory-filled with inert gas. Leave this

service 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 transportation

?Fig. 6

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. 7

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!

Provide adequate clearance for maintenance work.

Ensure adequate compressor ventilation.

Fig. 8

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

Fig. 9 Fig. 10

Setup on an even surface or frame with sufficient load-bearing capacity. Only erect on a slant in consultation with the manufacturer. Single compressor preferably on vibration damper. Duplex and parallel circuits always rigid.

4.3 Pipe connections

ATTENTION

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).

AQ451930031820en-000201 | 9

4| Compressor assembly

Fig. 11: graduated internal diameter

Material soldering/welding connection suction valve: S235JR
Material soldering/welding connection discharge valve: P250GH 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.

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.

D 4.5 Laying suction and pressure lines
GB

ATTENTION Property damage possible.

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.

Rigid fixed point

As short as possible

10 | AQ451930031820en-000201

Fig. 12
© Danfoss | Climate Solutions | 2023.07

4| Compressor assembly
4.6 Operating the shut-off valves Before opening or closing the shut-off valve, release the 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.

Release

Tighten

Valve spindle seal Fig. 13

Fig. 14

4.7 Operating mode of the lockable service connections

Service connection

closed

Pipe connection

Spindle

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.

Compressor Fig. 15

Service connection opened

Spindle

Connection open

Pipe connection

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

Compressor Fig. 16

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.

AQ451930031820en-000201 | 11

4| Compressor assembly
4.8 Suction pipe filter 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).

5| Electrical connection

5 Electrical connection

DANGER

Risk of electric shock! High voltage! 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 equipment, switching and monitoring devices must comply with the local safety regulations and established specifications (e.g. VDE) as well as the manufacturer’s specifications. Motor protection switches are required! Motor contactors, feed lines, fuses and motor protection switches must be rated according to the maximum operating current (see name plate). For motor protection, use a current-independent, 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.

12 | AQ451930031820en-000201

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

Sticker on the terminal box

/ Y

Star-delta start-up is only possible on 230 V voltage supply. Example:

Direct star

230 V

Star-delta start L1 L2 L3

400 V Y Direct start only

L1 L2 L3

GB
L1 L2 L3
F

INFO

The connection examples shown refer to the standard version.

In the case of special voltages, the instructions affixe to the

terminal box apply.

AQ451930031820en-000201 | 13

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

QA1

FC1.1

I> I> I>

QA2

FC2

SF1

QA2

FC1.1

L1 L2 L3 N PE

-EC1 3~

BT1

12 14 11 L N B1 B2

INT69G
CAonmspchrelusßsokrastetermn iVnearldbiocxhter
Fig. 17

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

14 | AQ451930031820en-000201

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

EB1 P>
BP1
BT2
BT2

QA2

BP2

BT3

N PE
D GB F E

FC1.1 FC2 INT69 G QA1 QA2 SF1

Motor protection switch Control power circuit fuse Electronic trigger unit INT69 G Main switch Net switch Control voltage switch

AQ451930031820en-000201 | 15

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.

5.5 Connection of the trigger unit INT69 G

D
1
GB F E

INFO

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 first element in the control power circuit.

or Protection MP10

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

B1 B2

12 14 11

+
Steuerstrom- BT1
–
kreis

+
BT2
–

+
BT1
+
BT2
–

N L
CSotenutreorlstcriorcmu-it
kreis
Fig. 18 Terminal box

5.6 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 gauge.

16 | AQ451930031820en-000201

5| Electrical connection

Gauge state 1. Deactivated state 2. INT69 G switch-on 3. Remove PTC connector 4. Insert PTC connector 5. Reset after mains on

Relay position 11-12 11-14 11-12 11-12 11-14

Relay position INT69 G B2 12 14 11

5.7 Oil sump heater (accessories) In order to avoid damage to the compressor, the compressor must be equipped withFaing.o1il9sump heater.
ATTENTION The oil sump heater must generally be connected and operated!

