Danfoss BOCK HG44e User manual

AQ452044031215en-000201
BOCK®HG44e/HG56e (HC/LG)
Operating guide
HG(X)44e/475-4 (S) HG(X)56e/850-4 (S)
HG(X)44e/565-4 (S) HG(X)56e/995-4 (S)
HG(X)44e/665-4 (S) HG(X)56e/1155-4 (S)
HG(X)44e/770-4 (S)
HG44e/475-4 (S) HC ............................... HG44e/770-4 (S) HC
HG56e/850-4 (S) HC ............................. HG56e/1155-4 (S) HC
HGX44e/475 (S/ML) 9 LG ................. HGX44e/770 (S/ML) 22 LG
HGX56e/850 (S/ML) 18 LG ............. HGX56e/1155 (S/ML) 35 LG
Translation of the original instructions

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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
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.

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Contents Page
5AreasofapplicationonHCandLGcompressors 12
5.1 Refrigerants
 5.2 Oilcharge
 5.3 Limitsofapplication
6Compressorassembly 13
 6.1 Storageandtransport
 6.2 Settingup
 6.3 Pipeconnections
 6.4 Pipes
 6.5 Layingsuctionanspressurelines
 6.6 Operatingtheshut-offvalves
 6.7 Operatingmodeofthelockableserviceconnections
 6.8 Suctionpipelterandlterdrier
 7 Electricalconnection 17
 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withspecialmotor
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
 8.8 Connectionofoillevelregulator
9 Maintenance 31
 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ammablerefrigerants
 10 Accessories 33
 10.1Capacityregulator
 11 Technicaldata 35
 12 Dimensionsandconnections 37
 13 Declarationofincorporation 39

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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:

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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!

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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.

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• HG44e:Semi-hermeticfour-cylinderreciprocatingcompressorwithsuction-gascooleddrivemotor.
• HG56e:Semi-hermeticsix-cylinderreciprocatingcompressorwithsuction-gascooleddrivemotor.
• Preferredapplicationrange:normalrefrigeratingandair-conditioning.
3|Product description
Nameplate
Fig.1
3.1 Short description
Valveplate Cylinder
cover
DimensionandconnectionvaluescanbefoundinChapter 12
Transporteyelet
Discharge
shut-offvalve
Oilpump
Suction
shut-offvalve
Oilsightglass
Drivesection
Motorsection
Fig.2
HG44e
HG56e
Terminalbox

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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 e12 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
}
3|Product description
Fig.3
3.2 Nameplate (example)
1
2
3
4
5
6
7
8
9
10
11
12
13
BB12345A001
HGX44e/770-4S
35,0A
101A 174 A
67,0
80,4
SE 55
/
HG 44 e 770-4 SX
¹)HG-HermeticGas-Cooled(suctiongas-cooled)
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(optimizedefciency)
Numbersofcylinders
Size
Oilcharge²)
Series¹)
3.3 Typekey (example)
Bock GmbH, Benzstr. 7
72636 Frickenhausen, Germany
BOCK
BOCKlubE55

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3|Product description
/
/
HG
HG
4
4
4
4
e
e
770-
770
HC
LG
4
S
S
22X
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)
Low-GWP
Engineperformanceinhp
Motorvariant3)
Sweptvolume
e-series
Numbersofcylinders
Size
Oillling²)
Series¹)

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ATTENTION The oil level must be in the
visiblepartofthesightglass;
damage to the compressor
is possible if overfilled or
underfilled!
4 |Areas of application
Thecompressorsarelledatthefactorywiththefollowingoiltype:
-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.HGX44e/770-4).
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 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.
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.
(For more on the subject of frequency converters, see chapter
7.13,p.27)
4.3 Limitsofapplication
max.
min.
oillevel
Fig.4Fig.4Fig.4
HG44e
1,6Ltr.
HG56e
1,4Ltr.
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