BOCK HG66e/1340-4 Manuale utente

BOCK HG66e (HC/LG)

Assembly instructions

96446-11.2022-Gb

Translation of the original instructions

colour the world

of tomorrow

BOCK®

HG(X)66e/1340-4 (S) HG66e/1340-4 (S) HC

HG(X)66e/1540-4 (S) HG66e/1540-4 (S) HC

HG(X)66e/1750-4 (S) HG66e/1750-4 (S) HC

HG(X)66e/2070-4 (S) HG66e/2070-4 (S) HC

HGX66e/1340 ML 31 LG HGX66e/1340 S 37 LG

HGX66e/1540 ML 36 LG HGX66e/1540 S 42 LG

HGX66e/1750 ML 44 LG HGX66e/1750 S 50 LG

HGX66e/2070 ML 50 LG HGX66e/2070 S 60 LG

96446-11.2022-DGbFEIRu

About these instructions

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

standings and prevent damage. Improper assembly and use of the compressor can result in serious

or fatal injury.

Observe the safety instructions contained in these instructions.

These instructions must be passed onto the end customer along with the unit in which the compres-

sor is installed.

Bock GmbH

72636 Frickenhausen

Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Phone +49 7022 9454-0

Fax +49 7022 9454-137

www.bock.de

[email protected]

Manufacturer

Contact

Contents Page

1 Safety 4

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

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

1.3 General safety instructions

1.4 Intended use

 2 Safetyinstructionsforuseofammablerefrigerants 6

2.1 Safety instructions

 2.2 Qualicationsrequiredofpersonnel

3 Product description 7

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 10

4.1 Refrigerants

4.2 Oil charge

4.3 Limits of application

96446-11.2022-DGbFEIRu

Contents Page

5 AreasofapplicationonHCandLGcompressors 11

5.1 Refrigerants

5.2 Oil charge

5.3 Limits of application

6Compressorassembly 12

6.1 Storage and transport

6.2 Setting up

6.3 Pipe connections

6.4 Pipes

6.5 Start unloader (external)

6.6 Laying suction and pressure lines

6.7 Operating the shut-off valves

6.8 Operating mode of the lockable service connections

 6.9 Suctionpipelterandlterdrier

 7 Electricalconnection 16

7.1 Information for contactor and motor contactor selection

7.2 Standard motor, design for direct or partial winding start

7.3 Basic circuit diagram for partial winding start with standard motor

7.4 Special motor: design for direct or star-delta start

7.5 Basic circuit diagram for star-delta start 230 V ∆/ 400 V Y

7.6 Electronic trigger unit INT69 G

7.7 Connecting of the trigger unit INT69 G

7.8 Functional test of the trigger unit INT69 G

7.9 Electronic trigger unit INT69 G on HC and LG compressors

7.10 Oil sump heater (accessories)

7.11 Oil sump heater on HC and LG compressors

7.12 Capacity regulator (accessories)

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

 8 Commissioning 28

8.1 Preparations for start-up

8.2 Pressure integrity test

8.3 Leak test

8.4 Evacuation

8.5 Refrigerant charge

8.6 Start-up

8.7 Avoid slugging

9 Maintenance 31

9.1 Preparation

9.2 Work to be carried out

9.3 Spare parts recommendation

9.4 Lubricants / oil

9.5 Decommissioning

 9.6 Additionalinformationwhenusingammablerefrigerants

 10 Accessories 33

10.1 Capacity regulator

10.2 Oil separator

10.3 Oil level regulator

 11 Technicaldata 36

 12 Dimensionsandconnections 37

 13 Declarationofincorporation 39

14 Service 41

96446-11.2022-DGbFEIRu

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:

96446-11.2022-DGbFEIRu

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

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, 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!

96446-11.2022-DGbFEIRu

2 |Safety instructions for use of

flammable refrigerants

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 classied into the safety group A3 (highly-

inammablerefrigerant)accordingtoEN378.

•HFOrefrigerantsareclassiedintothesafetygroupA2L(hardly-

inammable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refriger-

ant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).

2.1 Safety instructions

2.2 Qualicationsrequiredofpersonnel

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inhandling

ammablerefrigerants.

96446-11.2022-DGbFEIRu

3 |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

3.1 Short description

Dimension and connection values can be found in Chapter 12

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

96446-11.2022-DGbFEIRu

3 |Product description

3.2 Nameplate (example)

3.3 Typekey (example)

IP 65

BB12345-A001

HGX66e/2070-4

HG 66 e2070 -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

e 12 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 GmbH, Benzstr. 7

72636 Frickenhausen, Germany

BOCK

BOCKlub E55

96446-11.2022-DGbFEIRu

3 |Product description

2070-

2070

3.4 Typekey HCcompressor (example)

3.5 Typkey LGcompressor (example)

¹) HG - Hermetic Gas-Cooled (suction gas-cooled)

²) S - More powerful motor

¹) HG - Hermetic Gas-Cooled (suction gas-cooled)

²) X

- Ester oil charge

3) S - More powerful motor

ML - Motor for normal cooling and deep freezing

Hydrocarbons

Motor variant ²)

Number of poles

Swept volume

e-series

Numbers of cylinders

Size

Series ¹)

HFO refrigerant

Engine performance in hp

Motor variant 3)

Swept volume

e-series

Numbers of cylinders

Size

Oillling²)

Series ¹)

96446-11.2022-DGbFEIRu

4 |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7.13,p.27)

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!

4.3 Limitsofapplication

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

- für R134a, R404A/R507, R407C, R407F BOCKlub E55

- für R22 BOCKlub A46

Compressors with ester oil charge (BOCKlub E55) are marked with an X in the type

designation (e.g. HGX66e/2070-4).

4.1 Refrigerants

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

4.2 Oilcharge

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

Alternatives:see chapter 9.4

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

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