Danfoss BOCK HG66e User Manual Download

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AQ450740142615en-000201

BOCK

HG66e

Operating guide

HG66e/1340-4
HG66e/1540-4
HG66e/1750-4
HG66e/2070-4

HGX66e/1340-4
HGX66e/1540-4
HGX66e/1750-4
HGX66e/2070-4

HG66e/1340-4 S
HG66e/1540-4 S
HG66e/1750-4 S
HG66e/2070-4 S

HGX66e/1340-4 S
HGX66e/1540-4 S
HGX66e/1750-4 S
HGX66e/2070-4 S

Translation of the original instructions

Summary of Contents for BOCK HG66e

Page 1: ... 4 HG66e 1540 4 HG66e 1750 4 HG66e 2070 4 HGX66e 1340 4 HGX66e 1540 4 HGX66e 1750 4 HGX66e 2070 4 HG66e 1340 4 S HG66e 1540 4 S HG66e 1750 4 S HG66e 2070 4 S HGX66e 1340 4 S HGX66e 1540 4 S HGX66e 1750 4 S HGX66e 2070 4 S Translation of the original instructions ...

Page 2: ...nd before using the compressor This will avoid misunder standings and prevent damage Improper assembly and use of the compressor can lead to 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 ...

Page 3: ...n 5 2 Standard motor design for direct or partial winding start 5 3 Basic circuit diagram for partial winding start with standard motor 5 4 Special motor design for direct or star delta start 5 5 Basic circuit diagram for star delta start 230 V 400 V Y 5 6 Electronic trigger unit INT69 G 5 7 Connecting of the trigger unit INT69 G 5 8 Functional test of the trigger unit INT69 G 5 9 Oil sump heater ...

Page 4: ...cause property damage INFO Important information or tips on simplifying work 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 profe...

Page 5: ...compressor may not be used in potentially explosive environments These assembly instructions describe the standard version of the compressor named in the title man ufactured 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 Pressure Equipment Directive Commissioning is permiss...

Page 6: ... of the evaporator flows over the motor and cools it intensively In this way the motor can be kept at a relatively low temperature level particularly under high loads Fig 1 2 1 Short description Dimension and connection values can be found in Chapter 10 Cylinder cover Terminal box Suction shut off valve Transport eyelet Name plate Motor section Drive section Valve plate Discharge shut off valve Oi...

Page 7: ...e Oil charge Series 107 0 A YY 335 0 A Y 196 0 A 180 0 217 2 380 420 Y YY 440 480 Y YY 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 Y Part winding 1 10 Nominal rotation speed YY Part windings 1 and 2 11 Displacement 5 ND LP Max admissible operating pre...

Page 8: ...e system can not under certain circumstances ensure that suffi cient oil is transported back to the compressor For operation with frequency converter 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 Max 60 Hz For more on the frequency converter see chapter 5 10 p 24 When operating in the...

Page 9: ... Ru Danfoss Climate Solutions 2023 07 AQ450740142615en 000201 9 3 Areas of application Maximum admissible operating pressure LP HP 1 19 28 bar Maximum admissible frequency 60 Hz 1 LP Low pressure HP High pressure ...

Page 10: ...g parts etc directly to the compressor are not permissible Setup on an even surface or frame with sufficient load bearing capacity Single compressor preferably on vibration damper Duplex and parallel circuits always rigid Provide adequate clearance for maintenance work Ensure adequate compressor ventilation Do not use in a corrosive dusty damp atmosphere or a combustible environment 4 2 Setting up...

Page 11: ...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 4 5 Start unloader external A internal start unloader ex factory is not available Alternatively a start unlo...

Page 12: ...nd discharge lines directly after the compressor is integral to the system s smooth running and vibration behaviour Important Start unloader may only be employed during the starting phase Check the solenoid valve and the non return valve regularly for tightness In addition we recommend to use a heat protection thermostat on the discharge side of the com pressor This protects the compressor against...