Connexion: The oil sump heater must be connected via an auxiliary contact (or parallel wired auxiliary

contact) of the compressor contactor to a seperate electric circuit.

Electrical data: 110 – 240 V – 1 – 50/60 Hz, 50 – 120 W, PTC-heater adjusting.

5.8 Selection and operation of compressors with frequency converters For safe operation of the compressor, the frequency converter must be able to apply an overload of

at least 160% of the compressor’s maximum current (I-max.) for at least 3 seconds.

When using frequency converters, the following things must also be observed:
1. The maximum permissible operating current of the compressor (I-max) (see type plate or
technical data) must not be exceeded. 2. If abnormal vibrations occur in the system, the affected frequency ranges in the frequency
converter must be blanked out accordingly. 3. The maximum output current of the frequency converter must be greater than the maximum
current of the compressor (I-max).
4. Carry out all designs and installations in accordance with the local safety regulations and common rules (e.g. VDE) and regulations as well as in accordance with the specifications of the frequency converter manufacturer

The permissible frequency range can be found in the technical data chapter 8, p. 24.

Rotational speed range

0 – f-min

f-min – f-max

Start-up time

< 1 s

ca. 4 s

Switch-off time

immediately

f-min/f-max see chapter 8: Technical data: permissible frequency range

AQ451930031820en-000201 | 17

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!

WARNING

When the compressor is not running, depending on ambient temperature and amount of refrigerant charge, it is possible that the pressure may rise and exceed permitted levels for the compressor. Adequate precautions must be taken to prevent this happening (e.g. using a cold storage medium, a receiver tank, a secondary refrigerant system, or pressure relief devices).

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.

E 6.3 Leak test

DANGER

Risk of bursting! The compressor must only be pressurised using nitrogen (N2). Never pressurise 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.

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.

18 | AQ451930031820en-000201

6| Commissioning

6.4 Evacuation

ATTENTION

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.

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. Turn on the oil sump heater. 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 when the pump is switched off. Repeat this process as often as is required.

6.5 Refrigerant charge

CAUTION Wear personal protective clothing such as goggles and protective

gloves!

F Make sure that the suction and pressure line shut-off valves are open.

INFO

Depending upon design of the CO2 refrigerant filling bottle

(with/without tubing) CO2 can be filled in liquid after weight or

gaseously.

Use only high-dried CO2 quality (see chapter 3.1)!

Filling the liquid refrigerant: It is recommended that the system first be filled

at standstill with gas on the high-pressure side up to a system pressure of at
least 5.2 bar (if it is filled below 5.2 bar with liquid, there is a risk of dry ice formation). Further filling according to system.

To eliminate the possibility of dry ice formation when the system is operating (during and after the filling process), the shut-off point of the low-pressure

switch should be set to a value of at least 5.2 bar.

WARNING Never exceed the max. permissible pressures while charging. Precautions must be taken in time.

· A refrigerant supplement, which may become necessary after start-up, can be topped up in vapour form on the suction side.

ATTENTION

Avoid overfilling the machine with refrigerant! Do not charge liquid refrigerant into the suction-side on the compressor.
Do not mix additives with the oil and refrigerant.

AQ451930031820en-000201 | 19

6| Commissioning

6.6 Start-up
WARNING Ensure that both shut-off valves are open before starting the compressor!
Check that the safety and protection devices (pressure switch, motor protection, electrical contact protection measures, etc.) are functioning properly. Switch on the compressor and let it run for at least 10 minutes. The machine should reach a state of equilibrium. Check the oil level: The oil level must be visible in the sight glass. After a compressor is replaced, the oil level must be checked again. If the level is too high, oil must be drained off (danger of oil liquid shocks; reduced capacity of the refrigerating system).
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 Decompression valves

ATTENTION The compressor is fitted with two decompression valves. One valve

each on the suction and discharge side. If excessive pressures are

reached, the valves open and prevent further pressure increase.

