BOCK HG66e/1340-4 Assembly Instructions Manual

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BOCK HG66e (HC/LG)

Assembly instructions

96446-11.2022-Gb

Translation of the original instructions

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

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

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

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

HGX66e/1340 ML 31 LG

HGX66e/1540 ML 36 LG

HGX66e/1750 ML 44 LG

HGX66e/2070 ML 50 LG

BOCK

HG66e/1340-4 (S) HC

HG66e/1540-4 (S) HC

HG66e/1750-4 (S) HC

HG66e/2070-4 (S) HC

HGX66e/1340 S 37 LG

HGX66e/1540 S 42 LG

HGX66e/1750 S 50 LG

HGX66e/2070 S 60 LG

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Page 1 BOCK HG66e (HC/LG) Assembly instructions 96446-11.2022-Gb Translation of the original instructions 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...
Page 2: Table Of Contents
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. Manufacturer Bock GmbH 72636 Frickenhausen Contact Bock GmbH Benzstraße 7...
Page 3 Contents Page Areas of application on HC and LG compressors 5.1 Refrigerants 5.2 Oil charge 5.3 Limits of application Compressor assembly 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 filter and filter drier Electrical connection...
Page 4: Safety
1| Safety 1.1 Identification of safety instructions: 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. 1.2 Qualifications required of personnel 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 professions with comparable training, which enables personnel to assemble, install, maintain and repair refrigeration and air-conditioning systems.
Page 5: General Safety Instructions
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).
Page 6: Safety Instructions For Use Of Flammable Refrigerants
2 | Safety instructions for use of flammable refrigerants 2.1 Safety instructions 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 classified into the safety group A3 (highly- inflammable refrigerant) according to EN 378.
Page 7: Product Description
3 | Product description 3.1 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 8 3 | Product description 3.2 Name plate (example) BOCK Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany 380-420 Y/YY HGX66e/2070-4 BB12345-A001 180,0 440-480 Y/YY 107,0 A Y: 196,0 A YY: 335,0 A 217,2 BOCK lub E55 IP 65 Fig. 2 Type designation Voltage, circuit, frequency...
Page 9: Type Key
3 | Product description 3.4 Type key HC compressor (example) 2070- Hydrocarbons Motor variant ² Number of poles Swept volume e-series Numbers of cylinders Size Series ¹ ¹ HG - Hermetic Gas-Cooled (suction gas-cooled) ² S - More powerful motor 3.5 Typ key LG compressor (example) 2070 HFO refrigerant Engine performance in hp...
Page 10: Areas Of Application
- für R134a, R404A/R507, R407C, R407F BOCK lub E55 - für 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). INFO For refilling, we recommend the above oil types.
Page 11: Areas Of Application On Hc And Lg Compressors
BOCK lub E85 (from t > 15°C, must be specified in the order) 5.3 Operating limits 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 and the follo- wing notes: - Minimum superheating ∆t = 20 K (only at HC compressors) In order to guarantee the required minimum superheating of ∆t = 20 K, an internal heat exchanger IHX may have to be installed.
Page 12: Compressor Assembly
6 | Compressor assembly INFO 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. 6.1 Storage and transport 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.
Page 13: Pipe Connections
6 | Compressor assembly 6.3 Pipe connections ATTENTION Damage possible. Superheating can damage the valve. Remove the pipe supports from the valve for soldering. Only solder using inert gas to inhibit oxidation products (scale). The discharge gas connection can be moved upwards with an adapter (accessory). This makes it easier to remove the com- pressor from a refrigerating system. Pipe connections on the compressor are available for soldering or welding (accessories). The discharge and suction line valves have graduated inside diameters so that pipes with standard millimetre and inch dimensions can be used. The pipe will be immersed more or less deeply according to dimension.
Page 14: Laying Suction And Pressure Lines
6 | 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 to use a heat protection thermostat on the discharge side of the com- pressor.
Page 15: Operating The Shut-Off Valves
6 | Compressor assembly 6.7 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 Fig.
Page 16: Suction Pipe Filter And Filter Drier
6 | Compressor assembly 6.9 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 be renewed depending on the degree of contamination (reduced pressure loss). Moisture in the refrigeration circuit can lead to crystal and hydrate formation. For this reason, we recommend using a filter drier and a sight glass with a moisture indicator.
Page 17: Standard Motor, Design For Direct Or Partial Winding Start
7 | Electrical connection 7.2 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 18 7.3 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 Datum...
Page 19 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 switch over Main switch PW INT69 HG44/66 Mains contactor (part winding 1) Mains contactor (part winding 2) BOCK COMPRESSORS Control voltage switch...
Page 20: Special Motor: Design For Direct Or Star-Delta Start
7 | Electrical connection 5.4 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 21 ∆ / Y ∆ / Y ∆ / Y 7 | Electrical connection Stern-Dreieck-Anlauf ist nur im Spannungsbereich ∆ (230 V) möglich. Beispiel: Stern-Dreieck-Anlauf ist nur im Spannungsbereich ∆ (230 V) möglich. Beispiel: Stern-Dreieck-Anlauf ist nur im Spannungsbereich ∆ (230 V) möglich. Beispiel: Star-delta start-up is only possible for ∆ (230 V) power supply. Example: 230 V ∆...
Page 22: Basic Circuit Diagram For Star-Delta Start 230 V ∆ / 400 V Y
7.5 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) Oil temperature sensor Release switch (thermostat)
