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Reciprocating Compressor
BOCK UL-HGX 44 e/UL-HGX 5 6e
Assembly instructions
96547-10.2021-Us
(Translation of the original instructions)
UL-HGX44e/475 ML 9
UL-HGX44e/475 S 12
UL-HGX44e/565 ML 12
UL-HGX44e/565 S 15
UL-HGX44e/665 ML 14
UL-HGX44e/665 S 20
UL-HGX44e/770 ML 15
UL-HGX44e/770 S 22
Bock GmbH, Benzstr. 7, 72636 Frickenhausen, Germany
Phone: +49 7022 9454-0, Fax: +49 7022 9454-137
www.bock.de, service@bock.de
BOCK
®
UL-HGX56e/850 ML 18
UL-HGX56e/850 S 25
UL-HGX56e/995 ML 23
UL-HGX56e/995 S 30
UL-HGX56e/1155 ML 28
UL-HGX56e/1155 S 35
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Summary of Contents for BOCK UL-HGX44e
- Page 1 UL-HGX44e/665 ML 14 UL-HGX56e/1155 ML 28 UL-HGX44e/665 S 20 UL-HGX56e/1155 S 35 UL-HGX44e/770 ML 15 UL-HGX44e/770 S 22 Bock GmbH, Benzstr. 7, 72636 Frickenhausen, Germany Phone: +49 7022 9454-0, Fax: +49 7022 9454-137 www.bock.de, service@bock.de BOCK ® colour the world...
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Page 2: Table Of Contents
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. - Page 3 Contents Page Compressor assembly ....................10 Storage and transport ...................... 10 Setting up ........................10 Pipe connections ......................11 Pipes ..........................11 Laying suction and pressure lines ..................11 Operating the shut-off valves ................... 12 Operating mode of the lockable service connections ............13 Suction pipe filter and filter drier ..................
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Page 4: Safety
1| Safety Identification of safety instructions 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. -
Page 5: Intended Use
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). -
Page 6: Product Description
2| Product description 2.1 Short description • UL-HGX44e: Semi-hermetic four-cylinder reciprocating compressor with suction-gas cooled drive motor. • UL-HGX56e: Semi-hermetic six-cylinder reciprocating compressor with suction-gas cooled drive motor. • Preferred application range: normal refrigerating and air-conditioning. • The stream of refrigerant sucked out of the evaporator flows over the motor and cools it intensively. -
Page 7: Name Plate (Example)
2| Product description 2.2 Name plate (example) BOCK Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany thermally protected system 380-420 Y/YY Type : UL-HGX44e/770 S 22 BB12345-A001 : BB12345A001 2365 cfh 180,0 440-480 Y/YY 107,0 A 35,0 A Y: 196, YY: 174 A... -
Page 8: Areas Of Application
More informations about approved refrigerants on Bock compressor selection tool VAP (vap.bock.de). 3.2 Oil charge The compressors are filled at the factory with the following oil type: BOCK lub E55 For refilling, we recommend the above oil types. Alternatives: see chapter 7.4 The oil level must be in the Max. -
Page 9: Limits Of Application
3 | Areas of application 3.3 Limits 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. -
Page 10: Compressor Assembly
4 | Compressor assembly 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 Storage at (-30°C) - (+70°C), (-22 °F) - (158 °F), maximum permis- sible relative humidity 10% - 95%, no condensation Do not store in a corrosive, dusty, vaporous atmosphere or in a com- bustible environment. -
Page 11: Pipe Connections
4 | Compressor assembly 4.3 Pipe connections 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). -
Page 12: Operating The Shut-Off Valves
4 | Compressor assembly A rule of thumb: Always lay the first pipe section starting from the shut-off valve downwards and parallel to the drive shaft. Rigid As short as fixed point possible Fig. 6 a) For HG44e a intermediate flange (height 27 mm) is optional available, Art-Nr. -
Page 13: Operating Mode Of The Lockable Service Connections
4 | Compressor assembly 4.7 Operating mode of the lockable service connections Connection cannot Service connection be shut off closed Pipe connection Connection Spindle blocked Fig. 9 Opening the shut-off valve: Compressor Spindle: turn to the left (counter-clockwise) as far as it will go. —>... -
Page 14: Electrical Connection
5 | Electrical connection 5.1 General safety Risk of electric shock! High voltage! Only carry out work when the electrical system is disconnected from the power supply! When attaching accessories with an electrical cable, a minimum bending radius of 3 x the cable diameter must be maintained for laying the cable. - Page 15 5 | Electrical connection The motor is wired for direct start (YY) at the factory. For part winding start Y / YY, the bridges must be removed and the motor feed line connected according to the circuit diagram: 400 V Direktstart YY Teilwicklungsstart Y/YY Direct start YY...
