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BOCK HGX 5 6e CO
Assembly instructions
96747-02.2025-Gb
Translation of the original instructions
HGX56e/480-4 ML CO
HGX56e/540-4 ML CO
HGX56e/610-4 ML CO
HGX56e/680-4 ML CO
BOCK
®
LT
HGX56e/480-4 S CO
2
LT
HGX56e/540-4 S CO
2
LT
HGX56e/610-4 S CO
2
LT
HGX56e/680-4 S CO
2
LT
2
LT
2
LT
2
LT
2
LT
2
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Table of Contents
Related Manuals for BOCK HGX56e CO2 LT Series
Summary of Contents for BOCK HGX56e CO2 LT Series
- Page 1 BOCK HGX 5 6e CO Assembly instructions 96747-02.2025-Gb Translation of the original instructions HGX56e/480-4 ML CO HGX56e/480-4 S CO HGX56e/540-4 ML CO HGX56e/540-4 S CO HGX56e/610-4 ML CO HGX56e/610-4 S CO HGX56e/680-4 ML CO HGX56e/680-4 S CO 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 Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application Compressor assembly 4.1 Storage and transportation 4.2 Setting up 4.3 Connecting the pipelines - solder system 4.4 Pipes 4.5 Flange shut-off valves (HP/LP) 4.6 Laying suction and pressure lines 4.7 Operating the shut-off valves 4.8 Operating mode of the lockable service connections 4.9 Oil return...
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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 imme- diately cause fairly severe or minor injury. -
Page 5: Safety Instructions
These assembly instructions describe the standard version of the compressors named in the ti- tle manufactured by Bock. Bock refrigerating compressors are intended for installing in a machine (within the EU according to the EU Directives 2006/42/EC Machinery Directive and 2014/68/EU Pressure Equipment Directive). -
Page 6: Product Description
2 | Product description 2.1 Short description • Semi-hermetic six-cylinder reciprocating compressor with suction gas cooled driving motor. • T he 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 on a relatively low temperature level specially during high load. •... -
Page 7: Type Key
2 | Product description 2.2 Name plate (example) BOCK Bock GmbH, Benzstraße 7 72636 Frickenhausen, Germany HGX56e/680-4 S CO 59,1 BC12345-001 188,0 A 70,9 592 A 834 A BOCK lub E85 100/100 bar Fig. 3 Type designation Voltage, circuit, frequency 50 Hz... -
Page 8: Areas Of Application
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). -
Page 9: Compressor Assembly
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. Immediately after refrigeration technological connection of the compressor close the shut-off devices in suction-, dis- charge-, oil return line etc. -
Page 10: Connecting The Pipelines - Solder System
4 | Compressor assembly 4.3 Connecting the pipelines - solder system 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). Material soldering / welding connection: S235 (JRG2C) The pipe connections have graduated inside diameters so that pipes with standard millimetre and inch dimensions can be used. -
Page 11: Flange Shut-Off Valves (Hp/Lp)
4 | Compressor assembly 4.5 Flange shut-off valves (HP/LP) CAUTION Risk of injury. The compressor must be depressurized through connections A and B before commencing any work and prior to connecting to the refrigerant system. Fig. 6 Fig. 7... -
Page 12: Laying Suction And Pressure Lines
4 | Compressor assembly 4.6 Laying suction and pressure lines ATTENTION Property damage possible. Improperly installed pipes can cause cracks and tears which can result in a loss of refrigerant. INFO Proper layout of the suction and pressure lines directly after the compressor is integral to the smooth running and vibration behaviour of the system. -
Page 13: Operating Mode Of The Lockable Service Connections
After activating the spindle, generally fit the spindle protection cap again and tighten with 40 - 50 Nm. This serves as a second sealing feature during operation. 4.9 Oil return To ensure the oil return function will work reliably no matter what kind of system configuration you are using, Bock recommends incorporating oil separators or oil level monitoring equipment. The "O" connection is already available from the factory for the purpose of installing the additional oil level monitoring component. Oil should be returned from the oil separator to the compressor via the "D1" connection provided for this purpose on the compressor. -
Page 14: Electrical Connection
5 | 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. -
Page 15: Standard Motor, Designed For Direct Or Part Winding Start
5 | Electrical connection 5.2 Standard motor, designed for direct or part winding start Designation on the name plate Y/YY Compressors marked in this way are suitable for direct or part winding start. The motor winding is divided into two parts: part winding 1 = 50 % and part winding 2 = 50 %. This winding division reduces the start-up current during a part winding start to approx. -
Page 16: Basic Circuit Diagram For Part Winding Start
5.3 Basic circuit diagram for part winding start FC1.2 FC1.1 I> I> I> I> I> I> FC1.1 FC1.2 L3 N PE Y/YY Compressor Anschlußkasten Verdichter terminal box B1 B2 INT69 Θ INT69 42 41 40 14 13 14 13 12 11 Θ... - Page 17 Control power circuit fuse PW INT69 HG44/68 INT69 G Electronic trigger unit INT69 G Delay relay for contactor switch over BOCK COMPRESSORS Oil level Oil level regulation COM 20 P Optional Pressure transducer (optional) Main switch Mains contactor (part winding 1)
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Page 18: Special Motor: Design For Direct Or Star-Delta Start
5 | Electrical connection 5.4 Special motor: design for direct or star-delta start Designation on the name plate ∆ / Y... - Page 19 5 | Electrical connection Star-delta start-up is only possible for 230 V power supply. Example: 230 V Δ Direct start Star-delta start 400 V Y Direct start only...
