Danfoss BOCK HGX22e/125-4 A Bedienungsanleitung

AQ452755960718en-000201

BOCK®HGX

(P)(e) A

Operating guide

HGX22e/125-4 A HGX22e/125-4 S A

HGX22e/160-4 A HGX22e/160-4 S A

HGX22e/190-4 A HGX22e/190-4 S A

HGX22P/125-4 A HGX22P/125-4 S A

HGX22P/160-4 A HGX22P/160-4 S A

HGX22P/190-4 A HGX22P/190-4 S A

Translation of the original instructions

2 | AQ452755960718en-000201 © Danfoss | Climate Solutions | 2023.06

About these instructions

Read these instructions before assembly and before using the compressor. This will avoid misunder-

standings 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 compres-

sor is installed.

Contents Page

1 Safety 4

 1.1 Identicationofsafetyinstructions

 1.2 Qualicationsrequiredofpersonnel

1.3 General safety instructions

1.4 Intended use

2 Product description 6

2.1 Short description

2.2 Name plate

2.3 Type key

3 Areas of application 8

3.1 Refrigerants

3.2 Oil charge

3.3 Limits of application

4Compressor assembly 10

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lterandlterdrier

5 Electrical connection 14

5.1 Information for contactor and motor contactor selection

5.2 Connection of the driving 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 INT69 G

5.7 Function test of the trigger unit INT69 G

6 Commissioning 20

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 slugging

7 Maintenance 22

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 24

9 Dimensions and connections 25

10 Declaration of incorporation 26

4 | AQ452755960718en-000201 © Danfoss | Climate Solutions | 2023.06

1|Safety

1.2 Qualicationsrequiredofpersonnel

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.

WARNING Inadequatelyqualiedpersonnelposes theriskof accidents, the

consequencebeingseriousorfatalinjury.Workon compressors

isthereforereservedforpersonnelwhichisqualied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.

1.1 Identicationofsafetyinstructions:

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

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 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speciedintheseinstructionsmaybeused.

Any other use of the compressor is prohibited!

6 | AQ452755960718en-000201 © Danfoss | Climate Solutions | 2023.06

2|Product description

• Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication.

• Lightweight aluminum design

• Suction gas cooled drive motor

Name plate

Fig. 1

2.1 Short description

Fig. 2

Oil sight glass

Valve plate

Cylinder cover

Discharge shut-

off valve

Oil pump

Terminal box

Suction

shut-off valve

Drive section

Motor section

Dimension and connection values can be found in Chapter 9

Transport eyelet

1 Typedesignation 6 Voltage,circuit,frequency

2 Machine number 7 Nominal rotation speed

3 maximum operating current 8 Displacement

4 Startingcurrent(rotorblocked) 9 Voltage,circuit,frequency

5 ND(LP):max.admissibleoperating 10 Nominalrotationspeed

pressure (g)Low pressure side 11 Displacement

 HD(HP):

max. admissible operating

 12 Oiltypelledatthefactory

pressur

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

Observe the limits of application Electrical accessories can change

diagrams! the IP protection class!

50 Hz

}

60 Hz

}

2|Product description

HG 22 e 190-4 S AX

2.3 Type key (example)

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

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)

2.2 Name plate(example)

Fig. 3

Typschild (Beispiel)

513

1 Typbezeichnung

2 Maschinennummer

3 maximaler Betriebsstrom

4 Anlaufstrom (Rotor blockiert)

5 ND (LP): max. zulässiger Stillstandsdruck

Saugseite

HD (HP): max. zulässiger Betriebsdruck

Hochdruckseite

Einsatzgrenzendiagramme beachten!

