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Summary of Contents for Danfoss BOCK UL-HGX12e CO2 LT
- Page 1 Reciprocating Compressor BOCK UL-HGX e CO ® Operating guide UL-HGX12e/20 ML 0,7 CO UL-HGX12e/20 S 1 CO UL-HGX12e/30 ML 1 CO UL-HGX12e/30 S 2 CO UL-HGX12e/40 ML 2 CO UL-HGX12e/40 S 3 CO Translation of the original instructions AQ450435606290en-US0201...
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Page 2: Table Of Contents
Unauthorized changes and modifications to the product not covered by this manual are prohibited and will void the warranty! This instruction manual is a mandatory part of the product. It must be available to the personnel who operate and maintain this product. 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. Contents Page Safety..........................4 1.1 Identification of safety instructions..................4 1.2 Qualifications required of personnel..................4 1.3 Safety instructions......................... 5 1.4 Intended use.......................... 5 Product description....................... 6 2.1 Short description........................6 2.2 Name plate..........................7 2.3 Type key.......................... 7 © Danfoss | Climate Solutions | 2023.06 2 | AQ450435606290en-US0201... - Page 3 6.9 Avoiding slugging........................ 2 6 6.10 Filter dryer..........................26 Maintenance........................26 7.1 Preparation..........................26 7.2 Work to be carried out......................27 7.3 Spare parts recommendation / accessories................27 7.4 Lubricants.......................... 2 7 7.5 Decommissioning........................27 Technical data....................... 28 Dimensions and connections..................30 Declaration of incorporation..................32 11 UL-Certificate of Compliance..................34 © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 3...
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Page 4: Safety
140°F (60°C) on the pressure side or below 32°F (0°C) on the suction side can be reached. • Avoid contact with refrigerant under any circumstances. Contact with refrigerant can lead to severe burns and skin irritations. © Danfoss | Climate Solutions | 2023.06 4 | AQ450435606290en-US0201... -
Page 5: Qualifications Required Of Personnel
Inadequately qualified personnel poses the risk of accidents, the consequence being serious or fatal injury. Work on compressors must therefore only be performed by personnel with the qualifications listed below: • e.g., a refrigeration technician or refrigeration mechatronics engineer. • As well as professions with comparable training, which enable 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 recognizing any potential dangers. © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 5... -
Page 6: Product Description
2.1 Short description • Semi-hermetic two-cylinder reciprocating compressor with suction gas cooled driving motor. • The flow of refrigerant sucked in from the evaporator is led over the engine and provides for a particularly intensive cooling. Thus the engine can be kept on a relatively low temperature level specially during high load. • Oil pump independent of direction of rotation for reliable and safe oil supply. • O ne decompression valve each on the low and high pressure side, which vent into the atmos- phere when inadmissibly high pressure levels are reached. Transport eyelet Valve plate Name plate Oil pump Oil sight glass Fig. 1 Cylinder cover Terminal box Discharge shut-off valve Suction shut-off valve Fig. 2 Dimension and connection values can be found in chapter 9 © Danfoss | Climate Solutions | 2023.06 6 | AQ450435606290en-US0201... -
Page 7: Type Key
1 2 e 40 S Low Temperature version HP code for motor size Compressor version Swept volume e-series Number of cylinders Size Oil charge ² Series ¹ Identification UL compressor ¹ HG - Hermetic Gas-Cooled (suction gas-cooled) ² - Ester oil charge ³ ML - Deep freezing at low and medium evaporation temperatures S - For frequency regulation and extended limits of application © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 7... -
Page 8: Areas Of Application
Property damage possible. max. The oil level must be in the visible part of the sight glass; 21 fl.oz Oil level damage to the compressor 0,6 Ltr. min. is possible if overfilled or Fig. 4 underfilled! © Danfoss | Climate Solutions | 2023.06 8 | AQ450435606290en-US0201... -
Page 9: Limits Of Application
- Max. permissible switching frequency 12x /h. - A minimum running time of 3 min. steady-state condition (continuous operation) must be achieved. Avoid continuous operation in limit range. Max. permissible operating pressure (LP/HP) : 1450/1450 psig, 100/100 bar LP = Low pressure HP = High pressure © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 9... -
Page 10: Compressor Assembly
Use transport eyelet. Do not lift manually! Use lifting gear! 4.2 Setting up Attachments (e.g. pipe holders, additional units, fastening parts, etc.) directly to the compressor are not permissible! Provide adequate clearance for maintenance work. Ensure adequate compressor ventilation. Do not use in a corrosive, dusty, damp atmosphere or a com- bustible environment. Setup on an even surface or frame with sufficient load-bearing capacity. Single compressor preferably on vibration damper. Compound connection basically rigid. © Danfoss | Climate Solutions | 2023.06 10 | AQ450435606290en-US0201... -
