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Reciprocating Compressor
BOCK UL-HGX66e
Assembly instructions
(Translation of the original instructions)
96548-10.2021-Us
UL-HGX66e/1340 ML 31
UL-HGX66e/1540 ML 36
UL-HGX66e/1750 ML 44
UL-HGX66e/2070 ML 50
Bock GmbH, Benzstr. 7, 72636 Frickenhausen, Germany
Phone: +49 7022 9454-0, Fax: +49 7022 9454-137
www.bock.de, service@bock.de
BOCK
®
UL-HGX66e/1340 S 37
UL-HGX66e/1540 S 42
UL-HGX66e/1750 S 50
UL-HGX66e/2070 S 60
colour the world
of tomorrow
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Table of Contents
Related Manuals for BOCK UL-HGX66e/1340 ML 31
Summary of Contents for BOCK UL-HGX66e/1340 ML 31
- Page 1 UL-HGX66e/1540 ML 36 UL-HGX66e/1540 S 42 UL-HGX66e/1750 ML 44 UL-HGX66e/1750 S 50 UL-HGX66e/2070 ML 50 UL-HGX66e/2070 S 60 Bock GmbH, Benzstr. 7, 72636 Frickenhausen, Germany Phone: +49 7022 9454-0, Fax: +49 7022 9454-137 www.bock.de, service@bock.de BOCK ® colour the world...
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Page 2: Table Of Contents
It must be passed onto the end customer along with the unit in which the compressor is installed. This document is subject to the copyright of BOCK GmbH, Germany. The information provided in this manual is subject to change and improvements without notice. - Page 3 Contents Page Compressor assembly ..................... 9 Storage and transport ......................9 Setting up .......................... 9 Pipe connections ......................10 Pipes ..........................10 Starting unloader (external) ..................... 10 Laying suction and pressure lines ..................11 Operating the shut-off valves ................... 12 Operating mode of the lockable service connections ............
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Page 4: Safety
1| Safety Identification of safety instructions Indicates a dangerous situation which, if not avoided, will cause immediate fatal or serious injury. Indicates a dangerous situation which, if not avoided, may cause fatal or serious injury. Indicates a dangerous situation which, if not avoided, may cause fairly severe or minor injury. -
Page 5: Intended Use
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 ma- chine (within the EU according to the EU Directives 2006/42/EC Machinery Directive, 2014/68/ EU Pressure Equipment Directive, outside the EU according to the respective national regulations and guidelines). -
Page 6: Product Description
2| Product description Short 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. -
Page 7: Name Plate (Example)
2| Product description Name plate (example) BOCK Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany thermally protected system 380-420 Y/YY : UL-HGX66e/2070 S 60 Type : BB12345-A001 6356 cfh 440-480 Y/YY 107,0 A Y: 196,0 A YY: 335,0 A 7627 cfh... -
Page 8: Areas Of Application
More informations about approved refrigerants on Bock compressor selection tool VAP (vap.bock.de). Oil charge The compressors are filled at the factory with the following oil type: BOCK lub E55 For refilling, we recommend the above oil types. See also section 7.4. -
Page 9: Compressor Assembly
4| Compressor assembly New compressors are factory-filled 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. Storage and transport Storage at -30°C...+70°C (-22°F...+158°F), maximum permissible relative humidity 10% - 95%, no condensation Do not store in a corrosive, dusty, vaporous atmosphere or in a com-... -
Page 10: Pipe Connections
4| Compressor assembly Pipe connections 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). -
Page 11: Laying Suction And Pressure Lines
4| Compressor assembly Solenoid valve dead Non-return valve open Fig. 6 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 using a heat protection thermostat on the discharge side of the com- pressor. -
Page 12: Operating The Shut-Off Valves
4| Compressor assembly 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... -
Page 13: Suction Pipe Filter And Filter Drier
4| Compressor assembly 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 renewed depending on the degree of contamination (reduced pressure loss). Moisture in the refrigeration circuit can lead to crystal and hydrate formation. -
Page 14: Standard Motor, Design For Direct Or Partial Winding Start
5| Electrical connection Standard motor, design for direct or partial winding start Designation on the name plate Y/YY Compressors with this marking are suitable for direct or partial winding start. The motor winding is subdivided into two parts: Part winding 1 = 50% and part winding 2 = 50%. This winding division reduces the start-up current needed for a part winding start to approx. - Page 15 5| Electrical connection 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: 400 V 460 V Direktstart YY Teilwicklungsstart Y/YY Direct start YY Part winding start Y/YY...