Thereby CO2 is blown off to the ambient!

In the event that a pressure relief valve activates repeatedly, check

valve and replace if necessary as during blow-off extreme condi-

tions can occure, which may result in a permanent leak. Always

check system for refrigerant loss after activation of pressure relief

valve!

The decompression valves do not replace any pressure switches and the additional safety valves in the system. Pressure switches must always be installed in the system and designed or adjusted in accordance with EN 378-2 or appropriate safety standards.
Failure to observe can result in risk of injury from CO2 streaming out of the two decompression valves!

20 | AQ451930031820en-000201

CO2 streaming out
Fig. 22
© Danfoss | Climate Solutions | 2023.07

6| Commissioning

6.8 Avoid slugging
ATTENTION Slugging can result in damage to the compressor and cause refrigerant 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 15 K. (Check the setting of the expansion valve). Regard oil temperature and pressure gas temperature. (The pressure gas temperature has to be high enough min. 50°C, so the oil temperature is > 30°C). 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.

6.9 Filter dryer Gaseous CO2 has a significantly lower solubility in water than other refrigerants. At low temperatures

it can therefore cause blocking of valves and filters due to ice or hydrate. For this reason we recom- GB

mend the use of an adequately sized filter drier and a sight glass with a moisture indicator.

6.10 Connection of oil level regulator

The connection “O” is provided for installing an oil level regulator. A corresponding adapter must be

obtained from the trade.

AQ451930031820en-000201 | 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

In order to guarantee optimum operational reliability and service life of the compressor, we recommend

carrying out servicing and inspection work at regular intervals:

Oil change:

– not mandatory for factory-produced series systems.

– for field installations or when operating near the application limit: for the first 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

auxiliary devices such as oil sump heater, pressure switch.

7.3 Recommended spare parts/accessories

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!

7.4 Lubricants For operation with CO2 the BOCK lub E85 is necessary!

22 | AQ451930031820en-000201

7| Maintenance
7.5 Decommissioning Close the shut-off valves on the compressor. CO2 does not need to be recycled and can therefore be blown off into the environment. It is essential to ensure good ventilation or conduct the CO2 into the outdoors to avoid danger of suffocation. When releasing CO2, avoid a fast drop in pressure to prevent oil from exiting with it. If the compressor is unpressurized, remove the piping on the pressureand suction-side (e.g. dismantling of the shut-off valve, etc.) and remove the compressor using an appropriate hoist. Dispose of the oil inside in accordance with the applicable national regulations. When decommissioning the compressor (eg. for service or replacement of the compressor) larger amounts of CO2 in the oil can be set free. If the decompression of the compressor is not sufficient enough, closed shut-off valves may lead to intolerable excessive pressure. For this reason the suction side (LP) and the high pressure side (HP) of the compressor have to be secured by decompression valves.
D GB F E

AQ451930031820en-000201 | 23

8| Technical data
Oil charge

Weight
permissible frequency range
D GB F E

No. of cylinders Type HGX12e/
24 | AQ451930031820en-000201

20-4 S CO2

Displacement 50 / 60 Hz (1450 / 1740 1/min)

Voltage

Electrical data

Max. Operating current
2 / Y

Max. power consump-
tion
2

3
Starting current
(rotor locked) / Y

m3/h

1,6 / 1,9

4,0 / 2,3

1,2

24 / 14

Connections 4

Discharge
line DV

Suction line SV

kg mm (inch) mm (inch) Ltr. 49

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

30-4 S CO2

2,6 / 3,1

6,0 / 3,5

1,8

40 / 23

40-4 S CO2 2
50-4 S CO2

3,6 / 4,3 4,5 / 5,4

8,3 / 4,8 9,7 / 5,6

2,6

40 / 23

3,3

43 / 25

30 – 70

50 12 (1/2) 16 (5/8)

0,8

60-4 S CO2

5,4 / 6,5

12,5 / 7,2

3,9

71 / 41

75-4 S CO2

6,4 / 7,7

14,3 / 8,2

4,7

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

71 / 41

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

125 125 125
125

289 +2 243 9 8

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2200,,55 3300

243 9 8

208 J 192F F Halbhermetischer Verdichter HG / Semi-hermetic compressor HG Zeichn.- Typ /

Teile-N . / Typ /

Teil -Nr. /

X type 125

part-no. type

part-no.

