Danfoss BOCK EX-HG4 Semi Hermertic Compressor Motor Instruction Manual

*Kit (item no.)Danfoss BOCK EX-HG4 Semi Hermertic Compressor Motor Instruction Manual

**

SYMBOL

WARNING! This symbol indicates that disregard of the instructions may cause personal injury or damage to the compressor or refrigeration system.

 This symbol indicates important information that must be strictly observed.

 This symbol indicates parts that must be moistened with a  refrigeration oil before installation(see type plate for oil type).

 This symbol states the tightening torque for bolts.

 This symbol state the pemissible electr. resistance of the heat protection themostate.

General safety instructions

• Work on the compressor may only be performed by persons whose technical training, skills and  experience ensure that the work is correctly assessed and possible dangers are identified

•  National safety regulations, accidentprevention regulations, generally recognized technical rules and specific requirements (EN 378, EN60204, EN 60335, IEC/EN 60079-14, EN 60079-17, EC directive 1999/92/EG–ATEX 137, ElexV, German Work Safety Regulation ‘Betriebssicherheitsverordnung’ a

• Work must never be performed in explosive gas atmospheres!

• Smoking, open fire and flames are strictly prohibited! Mobile phones must be switched off!

• Any processes generating a significant charge must be prevented within a range of 2 metres around the compressor. The contact of highvelocity particles with the compressor surface must be prevented.

• Compressor must only be lifted with lifting devices of sufficient capacity

• Compressor must only be used in refrigeration systems using an approved refrigerant and refrigerant oil.

• Hydrocarbons (flammable refrigerants) must only be used if all relevant and applicable regulations, standards and technical rules are complied with. National safety regulations must be observed. The following applicable regulations and standards must also be considered: EN 378, Draft DIN 7003, BGR 500, EC direct
  Please observe the section “Important notes on the use of Hydrocarbons” in the assembly instruction of Hydrocarbons” in the operating .

• Do not exceed the permissible operating pressure. This also applies for testing

• Do not restart refrigeration system if any signs of damage, leaks and/or corrosion are visible

• Evacuate refrigeration system and compressor carefully and fill with refrigerant before start-up.

• Never render the safety switch inoperable

• Depending on the operating conditions, surface temperatures of above 100 °C on the pressure side and below 0 °C on the suction side may occur.

• Work safety regulations must be observed at all times! (e.g. as per  German BGR 132: conductive shoes, clothing etc.)

Safety instructions for removal/installation

Warning! Refrigerant compressors are pressurized devices and hence require special care when being  handled.

Before performing any work on the compressor

• Obtain written approval for work.
• Use only tools approved for explosionproof devices.
• When working on electric circuits they have to be disconnected and secured against unintentional reconnection. Before starting any work, Switch off plant and prevent.
• Close pressure and suction shut-off valves
• Warning! Relief pressure from compressor before commencing any  work. Prevent injuries to skin and eyes. Wear safety goggles at all  times
• Remove refrigerant and dispose it in accordance with environmental regulations.
• Use only BOCK spare-part kits.

After completion of work:

• Check refrigerant circuit/compressor for leaks after any manipulation according to EN 1779
• Check all safety and protection devices (pressure switches, motor protection, electrical contact protection  etc.) for correct function.
• Check all user-installed components for correct and pressure-proof connection to the compressor (pipes, plugs, union nuts, replaced parts etc.) before start-up.
• Evacuate compressor
• Open pressure and suction shut-off valves before start-up of compressor.
• Remove restart protection.
• Do not start the compressor under vacuum! Operate only with charged system.
• Observe the information given in the section “Start-up” in the operating manual of the compressor.
• Check system for compliance with permissible operating conditions (see operating manual and technical information) after the steady state (permanent operating conditions) has been reached
• Any maintenance, repair and service work must be documented in writing.

 The compressor may only be used when free of any defects.

Valve plate Removal/Installation

Before performing any work on the compressor, observe the safety instructions on page 3 – 5!

