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Bock Compressors for Mobile Applications

FOR BUS, TRAIN AIR CONDITIONING AND TRANSPORT COOLING

Southern Sales & Services are the UK’s largest distributor of Bock mobile compressors offering both open and semi-hermetic types. Based in the south of England we have enjoyed our Bock dealership for over 20 years and intend to uphold our much respected knowledge and first class performance for at least another 20 years to come.

Today, air conditioning systems for buses and trains are required to provide optimum comfort for drivers and passengers. The highest possible energy efficiency for the vehicle and the best environmental compatibility are priorities. The focus is on heating the vehicles using environmentally friendly and emission-free heat pumps. The weight of the refrigeration system is important for the air conditioning of buses, trains or in transport cooling. When it comes to compressors, emphasis is placed on robust and smooth-running lightweights that also make a decisive contribution to increasing the efficiency of the overall system.

Thanks to their proven design and constant innovation, the mobile aluminum compressors from BOCK make an important contribution to environmental protection and ensure a good climate in buses and trains as well as in transport cooling.

If you have an enquiry that you think that we can help with, then please do not hesitate to contact us by phone or through our online quick contact form at the bottom of the page.

GEA Bock mobile compressors

NEW: Bock StarCO2mpressor – HR40 & HR60

Naturally Innovative

The Bock StarCO2mpressor HR40 & HR60, the new generation of mobile CO2 compressors for electric bus and railway air conditioning and heating, launched at the world’s largest bus trade fair in Brussels last year, is available now from Southern Sales.

 

Lowest overall height, lowest weight and constantly safe operation

The core of the StarCompressor is a radial piston technology which is specially designed for transcritical use with the natural refrigerant CO2 (R744) and enables a very compact system design with numerous technical and constructive innovations. This makes the new mobile CO2 compressor perfectly suited for space-saving roof installation in electric buses and railways,” says Ulrich Frey. “This includes the lowest overall height in the industry of only 220 mm and the light weight of only 83 kg, which is at least 25 percent below the standard compressor in this performance class.”

Further advantages of the StarCompressor: Energy-saving heat generation even at low outside temperatures down to -20 °C without power-consuming electric or environmentally harmful fuel-operated auxiliary heaters. This increases range of an electric bus by up to 40 percent. And all this with reliable, quiet running thanks to multiple bearings and safe operation even at large angles of inclination. “The innovative technology of the StarCompressor has already successfully proven its practical suitability in extensive field tests with renowned manufacturers,” explains Frey.

With the new StarCompressor, Bock is expanding its portfolio of compressors for natural refrigerants with an ecologically and economically efficient technology for the future electromobility market.

INNOVATIVE “STAR” DRIVE DESIGN HR40 AND HR60

ENERGY SAVING AND LONGER RANGE

The cylinders of the radial piston compressor are arranged in a star configuration around the crankshaft. This results in an extremely compact compressor design that is perfectly matched to the natural refrigerant CO2 (R744) and which is perfect for mobile use.

  • No need for energy-consuming auxiliary heaters
  • Up to 20% higher efficiency of the CO2 heat pump
  • Approx. 40 % more vehicle range
ECONOMICALLY AND ECOLOGICALLY SUSTAINABLE INVESTMENT

The innovative “star” drive design of the StarCO2mpressor opens new possibilities in electric bus and train air conditioning: space-saving roof installation thanks to the industry’s lowest overall height and lowest weight. Energy-saving and environmentally friendly heat generation with a CO2 heat pump without auxiliary heater even at outside temperatures down to -20 °C.

  • Innovative radial piston technology developed for mobile CO2 applications
  • Welded, robust steel housing with lowest risk of leakage
  • Lowest overall height (219mm) and weight (81kg) in this power class
  • Wide speed range for optimum coverage of the broad power requirements for vehicle air conditioning, heating and battery conditioning
  • Specially adapted oil management for the vehicle application
  • Proven practicality in successful series operation
  • robust ring valve design
ADVANTAGES AT A GLANCE

STARCO2MPRESSOR uses R744 /CO2 as refrigerant!

NATURALLY, SUSTAINABILITY IS IMPORTANT

CO2 is a natural refrigerant, environmentally friendly, inexpensive, compared with fluorinated refrigerants. It is colourless, non-flammable and non-toxic. CO2 is the basis for determining the CO2 equivalent of refrigerants.

R744 has a GWP value of 1 and is excluded from the so-called “Phase-Down-Zenario” (F-Gas-Regulation). From a weight of 5 tonnes CO2 equivalent, the leak test of a refrigeration system is mandatory. Therefore, the leak test is not required for refrigeration systems with R744 below a charge of 5 tonnes. If CO2 is released into the environment during service work, there is no need for costly refrigerant recovery.