Page 11: Pipe Connections
4.5 Flange shut-off valves (HP/LP) Risk of injury. The compressor must be depressurized through connections A1 and B1 before commencing any work and prior to connecting to the refrigerant system. Fig. 6 Fig. 7 © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 11... -
Page 12: Laying Suction And Pressure Lines
Rigid fixed As short as possible point Fig. 8 4.7 Operating the shut-off valves (example) Before opening or closing the shut-off valve, release the valve spindle seal by approx. of a turn counter-clockwise. After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise. Tighten Release Valve spindle seal Fig. 10 Fig. 9 © Danfoss | Climate Solutions | 2023.06 12 | AQ450435606290en-US0201... -
Page 13: Operating Mode Of The Lockable Service Connections
Service connec- tion closed Pipe connection Connection Spindle blocked Fig. 11 Compressor Opening the shut-off valve: Spindle: turn to the left (counter-clockwise) as far as it will go. —> Shut-off valve completely opened / service connection closed. Service connec- tion opened Pipe connection Connection Spindle open Fig. 12 Opening the service connection Compressor 1 / 2 Spindle: Turn - 1 turn to the right clockwise. —> Service connection opened / shut-off valve opened. After activating the spindle, generally fit the spindle protection cap again and tighten with 40 - 50 Nm. This serves as a second sealing feature during operation. © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 13... -
Page 14: Oil Return
4 | Compressor assembly 4.9 Oil return To ensure the oil return function will work reliably no matter what kind of system configuration you are using, Bock recommends incorporating oil separators or oil level monitoring equipment. The "O" connection is already available from the factory for the purpose of installing the additional oil level monitoring component. Oil should be returned from the oil separator to the compressor via the "D1" connection provided for this purpose on the compressor. 4.10 Suction pipe filter For systems with long pipes and higher degree of contamination, a filter on the suction-side is recommended. The filter has to be be renewed depending on the degree of contamina- tion (reduced pressure loss). © Danfoss | Climate Solutions | 2023.06 14 | AQ450435606290en-US0201... -
Page 15: Electrical Connection
(e.g. VDE) as well as the manufacturer’s specifications. Motor protection switches are required! Motor contactors, feed lines, fuses and motor protec- tion switches must be rated according to the maximum operating current (see name plate). For motor protection, use a current-dependent, time-delayed overload protection device for monitoring all three phases. Adjust the overload protection device so that it must be actuated within 2 hours at 1.2 times the maximum working current. © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 15... -
Page 16: Connection Of The Driving Motor
5| Electrical connection 5.2 Connection of the driving motor The compressor is designed with a motor for star-delta circuits. Designation on the name plate ∆ / Y © Danfoss | Climate Solutions | 2023.06 16 | AQ450435606290en-US0201... - Page 17 96027-11.06-DGbF Insulators L1 L2 INFO The supplied insulators must be mounted according to the illustrations as shown. The connection examples shown refer to the standard version. In the case 96027-11.06-DGbF of special voltages, the instructions affixed to the terminal box apply. © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 17...
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Page 18: Oil Sump Heater
5.3 Circuit diagramm for direct start 280 V ∆ / 460 V Y FC1.1 I> I> I> FC1.1 L3 N PE ∆ / Y -EC1 Θ 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) Release switch (thermostat) Oil sump heater Compressor motor © Danfoss | Climate Solutions | 2023.06 18 | AQ450435606290en-US0201... - Page 19 L1.1 L2.1 L3.1 L1.2 P> Θ Θ FC1.1 Motor protection switch Control power circuit fuse INT69 G Electronic trigger unit INT69 G Main switch Net switch Control voltage switch © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 19...
- Page 20 B1 B2 voltage. N 43 43 11 X2 1 This would destroy the trigger unit Θ Θ Θ INT69 G and PTC Steuerstrom- Control circuit Steuerstrom- sensors. kreis kreis Θ Fig. 14 Terminal box © Danfoss | Climate Solutions | 2023.06 20 | AQ450435606290en-US0201...
- Page 21 5.8 Selection and operation of compressors with frequency converters For safe operation of the compressor, the frequency converter must be able to apply an overload of at least 160% of the compressor's maximum current (I-max.) for at least 3 seconds. When using frequency converters, the following things must also be observed: 1. The maximum permissible operating current of the compressor (I-max) (see type plate or technical data) must not be exceeded. 2. If abnormal vibrations occur in the system, the affected frequency ranges 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 The permissible frequency range can be found in the technical data. Rotational speed 0 - f-min f-min - f-max range Start-up time < 1 s ca. 4 s immediately Switch-off time f-min/f-max see chapter: Technical data: permissible frequency range © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 21...