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92 HGX12e/40-4 S CO2 10956 HGX12e/75-4 S CO2 10959

9 8

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(L)* = Lötanschluss Connection oil leveClorne

(L)* ** =

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X X Maße in ( ) für HGX12e/60+75-4 S CO2

66 66 317,5 (334167),5 (346) Dimensions in ( ) for HGX12e/60+75-4 S CO2

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20,5 3 0
20,5 3 0

Gußtoleranzen –

General

casting

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400 1000

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20,5 3 0
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1. 0850 -31095 HGX12e/4H0G-4XS12CeO/420-4 S10C9O562 H1G09X5162e/7H5G-4XS12CeO/725-4 S1Ge0Cw9iOc5ht92/ Weigh1t:0(k9g5) 9-

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1 Allgemeintoleranzen E Connection oil pressure gauge /8″ NPTF DIN ISO 2768-mK-E

/UGnbeenmearßatel tRoaledrieann/cUensdimensioned

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Ob –

über / above 0.5 6 30 120 400

DIN EN ISO 1302

–

Der Lieferant muss sicherstellen, dass die Ware
F Oil drain M8 MK |KKlelemmmmkkaassteteni(TnnKr5aonr5re0soipns00owior0atn2)n.s2ds9cfr9heuieetzmer, srsVeZeuetrspzttaazntckdtudndagunugrefcrülierchfehsritKchKewlreielrdenmm00mef m||KkBklaeeamtsrismftfettkeBanlsnatt5etn521513037027292ersetzt durch Klemmkasten 51372

1 | |BBeetrtirfifftftBBlalatttt22The supplier has to ensure the delivery of parts

in proper conditions (corrosion packaging for safe transportation).

prevention, 0d | Betrifft Blatt 2

99999911 99772233

9991 9723 9657

0077.0.00272..10.127.717 16.03.16
1166.0.03134..1.0116.616

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H Oil charge plug /4″ NPTF 1. 0 | |BBeetrtirfifftftBBlalatttt22Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind ver-

0c | Betrifft Blatt 3:Pos.310 u.630 auf Pos.2120 u.2125 geändert

boten, soweit nicht ausdrücklich gestattet. Zuwider-

99665577 9593 1144.0.00191..11.016.165 BGBuneucitckink_g_TTaa

handlungen verpflichten Rechte für den Fall der

zu Schadenersatz. Alle Patent-, Gebrauchsmuster-

Betrifft

Blatt

Spannstift

Lagerflansch

Text

Position

entfernt

9580

01.10.15 Gneiting

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18.12.1999558800

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AQ451930031820en-000201 | 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 GmbH Benzstraße 7 72636 Frickenhausen, Germany

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

Name: Types:

Name:

Types:

