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BOCK HA
Assembly instructions
96417-05.2025-Gb
Translation of the original instructions
HA22e/125-4
HA22e/160-4
HA22e/190-4
HA34e/215-4
HA34e/255-4
HA34e/315-4
HA34e/380-4
BOCK
®
22
e/HA 34 e (LG)
HAX22e/125-4
HAX22e/160-4
HAX22e/190-4
HAX34e/215-4
HAX34e/255-4
HAX34e/315-4
HAX34e/380-4
HAX22e/125 LT 2 LG
HAX22e/160 LT 2 LG
HAX22e/190 LT 3 LG
HAX34e/215 LT 3 LG
HAX34e/255 LT 4 LG
HAX34e/315 LT 5 LG
HAX34e/380 LT 6 LG
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Table of Contents
Summary of Contents for BOCK HA22e
- Page 1 34 e (LG) BOCK HA Assembly instructions 96417-05.2025-Gb Translation of the original instructions HA22e/125-4 HAX22e/125-4 HAX22e/125 LT 2 LG HA22e/160-4 HAX22e/160-4 HAX22e/160 LT 2 LG HA22e/190-4 HAX22e/190-4 HAX22e/190 LT 3 LG HA34e/215-4 HAX34e/215-4 HAX34e/215 LT 3 LG HA34e/255-4 HAX34e/255-4 HAX34e/255 LT 4 LG HA34e/315-4 HAX34e/315-4 HAX34e/315 LT 5 LG HA34e/380-4 HAX34e/380-4 HAX34e/380 LT 6 LG BOCK ® colour the world...
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Page 2: Table Of Contents
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. Manufacturer Bock GmbH 72636 Frickenhausen Contact Bock GmbH Benzstraße 7... - Page 3 Contents Page Additional information on LG compressors 5.1 Refrigerants 5.2 Oil charge 5.3 Limits of application Compressor assembly 6.1 Storage and transport 6.2 Setting up 6.3 Pipe connections 6.4 Pipes 6.5 Laying suction and pressure lines 6.6 Operating the shut-off valves 6.7 Operating mode of the lockable service connections 6.8 Suction pipe filter and filter drier Electrical connection 7.1 Information for contactor and motor contactor selection...
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Page 4: Safety
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. -
Page 5: General Safety Instructions
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 Pres- sure Equipment Directive). -
Page 6: Safety Instructions For Use Of Flammable Refrigerants
2 | Safety instructions for use of flammable refrigerants 2.1 Safety instructions DANGER • Explosion and fire risk! Hydrocarbons and synthetic HFO refrigerants are colourless, combustible gases which occur naturally and which are explosive in a certain blend! • Hydrocarbons are classified into the safety group A3 (highly- inflammable refrigerant) according to EN 378. -
Page 7: Product Description
3| Product description 3.1 Short description • HA22e: Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication. • HA34e: Semi-hermetic four-cylinder reciprocating compressor with oil pump lubrication. • Air cooled drive motor. Transport eyelet Suction shut-off valve Valve plate Name plate Oil pump Oil sight glass Fig. -
Page 8: Type Key
3| Product description Typschild (Beispiel) 3.2 Name plate (example) BOCK Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany HAX34e/315-4 AS35830A001 17,1/9,9 A 111A BOCK lub E55 Fig. 3 Typbezeichnung Spannung, Schaltung, Frequenz 50 Hz Maschinennummer Type designation Voltage, circuit, frequency Nenndrehzahl 50 Hz maximaler Betriebsstrom... - Page 9 3| Product description 3.4 Typ key LG compressor (example) LT 9 3 e 380 Low-GWP Engine performance in hp Engine for deep-freezing Swept volume e-series Numbers of cylinders Size Oil filling ² Series ¹ ¹ HA - Hermetic Air-cooled (air-cooled) for deep freezing ² X - Ester oil charge...
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Page 10: Areas Of Application
The compressors are filled at the factory with the following oil type: - for R404A/R507 BOCK lub E55 - for R22 BOCK lub A 46 Compressors with ester oil charge ( BOCK lub E55 ) are marked with an X in the type designation (e.g. HAX34e/315-4). INFO For refilling, we recommend the above oil types. Alternatives: see chapter 9.4 ATTENTION The oil level must be in the max. -
Page 11: Additional Information On Lg Compressors
The compressors are factory-charged with the following oil type: • LG compressors: BOCK lub E55 5.3 Operating limits 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 and the follo- wing notes: - Min. pressure gas temperature ≥ 50 °C (min. 20K over condens- ing temperature). Suction gas superheating on compressor ent- rance should be min. 7 - 10 K, must be increased if necessary (only at LG compressors) - Min. oil temperature ≥... -
Page 12: Compressor Assembly
6| 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. 6.1 Storage and transport 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. -
Page 13: Pipe Connections
6| Compressor assembly 6.3 Pipe connections ATTENTION 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). 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. -
Page 14: Operating The Shut-Off Valves
6| Compressor assembly 6.6 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. 8 Fig. -
Page 15: Electrical Connection
7| Electrical connection 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. - Page 16 7.3 Circuit diagramm for direct start 230 V ∆ / 400 V Y FC1.1 I> I> I> FC1.1 L3 N PE -EC1 Θ B1 B2 INT69G Compressor terminal box Anschlußkasten Verdichter Fig. 11 Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Load circuit safety switches Control power circuit fuse High pressure safety monitor Safety chain (high/low pressure monitoring ) Main switch...