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Page 22: Commissioning
C arry out the leak test on the refrigerating plant in accordance with UL-/CSA-Standards or a corresponding safety standard, while always observing the maximum permissible overpressure for the compressor. Only dry test gases may be used for the leak test, e.g. nitrogen N2 min. 4.6 (= purity 99.996 % or higher). © Danfoss | Climate Solutions | 2023.06 22 | AQ450435606290en-US0201... -
Page 23: Evacuation
A refrigerant supplement, which may become necessary after start-up, can be topped up in vapor form on the suction side. Avoid overfilling the machine with refrigerant! Do not charge liquid refrigerant into the suction-side on the compressor. Do not mix additives with the oil and refrigerant. © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 23... -
Page 24: Start-Up
If larger quantities of oil have to be topped up, there is a risk of oil impact effects. If this is the case, check the oil return! 6.7 Pressure switch Suitably adjusted pressure switches according to UL 207 / EN 378 or national standards that switch off the compressor before reaching the maximum permissible operating pressure must be installed in the system. The pressure reduction for the pressure switches can occur either at the suction and pressure lines between the shut-off valve and compressor or at the non-lockable connections for the shut-off valves (connections A and B, see Chapter 9). © Danfoss | Climate Solutions | 2023.06 24 | AQ450435606290en-US0201... -
Page 25: Pressure Relief Valves
EN 378-2 or appropriate safety standards. Failure to observe can result in risk of injury from CO streaming out of the two pressure relief valves! streaming Fig. 16 © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 25... -
Page 26: Avoiding Slugging
CO is produced which blocks the outlet and could hinder the streaming out of CO . Otherwise, there is the danger that pressure can be built up again. © Danfoss | Climate Solutions | 2023.06 26 | AQ450435606290en-US0201... -
Page 27: Work To Be Carried Out
ML and S: BOCKlub E85 7.5 Decommissioning Close the shut-off valves on the compressor. CO does not need to be recycled and can therefore be blown off into the environment. It is essential to ensure good ventilation or conduct the CO into the outdoors to avoid danger of suffocation. When releasing CO , avoid a fast drop in pressure to prevent oil from exiting with it. If the compressor is unpressurized, remove the piping on the pressure- and suction-side (e.g. dismantling of the shut-off valve, etc.) and remove the compressor using an appro- priate hoist. Dispose of the oil inside in accordance with the applicable national regulations. When decommissioning the compressor (eg. for service or replacement of the compressor) larger amounts of CO in the oil can be set free. If the decompression of the compressor is not sufficient enough, closed shut-off valves may lead to intolerable excessive pressure. For this reason the suction side (LP) and the high pressure side (HP) of the compressor have to be secured by decompression valves. © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 27... -
Page 28: Technical Data
Suction line Discharge line Weight permissible 30 - 70 frequency range Starting current (rotor locked) Max. power consumption Max. operating current Voltage 265-290 V ∆ / 440-480 V Y - 3 - 60 Hz Displacement (1450 / 1740 rpm) No. of cylinders Type UL-HGX12e/ © Danfoss | Climate Solutions | 2023.06 28 | AQ450435606290en-US0201... - Page 29 8 | Technical data © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 29...
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Page 30: Dimensions And Connections
Unbemaßte Radien / Undimensioned radii: Unbemaßte Radie . All rights reserved in the event © Danfoss | Climate Solutions | 2023.06 The supplier has to ensure the delivery of parts 30 | AQ450435606290en-US0201 payment of damages. All rights reserved in the event Zust. - Page 31 3 / 8 “ NPTF Connection Oil sump heater 2 x 1 1 / 8 “ - 18 UNEF Sight glass 1 / 8 “ NPTF Connection thermal protection thermostat 2 x 1 1 / 8 “ - 18 UNEF Connection oil level regulator 1 / 8 “ NPTF Connection oil temperature sensor Decompression valve HP M22x1.5 Decompression valve LP M22x1.5 © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 31...
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Page 32: Declaration Of Incorporation
Bock GmbH Authorized person for compiling and handing Alexander Layh over technical documentation: Benzstraße 7 72636 Frickenhausen, Germany Frickenhausen, 04th of January 2021 i. A. Alexander Layh, Global Head of R&D © Danfoss | Climate Solutions | 2023.06 32 | AQ450435606290en-US0201... - Page 33 Bock GmbH Authorized person for compiling and handing Alexander Layh over technical documentation: Benzstraße 7 72636 Frickenhausen, Germany Frickenhausen, 14th of October 2022 i. A. Alexander Layh, Global Head of R&D © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 33...
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Page 34: Ul-Certificate Of Compliance
11 | 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/COC CO2 trans.pdf © Danfoss | Climate Solutions | 2023.06 34 | AQ450435606290en-US0201... - Page 35 © Danfoss | Climate Solutions | 2023.06 AQ450435606290en-US0201| 35...
- Page 36 © Danfoss | Climate Solutions | 2023.06 36 | AQ450435606290en-US0201...
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