Danfoss HG12P Semi Hermetic Atex User Guide

User Guide for Danfoss models including: HG X 12P-60-4 S, HG X 12P-75-4 S, HG X 12P-90-4 S, HG X 12P-110-4 S, HGX12P-75 ML 1 LG, HGX12P-90 ML 2 LG, HGX12P-110 ML 2 LG, HG12P-60-4 S HC, HG12P-75-4 S HC, HG12P-90-4 S HC, HG12P-110-4 S HC, HGX12P-60 S 0.7 LG, HGX12P-75 S 1 LG, HGX12P-90 S 2 LG, HGX12P-110 S 3 LG, HG12P Semi Hermetic Atex, HG12P, Semi Hermetic Atex, Hermetic Atex, Atex

Operating guide BOCK HG12P (HC/LG)

BOCK HG12P (HC/LG)

File Info : application/pdf, 29 Pages, 2.66MB

AQ451444787718en-000401

BOCK® HG12P (HC/LG)
Operating guide

HG(X)12P/60-4 S HG(X)12P/75-4 (S) HG(X)12P/90-4 (S) HG(X)12P/110-4 (S)
HGX12P/75 ML 1 LG HGX12P/90 ML 2 LG HGX12P/110 ML 2 LG

HG12P/60-4 S HC HG12P/75-4 (S) HC HG12P/90-4 (S) HC HG12P/110-4 (S) HC
HGX12P/60 S 0,7 LG HGX12P/75 S 1 LG HGX12P/90 S 2 LG HGX12P/110 S 3 LG

Translation of the original instructions

AQ451444787718en-000401

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.

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 Safety instructions for use of flammable refrigerants D
2.1 Safety instructions

2.2 Qualifications required of personnel

3 Product description

3.1 Short description

3.2 Name plate

3.3 Type key

3.4 Type key HC compressors

3.5 Type key LG compressors

4 Areas of application

4.1 Refrigerants

4.2 Oil charge 4.3 Limits of application

5 Areas of application on HC and LG compressors

5.1 Refrigerants 5.2 Oil charge

5.3 Limits of application

6 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 Suction pipe filter and filter drier

6.7 Operating the shut-off valves

6.8 Operating mode of the lockable service connections

Page 4
6 7
10 11 12

2 | AQ451444787718en-000401

Contents
7 Electrical connection 7.1 Information for contactor and motor contactor selection 7.2 Connection of the driving motor 7.3 Circuit diagram for direct start 230 V / 400 V Y 7.4 Electronic trigger unit INT69 G 7.5 Connection of the electronic trigger unit INT69 G 7.6 Functional test of the electronic trigger unit INT69 G 7.7 Electronic trigger unit INT69 G on HC and LG compressors 7.8 Oil sump heater on HC and LG compressors 7.9 Sele ction and operation of compressors with frequency converters 8 Commissioning 8.1 Preparations for start-up 8.2 Pressure strength test 8.3 Leak test 8.4 Evacuation 8.5 Refrigerant charge 8.6 Start-up 8.7 Avoiding slugging 8.8 Connection of oil level regulator
9 Maintenance 9.1 Preparation 9.2 Work to be carried out 9.3 Condensate drainage 9.4 Spare parts recommendation/accessories 9.5 Lubricants / oil 9.6 Decommissioning 9.7 Additional information when using flammable refrigerants 10 Technical data 11 Dimensions and connections 12 Declaration of incorporation

Page 15

Ru 25 26 27

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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.

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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- Ru 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 specified in these instructions may be used. Any other use of the compressor is prohibited!

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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 (highlyinflammable refrigerant) according to EN 378.

· HFO refrigerants are classified into the safety group A2L (hardlyinflammable refrigerant) according to EN 378.
As they are heavier than air, the operating location must be above ground level to allow unrestricted discharge of the gas.