Demanding factors are the high operating pressure of the refrigerant, the low critical point, dry ice formation when the temperature falls below the triple point and the very high standstill pressures. The requirements and component selection of the refrigeration system must be considered accordingly.

It’s good to have an expert on hand so if you need more information about CO2 cooling, please get in touch.

Environmentally friendly and future-proof

AIR CONDITIONING AND HEATING WITH CLIMATE-NEUTRAL REFRIGERANT R744
  • Natural, non-flammable refrigerant
  • Climate neutral: no ozone depletion, potential (ODP = 0)
  • The lowest global warming potential (GWP = 1)
  • Efficient operation of heat pumps down to an outside temperature of -20 °C
  • Up to 75% energy savings compared to electric heating
  • Meets the criteria of the “Blue Angel” Eco-label
  • Meets the subsidy requirements for electric bus air conditioners in Germany

Radial reciprocating piston technology

RADIAL RECIPROCATING PISTON TECHNOLOGY, SPECIALLY DEVELOPED FOR MOBILE CO2 APPLICATIONS:
  • Efficient reciprocating piston technology, especially part-load optimised for heat pump applications
  • Very wide speed range
  • Lowest overall height, lowest weight
  • Welded housing with reduced interfaces for lowest risk of leakage
  • Space-saving roof installation in electric buses and trains
  • Robust and reliable, proven in practice

STARCO2MPRESSOR: Performance data

THE BOCK STARCO2MPRESSOR: DESIGNED FOR TODAY AND TOMORROW!
  • Four-cylinder radial reciprocating compressor HR40 and HR60
  • Max. permissible overpressure: 150 bar/100 bar (HP/LP)
  • Weight: 81 kg
  • Height: approx. 219 mm, overall length: 600 mm
  • Wide speed range from 750 to 4,350 rpm / 12.5-75 Hz (HR60 65 Hz) for
    heat pump application and thermal management
  • Maximum permissible inclination: 22° continuous operation, 30° short term
  • Pipe connection with flange connection, optional solder flange
  • Displacement at 50 Hz / 2,900 1/min: HR40: 7.3 m³/h / HR60: 10,9 m³/h
  • Cooling capacity 1)HR40: 7 – 35 kW/ HR60: 9 – 47 kW
  • Heating capacity 2)HR40: 4 – 27 kW/ HR60: 6 – 35 kW

1) +10°C/ 40°C (100 bar) / 10 K
2) -20°C / +25°C (80 bar) /10 K 

Bock FK Compressor Range

THE MARKET LEADER WITH TRADITION AND INNOVATION

Bock vehicle compressors of the FK range are the result of many years of experience in the domain of mobile cooling systems. The unsurpassed light, compact, robust design and wide rpm range are only some of the outstanding features of this unique product range of 2-, 4- and 6-cylinder compressors.

  • FK Compressors for Bus and Rail Air Conditioning
  • FK Compressors for Transport Refrigeration

FK for bus and train air-conditioning

Bock vehicle compressors in the FK series are the result of decades of experience in mobile refrigeration. Particularly when it comes to bus air-conditioning, they are the standard of all renowned manufacturers. Unsurpassed lightweight, compact and robust design with a large speed range – these are just a few of the outstanding features of this unique product range with 2, 4 and 6 cylinder compressors. Tailor-made to the individual application with many different design versions. One special innovation constitutes the so-called K version with a unique valve plate system for the toughest demands in mobile air-conditioning.

N version

  • Compressor with universal valve plate system for all possible applications.

K version

  • Compressor with unique valve plate system for the toughest demands in bus air-conditioning.

FEATURES

  • Optimised heat dissipation due to ribbed surface
  • Efficient over the entire speed range
  • Robust crankshaft design with roller bearings on both sides: works extremely reliably and with high speed stability
  • Split screwed aluminium connecting rods: stable and robust, thus easy to handle
  • Reliable pressure lubrication with powerful oil pump independent of direction of rotation
  • Extremely low wear, thus extremely durable
  • Valve plate systems specially adapted to the field of application

TECHNICAL

Types Swept volume ccm Former types
FKX30 233 FKX30
FKX40 385466554650755 FKX30
FKX50 662776831976 FKX50

More information about the FK compressors for bus and rail air conditioning (e.g. technical/performance data, drawings, spare part lists, operating limits) can be found in the compressor selection tool VAP via the following link:

VAP compressor selection FK compressors

3 SIZES AND 11 DISPLACEMENTS
REFRIGERANT OVERVIEW

FK for transport refrigeration and other applications

The unsurpassed light, compact, robust design and wide rpm range are only some of the outstanding features of this unique product range of 2-, 4- and 6-cylinder compressors. A wide variety of designs can be tailored to suit individual requirements. For low temperature applications, an optimized TK model is available.

N version

  • Compressor with universal valve plate system for all possible applications.

TK version

  • Compressor in basic N-version with additional optimisation for deep-freezing.

