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Summary of Contents for Danfoss BOCK HA44e
- Page 1 HA 44 e (LG) BOCK ® Operating guide HA44e/475-4 HAX44e/475-4 HA44e/565-4 HAX44e/565-4 HA44e/665-4 HAX44e/665-4 HAX44e/475 LT 9 LG HAX44e/565 LT 12 LG HAX44e/665 LT 14 LG Translation of the original instructions AQ452839384735en-000301...
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Page 2: Table Of Contents
1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use Safety instructions for use of flammable refrigerants 2.1 Safety instructions 2.2 Qualifications required of personnel Product description 3.1 Short description 3.2 Name plate 3.3 Type key 3.4 Type key LG compressors Areas of application 4.1 Refrigerants 4.2 Oil charge 4.3 Limits of application 2 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... - Page 3 8.5 Refrigerant charge 8.6 Start-up 8.7 Avoid slugging 8.8 Connection of oil level regulator Maintenance 9.1 Preparation 9.2 Work to be carried out 9.3 Spare parts recommendation/accessories 9.4 Lubricants / oil 9.5 Decommissioning 9.6 Additional information when using flammable refrigerants 10 Accessories 10.1 Capacity regulator 11 Technical data 12 Dimensions and connections 13 Declaration of incorporation AQ452839384735en-000301 | 3 © Danfoss | Climate Solutions | 2024.03...
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Page 4: Safety
• F or 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. 4 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
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). 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 specified in these instructions may be used. Any other use of the compressor is prohibited! AQ452839384735en-000301 | 5 © Danfoss | Climate Solutions | 2024.03... -
Page 6: Safety Instructions For Use Of Flammable Refrigerants
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. Semi-hermetic compressors are to be classified as "technically INFO tight" (see e.g. TRBS 2152 part 2 / TRGS 722). 2.2 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 in handling flammable refrigerants. 6 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 7: Product Description
3| Product description 3.1 Short description • Semi-hermetic four-cylinder reciprocating compressor with oil pump lubrication. • Flange-mounted drive motor on the compressor case. • Specially or deep cooling with air-cooled motor and direct suction at the cylinder. Terminal box Discharge Transport shut-off valve eyelet Valve plate Cylinder cover Oil pump Name plate Oil sight glass Fig. 1 Suction shutoff valve Air guide hood with fan Fig. 2 Dimension and connection values can be found in Chapter 12. AQ452839384735en-000301 | 7 © Danfoss | Climate Solutions | 2024.03... -
Page 8: Type Key
ND (LP): max. admissible operating pressure 12 Oil type filled at the factory Low pressure side 13 Protection class Electrical accessories can change HD (HP): max. admissible operating pressure High pressure side the IP protection class! Observe the limits of application diagrams! 3.3 Type key (example) 4 e 665- 4 Number of poles Swept volume e-series Numbers of cylinders Size Oil charge ² Series ¹ HA - Hermetic Air-cooled for deep-freezing ¹ X - Ester oil charge (HFC refrigerant, e.g. R404A/R507) ² 8 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... - Page 9 3| Product description 3.4 Typ key LG compressor (example) LT 9 4 e 475 Low-GWP Engine performance in hp Engine for deep-freezing Swept volume e-series Numbers of cylinders Size Oil charge ² Series ¹ HA - Hermetic Air-cooled for deep-freezing ¹ X - Ester oil charge ² AQ452839384735en-000301 | 9 © Danfoss | Climate Solutions | 2024.03...