· By means of a risk and hazard analysis, appropriate technical

measures are to be identified in order to achieve sufficient risk

reduction. If necessary, a classification of the hazardous areas

according to EN60079-10-1 should be carried out. If the refrigerant concentration exceeds the value of 25% of the lower flamma-

bility limit (LEL), all equipment in the hazardous area which is not

permitted for operation in hazardous areas must be immediately

switched off without any voltage.

· Use only suitable equipment approved for flammable refrigerants.

· Observe the national regulations.

INFO

Semi-hermetic compressors are to be classified as "technically

tight" (see e.g. TRBS 2152 part 2 / TRGS 722).

2.2 Qualifications required of personnel

WARNING

Inadequately qualified personnel poses the risk of accidents, the consequence being serious or fatal injury. Work on the compressor may therefore only be carried out by persons who are trained in handling flammable refrigerants.

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3| Product description
3.1 Short description
· Semi-hermetic two-cylinder reciprocating compressor with oil pump lubrication. · Suction gas cooled drive motor.

Transport eyelet Valve plate Oil pump
Terminal box

Fig. 1

Name plate D

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 11
© Danfoss | Climate Solutions | 2024.09

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3| Product description
3.2 Name plate (example)

BOCK Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany

1 2
33 44
5
Fig. 3

HGX12P/110-4S AASS3355883300AA000101 10,6/6,1A
45A 26A

9,4

11,3

1100 1111

BOCK lub E55

1122

1133

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) 5 ND (LP): max. admissible operating

9 Voltage, circuit, frequency
} 10 Nominal rotation speed 60 Hz

pressure (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!

3.3 Type key (example)

Ru HG X 1 2 P / 110- 4 S

Motor variant 4) Number of poles Swept volume
³) Numbers of cylinders Size Oil charge ²) Series ¹)
¹) HG - Hermetic Gas-cooled (suction gas-cooled) for the normal- / air conditioning applications ²) X - Ester oil charge (HFC refrigerant, e.g. R134a, R404A/R507, R407C) ³) Additional declaration for Pluscom compressors 4) S - More powerful motor, e.g. for air-conditioning applications

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3| Product description

3.4 Type key HC compressor (example)
HG 1 2 P / 110- 4 S HC

Hydrocarbons Motor variant ³)

Number of poles

Swept volume ²)

Numbers of cylinders

Size Series ¹)

¹) HG - Hermetic Gas-Cooled (suction gas-cooled) ²) Additional declaration for Pluscom compressors ³) S - More powerful motor
D

3.5 Typ key LG compressor (example)

HG X 1 2 P / 110 S 3 LG

HFO refrigerant

Engine performance in hp

Motor variant 4)

Swept volume ³)

Numbers of cylinders

Size Oil charge ²) Series ¹) ¹) HG - Hermetic Gas-Cooled (suction gas-cooled) ²) X - Ester oil charge ³) Additional declaration for Pluscom compressors 4) S - More powerful motor, e.g. for air-conditioning applications

ML - Motor for normal cooling and deep freezing

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4| Areas of application

4.1 Refrigerants
· HFKW / HFC: · (H)FCKW / (H)CFC:

R134a, R404A/R507, R407C R22

4.2 Oil charge

The compressors are filled at the factory with the following oil type:

- for R404A/R507

BOCK lub E55

- for R22

BOCK lub A46

Compressors with ester oil charge (BOCK lub E55) are marked with an X in the type designation (e.g. HGX12P/110-4).

INFO

For refilling, we recommend the above oil types.

Alternatives: see chapter 9.5.

ATTENTION

The oil level must be in the visible part of the sight glass;

max.

damage to the compressor is oil level

~~ 0,5 Ltr.

possible if overfilled or underfilled!

min.

Fig. 4

4.3 Limits of application F

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 threshold.

For operation with frequency converter (see also chapter 7.9): - 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.