Page 13: ...onnection Spindle Turn 1 2 1 turn clockwise Service connection opened shut off valve opened Connection blocked Spindle Spindle Connection open Compressor Compressor Service connection closed Service connection opened 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 4 7 Operating the shut o...

Page 14: ...t 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 relieves 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 DANGER Risk of electric shock High voltage Onl...

Page 15: ...rt up current needed for a part winding start to approx 50 of that for a direct start The motor is wired for direct start YY at the factory For part winding start Y YY the bridges must be removed and the motor feed line connected according to the circuit diagram ATTENTION Failure to do this results in opposed rotary fields and results in damage to the motor After the motor starts up via partial wi...

Page 16: ...E FC1 1 I I I QA2 1U1 1V1 1W1 PE EC1 M Y YY 2U1 2V1 2W1 FC1 2 I I I QA3 FC1 1 FC1 2 FC2 SF1 QA2 11 12 14 L N B1 B2 12 11 10 9 8 7 6 5 4 3 2 1 21 20 50 50 Compressor terminal box BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor BT3 Oil temperature sensor BT4 Release switch thermost...

Page 17: ... P QA2 KF1 KF1 2 8 3 8 6 c 8 L1 1 L2 1 L3 1 L1 2 N PE QA3 BT4 BT2 Θ Θ vio bn bu gr Θ EB1 pk og BT3 Θ FC1 1 1 2 Motor protection switch FC2 Control power circuit fuse INT69 G Electronic trigger unit INT69 G KF1 Delay relay for contactor switch over QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch ...

Page 18: ...er on the terminal box Y 5 4 Sondermotor Ausführung für Direkt oder Stern Dreieck Anlauf Für den Stern Dreieck Anlauf ist eine mechanische Anlaufentlastung mit Bypass Magnetventil Zubehör erforderlich Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Y Stern Dreieck Anlauf ist nur im Spannungsbereich 230 V möglich Beispiel 230 V Direktstart Stern Dreieck Start L3 L1 V1 W1 U1 V2 U2 W2 L1 L2...

Page 19: ... V möglich Beispiel 230 V Direktstart Stern Dreieck Start L3 L1 V1 W1 U1 V2 U2 W2 L1 L2 L3 L2 V1 W1 U1 V2 U2 W2 L3 L2 L1 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 Y Stern Dreieck Anlauf ist nur im Spannungsbereich 230 V möglich Beispiel 230 V Direktstart Stern Dreieck Start L3 L1 V1 W1 U1 V2 U2 W2 L1 L2 L3 L2 V1 W1 U1 V2 U2 W2 L3 L2 L1 400 V Y nur Direktstart V1 W1 U1 V2 U2 W2 L1 L2 L3 Y ...

Page 20: ...2 W2 FC1 1 FC1 2 FC2 SF1 QA2 11 12 14 L N B1 B2 12 11 10 9 8 7 6 5 4 3 2 1 FC1 1 I I I 1 2 QA2 FC1 2 I I I 3 4 5 6 1 2 QA4 Y 3 4 5 6 1 2 QA3 D 3 4 5 6 EC1 M 3 20 21 Compressor terminal box BP2 High pressure safety monitor BP3 Safety chain high low pressure monitoring BT1 Cold conductor PTC sensor motor winding BT2 Thermal protection thermostat PTC sensor BT3 Oil temperature sensor BT4 Release swit...

Page 21: ...T4 BT2 Θ Θ vio bn bu gr pk og Θ EB1 QA2 QA2 2 9 4 7 6 b 7 6 d 7 QA4 KF1 QA4 QA3 4 8 6 b 8 6 d 7 KF1 QA3 QA4 4 8 6 b 8 6 d 7 KF1 BT3 Θ FC1 1 1 2 Motor protection switch FC2 Control power circuit fuse INT69 G Electronic trigger unit INT69 G KF1 Delay relay for contactor switch over QA1 Main switch QA2 Mains contactor part winding 1 QA3 Mains contactor part winding 2 SF1 Control voltage switch ...