Page 23 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 switch over Main switch Mains contactor D/S INT69 HG44/66 neu Δ-contactor BOCK COMPRESSORS Y-contactor Control voltage switch...
Page 24: Electronic Trigger Unit Int69 G
7 | Electrical connection 7.6 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 25 7 | Electrical connection 7.8 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 gauge. Relay position INT69 G Gauge state Relay position Deactivated state 11-12 INT69 G switch-on...
Page 26: Oil Sump Heater (Accessories)
7 | Electrical connection 7.10 Oil sump heater (accessories) 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 shocks under certain circumstances.
Page 27: Capacity Regulator (Accessories)
7 | Electrical connection 7.12 Capacity regulator (Accessories) ATTENTION A fuse (max. 3xlB in accordance with IEC 60127-2-1) corresponding to the rated current must be placed in front of every magnetic coil of the capacity regulator as short-circuit protection. The ra- ted voltage of the fuse must be equal to or greater than the rated voltage of the magnetic coil. The ability of the fuses to switch off must be greater than or equal to the maximum assumable short- circuit current at the installation location. 7.13 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 140% 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.
Page 28: Preparations For Start-Up
8 | Commissioning 8.1 Preparations for start-up INFO 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. Check the compressor for transport damage! 8.2 Pressure integrity test The compressor has been tested in the factory for pressure integrity. If however the entire system is to be subjected to a pressure integrity test, this should be carried out in accordance with EN 378-2 or a corresponding safety standard without the inclusion of the compressor.
Page 29: Refrigerant Charge
8 | Commissioning 8.5 Refrigerant charge CAUTION 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. If the refrigerant needs topping up after starting the compressor, it can be topped up in vapour form on the suction side, or, taking suitable precautions, also in liquid form at the inlet to the evaporator.
Page 30 8 | Commissioning There should be no movement of coolant whatsoever while the compressor is at a standstill. The use of a check valve is strongly recommended, especially for heat pump applications. Otherwise there is a risk of back condensation, which can result in compressor damage.
Page 31: Maintenance
Annual checks: Oil level, leak tightness, running noises, pressures, temperatures, function of auxiliary devices such as oil sump heater, pressure switch. 9.3 Spare parts recommendation/accessories 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! 9.4 Lubricants / oil The oil type filled as standard in the factory is marked on the name plate, and this should always be used, even in the case of maintenance units.
Page 32: Decommissioning
9 | Maintenance 9.5 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 compressor is depressurised, undo the fastening screws of the shut-off valves. Remove the compressor using an appropriate hoist. Dispose of the oil inside in accordance with the applicable national regulations.
Page 33: Accessories
10 | Accessories 10.1 Capacity regulator ATTENTION If the capacity regulator is installed at the factory, the control component (pilot valve) is subsequently installed and connected by the customer. LR 1 LR 2 Delivery condition 1 (from the factory): Fig. 19 Fig. 18 Cylinder cover prepared for capacity regulator. Cover Fig. 21 Fig. 20 Before start-up, remove the cover at the Delivery condition 2 (from the factory): capacity regulator and replace it with the...
Page 34: Oil Separator
Information about the use, operation, maintenance and servicing of the components is available in the printed literature or on the internet under vap.bock.de. 10.2 Oil separator ATTENTION Oil slugging can result in damage to the compressor.
Page 35: Oil Level Regulator
10 | Accessories 10.3 Oil level regulator Oil level regulation systems have proven themselves with parallel circuits of several compressors. The connection "0" is provided for installing an oil level regulator (see dimensions drawing). All common mechanical oil level regulators from AC&R, ESK, Carly as well as the electronic oil level regulation system from AC&R, Teklab, OM3 TraxOil from Alco and ESK (only long version) can be connected directly without adapters (see fig.23).
Page 36: Technical Data
11 | Technical data Oil charge (sight glass centre) Oil charge (ex works) Suction line Discharge line Weight permissible fre- 25 - 60 quency range Starting current (rotor locked) Max. power consumption Max. operating current 380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW Voltage PW = Part Winding Winding ratio : 50 % / 50 %...
Page 37: Dimensions And Connections
11494 (11495) HG66e/2070-4 HC 11504 HGX66e/2070 ML 50 LG 16307 UL-HGX66e/2070 ML 50 16366 Connection oil level regulator Schauglas HG(X)66e/1340-4 S 11484 (11485) HG66e/1340-4 S HC 11499 HGX66e/1340 S 37 LG 16302 UL-HGX66e/1340 S 37 16361 Anschluss Ölserviceventil 3xM6 ÖV Zoll / inch 1/4"...
Page 38 12| Dimensions and connections Suction line see technical data, chapter 11 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 “...
Page 39: Declaration Of Incorporation
13 | 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 Name:...
Page 40 Declaration of incorporation of partly completed machinery in accordance with UK Statutory Instrument Supply of Machinery (Safety) Regulations 2008, Annex II 1. B Manufacturer: Bock GmbH Benzstraße 7 72636 Frickenhausen, Germany We, as manufacturer, declare in sole responsibility that the partly completed machinery...
Page 41: Service
14 | 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 faithfully Bock GmbH...

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BOCK HG66e/1340-4 Assembly Instructions Manual

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