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

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5 | Areas of application at HC and LG compressors

5.1 Refrigerants
· Hydrocarbons: · HFO refrigerants:

R290, R1270 (Recommendation quality 2.5 (< 50 ppm H2O)) R1234ze, R1234yf, R455A, R454C

5.2 Oil charge

The compressors are factory-charged with the following oil type:

· HC compressors:

BOCK lub G68

· LG compressors:

BOCK lub E55

BOCK lub E85 (from tO > 15 °C, must be specified in the order)

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 following notes:

- Min. pressure gas temperature 50 °C (min. 20K over condens-

ing temperature). Suction gas superheating on compressor entrance should be min. 7 - 10 K, must be increased if necessary.

- Min. oil temperature 30 °C.

- Operation in the vacuum range is not permitted.

- When using a additional fan, the ambient temperature must not

exceed 50 °C.

During operation in the vacuum range, there is a danger of air entering on the suction side. This can cause chemical reactions, pressure rise in the condenser and an excessive pressure gas temperature as well as shifting of the refrigerant ignition limit into the critical range. Avoid absolutely any entry of air! Use a low pressure switch! Select a shut-off point min. 50 Pa higher than the prevailing surrounding pressure!

Maximum permissible operating pressure (LP/HP)1): 19/28 bar

1) LP = Low pressure HP = High pressure

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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 combustible environment.

6.2 Setting up

Use transport eyelet. Do not lift manually! Use lifting gear!

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.

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

combustible environment.

Setup on an even surface or frame with sufficient loadbearing capacity. Single compressor preferably on vibration damper. Duplex and parallel circuits always rigid.
Sun protection: If the compressor is set up outdoors, it has to be protected from direct sunlight.

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).

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6| Compressor assembly

Fig. 5: graduated internal diameter

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.

6.4 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.

6.5 Laying suction and pressure lines

ATTENTION 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

Fig. 6

6.6 Suction pipe filter and filter drier
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). Moisture in the refrigeration circuit can lead to crystal and hydrate formation. For this reason, we recommend using a filter drier and a sight glass with a moisture indicator.

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6| Compressor assembly
6.7 Operating the shut-off valves Before opening or closing the shut-off valve, release the valve spindle seal by approx. 1/4 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. 7

Fig. 8

6.8 Operating mode of the lockable service connections

Service connec-

tion closed
GB

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.

Service connection opened

Pipe connection
Compressor Fig. 9

Spindle

Connection open

Pipe connection

Opening the service connection Spindle: Turn 1/2 - 1 turn to the right clockwise.
--> Service connection opened / shut-off valve opened.

Compressor Fig. 10

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.

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7| 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.

7.1 Information for contactor and motor contactor selection

All protection devices and switching or monitoring units must be fitted in accordance with the local

safety regulations and established specifications (e.g. VDE) as well as with the manufacturer's infor-

mation. Motor protection switches are required! Motor contactors, feed lines, fuses and motor

protection switches must be rated on the basis of the maximum working current (see name plate).

For motor protection use a current-dependent and time-delayed overload protection device for moni- GB toring all three phases. Set the overload protection device so that it must be actuated within 2 hours,

if there is 1.2 times the max. working current.

7.2 Connection of the driving motor

The compressor is designed with a motor for star-delta circuits.

Designation on the name plate

/ Y

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

230 V

400 V Y

Direct start

Star-delta start

Direct start only

L1 L2 L3

L1 L2 L3 INFO

L1 L2 L3

The connection examples shown refer to the standard version. In the case of special voltages, the instructions affixed to the terminal box apply.