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Page 16: Basic Circuit Diagram For Part Winding Start With Standard Motor
Basic circuit diagram for part winding start with standard motor FC1.2 FC1.1 I> I> I> I> I> I> FC1.1 FC1.2 L3 N PE Y/YY B1 B2 INT69 Compressor terminal box Anschlußkasten Verdichter Fig. 12 High pressure safety monitor Safety chain (high/low pressure monitoring) Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) Oil temperature sensor... - Page 17 FC1.1/1.2 Motor protection switch 6.c.8 Control power circuit fuse INT69 G Electronic trigger unit INT69 G Delay relay for contactor switchover Main switch PW INT69 HG44/66 Mains contactor (part winding 1) Mains contactor (part winding 2) BOCK COMPRESSORS Control voltage switch...
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Page 18: Special Motor: Design For Direct Or Star-Delta Start
5| Electrical connection Special motor: design for direct or star-delta start A mechanical unloaded start with bypass solenoid valve is required for the star-delta start. Designation on the name plate ∆ / Y... - Page 19 (Zubehör) erforderlich. (Zubehör) erforderlich. (Zubehör) erforderlich. Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten 5| Electrical connection ∆ / Y ∆ / Y ∆ / Y Star-delta start-up is only possible for ∆ (230 V) power supply. Example: Stern-Dreieck-Anlauf ist nur im Spannungsbereich ∆...
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Page 20: Basic Circuit Diagram For Star-Delta Start 230 V ∆ / 400 V Y
Basic circuit diagram for star-delta start 230 V ∆ / 400 V Y FC1.1 I> I> I> FC1.1 FC1.2 FC1.2 I> I> I> L3 N PE ˜ B1 B2 INT69G Compressor terminal box Anschlußkasten Verdichter Fig. 13 High pressure safety monitor Safety chain (high/low pressure monitoring) Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) - Page 21 6.b.8 6.b.7 FC1.1/1.2 Motor protection switch 6.d.7 6.d.7 6.d.7 Control power circuit fuse INT69 G Electronic trigger unit INT69 G Delay relay for contactor switchover Main switch Mains contactor D/S INT69 HG44/66 neu Δ-contactor BOCK COMPRESSORS Y-contactor Control voltage switch...
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Page 22: Electronic Trigger Unit Int69 G
5| Electrical connection 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. -
Page 23: Function Test Of The Trigger Unit Int69 G
5| Electrical connection 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 gage. Relay position INT69 G Gage state Relay position Deactivated state... -
Page 24: Commissioning
6| Commissioning Preparations for start-up 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. -
Page 25: Refrigerant Charge
6| Commissioning Refrigerant charge 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. -
Page 26: Maintenance
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. -
Page 27: Accessories
8| Accessories Oil separator Oil slugging can result in damage to the compressor. To prevent oil slugging: The oil return from the oil separator must be guided back at the intended connection (D1) on the compressor housing. A direct oil return into the suction line from the oil separator is not permissible. Ensure that the oil separator is properly dimensioned. -
Page 28: Technical Data
9| Technical data Oil charge (sight glass center) Oil charge (ex works) Suction line Discharge line Weight Starting current (rotor locked) Max. power consumption Max. operating current 380-420 V Y/YY - 3 - 50 Hz PW Voltage 440-480 V Y/YY - 3 - 60 Hz PW PW = Part Winding, Winding ratio : 50%/50% Displacement (1450 rpm / 1740 rpm) -
Page 29: Dimensions And Connections
Anschluss Ölrückführung vom Ölabscheider HG(X)66e/1340-4 11482 (11483) HG66e/1340-4 HC 11498 HGX66e/1340 ML 31 LG 16301 UL-HGX66e/1340 ML 31 16360 Zoll / inch 1/4" NPTF (L)* = Lötanschluss / brazing connection Connection oil return from oil separator Dreilochanschluss für TRAXOIL (3xM6x10) /... - Page 30 10| Dimensions and connections Suction line see technical data, chapter 9 Discharge line Connection suction side, not lockable “ NPTF 7 / 16 Connection suction side, lockable “ UNF 1 / 8 Connection discharge side, not lockable “ NPTF 7 / 16 Connection discharge side, lockable “...
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Page 31: Declaration Of Incorporation
11| 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... -
Page 32: Ul-Certificate Of Compliance
12| UL-Certificate of Compliance Dear customer, the Certificate of Compliance can be downloaded by the following QR-Code: https://vap.bock.de/stationaryapplication/Data/ DocumentationFiles/UL-Certificateofconformity.pdf... -
Page 33: Service
Dear customer, if you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The Bock service team can be contacted by phone, +49 (0)7022 9454-0 or via service@bock.de Yours sincerely, Bock GmbH... - Page 34 BOCK ® Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Phone +49 7022 9454-0 +49 7022 9454-137 www.bock.de © Bock GmbH. All rights reserved. Subject to modifications.