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Page 10: Areas Of Application
(continuous operation) must be achieved. 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 sufficient 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. (For more on the subject of frequency converters, see chapter 7.14, 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! 10 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 11: Limits Of Application
During operation in the vacuum range, there is a danger of air entering on the suction side. This can cause chemical reactions, pressure rise in the condenser and an excessive pressure gas tem- perature as well as shifting of the refrigerant ignition limit into the critical range. Avoid absolutely any entry of air! Use a low pressure switch! Select a shut-off point min. 50 Pa higher than the prevailing surrounding pressure! LP = Low pressure HP = High pressure Maximum permissible operating : 19/32 bar pressure (LP/HP) AQ452839384735en-000301 | 11 © Danfoss | Climate Solutions | 2024.03... -
Page 12: Compressor Assembly
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. Use transport eyelet. Do not lift manually! Use lifting gear! 6.2 Setting up ATTENTION 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. The compressor must not be in the air stream to another component of the refrigeration system (e.g. condenser). The cooling of the drive motor must be reliable guaranteed. Do not use in a corrosive, dusty, damp atmosphere or a combustible environment. Setup on an even surface or frame with sufficient load- bearing capacity. Single compressor preferably on vibration damper. Duplex and parallel circuits always rigid. Sun protection: If the compressor is set up outdoors, it has to be protected from direct sunlight. 12 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 13: Pipe Connections
Ensure a proper oil return. Keep pressure losses to an absolute minimum. 6.5 Laying suction and pressure lines ATTENTION Improperly installed pipes can cause cracks and tears, the result being a loss of refrigerant. Proper layout of the suction and discharge lines directly after INFO the compressor is integral to the system’s smooth running and vibration behaviour. AQ452839384735en-000301 | 13 © Danfoss | Climate Solutions | 2024.03... -
Page 14: Operating The Shut-Off Valves
6| Compressor assembly A rule of thumb: Always lay the first pipe section starting from the shut-off valve downwards and parallel to the drive shaft. Rigid fixed point As short as Fig. 6 possible 6.6 Operating the shut-off valves Before opening or closing the shut-off valve, release the valve spindle seal by approx. ¼ 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. 7 Fig. 8 14 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 15: Operating Mode Of The Lockable Service Connections
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. AQ452839384735en-000301 | 15 © Danfoss | Climate Solutions | 2024.03... -
Page 16: Electrical Connection
ATTENTION When attaching accessories with an electrical cable, a minimum bending radius of 3 x the cable diameter must be maintained for laying the cable. Connect the compressor motor in accordance with the circuit diagram INFO (see inside of terminal box). Use suitable cable entry point of the correct protection type (see name plate) for routing cables into the terminal box. Insert the strain reliefs and prevent chafe marks on the cables. Compare the voltage and frequency values with the data for the mains power supply. Only connect the motor if these values are the same. 7.1 Information for contactor and motor contactor selection All protection equipment, switching and monitoring devices must comply with the local safety regula- tions and established specifications (e.g. VDE) and regulations as well as the manufacturer’s speci- fications. Motor protection switches are required! Motor contactors, feed lines, fuses and motor protection switches must be rated according to the maximum operating current (see name plate). For motor protection, use a current-independent, time-delayed overload protection device for monitor- ing 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. 16 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
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. 50% of that for a direct start. INFO A mechanical unloaded start with bypass solenoid valve is not required. AQ452839384735en-000301 | 17 © Danfoss | Climate Solutions | 2024.03... -
Page 18: Basic Circuit Diagram For Partial Winding Start With Standard Motor
DELTA-P II Oil differential pressure sensor DELTA-P II (accessorie) Bearb. bauknecht Bearb. bauknecht Oil sump heater Gepr. 19.06.2017 Gepr. 26.11.2020 Οnderung Datum Name Norm Urspr. Ers. f. Ers. d. Οnderung Datum Name Norm Urspr. Ers. f. Ers. d. Compressor motor 18 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... - Page 19 Electronic trigger INT69 G at LG compressors has to be installed outside any Θ DELTA- P II danger area! See also chapter 7.9. Θ FC1.1/1.2 Motor protection switch Control power circuit fuse Fan motor INT69 G Electronic trigger unit INT69 G Delay relay for contactor switchover Main switch PW INT69 HA44 neu Mains contactor (part winding 1) Mains contactor (part winding 2) BOCK COMPRESSORS Control voltage switch AQ452839384735en-000301 | 19 © Danfoss | Climate Solutions | 2024.03...
- Page 20 7| 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 Part winding start Y/YY Direct start YY Direktstart YY Teilwicklungsstart Y/YY ATTENTION Failure to do this results in opposed rotary fields and results in damage to the motor. After the motor starts up via partial winding 1, partial winding 2 must be switched on after a maximum delay of one second . Failure to comply can adversely affect the service life of the motor. 20 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03...