AQ451444787718en-000401 | 15

7.3 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

M -EC1 3~

8 9

BT1

12 14 11 L N B1 B2

INT69G

CAonmspcrhelussßokratsetremninVael rbdoixchter
Fig. 11

BT1

Cold conductor (PTC sensor) motor winding

BT2

Thermal protection thermostat (PTC sensor)

FC1

Load circuit safety switches

FC2

Control power circuit fuse

BP1 High pressure safety monitor

BP2

Safety chain (high/low pressure monitoring)

BT3

Release switch (thermostat)

16 | AQ451444787718en-000401

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

QA2 N PE

EB1

BP1

BP2

BT3

BT2
BT2

DANGER

Explosion risk! Electronic trigger INT69 G at HC and LG compressors has to be installed outside any danger area! See also chapter 7.7.

QA1 SF1 EC1 QA2 INT69 G EB1

Main switch Control voltage switch Compressor motor Compressor contactor Electronic trigger unit INT69 G Oil sump heater

AQ451444787718en-000401 | 17

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.
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.

7.5 Connection of the trigger unit INT69 G

GB F 1 E I

INFO

Connect the trigger unit INT69 G in accordance with the circuit dia-

2 gram. Protect the t3rigger unit with a delay4ed-action fuse (FC2) of5

max. 4 A. In order to guarantee the protection function, install the

trigger unit as the first element in the control power circuit.

Ru 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. 12 Terminal box

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7| Electrical connection
7.6 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.

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 Fig. 13

7.7 Electronic trigger unit INT69 G at HC and LG compressors

The supplied INT69 G must be connected according to the wiring diagram shown here in a separate

1control cabinet, which2 must be installed out3side each danger zone4.

D 6

ATTENTI2ON Install heat pro3tection thermostats a4 nd cold conductor m5 otor

winding in series!

Schaltschrank

I SwSictchhalctsacbhinraetnk
Ru

INT69G

1 2 3 4 5 6 7 8 09 10 11 12 1 2 3 4 5 6 7 8 09 10 11 12

EB1

BT1 BT2

EB1

BT1 BT2

BT1 BT2 EB1
Fig. 14

Cold conductor (PTC sensor) motor winding
Heat protection thermostat (PTC sensor)
Oil sump heater

AQ451444787718en-000401 | 19

7 | Electrical connection
7.8 Oil sump heater at HC and LG compressors As the solubility of hydrocarbons and HFO refrigerants in oil can be very high, especially at high suction pressures, the compressor must be equipped with an oil sump heater. For this reason, a pump-down circuit is recommended during standstill to reduce the suction-side standstill pressures.
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.

7.9 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 tech-

nical 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. After each compressor start, run for at least 1 minute at a minimum frequency of 50 Hz.

5. 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 chapter 10.

Rotational speed range
Start-up time
Switch-off time

0 - f-min < 1 s

immediately

f-min - f-max ca. 4 s

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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.

8.3 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 Ru safety standard, while always observing the maximum permissible overpressure for the compressor.

8.4 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.
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. For HC and LG compressors suitable equipment approved for flammable refrigerants must be used.

AQ451444787718en-000401 | 21

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.

ATTENTION Avoid overfilling the system with refrigerant!

To avoid shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always only be filled into the refrigerating plant in liquid form.

Do not pour liquid coolant through the suction line valve on the compressor. It is not permissible to mix additives with the oil and refrigerant.

8.6 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 all functioning properly.

Switch on the compressor and let it run for at least 1 minute at a frequency of at least 50 Hz.

Only then may the speed of the compressor be reduced. Check the oil level by: The oil must be visible in the sightglass.

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!

8.7 Avoiding slugging
ATTENTION Slugging can damage 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 min. 7 - 10 K. (check the setting of the expansion valve). For HC and LG compressors see chapter 5.3. 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.

22 | AQ451444787718en-000401

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, especially for heat pump applications. Otherwise there is a risk of back condensation, which can result in compressor damage.

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.

Prevent air from infiltrating the system!

After maintenance has been performed:

Connect safety switch. Evacuate compressor.

Release switch lock.

9.2 Work to be carried out

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

9.3 Condensate drainage The terminal box has the option for Condensate drainage (see Fig. 15).

ATTENTION When the condensate drain is used, the protection rating of the terminal box is reduced from IP65 to IP32!