Compressor type

EX-HG4/465: 097B8039
EX-HG4/555: 097B80392
EX-HG4/650: 097B80392

kit

Compressor type: Kit (item no.)
EX-HG5: 097B80393
Compressor type: Kit (item no.)
EX-HG6: 097B80394

Please note that the legacy BOCK code numbers  are without 097B

Removal (see fig. a)

• In sequence as indicated (1, 2, 3…)
• Carefully remove any sealant from sealing surfaces.
• Note: Do not allow any sealant particles to drop into the compressor

Installation (see fig. a)

• Install in reversed order (6, 5, 4…).
• When selecting the valve plate gasket (6), observe the correct allocation to the compressor’s piston diameter. The bore diameter of the compressor must be identical to the piston diameter/compressor type indicated on the valve plate gasket (6).
• Tighten cylinder head bolts in the sequence shown in fig. b to the correct torque.

Check for leaks

• Check heat protection thermostats and electronic motor protection MP10 as follows.
• Check resistance of heat protection thermostat (To measure, disconnect feed line of the thermal protection thermostats at terminals 3 and 4 in the terminal box): Cold resistance of each heat protection thermostat: ≤ 100 Ω (Rcold at 25 °C
• Check function of electronic motor protection MP10 as specified in  operating manual of compressor.

Oil pump  Removal/Installation

Before performing any work on the compressor, observe the safety instructions on page 3 – 5!

Compressor type Kit (item no.)*

Removal (see fig. c)

• In sequence as indicated (1, 2, 3…)
• Carefully clean oil pump recess
• If excessive wear or abrasion from other components is visible, the cause must be determined and the  compressor be repaired at the manufacturer’s plant, if required.
• Change oil and oil strainer in case of severe contamination (see fig. g). Clean oil pan from foreign particles if required.

After removal of the oil pump, remove any gasket residue that may adhere to the compressor housing.

Installation (see fig. c)

• Install in reversed order (3, 2, 1)

• When mounting the oil pump (2) to EX-HG(X)4+5, make sure that the drive bolt of the oil pump engages in the groove of the crankshaft.

When mounting the oil pump (2) to EX-HG(X)6, make sure that the surface on the drive bolt of the crankshaft engages in the appropriate opening on the oil pump.

Danger of compressor damage! When mounting, make sure that the oil pump (2) and the seal for the oil pump (3) are aligned according to Fig. c.

Align the oil pump in such a way that the “TOP” designation is in the  12 o’clock position.

The seal for the oil pump must be aligned in such a way that the cross-section surface of the oil inlet duct on the compressor housing is not covered by the seal for the oil pump.

• Screw oil pump with the hexagon head screws (1/1.1) tightly onto the compressor housing. For EXHG(X)6, make sure that the bolts, which are of varying lengths, have been assigned correctly. Tighten fastening screws evenly
• Check for leaks
•  Risk of damage to compressor!Verify oil pressure (connection E, 7/16“ UNF). During restart the oilpressure must set up immediately. Oil pressure at operating temperature > 0,65 bar.

Flange shut-off valve (LP) Removal/Installation

Before performing any work on the compressor, observe the safety instructions on page 3 – 5

Warning! Soldering work must only be performed if no explosive atmosphere is present. Observe the information concerning usage of Hydrocarbons (flammable refrigerants) in the assembly instruction of the compressor!

Compressor type Kit (item no.)
EX-HG4/465- 4 (S) 097B80429
EX-HG4/555- 4 (S) 097B80429

Compressor type Kit (item no.)
EX-HG4/650- 4 (S) 097B80430
Compressor type Kit (item no.)
EX-HG5/725- 4 (S) 097B80430
EX-HG5/830- 4 (S) 097B80430

Item Designation*

EX-HG5/945-4 (S) 097B80432
Compressor type Kit (item no.)*
EX-HG6/1080-4 (S)
EX-HG6/1240- 4 (S)
EX-HG6/1410-4 (S)

Removal (see fig)

• In sequence as indicated (1, 2, 3…)
• Carefully remove any sealant from sealing surfaces.