FEATURES

  • Optimised heat dissipation due to ribbed surface
  • Efficient over the entire speed range
  • Robust crankshaft design with roller bearings on both sides: works extremely reliably and with high speed stability
  • Split screwed aluminium connecting rods: stable and robust, thus easy to handle
  • Reliable pressure lubrication with powerful oil pump independent of direction of rotation
  • Extremely low wear, thus extremely durable
  • Valve plate systems specially adapted to the field of application

TECHNICAL

Types Swept volume ccm Former types
FKX30 233277325 FKX30
FKX40 385466554650 FKX30 FKX50

More information about the FK range of GEA Bock mobile compressors for transport refrigeration (e.g. technical/performance data, drawings, spare part lists, operating limits) can be found in the compressor selection tool VAP via the following link:

VAP compressor selection FK compressors

3 SIZES AND 11 DISPLACEMENTS
REFRIGERANT OVERVIEW

ADVANTAGES AT A GLANCE

Vehicle compressor FK40 with Valve Plate K

VEHICLE COMPRESSOR WITH VALVE PLATE IN K-VERSION

Unique FK valve plate system specially developed for air-conditioning!

  • Valve plate made of aluminium
  • Working valves made of high-quality, impact-resistant spring steel
  • Extremely robust and reliable in the face of speed and pressure fluctuations as well as exposure to liquids
  • Long service life due to loosely guided annular discs which prevent bending and torsional forces
  • Highest operational safety and efficiency

Vehicle compressor FK40 with Valve Plate N

VEHICLE COMPRESSOR WITH VALVE PLATE IN N-DESIGN: FOR AIR-CONDITIONING AND NORMAL COOLING!
  • For universal use in mobile applications
  • Lamellas clamped on one side, which are exposed to bending and torsional forces; therefore limited load-bearing capacity at  high speed and exposure to liquids

Vehicle compressor FK40 version for low temperature cooling

VEHICLE COMPRESSOR LOW TEMPERATURE VERSION WITH VALVE PLATE IN TK-VERSION
  • Specially adapted version for low temperature cooling
  • Valve plate TK design for low evaporating temperatures, based on the N-valve plate basic concept with torsionally stiff lamellas
  • With additional measures for delivery rate optimization at low evaporating temperatures
  • Piston crowns provided with grooves in the suction lamella contour: for further damage space minimization and increased performance in the low-temperature range
  • Increased efficiency and performance in the low temperature cooling range

Vehicle compressor FK40 K1 for direct engine mounting

Due to special requirements by customers, there is a demand for additional fastening options on the compressor housing – particularly where there is little installation space available, as is the case in many Euro 6 buses. This has been achieved by means of the K1 special housing, which creates a higher level of stability thanks to the compressor being fastened directly to the vehicle motor.

Special features of the K1 housing:

  • Optimized housing
  • With intermediate flange 46 mm for suction and pressure shut-off valve
  • Available models FKX40/470 K1, 560 K1, 655 K1 and 755 K1
  • 6-cylinder compressor series FK50 with K1 housing with additional mounting points on request

VIDEO

PRODUCT QUICK-CHECK

  1. Wear-resistant and durable power unit
  2. Forged aluminium connecting rods for maximum stability and robustness
  3.  Two easily visible sight glasses
  4. Integrated oil collection system with large storage volume
  5. Special valve plate systems for bus and transport cooling

Bock HG Compressor Range

LIGHTWEIGHT ALUMINIUM CONSTRUCTION

The all-aluminum lightweight design of the HGX34 and HGX22 compressors compressors is ideal for mobile refrigeration and air conditioning applications. Compressor weight and compressor efficiency are critical. Thanks to the lightweight aluminum design, the mobile semi-hermetic compressors are 40% lighter than the standard compressor. System manufacturers in the field of bus-/railway air- conditioning and transport cooling are thus offered new possibilities.

BOCK mobile compressors are available in 2 and 4 pole versions. The 2-pole version of the HG34 offers a significant increase in performance with identical dimensions.

The compressors are available with a terminal box in reduced height and are more compact than the standard version. BOCK mobile aluminum compressors meet the highest fire protection class HL3 of EN45545 for railroad applications.

  • HG 2-Pole Compressors
  • HG Aluminium Compressors

HG 2-Pole compressors for mobile cooling

Based on the HG standard compressors with their outstanding advantages and features, versions with 2-pole drive motor are available with up to 70% increased cooling capacity with the same external dimensions. This is made possible by doubling the speed at the same mains frequency. Together with the robust and reliable BOCK K valve plate, this results in the optimal solution for bus air conditioning and many other mobile applications.