Condensate drainage Fig. 15
© Danfoss | Climate Solutions | 2024.09

AQ451444787718en-000401 | 23

9| Maintenance

9.4 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!
9.5 Lubricants / oil
The oil type filled as standard in the factory is marked on the name plate, and this should always be used, even in the case of maintenance units. Alternative oil types can vary significantly in quality due to additives or inferior raw materials by the manufacturer. Validation within the compressors entire operating limits can not be guaranteed, if such alternative oil types are used. 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.

PAG oils such as BOCKlub G68 are highly hygroscopic, which makes them tend to absorb moisture quickly and at a high rate. As a result, the contact of the oil with ambient air must be avoided.

Refrigerants

Bock standard oil types

HFC (e.g. R134a, R407C, R404A)

BOCK lub E55

GB F

HFO (e.g. R1234yf, R1234ze, R455A, R454C)

BOCK lub E55 BOCK lub E85 (from tO > 15 °C)

HCFC (e.g. R22)

BOCK lub A46

HC (e.g. R290)

BOCK lub G68

9.6 Decommissioning

Close the shut-off valves on the compressor. Drain the refrigerant (it must not be discharged into the environment) and dispose of it according to the regulations. When the compressor is depressurised, undo the fastening screws of the shut-off valves. Remove the compressor using an appropriate hoist.
Dispose of the oil inside in accordance with the applicable national regulations.

9.7 Additional information when using flammable refrigerants

WARNING

· During maintenance and repair, it must be noted that hydrocarbon and synthetic HFO refrigerants residues may dissolve in the oil. Therefore, electrical tests must not be conducted while oil remains in the compressor.

· If the compressor is to be removed from the system for maintenance or repair, the remaining refrigerant must be suctioned out and the compressor evacuated. The compressor must then be filled with nitrogen (max. 0.5 bar) and sealed gas-tight.

24 | AQ451444787718en-000401

10| Technical data

Sound pressure level

Oil charge
(sight glass centre)
Oil charge
(ex works)
Suction line SV

Weight

Discharge line DV

Permissible frequency range

Starting

current

(rotor locked)

Max. power

consumption

Max. operating
current

Voltage

Displacement
(1450 / 1740 rpm)
No. of cylinders

Type*

Electrical data 3

Connections 4

HG12P/60-4 S

50 / 60 Hz

m3/h

/ Y

L/M/H 5

Hz kg mm (inch) mm (inch) ltr ltr

dB(A)

5.4 / 6.4

6.8 / 3.9 2.2 40 / 23

58.5 / 58 / 57

30-70

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

HG12P/75-4

6.7 / 8.1

7.1 / 4.1 2.3 40 / 23

59 / 58.5 / 58

HG12P/75-4 S

6.7 / 8.1

8.0 / 4.6 2.6 43 / 25

59 / 58.5 / 58

HG12P/90-4 2 HG12P/90-4 S

8.0 / 9.6 8.0 / 9.6

8.5 / 4.9 2.8 43 / 25 8.8 / 5.1 2.9 45 / 26

49 12 (1/2) 49

16 (5/8) 0.8 0.6 59.5 / 59 / 58 59.5 / 59 / 58

HG12P/110-4

9.4 / 11.3

9.2 / 5.3 3.1 43 / 25

60 / 59 / 58

HG12P/110-4 S

9.4 / 11.3

10.6 / 6.1 3.6 45 / 26

60 / 59 / 58

* The technical data for the HC and LG compressors are identical to the standard compressors. Therefore, these designations are not included in the compressor type specification.

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 50 Hz operation. For 60 Hz 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

3 All specifications are based on the average of the voltage range
4 For solder connections 5 L = low temperature (-35 / 40 °C), M = normal cooling (-10 / 45 °C),
H = air conditioning (5 / 50 °C) sound pressure level measured in low reflection measuring area, measuring distance 1m. Compressor operation at 50 Hz (1450 rpm), refrigerant R404A. Values stated are average values, tolerance ± 2 dB(A).