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Page 20: Basic Circuit Diagram For Star-Delta Start With Special Motor
5.5 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 ˜ Compressor Anschlußkasten Verdichter terminal box B1 B2 Θ INT69 INT69 42 41 40 14 13 14 13 12 11 Θ... - Page 21 FC1.1/1.2 Motor protection switch Control power circuit fuse INT69 G Electronic trigger unit INT69 G D/S HG44/66 neu Delay relay for contactor switch over BOCK COMPRESSORS Oil level Oil level regulation COM 20 P Optional Pressure transducer (optional) Main switch Mains contactor Δ-contactor...
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Page 22: Electronic Trigger Unit Int69 Ggb
5 | Electrical connection 5.6 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: Oil Sump Heater
5 | Electrical connection Relay position INT69 G Trigger unit state Relay position Deactivated state 11-12 INT69 G switch-on 11-14 B2 12 14 11 Remove PTC connector 11-12 Fig. 16 Insert PTC connector 11-12 Reset after mains on 11-14 5.9 Oil sump heater In order to avoid damage to the compressor, the compressor is equipped with an oil sump heater as a standard feature. -
Page 24: Commissioning
6 | Commissioning 6.1 Preparations for start-up INFO In order to protect the compressor against inadmissible operating conditions, high-pressure and low-pressure pressostats controls 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: Evacuation
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;... -
Page 26: Start-Up
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 1 minute at a minimum frequency of 50 Hz. Afterwards the compressor speed may be reduced. The machine should reach a state of equilibrium. -
Page 27: Decompression Valves
6 | Commissioning 6.8 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 CO 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 con- ditions can occur, which may result in a permanent leak. -
Page 28: Avoiding Slugging
6 | Commissioning 6.9 Avoiding slugging ATTENTION Slugging can result in damage to the compressor and cause refrigerant to leak. To prevent slugging: The complete refrigeration plant must be properly designed. All components must be compatibly rated with each other with regard to output (particularly the evaporator and expansion valves). -
Page 29: Work To Be Carried Out
7.4 Lubricants For operation with CO the following oil types are necessary: compressor version ML and S: BOCK lub E85 7.5 Decommissioning Close the shut-off valves on the compressor. CO does not need to be recycled and can therefore be blown off into the environment. -
Page 30: Technical Data
8 | Technical data Oil charge (sight glass centre) Oil charge (ex works) Suction line Discharge line Weight Adjustable 20 - 70 frequency range 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... - Page 31 8 | Technical data...
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Page 32: Dimensions And Connections
HGX56/540-4 ML(S)[SH] CO2 T 16459(16463)[16467] UL-HGX56/540 ML(S)[SH] 64([89]) CO2 T 16637(16641)[16645] HGX56e/540-4 ML(S) CO2 LT 16559(16563) UL-HGX56e/540 ML(S) 30(39) CO2 LT 16649(16653 Massenschwerpunkt 38,81 BOCK ® Centre of gravity HGX56/610-4 ML(S)[SH] CO2 T 16460(16464)[16468] UL-HGX56/610 ML(S)[SH] 74([102]) CO2 T 16638(16642)[16646] HGX56e/610-4 ML(S) CO2 LT 16560(16564) UL-HGX56e/610 ML(S) 34(45) CO2 LT 16650(16654... - Page 33 9 | Dimensions and connections Suction line see technical data, chapter 8 Discharge line Connection suction side, not lockable 16 “ UNF Connection suction side, lockable 16 “ UNF Connection suction side, not lockable 8 “ NPTF Connection discharge side, not lockable 16 “...
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Page 34: Declaration Of Installation
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 35 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 36: Service
11| Service Dear customer, Bock compressors are top-quality, reliable and service-friendly quality products. 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 38 BOCK ® Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Phone +49 7022 9454-0 +49 7022 9454-137 bock.danfoss.com © Bock GmbH. All rights reserved. Subject to modifications.
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