Danfoss BOCK HG66e Manuel utilisateur

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

2 | AQ450740142615en-000201 © Danfoss | Climate Solutions | 2023.07

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 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.

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 Pipe connections

4.4 Pipes

4.5 Start unloader (external)

4.6 Laying suction and pressure lines

4.7 Operating the shut-off valves

4.8 Operating mode of the lockable service connections

 4.9 Suctionpipelterandlterdrier

5 Electrical connection 14

5.1 Information for contactor and motor contactor selection

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

5.10 Selectionandoperationofcompressorswithfrequencyconverters

6 Commissioning 24

6.1 Preparations for start-up

6.2 Pressure integrity test

6.3 Leak test

6.4 Evacuation

6.5 Refrigerant charge

6.6 Start-up

6.7 Avoid slugging

7 Maintenance 26

7.1 Preparation

7.2 Work to be carried out

7.3 Spare parts recommendation / accessories

7.4 Lubricants / oil

7.5 Decommissioning

8 Accessories 28

8.1 Capacity regulator

8.2 Oil separator

8.3 Oil level regulator

9 Technical data 31

10 Dimensions and connections 32

11 Declaration of incorporation

Contents Page

4 | AQ450740142615en-000201 © Danfoss | Climate Solutions | 2023.07

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

1.4 Intended use

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.

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 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 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 | AQ450740142615en-000201 © Danfoss | Climate Solutions | 2023.07

2|Product description

• Semi-hermetic six-cylinder reciprocating compressor with suction-gas cooled drive motor.

• The stream of refrigerant sucked out 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

Oil pump

Oil sight glass

2|Product description

2.2 Name plate (example)

2.3 Type key (example)

IP 66

BB12345D001

HGX66e/2070-4

HG 66 e 2070 -4 SX

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, R407F)

3) S - More powerful motor, e.g. for air-conditioning applications

Motor variant 3)

Number of poles

Swept volume

e-series

Numbers of cylinders

Size

Oil charge ²)

Series ¹)

107,0 A

YY: 335,0 AY: 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 pressur

e12 Oiltypelledatthefactory

(g) Low pressure side 13 Terminal box protection type

HD (HP):

Max. admissible operating

Electrical accessories can change

pressur

e(g) High pressure side the IP protection class!

Observe the limits of application

diagrams!

50 Hz

}

60 Hz

}

Fig. 2

BOCK

BOCK lub E55

8 | AQ450740142615en-000201 © Danfoss | Climate Solutions | 2023.07

3|Areas of application

ATTENTION Compressor operation is possible within the operating limits.

These can be found in Bock compressor selection tool (VAP)

under vap.bock.de. Observe the information given there.

- Permissible ambient temperature (-20°C) - (+60°C)

- Max. permissible discharge end temperature 140°C.

-Max.permissibleswitchingfrequency12x/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.

- Additional fans (accessories) can be used for additional cooling.

For operation with capacity regulator:

Continuous operation, when the capacity regulator is activated,

is not permissible and can cause damage to the compressor.

- The suction gas superheat temperature may need to be reduced

or set individually when operating near to the threshold.

- When the capacity regulator is activated, the gas velocity in the

systemcannotundercertaincircumstancesensurethatsuf-

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 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!

3.3 Limits of application

3.1 Refrigerants

• HFKW / HFC: R134a, R404A/R507, R407C, R407F • (H)FCKW / (H)CFC: R22

3.2 Oil charge

INFO For refilling, we recommend the above oil types.

Alternatives: see lubricants table, Chapter 7.4

ATTENTION The oil level must be in the

visible part of the sight glass;

damage to the compressor is

possible if overfilled or under-

filled!

Max.

Min.

1,9 Ltr.

Oil level

Fig. 3

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

- for R134a, R404A/R507, R407C 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. HGX66e/2070-4).

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

10 | AQ450740142615en-000201 © Danfoss | Climate Solutions | 2023.07

4|Compressor assembly

 Installationofpipevibrationmufersisrecommended!

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

INFO New compressors are factory-lled with inert gas. Leave this

service charge in the compressor for as long as possible and pre-

vent the ingress of air. Check the compressor for transport damage

before starting any work.

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

etc.) directly to the compressor are not permissible!

 Setuponanevensurfaceorframewithsufcient

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

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.

Ce manuel convient aux modèles suivants

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