Note: Do not allow any sealant particles to drop into the compressor

Installation (see fig. d)

• Install in reversed order (9, 8, 7…)
• When soldering in the suction line, be sure to disconnect the soldering supports (4) from the valve body (7) and ring seal (5). Risk of damage to shut-off valve.
• Check for leaks.

Flange shut-off valve (HP) Removal/Installation

Before performing any work on the compressor, observe the safety instructions on page 3 – 5!

Warning! Soldering work must only be performed if no explosive atmosphere is present. Observe the information concerning usage of hydrocarbons (flammable refrigerants) in the

operating manual of the compressor!

Compressor type Kit (item no.)*

EX-HG4/465-4 (S
EX-HG4/555-4 (S
EX-HG4/650-4 (S

**Compressor type Kit (item no.)***

EX-HG5/725-4 (S) 097B80428
EX-HG5/830-4 (S) 097B80428

*Please note that the legacy BOCK code numbers are without 097B

**Compressor type Kit (item no.)***

EX-HG5/945-4 (S) 097B80431
**Compressor type Kit (item no.)***

EX-HG6/1080-4 (S)
EX-HG6/1240-4 (S) 097B80431
EX-HG6/1410-4 (S

Removal (see fig. e)

• Remove as shown in fig. e and in the sequence as indicated (1, 2, 3.)
• Carefully remove any sealant from sealing surface sealing surfaces

Note: Do not allow any sealant particles to drop into the compressor.

Installation (see fig. e)

• When soldering the pressure line, be sure to disconnect the soldering supports (4) from the valve body (7) and ring seal (5).
• Installin reversed order (8,7,6…).

Heat protection thermostat Removal/lnstallation

Before performing any work on the  compressor, observe the safety instructions on page 3 – 5! .

Compressor type Kit (item no.)

EX-HG4
EX-HG5 097808860
EX-HG6

2     Serre-câble

3      Thermostat de protection thermique
4      Gaine thermorétractable Ø 6×30
| =Inclus dans le kit

Removal (see fig. f)

• In sequence as indicated (1, 2, 3).

Installation (see fig. f)

• Install in reversed order (3,2, 1).
• Seal heat protection thermostat hen inserting into the taper thread  using Loctite 566, do not use Teflon tape.
• Check for leaks.
• Check heat protection thermostats (3) and electronic motor protection MP10 as  follows
• Check resistance of heat protection thermostats (To measure, disconnect feed line of the thermal protection thermostats at terminals 3 and 4 in the terminal box). Cold resistance of each heat protection thermostat: < 100 Q (Ren @t 25 °C)
• Check function of electronic motor protection MP10 as specified in the assembly instruction of compressor.
• The low impedance of the protective earth system between cable shield and central PE connection on the compressor must be tested in accordance with
• EN 60204-1! (see Fig. f2) Shrink heat shrink tube onto the PTC sensor lead in accordance with Fig.f1″.
• Reclose all openings at the journal box properly in order to achieve the protection class IP 65.
• Set up intrinsically safe electrical circuit!
  

Oil strainer / oil change

Before performing any work on the  compressor, observe the safety instructions on page 3 – 5!

**Compressor type Kit (item no.)***

EX-HG4 097880382
EX-HGS 097880382

*Please note that the legacy BOCK code numbers. are without 0978 \

Removal (see fig. g)

• In sequence as indicated.
• Drain oil from the compressor into a suitable collecting vessel
• Remove seal ring (2)

Al national environmental regulations concerning the disposal of used oil must be observed!

Installation (see fig. g)

• llation (see fig. g) Install in reversed order.

• If necessary clean the oil filter carefully.

• Observe the information concerning oil changes and the approved lubricants in the assembly instruction of the compressor!

• Carry out oi filing through connection H. Observe the information conceming filling quantity and level in the assembly instruction of the compressor (p. 10/28/31).
  Check for leaks.