50 Hz

60 Hz

6 Spannung, Schaltung, Frequenz

7 Nenndrehzahl

8 Hubvolumen

9 Spannung, Schaltung, Frequenz

10 Nenndrehzahl

11 Hubvolumen

12 Werkseitig eingefüllte Ölsorte

13 Schutzart Klemmenkasten

HGX22e/190-4 S A

SE 55

AS35830A001

16,2/9,4A

87A 50A

Bock GmbH, Benzstr. 7

72636 Frickenhausen, Germany

BOCK

BOCK lub E55

8 | AQ452755960718en-000201 © Danfoss | Climate Solutions | 2023.06

3|Areas of application

 Thecompressorsarelledatthefactorywiththefollowingoiltype:

- 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. HGX22e/190-4A).

3.1 Refrigerants

• HFKW/HFC:  R134a, R404A/R507, R407C, R513A

3.2 Oil charge

INFO! For refilling, we recommend the above oil types.

Alternatives: see chapter 7.4

The oil level must be in the

visible part of the sight

glass; damage to the com-

pressor is possible if over-

filled or underfilled!

ATTENTION!max.

min.

0,8 Ltr.

oil level

Fig. 4

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 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 limits.

 Foroperationwithfrequencyconverter:

- The potential control range of the compressor is 30-70 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.

3.3 Limits of application

ATTENTION! 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

1) LP = Low pressure

HP = High pressure

10 | AQ452755960718en-000201 © Danfoss | Climate Solutions | 2023.06

4|Compressor assembly

 Setuponanevensurfaceorframewithsufcientload-

bearing capacity.

 Provideadequateclearanceformaintenancework.

 Ensureadequatecompressorventilation.

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

environment.

Fig. 7

Fig. 8

Fig. 9

Tol.-Ang. DIN ISO 2768-mK

Ra Rz

Maß

Passung

Freigabe

Alternativbezug:

Baumustergeprüft

Teil inaktiv

Lieferantenzeichnung

K.-Auftrag:

PL:

Zeichnung ungültig

Entwicklungsstand

Teil keine Serie

120

400

±0.5

über 0.5

bis 6

Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de

Unbemaßte Radien:

Diese Zeichnung ist unser Eigentum!

Sie darf ohne unsere Genehmigung weder nach-

gebildet, vervielfältigt, oder Dritten Personen zu-

gänglich gemacht werden. Der Nachbau nach

dieser Zeichnung, oder an Hand der nach dieser

Zeichnung hergestellten Gegenstände durch den

Abnehmer oder Dritte ist nicht gestattet.

Wir behalten uns alle Rechte, gemäß DIN ISO 16016

an dieser Zeichnung vor.

Bearb.

Datum

Änderungs-Nr.

Werkstoff:

Ausgangsteil, bzw. Rohteil:

Gepr.

Name

Datum

19.04.

Werkstückkanten

DIN ISO 13715

Ersatz für:

Ersetzt durch:

Erstellt

2010

Geprüft

Kurz

Zone

1/x

Oberflächenbehandlung / Härte:

Blatt:

Änderungsbeschreibung

400

Benennung:

±0.8

1000

±0.3

120

±0.2

Zeichn.-Nr. Teile-Nr.

Oberflächenangaben ISO 1302

x.xxxx-xxxxx.x

Zust.

Gußtoleranzen:

Gewicht: (kg)

±0.1

Maßstab:

1:1

Wasserwaage

für Indesign

Der Lieferant muß sicherstellen, dass die Ware in

einwandfreiem Zustand angeliefert wird (Korrosions-

schutz, Verpackung für sicheren Transport).

Rz 25

Rz 160

0,05

Rz 1,6

0,3

0,7

1,6

Rz 16

6,3

Rz 63

Rz 6,3

Rz 12,5

F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage

4.2 Setting up

4.1 Storage and transport

Use transport eyelet.

Do not lift manually!

Use lifting gear!

 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.

Fig. 6

Fig. 5

ATTENTION! Attachments (e.g. pipe holders, additional units, fastening parts,

etc.) directly to the compressor are not permissible!

INFO Newcompressorsarefactory-lled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.

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