FEATURES

  • Particularly powerful and compact due to 2-pole drive motor (2,900 1/min – 50 Hz)
  • Even more compact: reduced overall height of 300 mm due to optional terminal box
  • Lockable metal terminal box for access restriction
  • Terminal blocks with increased serviceability and railroad approval, shock and vibration resistant
  • Fire protection class HL3 according to railroad standard EN 45545-2 also with special track painting
  • Pressure lubrication with oil pump as standard
  • Electronic motor protection

TECHNICAL

Types Displacement at 50 Hz (2900 rpm) m³/h Former types
HGX34e 44.3 54.7 66.1 HGX34P (up to DK 056)
HGX34P 44.3 54.7 66.1

More information about the HG 2-pole compressors (e.g. technical/performance data, drawings, spare part lists, operating limits) can be found in the compressor selection tool VAP via the following link:

VAP compressor selection HG 2-pole compressors

2 SIZES AND 6 DISPLACEMENTS
REFRIGERANT OVERVIEW

PRODUCT QUICK-CHECK

  1.  40% lighter than cast iron version due to lightweight aluminium construction
  2. Power control also possible digitally in wide bandwidth
  3.  Reliable and efficient reciprocating piston technology with optimised valve plate system and low oil throw
  4.  Highly efficient 4-pole and 2-pole electric motors
  5. Wear-resistant and durable power unit

HG Aluminum compressors for mobile cooling

Suction gas cooled aluminum reciprocating compressors from BOCK, based on the classic HG compressor series in grey cast iron, are specially designed for mobile refrigeration applications due to their lightweight construction. They are approx. 40% lighter and have a reduced overall height, making them particularly suitable for roof mounting on vehicles.

FEATURES

  • Particularly powerful and compact due to 2-pole drive motor (2,900 1/min – 50 Hz)
  • Even more compact: reduced overall height of 300 mm due to optional terminal box
  • Lockable metal terminal box for access restriction
  • Terminal blocks with increased serviceability and railroad approval, shock and vibration resistant
  • Fire protection class HL3 according to railroad standard EN 45545-2 also with special track painting
  • Pressure lubrication with oil pump as standard
  • Electronic motor protection

TECHNICAL

Types Displacement at 50 Hz (1450 rpm) m³/h
HG22e 11.1 13.7 16.5
HG34e 18.8 22.1 27.3 33.1

More information about the HG Alu compressors (e.g. technical/performance data, drawings, spare part lists, operating limits) can be found in the compressor selection tool VAP via the following link:

VAP compressor selection HG Alu compressors

2 SIZES AND 7 DISPLACEMENTS
REFRIGERANT OVERVIEW

PRODUCT QUICK-CHECK

  1.  40% lighter than cast iron version due to lightweight aluminium construction
  2. Power control also possible digitally in wide bandwidth
  3.  Reliable and efficient reciprocating piston technology with optimised valve plate system and low oil throw
  4.  Highly efficient 4-pole and 2-pole electric motors
  5. Wear-resistant and durable power unit

ADVANTAGES AT A GLANCE

The Bock Valve K Plate

The K valve plate was specially developed by BOCK for mobile air-conditioning applications. Due to the use of annular lamellas, it is designed for higher loads and is extremely robust against speed and pressure fluctuations as well as the effects of liquids. It has already been used hundreds of thousands of times in bus air conditioning and is the worldwide benchmark for quality and reliability.

BOCK K VALVE PLATE ADVANTAGES AT A GLANCE:
  • Specially developed for bus air-conditioning
  • Highest operational safety: loosely guided annular disc packs prevent bending and torsional forces
  • Working valves made of high-quality, impact-resistant spring steel
  • Extremely resistant and reliable at
    • constant speed and pressure fluctuations
    • exposure to liquids
  • Weight-optimised valve plate made of aluminium

The Bock Valve N Plate

Worldwide proven valve design with reed lamellas clamped on one side. The valves are made of high-quality, impact-resistant spring steel. Limited load capacity compared to the K-valve plate at high speed and exposure to liquids.

BOCK N VALVE PLATE ADVANTAGES AT A GLANCE:
  • Cost-effective and simpler alternative to the K version
  • Universal use in mobile applications
  • Valve base plate made of steel

Electrical motor protection in 24 V and 230 V version

Electronic motor protection INT69 G Functions:

  • Motor temperature monitoring
  • Hot gas temperature monitoring (accessory)
  • Restart lockout
  • Reset function

TYPE CODE

  1. Series
  2. Ester oil filling X
  3. Size
  4. Number of cylinders
  5. e-series (efficiency) / Pluscom P
  6. Displacement
  7. Number of poles
  8. Motor version S
  9. Aluminum version
  10. Design variant with K valve plate

NOTE: In March 2021, BOCK was separated from the GEA Group. BOCK now trades as an independent company: BOCK Gmbh.

We continue to provide all of the BOCK products formerly produced under the GEA Group. As always we will aim to provide excellent advice and product support and can help with any enquiries you have regarding the transition or any products affected.

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