• Risk of damage to compressor! Verify oil pressure (connection E / 716″ UNF). During restart the oil pressure must set up immediately. Oil pressure at operating temperature > 0.65 bar.

Oil sight glass

Before performing any work on the compressor, observe the safety instructions on page 3 – 5!

**Compressor type Kit (item no.)***

EX-HG4
EX-HG4 EX-HG5 097880388 E
EX-HG6

Removal (see fig. h)

• Insequence as indicated

Installation (see fig. h

• Installin reversed order.
• Insert O-ring (3) into the appropriate countersink on the compressor housing and attach oil sightglass (2) to the compressor housing using the hex head bolts (1).
• Check for leaks.

Motor protection MP 10 (w/o fig.)
Removal/ Installation 

Before performing any work on the compressor, observe the safety instructions on page 3 – 5! When using the 24 V DC control voltage version of the MP 10, a protection class 3 (SELV or PELV) safety transformer must be installed in series. The safety transformer must conform to EN 60 950-1.

Compressor type Kit (item no.)

R emoval lnstallation

he installation of motor protection MP 10 is only permissible in a control cabinet outside of the potentially explosive area.

• Inaccordance with the wiring diagrams in the assembly instruction of the compressor!
• Check function of electronic motor protection MP10 as specified in the assembly instruction of compressor before starting the compressor.

AC double barrier (w/o ill)
Removal/ Installation

Before performing any work on the compressor, observe the safety instructions on page 3 – 5!

Compressortype Kit (item no.)

EX-HG4
EX-HG5 80427
EX-HG6

| AC double barrier with installation advia
---|---
| Assembly instruction
| = Included in kit

Removal / Installation

The installation of the AC double  barrier is only permissible in a  switch cabinet outside the potentially explosive area.

• Instalation i accordance wih the manufaciurer’s technical documentafion and the wiing diagrams in the assembly instruction of the compressor.

Gaskets and seals

Before performing any work on the Joints compressor, observe the safety compresseur, consulter les Seite 3-5 beachten! instructions on page 3 –

**Compressor type Kit (item no.)***

EXA 097880385 EX-HG4 097880385
EX-HGb 097880386
EX-HG6 097880387

Base plate gasket

Upper valve plate gasket
Lower valve plate gasket
Sealing ring Ø 27,8×24,2×2
Valve flange gasket
Ring seal dia. 42x34x1
O-ring Ø 70x54x1 1)2)
O-ring Ø 52x39x2 1)2)
O-ring Ø 75x61x2 2)3)
O-ring Ø 81,5x60x1 2/3)
Oil seal + bearing flange
Sealing ring Ø 27x22x2
O-ring Ø 34,59×2,62
O-ring Ø 238×5
O-ring Ø 32,99×2,62
O-ring Ø 82,22×2,62 1)2)
O-ring Ø 48×2,5 1)
O-ring Ø 45,69×2,62 2)3)
              =Included in kit

emoval/ Installation

• Valve plate gasket as shown in fig. aandas outlined on page 6-8.
• Gaskets of flange shut-off valves as shown in fig. d and e and as outiined on page 12-15. 0-ring seals according to Fig. H on
• page 20, Fig. | and k on pages 24- 25and Fig. | and m on page 25 Oil drain sealing ring as shown in Fig. g and as outlined on pages 18- 19.
• Oil pump seal as shown in Fig. ¢ and as outlined on pages 9-1

Gaskets and seals

Before performing any work on the compressor, observe the safety instructions on page 3 – 5!

• Disconnect feed lines of the heat protection thermostats from the terminals and take them out of the terminal box

• Place the compressor compartment so that oil cannot leak from the compressor compartment when the motor compartment is removed; drain beforehand if necessary (see oil change). After installation

• Fill compressor with ail (for oil type, see compressor name plate) Check for leaks.

• Check heat protection thermostats (3) and electronic motor protection MP10 as follows.