- Page 17 L1.1 L2.1 L3.1 L1.2 P> ˜ Θ Θ DANGER Explosion risk! Electronic trigger INT69 G at LG compressors has to be installed outside any danger area! See also chapter 7.8. Release switch (thermostat) Control voltage switch Compressor motor Fan motor Compressor contactor INT69 G Electronic trigger unit INT69 G Oil sump heater...
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Page 18: Electronic Trigger Unit Int69 G
7| Electrical connection 7.4 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. -
Page 19: Start Unloader
Reset after mains on 11-14 7.7 Start unloader To avoid current peaks during the starting phase we recommend using the Bock-ESS soft starting device (Electronic Soft Start). Refer to "Accessories" for further information. 7.8 Electronic trigger unit INT69 G at LG compressors The supplied INT69 G must be connected according to the wiring diagram shown here in a separate control cabinet, which must be installed outside each danger zone. -
Page 20: Oil Sump Heater On Lg Compressors
ATTENTION The oil sump heater must generally be connected and operated! • In a TT- or TN system, a residual current protection device (RCD) must be used. • In an IT system, an insulation monitoring device must be used. National standards and regulations must be observed. Compressor Electrical data HA22e... LG 230 V - 1 - 50/60 Hz, 160 W HA34e... LG 7.10 Capacity regulator (Accessories) ATTENTION A fuse (max. 3xlB in accordance with IEC 60127-2-1) corresponding to the rated current must be placed in front of every magnetic coil of the capacity regulator as short-circuit protection. The ra- ted voltage of the fuse must be equal to or greater than the rated voltage of the magnetic coil. The ability of the fuses to switch off... -
Page 21: Selection And Operation Of Compressors With Frequency Converters
7| Electrical connection 7.12 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 140% 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. -
Page 22: Preparations For Start-Up Ru
8| Commissioning 8.1 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! 8.2 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. -
Page 23: Refrigerant Charge
8| Commissioning 8.5 Refrigerant charge CAUTION 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. 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. -
Page 24: Connection Of Oil Level Regulator
8| Commissioning There should be no movement of coolant whatsoever while the compressor is at a standstill. The use of a check valve is strongly recommended. Otherwise, there is a risk of reverse condensation which may damage the compressor. 8.8 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. 9| Maintenance 9.1 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. -
Page 25: Spare Parts Recommendation/Accessories
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 26: Technical Data
30 - 70 quency range Starting current (rotor locked) Max. power consumption Max. operating current 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz Voltage 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz Displacement (1450 / 1740 rpm) No. of cylinders Type* HA22e/... - Page 27 10| Technical data Sound pressure level Oil charge (sight glass centre) Oil charge (ex works) Suction line Discharge line Weight permissible fre- 25 - 70 quency range Starting current (rotor locked) Max. power consumption Max. operating current 220-240 V ∆ / 380-420 V Y - 3 - 50 Hz Voltage 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz Displacement (1450 / 1740 rpm) No. of cylinders...
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Page 28: Dimensions And Connections
11| Dimensions and connections Anschlüsse / Connections HA22e (Dimensions and connections for LG compressors are identical to the standard compressors) Saugabsperrventil, R Suction line valve, tu Druckabsperrventil, Discharge line valve Anschluss Saugseite Connection suction s Anschluss Saugseite Connection suction s... - Page 29 CAD Gast contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event BOCK GmbH - B Zust. / Rev. Maß / Dimension Passung / Clearance Änd.-Nr. / Mod-No.
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Page 30: Declaration Of Incorporation
12| 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 31 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...
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Page 32: Service
13| 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 bock.info@danfoss.com Yours faithfully Bock GmbH... - Page 34 BOCK ® Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Tel +49 7022 9454-0 Fax +49 7022 9454-137 bock.danfoss.com © Bock GmbH. All rights reserved. Subject to modifications. Printed in Germany.
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