Semi-hermetic compressor HG(X)12P/60-4 S (HC) …………………… HG(X)88e/3235-4(S) (HC) UL-HGX12P/60 S 0,7……………………… UL-HGX66e/2070 S 60 HGX12P/60 S 0,7 LG …………………….. HGX88e/3235 (ML/S) 95 LG HG(X)22(P)(e)/125-4 A …………………… HG(X)34(P)(e)/380-4 (S) A HGX34(P)(e)/255-2 (A) ………………….. HGX34(P)(e)/380-2 (A)(K) HA(X)12P/60-4 ……………………………… HA(X)6/1410-4 HAX22e/125 LT 2 LG ……………………. HAX44e/665 LT 14 LG HGX12e/20-4 (ML/S) CO2 (LT) ……….. HGX44e/565-4 S CO2 UL-HGX12e/20 (S/ML) 0,7 CO2 (LT)… UL-HGX44e/565 S 31 CO2 HGX12/20-4 (ML/S/SH) CO2T………….. HGX46/440-4 (ML/S/SH) CO2 T UL-HGX12/20 ML(P) 2 CO2T…………. UL-HGX46/440 ML(P) 53 CO2T HGZ(X)7/1620-4 ……………………………. HGZ(X)7/2110-4 HGZ(X)66e/1340 LT 22…………………… HGZ(X)66e/2070 LT 35
HRX40-2 CO2 T H………………………….. HRX60-2 CO2 T H
Open type compressor
F(X)2 …………………………………… F(X)88/3235 (NH3)
FK(X)1………………………………….. FK(X)3
FK(X)20/120 (K/N/TK)…………….. FK(X)50/980 (K/N/TK)

Serial number:

BC00000A001 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.

Applied harmonised standards, in particular:

EN ISO 12100 :2010

EN 12693

:2008

Safety of machinery — General principles for design — Risk assessment and risk reduction Refrigerating systems and heat pumps — Safety and environmental requirements — Positive displacement refrigerant compressors

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

Frickenhausen, 04th of January 2021

i. A. Alexander Layh, Global Head of R&D

26 | AQ451930031820en-000201

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 GmbH Benzstraße 7 72636 Frickenhausen, Germany

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

Name: Types:

Semi-hermetic compressor HG(X)12P/60-4 S (HC) …………………… HG(X)88e/3235-4(S) (HC) UL-HGX12P/60 S 0,7……………………… UL-HGX66e/2070 S 60 HGX12P/60 S 0,7 LG …………………….. HGX88e/3235 (ML/S) 95 LG HG(X)22(P)(e)/125-4 A …………………… HG(X)34(P)(e)/380-4 (S) A HGX34(P)(e)/255-2 (A) ………………….. HGX34(P)(e)/380-2 (A)(K) HA(X)22e/125-4 ……………………………..HA(X)6/1410-4 HAX22e/125 LT 2 LG ……………………. HAX44e/665 LT 14 LG HGX12e/20-4 (ML/S) CO2 (LT) ……….. HGX44e/565-4 S CO2 UL-HGX12e/20 (S/ML) 0,7 CO2 (LT)… UL-HGX44e/565 S 31 CO2 HGX12/20-4 (ML/S/SH) CO2T………….. HGX46/440-4 (ML/S/SH) CO2 T UL-HGX12/20 ML(P) 2 CO2T…………… UL-HGX46/440 ML(P) 53 CO2T HGZ(X)7/1620-4 ……………………………. HGZ(X)7/2110-4 HGZ(X)66e/1340 LT 22…………………… HGZ(X)66e/2070 LT 35
HRX40-2 CO2 T H………………………….. HR(Z)X60-2 CO2 T (H)(V)

Name:

Open type compressor

Types:

F(X)2 …………………………………………… F(X)88/3235 (NH3) FK(X)1………………………………………….. FK(X)3

FK(X)20/120 (K/N/TK)…………………….. FK(X)50/980 (K/N/TK)

Serial number:

BC00000A001 BN99999Z999

complies with the following provisions of the above-mentioned Statutory instrument:
E
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

EN 12693

:2008

Remarks:

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 reasoned request from the individual national authorities by data transfer.
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 person for compiling and handing over technical documentation:

Bock GmbH Alexander Layh Benzstraße 7 72636 Frickenhausen, Germany

Frickenhausen, 14th of October 2022

i. A. Alexander Layh, Global Head of R&D

AQ451930031820en-000201 | 27

D GB F E

28 | AQ451930031820en-000201

D GB F E

AQ451930031820en-000201 | 29

30 | AQ451930031820en-000201