Page 22: ... 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 re...

Page 23: ...GB F When the compressor is at a standstill refrigerant diffuses into the lubricating oil of the compressors housing depending on pressure and ambient temperature This reduces the lubricating capacity of the oil When the compressor starts up the refrigerant contained in the oil evaporates out through the reduction in pressure The consequences can be foaming and migration of the oil causing oil sho...

Page 24: ... 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 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...

Page 25: ...thecompressoragainstinadmissibleoperatingconditions high pressure and low pressure pressostats are mandatory on the installation side 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 no...

Page 26: ...evices pressure switch motor protection electrical contact protection measures etc are all functioning properly Switch on the compressor and allow to run for a minimum of 10 min Check the oil level by The oil must be visible in the sight glass WARNING Ensure that both shut off valves are open before starting the compressor ATTENTION If larger quantities of oil have to be topped up there is a risk ...

Page 27: ...e 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 7 3 Spare parts recommendation accessories 7 5 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...

Page 28: ... it with knurled nut and connect it Fig 20 ATTENTION If the capacity regulator is installed at the factory the control component pilot valve is subsequently installed and connected by the customer Before start up remove the cover at the capacity regulator and replace it with the enclosed control unit pilot valve Attention Compressor is under pressure Depressurize the compressor first Delivery cond...

Page 29: ...em under certain circumstances does not guarantee sufficient oil return to the compressor with activated capacity regulator We recommend switching to unregulated operation 100 capac ity for at least 5 minutes per capacity regulated operating hour An assured oil return can also be realised by a 100 capacity requirement after each compressor restart Electrical actuation of the solenoid valve Normall...

Page 30: ... at the original position of the standard sight glass see fig 23 Mechanical oil level regulator at the O connection Fig 22 8 Accessories on Anschluss Ölspiegelregulator Bei Verbundschaltungen von mehreren Verdichtern haben sich Ölstandsregulierungssystemebewährt Für die Montage eines Ölspie gelregulators ist derAnschluss O vorgesehen siehe Maßzeichnung Alle gängigen Ölspiegelregulatoren von AC R E...

Page 31: ... 196 335 287 1540 4 133 8 160 5 62 37 170 275 280 1540 4 S 133 8 160 5 75 44 196 335 285 1750 4 152 2 182 6 72 42 196 335 280 1750 4 S 152 2 182 6 87 51 222 361 282 2070 4 180 0 216 0 85 51 196 335 276 64 2 5 8 2070 4 S 180 0 216 0 103 61 222 361 278 9 Technical data 1 2 3 2 4 Tolerance 10 relative to the mean value of the voltage range Other voltages and types of current on request The specificat...

Page 32: ...njection L Lötanschluss brazing connection 3 4 5 6 810 2 402 404 381 165 107 225 205 535 H D1 A L B W Q 36 4x 15 175 467 2 557 30 F D D B1 J1 L P1 A W A1 SV Halbhermetischer Verdichter HG Semi hermetic compressor HG Typ type Teile Nr part no Typ type Teile Nr part no Typ type Teile Nr part no Typ type Teile Nr part no HG66e 1340 4 41199 HGX66e 1340 4 41207 HG66e 1340 4 S 41200 HGX66e 1340 4 S 4120...

Page 33: ...16 UNF C Connection oil pressure safety switch OIL 1 8 NPTF D Connection oil pressure safetyswitch LP 7 16 UNF D1 Connection oil return from oil separator 1 4 NPTF F Oil drain M12x1 5 H Oil charge plug 1 4 NPTF J1 Oil sump heater 3 8 NPTF K Sight glass 3 x M6 L Connection thermal protection thermostat 1 8 NPTF M Oil filter M12x1 5 O Connection oil level regulator 3 x M6 P1 Oil pressure differentia...

Page 34: ...N 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 t...

Page 35: ...O 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 ...

Page 36: ...36 AQ450740142615en 000201 Danfoss Climate Solutions 2023 07 ...

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