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Page 21: Special Motor: Design For Direct Or Star-Delta Start
7| Electrical connection 7.4 Special motor: design for direct or star-delta start A mechanical unloaded start with bypass solenoid valve (accessories) is required for the star-delta start. Designation on the name plate ∆ ∆ ∆ ∆ / Y ∆ ∆ ∆ Star-delta start-up is only possible for 230 V power supply. Example: ∆ 230 V ∆ ∆ 400 V Y ∆ Star-delta start Direct start only Direct start AQ452839384735en-000301 | 21 © Danfoss | Climate Solutions | 2024.03... -
Page 22: Basic Circuit Diagram For Star-Delta Start With Special Motor
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 Release switch (thermostat) Datum 20.02.2009 Bearb. bauknecht DELTA PII Oil differential pressure sensor DELTA-P II (accessories) Gepr. 26.11.2020 Oil sump heater Οnderung Datum Name Norm Urspr. Ers. f. Ers. d. Compressor motor FC1.1/1.2 Motor protection switch 22 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... - Page 23 DANGER Explosion risk! Electronic trigger INT69 G Θ at LG compressors has to be installed outside any danger area! DELTA- P II Θ See also chapter 7.9. Control power circuit fuse Fan motor INT69 G Electronic trigger unit INT69 G Delay relay for contactor switchover Main switch D/S INT69 HA44 neu Mains contactor Δ-contactor BOCK COMPRESSORS Y-contactor Control voltage switch AQ452839384735en-000301 | 23 © Danfoss | Climate Solutions | 2024.03...
- Page 24 (PTC sensor) must not come into contact with external voltage. B1 B2 This would destroy the trigger unit INT69 G and PTC sensors. N 43 43 11 X2 1 Θ Θ Θ Steuerstrom- Steuerstrom- Control circuit kreis kreis Θ Fig. 13 Terminal box 24 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03...
- Page 25 11-12 Reset after mains on 11-14 7.9 Electronic trigger unit INT69 G at LG compressors The supplied INT69 G must be connected according to the wiring diagram shown here in a separate control cabinet, which must be installed outside each danger zone. ATTENTION Install heat protection thermostats and cold conductor motor winding in series! Switch cabinet Schaltschrank INT69G Cold conductor (PTC sensor) motor winding 10 11 12 13 20 21 Heat protection thermo- stat (PTC sensor) Oil temperature sensor Oil sump heater BT.3 Fig. 15 DELTA- P II AQ452839384735en-000301 | 25 © Danfoss | Climate Solutions | 2024.03...
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Page 26: Oil Sump Heater On Lg Compressors
Connection to the current path of the safety control chain is not ATTENTION permitted. 7.11 Oil sump heater on LG compressors As the solubility of HFO refrigerants in oil can be very high, especially at high suction pressures, the compressor must be equipped with an oil sump heater. For this reason, a pump-down circuit is recommended during standstill to reduce the suction-side standstill pressures. Electrical data: 230 V - 1 - 50/60 Hz, 160 W. ATTENTION The oil sump heater must generally be connected and operated! • In a TT- or TN system, a residual current protection device (RCD) must be used. • In an IT system, an insulation monitoring device must be used. National standards and regulations must be observed. 26 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 27: Capacity Regulator (Accessories)
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 chapter 11. Rotational speed 0 - f-min f-min - f-max range Start-up time < 1 s ca. 4 s immediately Switch-off time AQ452839384735en-000301 | 27 © Danfoss | Climate Solutions | 2024.03... -
Page 28: Commissioning
Do not mix any refrigerant with the nitrogen as this could cause the ignition limit to shift into the critical range. C arry out the leak test on the refrigerating plant in accordance with EN 378-2 or a corresponding safety standard, while always observing the maximum permissible overpressure for the compressor. 8.4 Evacuation Do not start the compressor if it is under vacuum. Do not apply ATTENTION any voltage - even for test purposes (must only be operated with r efrigerant). Under vacuum, the spark-over and creepage current distances of the terminal board connection bolts shorten; this can result in winding and terminal board damage. First evacuate the system and then include the compressor in the evacuation process. Relieve the compressor pressure. Open the suction and pressure line shut-off valves. Evacuate the suction and discharge pressure sides using the vacuum pump. At the end of the evacuation process, the vacuum should be < 1.5 mbar when the pump is switched off. Repeat this process as often as is required. For LG compressors suitable equipment approved for flammable refrigerants must be used. 28 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 29: Refrigerant Charge