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Page 16: Basic Circuit Diagramm For Part Winding Start With Standard Motor
5.4 Basic circuit diagram for part winding start with standard motor FC1.2 FC1.1 I> I> I> I> I> I> FC1.1 FC1.2 L3 N PE Y/YY B1 B2 INT69 Anschlußkasten Verdichter Compressor terminal box Fig. 11 High pressure safety monitor Safety chain (high/low pressure monitoring ) Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Oil temperature sensor... - Page 17 FC1.1/1.2 Motor protection switch Control power circuit fuse INT69 G Electronic trigger unit INT69 G Delay relay for contactor switchover Main switch PW INT69 HG44/66 Mains contactor (part winding 1) Mains contactor (part winding 2) BOCK COMPRESSORS Control voltage switch...
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Page 18: Special Motor: Design For Direct Or Star-Delta Start
5 | Electrical connection 5.5 Special motor: design for direct or star-delta start A mechanical unloaded start with bypass solenoid valve is required for the star-delta start. Designation on the name plate ∆ / Y... - Page 19 ∆ / Y ∆ / Y ∆ / Y 5 | Electrical connection Stern-Dreieck-Anlauf ist nur im Spannungsbereich ∆ (230 V) möglich. Beispiel: Stern-Dreieck-Anlauf ist nur im Spannungsbereich ∆ (230 V) möglich. Beispiel: Stern-Dreieck-Anlauf ist nur im Spannungsbereich ∆ (230 V) möglich. Beispiel: Star-delta start-up is only possible for 230 V power supply.
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Page 20: Basic Circuit Diagramm For Star-Delta Start With Special Motor
5.6 Basic circuit diagram for star-delta start with special motor FC1.1 I> I> I> FC1.1 FC1.2 FC1.2 I> I> I> L3 N PE ˜ B1 B2 INT69G Compressor terminal box Anschlußkasten Verdichter Fig. 12 High pressure safety monitor Safety chain (high/low pressure monitoring ) Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Oil temperature sensor... - Page 21 Θ DELTA- P II Θ FC1.1/1.2 Motor protection switch Control power circuit fuse INT69 G Electronic trigger unit INT69 G Delay relay for contactor switchover Main switch Mains contactor D/S INT69 HG44/66 neu Δ-contactor BOCK COMPRESSORS Y-contactor Control voltage switch...
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Page 22: Electronic Trigger Unit Int69 G
5 | Electrical connection 5.7 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. -
Page 23: Function Test Of The Trigger Unit Int69 G
5 | Electrical connection 5.9 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. Relay position INT69 G Gage state Relay position... -
Page 24: Commissioning
6 | Commissioning 6.1 Preparations for start-up 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. -
Page 25: Refrigerant Charge
6 | Commissioning 6.5 Refrigerant charge Wear personal protective clothing such as goggles and protective gloves! 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. -
Page 26: Maintenance
Annual checks: Oil level, leak tightness, running noises, pressures, temperatures, function of auxiliary devices such as oil sump heater, pressure switch. 7.3 Spare parts recommendation/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! -
Page 27: Lubricants / Oils
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. -
Page 28: Technical Data
8 | Technical data Oil charge (sight glass center) Oil charge (ex works) Suction line Discharge line Weight Starting current (rotor locked) Max. power consumption Max. operating current 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW Voltage PW = Part Winding Winding ratio : 50 % / 50 %... - Page 29 8 | Technical data Oil charge (sight glass center) Oil charge (ex works) Suction line Discharge line Weight Starting current (rotor locked) Max. power consumption Max. operating current 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW Voltage PW = Part Winding Winding ratio : 50 % / 50 %...
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Page 30: Dimensions And Connections
Freigabe / Approved 18.05.16 A. Layh A. Layh Maß Dimension Passung / Clearance BOCK GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de 0l | Betrifft Blatt 3 11375 19.03.21 S. Büttner A. Layh üft / Appr. Allgemeintoleranzen / General tolerances... - Page 31 A. Layh A. Layh Maß Dimension Passung / Clearance BOCK GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de Änd.-Nr. / Mod-No. Datum / Date Bearb. / Edited Geprüft / Appr. The supplier has to ensure the delivery of parts...
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Page 32: Declaration Of Incorporation
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... -
Page 33: Ul-Certificate Of Compliance
11 | UL-Certificate of Compliance Dear customer, the Certificate of Compliance can be downloaded by the following QR-Code: https://vap.bock.de/stationaryapplication/Data/ DocumentationFiles/UL-Certificateofconformity.pdf... -
Page 34: Service
Dear customer, if you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The Bock service team can be contacted by phone, +49 (0)7022 9454-0 or via service@bock.de Yours faithfully Bock GmbH... - Page 36 BOCK ® Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Phone +49 7022 9454-0 +49 7022 9454-137 www.bock.de © Bock GmbH. All rights reserved. Subject to modifications.
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