AQ451444787718en-000401 | 25

11| D7 imensions 6and connec5tions

115 4,53

HG12P

(Dimensions and connections for HC and LG compressors are identical to the standard compressors)

Centre of gravity

B1 DV

+ 2

+0,08

223 0 8,78 0

76 2,97

66 2,58

135 5,31

+0,08 0

243 9,57 98 3,86

SV 1) A1

281

+2 0

11,04

B,L,I C
F

4x 10 0,39

162 6,38

A
H,D1 K,O

Anschlüsse / Connections
Saugabsperrventil, Rohr SV
Suction line valve, tube Druckabsperrventil, Rohr DV Discharge line valve, tube Anschluss Saugseite, nich A Connection suction side, Anschluss Saugseite, abs A1 Connection suction side, Anschluss Druckseite, nic B Connection discharge sid Anschluss Druckseite, ab B1 Connection discharge sid Anschluss Öldrucksicherh C Connection oil pressure s
Anschluss Ölrückführung D1
Connection oil return from Ölablass F Oil drain Stopfen Ölfüllung H Oil charge plug Anschluss Heißgastempe I Connection hot gas tempe Anschluss Ölsumpfheizun J Connection oil sump heat Schauglas K Sight glass Anschluss Wärmeschutzt L Connection thermal prote Anschluss Ölspiegelregul O Connection oil level regul (L)* = Lötanschluss / braz

208 8,19

192 7,56

316 12,42

D GB F E I Ru

+ 2

+0,08

412 0 16,22 0

1) SV 90° rotatable

Dimensions in mm [inch] Fig. 16

SV DV
A
A1

Suction line Halbhermetischer Verdichter HG / Semi-hermetic compressor HG

see technical data, Chapter 10 Typ / Discharge line type

Teile-Nr. / part-no.

Typ / type

Teile-Nr. / Typ / part-no. type

Teile-Nr. / part-no.

HG(X)12P/60-4 S 14541 (14549) HG12P/60-4 S HC 10893 HGX12P/60 S 0,7 LG 14678 UL-HGX12P/60 S 0,7 14713

Connection suction side, not lockable HG(X)12P/75-4 14542 (14550) HG12P/75-4 HC HG(X)12P/75-4 S 14543 (14551) HG12P/75-4 S HC

10890 HGX12P/75 ML 1 LG 10894 HGX12P/75 S 2 LG

14679 UL-HGX12P/75 ML 1 14680 UL-HGX12P/75 S 2

14714 14715

HG(X)12P/90-4 14544 (14552) HG12P/90-4 HC

10891 HGX12P/90 ML 2 LG 14681 UL-HGX12P/90 ML 2 14716

HG(X)12P/90-4 S 14545 (14553) HG12P/90-4 S HC 10895 HGX12P/90 S 2 LG

14682 UL-HGX12P/90 S 2

14717

Connection suction side, lockable HG(X)12P/110-4 14546 (14554) HG12P/110-4 HC

10892 HGX12P/110 ML 2 LG 14683 UL-HGX12P/110 ML 2 14718

HG(X)12P/110-4 S 14547 (14555) HG12P/110-4 S HC 10896 HGX12P/110 S 3 LG 14684 UL-HGX12P/110 S 3 14719

Massenschwerpunkt Centre of gravity
1/8" NPTF 7/16" UNF

Änderungen v Subject to cha
Ze
1.