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. Avoid overfilling the system with refrigerant! ATTENTION To avoid shifts in concentration, zeotropic refrigerant blends must always only be filled into the refrigerating plant in liquid form. Do not pour liquid coolant through the suction line valve on the compressor. It is not permissible to mix additives with the oil and refrigerant. 8.6 Start-up WARNING Ensure that both shut-off valves are open before starting the compressor! Check that the safety and protection devices (pressure switch, motor protection, electrical contact protection measures, etc.) are all functioning properly. Switch on the compressor and let it run for at least 1 minute at a frequency of at least 50 Hz. Only then may the speed of the compressor be reduced. Check the oil level by: The oil must be visible in the sightglass. ATTENTION I f larger quantities of oil have to be topped up, there is a risk of oil hammer effects. If this is the case check the oil return! AQ452839384735en-000301 | 29 © Danfoss | Climate Solutions | 2024.03... -
Page 30: Connection Of Oil Level Regulator
8.8 Connection of 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 oil level regulators from AC&R, ESK and Carly as well as the OM3 TraxOil oil level regulation system from Alco can be connected directly without adapters (see Fig. 17). A sight glass on the oil level regulator is not required. M6 x 10 3 times each je 3 mal Fig. 17 47,6 3 hole connection diagramm for Mechanical oil level regulator 3-Loch-Anschlussbild für ESK, ESK, AC&R and CARLY AC&R und CARLY at the "O" connection 3-Loch-Anschlussbild für TraxOil 3 hole diagramm for TraxOil 30 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 31: Maintenance
200 operating hours, then approx. every 3 years or 10,000 - 12,000 operating hours. Dispose of used oil according to the regulations; observe national regulations. Annual checks: Oil level, leak tightness, running noises, pressures, temperatures, function of a uxiliary devices such as oil sump heater, pressure switch. 9.3 Condensate drainage The terminal box has the option for Condensate drainage (see Fig. 18). ATTENTION When the condensate drain is used, the protection rating of the terminal box is reduced from IP65 to IP32! Condensate drainage Fig. 18 AQ452839384735en-000301 | 31 © Danfoss | Climate Solutions | 2024.03... -
Page 32: Spare Parts Recommendation/Accessories
• If the compressor is to be removed from the system for maintenance or repair, the remaining refrigerant must be suctioned out and the compressor evacuated. The compressor must then be filled with nitrogen (max. 0.5 bar) and sealed gas-tight. 32 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 33: Accessories
O-ring joints and screws. Observe position and construction of the capacity regulator. Attention! Compressor is under pressure! Depressurize the compressor first. WARNING Several capacity regulators cannot switch at the same time during compressor operation! Otherwise the sudden change in load can damage the compressor! Comply with the switching interval of 60 s. • Comply with the switching sequence: Swiching on LR1 60s LR2 Swiching off LR2 60s AQ452839384735en-000301 | 33 © Danfoss | Climate Solutions | 2024.03... - Page 34 Continuous operation in the control stage is not recommended as the gas velocity in the plant system under certain circumstances does not guarantee sufficient oil return to the compressor with activated capacity regulator. W e recommend switching to unregulated operation (100% capac- ity) for at least 5 minutes per capacity-regulated operating hour. An assured oil return can also be realised by a 100% capacity requirement after each compressor restart. E lectrical actuation of the solenoid valve: Normally open, (cor- responds to 100 % compressor capacity). Special accessories are only premounted in the factory if ordered specially by customer. Retrofitting is possible in full compliance with the safety instructions and repair instructions enclosed with the kits. Information about the use, operation, maintenance and servicing of the components is available in the printed literature or on the internet under www.bock.de. For the capacity regulator a step protection is optional available, Art-Nr. 097B81449. Please note that the legacy BOCK ref. numbers are without 097B. Fig. 23 34 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03...
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Page 35: Technical Data
Oil charge (sight glass centre) Oil charge (ex works) Suction line Discharge line Weight permissible 25 - 70 frequency 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 % Displacement (1450 / 1740 rpm) No. of cylinders Type* HA44e/ AQ452839384735en-000301 | 35 © Danfoss | Climate Solutions | 2024.03... -
Page 36: Dimensions And Connections
Maß / Dimension Passung / Clearance Änd.-Nr. / Mod-No. Datum / Date Bearb. / Edited Geprüft / Appr. of the grant of a patent, utility model or design. Connection oil temperature sensor 8 “ NPTF 36 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03... -
Page 37: 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 AQ452839384735en-000301 | 37 © Danfoss | Climate Solutions | 2024.03... - Page 38 UKCA Experts Ltd. over technical documentation: Dept 302, 43 Owston Road Carcroft, Doncaster, DN6 8DA, United Kingdom Frickenhausen, 14th of October 2022 i. A. Alexander Layh, Global Head of R&D 38 | AQ452839384735en-000301 © Danfoss | Climate Solutions | 2024.03...
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