• Check resistance of heat protection thermostats (To measure, disconnect feed line of the thermal protection thermostats at terminals 3and 4 in the terminal box): Cold resistance of each heat protection thermostat: < 100 Q (Reod at 25 °C)

• Check function of electronic motor protection MP10 as specified in the assembly instruction of compressor. Reclose all openings at the journal box properly in order to achieve the protection class IP 65.\
  

• Remove the cheese head screws

• M10x60 used to attach the motor housing to the compressor housing (Fig. i1). With two cheese head screws

• M10x60, force the motor housing off the compressor housing evenly via the forcing-off thread provided for

• this purpose (Fig. i 2/3). Remove motor housing and O-ing. Place new, lightly oiled O-ring 238×5 in the groove provided for this purpose (Fig. i4) Re-install motor housing in the reverse order (Fig i5). Attention:

• Minor damage to the stator winding will result in a shorted coil and thus motor failure.

schematic

Capacity controller
Removal/nstallation (Fig.p-q)

Before performing any work on the compressor, observe the safety instructions on page 3 – 5! The “special conditions” of the EC type examination certifications must be observed! (See accompanying Compressor assemply instruction).

. 4280/4281 (Bock part-no. 70123, 70124, 70125) the permissible ambient temperature is reduced to (-20°C)— (50°C). Regard the name plate of the magnetic coil

**Compr. type Voltage Kit***
EX-HG4 230VAC 097881150
EX-HG4 120VAC 097B81160
EX-HG4 110VAC 097B81154
EX-HG4 24VDC 097B81158

10
11     12
13      14| Hexagon head set screw           M10 x 70 Cable clamp                         Cylinder cover for LR 87 incl. heat protection thermostat         Valve plate upper seal              Heat shrink tube Ø 6×30            Information sheet           “LR capacity controller”                      Assembly instruction
| = Included in kit

**Compr.type Voltage Kit***

EX-HG 5,6 230 VAC 097B81149
EX-HG 5,6 120V AC 097B81161
EX-HG 5,6 110VAC 097B81153
EX-HG 5,6 24VDC 097B81157

alve body LR

Removal/Installation (Fig.p-q)

efore performing any work on the  compressor, observe the safety instructions on page 3 – 5! The “special conditions” of the EC type examination certifications must be observed!

(See accompanying Compressor assembly instruction)

**Compressortype Kit (itemno.)***

EX-HG4 097880518 EX-HGb 097880519
EX-HG6 097880519

Assembly instruction
| = Included in kit

Removal (see fig. n-0)

• In sequence as indicated (1, 2, 3..) .
• Carefully remove any sealant from .sealing surfaces.
• ON Note: Do not allow any sealant particles to drop into the compressor.

Installation (see fig. n-o)

For the installation, use heatresistant lines with a temperature resistance of at least 140°

The connection line must be permanently emplaced. The cable and line entrance must be protected from effects of mechanical hazards. To ensure a secure seal of the valve body (8), the area of the sealing surface on the cylinder cover (12) must be carefully freed from paint residues. Do not let impurities enter the compressor!

Installin reversed order (14, 13, )

Tighten cylinder head bolts in the . sequence shown in Fig. b to the correct torque.

Attention! Every cylinder head must be monitored by a thermal protection thermostat according to the EC type examination certificate.

Perform electrical installation in the terminal box of the preassembled thermal protection thermostat in accordance with the accompanying compressor assembly instruction) (Electric chapter) and check it according to Fig. f and the explanations on page 16-17. Shrink heat shrink tube onto the PTC sensor lead in accordance with Figf1″.

rform electrical installation of the magnetic coil in accordance with the accompanying documentation and the assembly instruction of the compressor (Electric chapter). Within the potentially explosive area, the connection must be made in a terminal box designed according to a recognised ignition protection type!

Carry out electrical protection in accordance with the accompanying assembly instruction! Perform tightness test.

Information on operating the compressor with capacity controller can be taken from the “LR capacity controller” information sheet.