Connection discharge side, not lockable

B1 Connection discharge side, lockable

Connection oil pressure safety switch

D1 Connection oil return from oil separator

Oil drain

1/8" NPTF Gußtoleranzen / General casting tolerances:

Zeichnungs-N

-
7/16" UNF Baumustergeprüft / Type examination:
Nein / No Gewicht / Weight: (kg) -

Drawing-No.
1. 08

1/8" UNF Allgemeintoleranzen / General tolerances
DIN ISO 2768-mK-E

Benennun

über / above 0.5 6 30 120 400

1/4" NPTF bis / up to 6 30 120 400 1000 ±0.1 ±0.2 ±0.3 ±0.5 ±0.8

Unbemaßte Radien / Undimensioned radii: -
M8

Oberflächen Indication of DIN EN ISO

H Oil charge plug Der Lieferant muss sicherstellen, dass die Ware

in einwandfreiem Zustand angeliefert wird 1o | Gummisegment Klemmbrett an S1570 angepasst

(Korrosionsschutz, Verpackung für sicheren

Transport).

1n | Anschluss I Heißgastemperatursensor aufgenommen

12025 11857

19.02.24 13.09.23

M. Rist B. Nagel

J. Keuerleber J. Keuerleber

1/4" NPTF

The supplier has to ensure the delivery of parts

I Connection hot gas temperature sensor in proper conditions (corrosion
packaging for safe transportation).

prevention, 1m | Betrifft Blatt 2+3

Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind ver-

1m | Betrifft Blatt 3+4

11913,11971 11943

30.05.23 03.05.23

B. Nagel B. Nagel

J. Keuerleber J. Keuerleber

1/8" NPTF

boten, soweit nicht ausdrücklich gestattet. Zuwider-

J Connection oil sump heater handlungen verpflichten
Rechte für den Fall der

zu Schadenersatz. Alle Patent-, Gebrauchsmuster-

1l |

Betrifft Bl.3

oder Geschmacksmustereintragung vorbehalten. 1l | Betrifft Bl.2

The reproduction, distribution and utilization of this

11738 11831

15.12.22 14.12.22

C. Polizzi C. Polizzi

A. Layh J. Keuerleber

3/8" NPTF

document as well as the communication of its contents to others without express authorization is

BS-Befestigungsteile aus

Lieferumfang

entfernt

und

als Zubehör

ergänzt

11614

04.04.22

S. Büttner

A. Layh

K Sight glass prohibited. Offenders will be held liable for the

Zust. / Rev.

1 1/8"- 18 UNEF Änd.-Nr. / Mod-No. Datum / Date Bearb. / Edited Geprüft / Appr. Maß / Dimension

Passung / Clearance

Connection thermal protection thermostat

1/8" NPTF

Rz
s
BOCK GmbH -
3

Connection oil level regulator

1 1/8"- 18 UNEF

26 | AQ451444787718en-000401

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

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-HGX88e/3235 S 95 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.............. HGX56/680-4 (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

Name:

Open type compressor

Types:

F(X)2 ...................................................F(X)88/3235 (NH3)

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.
I

Applied harmonised standards, in particular:

EN ISO 12100 :2010 Safety of machinery; General principles for design, risk

assessment and risk reduction

EN 12693

:2008 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, 11th of September 2023

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

AQ451444787718en-000401 | 27

12| 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-HGX88e/3235 S 95 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.............. HGX56/680-4 (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:

Types:

GB
Serial number:

Open type compressor F(X)2 ................................................... F(X)88/3235 (NH3) FK(X)20/120 (K/N/TK).......................... FK(X)50/980 (K/N/TK)
BC00000A001 BN99999Z999

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

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.
I

Designated standards: EN ISO 12100 :2010 Safety of machinery -- General principles for design -- Risk

assessment and risk reduction

EN 12693

:2008 Refrigerating systems and heat pumps -- Safety and environmental

requirements -- Positive displacement refrigerant compressors

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 representative for compiling and handing over technical documentation:

Danfoss LTD., 22 Wycombe End, HP9 1NB, GB

Frickenhausen, 19th of January 2024

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

28 | AQ451444787718en-000401

29 | AQ451444787718en-000401

References

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