Oil sump heater Removalllnstallation

Before performing any work on the compressor, observe the safety instructions on page 3 – 5! The “special conditions” of the EC type examination certifications must be observed! (See accompanying compressor assembly instruction) Compressortype Kit (item no.)*
EX-HG4 097B804%

Compressortype Kit (item no.)
EX-HG5 097880497
EX-HG5 097880497
EX-HG6 097E80847

Removal (see fig. p-q)

• Remove blind plug J (standard design) or in sequence as indicated 12
• To avoid oil loss when opening the oil sump (“J” connection), we recommend lowering the compressor with a suitable lifting device to the suction valve or draining the oil.
• To prevent the oil from absorbing humidity, leave the compressor open only as long as is absolutely necessa

Installation (see fig. p-q

To ensure a secure seal, the area of the sealing surface on the cylinder cover must be carefully freed from paint residues before the oil sump heater is installed. Do not let impurities enter the compressor!

Reassembly in reverse sequence of numbering (2, 1)

Perform electrical installation in accordance with the accompanying documentation and the compressor assembly instruction (Electric chapter).

Within the potentially explosive area, the connection must be made in a terminal box designed according to a recognised ignition protection type!

Carry out electrical protection in accordance with the accompanying assembly instruction! Compensate for any oil loss!

Perform tightness test.

il pressure differential sensor
Removal / Installation 

Before performing any work on the compressor, observe the safety instructions on page 3-5! The “special conditions™ of the EC type examination certifications must be observed! (See accompanying assembly instruction)

Compressor type Kit

EX-HG4, 5,6 097B80553

0il pressure differential sensor with control relay

Before performing any work on the
compressor, observe the safety instructions on page 3-5! The “special conditions™ of the EC type examination certifications must be observed! (See accompanying assembly instruction)

**Compressor type Kit***

EX-HG4.5.6 097B80516

Schematic

Removal (see fig. r)

• Relieve pressure from compressor, disconnect electr. feed line from terminal clip and disconnect circuit part (1) by releasing union nut from screw-in part (2).
• Alternatively remove plug P “connection oil pressure differential sensor”
• Remove old seal ring, carefully clean sealing surfaces and check for damages.

Installation (see fig. r)

• elieve pressure from compressor, disconnect electr. feed line from terminal clip and disconnect circuit part (1) by releasing union nut from screw-in part (2).
• Alternatively remove plug P “connection oil pressure differential sensor”
• Remove old seal ring, carefully clean sealing surfaces and check for damages.

Installation (see fig. r)

• Screw in new CU-seal ring (3) with INT250 screw-in part (2) into oil pump.
  Screw circuit part with union nut on screw-on part handtight, cable outlet adjusted downwards.

• Feed line of circuit part (1) to nearby terminal box must be laid permanently. Within the potentially explosive area, the connection must be made in a terminal box designed according to a recognised ignition protection type!
  Set-up intrinsically safe electrical circuit, a switching repeater (4) is enclosed.

• Carry out a leak test when starting the compressor

• The screw-in part has been factory-tested for pressure resistance

• The kit comes with wo multifunctional relays (5) that control the deceleration/triggering behavior for the shutdown of the compressor when there is not enough oil. Integrate the multifunction relays according to circuit diagram of the installation instruction compressors into the safety chain and install in a switch cabinet outside of every zone. The multifunction relays have to be adjusted as shown in figure s. * Installation of oil pressure differential sensor according to EN 60079-14 or EN 60079-17

• Oberserve EC-type examination certificate and installation instruction of the manufactufrer!

schematic

• KF1 (Ansprechverzogert)
  Die gezeigte Einstellung entspricht einer Ansprechverzogerung von 90 Sekunden

• KF2 (Abfallverzogert)
  Die gezeigte Einstellung entspricht einer Abfallverzogerung von 90 Sekunden

• KF1 (ON delay) The setting shown
  corresponds to a ON delay of 90 seconds KF2 (OFF delay) The setting shown corresponds to a OFF delay of 90 seconds

• KF1 (Temporisation Marche)

References

• Danfoss BOCK® Compressors: Eco-Friendly Solutions for Refrigeration Systems | Danfoss

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