Danfoss HG(HA)12 Refrigerating Compressors Instruction Manual

: August 21, 2024
: Danfoss

Table of Contents

Danfoss HG(HA)12 Refrigerating Compressors
Product Information
Product Usage Instructions
Overview
SAFETY INSTRUCTIONS
General
Scope of supply
Dismantling the terminal board
Mounting the terminal board
Torques for Screwed Connections
Connections on the terminal board
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Danfoss HG(HA)12 Refrigerating Compressors

Product Information

Specifications:

Product Name: Terminal board for refrigerating compressors
Compatible Models: HG(HA)12 / 22 / 34 / 4 / 5 / 6, HG44e / 56e/66e, HG7, HG8, 88e, HR40
Manufacturer: Not specified

Product Usage Instructions

Safety Instructions
Always follow safety guidelines when working on the electric motor and compressor.
Scope of Supply
Check the kit number or ensemble to ensure you have all the necessary components for installation.
Dismantling the Terminal Board
Switch off the compressor and disconnect it from the mains.
Relieve pressure in the motor and compressor housing.
Open the terminal board cover and disconnect the power lead and fan cable.
Unscrew the terminal board screws and lift it up to access the cable harness side.
Disconnect and remove the motor cable from the terminal board, replacing the seal as needed.

FAQ:

Q: What should I do if I encounter difficulties during the dismantling process?
A: If you face any challenges during dismantling, refer to the manual for troubleshooting steps or contact customer support for assistance.

Overview

SAFETY INSTRUCTIONS

Caution!
Refrigerating compressors are pressurized machines and therefore require particularly careful handling.

Only qualified staff are allowed to handle refrigerating compressors.
Local safety regulations, accident prevention regulations, technical rules, and other valid specifications must be observed.
The compressor may only be operated in refrigerating systems, and only with the coolants approved by Bock.
The maximum tolerable operating over-pressure may not be exceeded (not even for test purposes).
Before starting the compressor, the pressure shut-off valve and suction shut-off valve are to be opened.
Before starting up, check that all compo-nents mounted by the user have been properly mounted and are connec-ted pressure-tight with the compressor (e.g. pipelines, bungs, union nuts, replaced parts, etc.)
When starting up, do not start the compressor in a vacuum. Only operate the compressor when the whole system has been filled.
Surface temperatures of more than 100 °C are possible on the pressure side respec-tively under 0°C on the suction side, depending on the operating conditions.

General

Sometimes, repairs to the electric motor, e.g. replace-ment of the stator, make it necessary to dismantle and then remount the terminal board on the compressor. These instructions describe the procedure for dismantling and remounting the terminal board to the refrigerating compressors series HA and HG.

Scope of supply

No.| Quantity and description| kit no*

Kit Number

---|---|---
Pos.| | | 097B80579| 097B08949| 097B80098| 097B80206| 097B81244| 097B82086
1| 1| Terminal board| 097B06727| 097B06747| 097B06864| 097B06977| 097B70160| 097B51865
2| 1| Terminal board seal| 097B06724| 097B06559| 097B06876| 097B06978| 097B06724| 097B51866
3| 4| Hexagonal screw M6x20| 097B05404| –| –| –| –|
3| 4| Hexagonal screw M6x25| –| –| –| –| 097B05405| –
3| 10| Hexagonal screws M8x25| –| 097B05421| –| –| –| –
3| 10| Hexagonal screws M10x35| –| –| 097B05447| –| –| –
3| 1| Cylinder screw M5x6| –| –| –| –| –| 097B51895
3| 5| Cylinder screw M8x20| –| –| –| –| –| 097B06330
3| 10| Cylinder screw M10x20| –| –| –| 097B05507| –| –
4| 1| Insulation foil NPN 5| –| 097B05073| 097B05074| –| –| –
4| 1| Insulation cover| –| –| –| 097B05066| –| –
5| 3| Bridge electrical connection| 097B06258| 097B05741| 097B05916| 097B06980| 097B06258| –
6| 6| Lock washers S M8| –| 097B05654| 097B05654| –| –|
6| 12| Disc B5,3| 097B05652| –| –| –| 097B05652| 097B05652
6| 12| Disc B10,5| –| –| –| 097B50010| –| –
7| 12| Spring washer B10| –| –| –| 097B50002| –| –
8| 6| Hexagonal nuts M8| –| 097B05629| 097B05629| –| –| –
8| 12| Hexagonal nuts M5| 097B05627| –| –| –| 097B05627| 097B05627
8| 12| Hexagonal nuts M10| –| –| –| 097B50006| –| –
9| 1| Terminal box gasket| –| –| –| 097B06979| –| –
10| 1| Operating instructions| 097B09977| 097B09977| 097B09977| 097B09977| 097B09977| 097B09977
11| 1| Important information| 097B09939| 097B09939| 097B09939| 097B09939| 097B09939| 097B09939

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

Dismantling the terminal board

Switch the compressor off and secure it to prevent it from being switched on again. Disconnect the machine from the mains. Relieve the pressure in the motor and compressor housing.
Open the terminal board cover. Disconnect the power lead. In HA compressors, also dismantle the electric capacitor (fig. 0). Disconnect the fan cable.
Unscrew the terminal board screws. Lift the terminal board and turn it to the side with the cable harness (to give you room to work).
Unscrew the fastening screw of the terminal board. Tip the terminal board over (fig. 1).
Note: Before continuing, check that the connection designations, cable lug markings, and color markings of the motor cables on the bottom of the terminal board are easily visible. Otherwise, clean these before disconnecting and mark them indelibly.
Disconnect and remove the motor cable from the bottom of the terminal board. Replace the seal.

Note:
In the larger Y/Δ-motor types (HG(HA) 6), there is an additional spacer (fig. 2) fitted under the terminal board to make it easier to connect up the rigid cable harnesses. When replacing the seal, ensure that both seals are replaced, i.e. both on and under the spacer.

Mounting the terminal board

The terminal board is mounted in reverse order.

Note: When you tip the terminal board over, the connection screws for the motor wires now appear „upside down“.
It is therefore vital to ensure that the connection terminals are positioned and connected correctly!
Caution! Comply with the instructions in the terminal box cover!
Important! Order for mounting of the screws for HH4-6 must be observed, see numbering:

Torques for Screwed Connections

Live connections
Brass screw connection
M 3,5 0,8 Nm
M 4 1,2 Nm
M 4,5 1,8 Nm
M 5 2 Nm
M 6 3 Nm

Connections on the terminal board

Connections on the terminal board for HG(HA) 12 with star delta circuit (Y/∆)

Connections on the terminal board for HG(HA) 22 and 34 with star delta circuit (Y / ∆)

Connections on terminal board for series HG(HA) 4, 5, 6 and HG44e, 56e, 66e with part winding circuit (PW Y / YY)

Connections on the terminal board for HG(HA) 4, 5, 6 and HG44e, 56e, 66e with star delta circuit (Y / ∆)

Connections on terminal board HG7 standard part winding (PW Y / YY)

Connections on terminal board HG7 Star delta (Y / ∆)

Connections on terminal board HG4 8/4 pole (∆/YY)

Connections on terminal board HG(HA)6 (26/30 kW) with star delta circuit (Y / ∆)
In series HG(HA)6 for 26 kW or 30 kW, the power supply from the terminal board to the motor consists of 2 cables for each connection lead because of the power involved. When mounting the terminal board, the two corresponding cables with the same designation are to be set at the same terminal. In addition, a spacer is to be inserted between the terminal board and com-pressor housing with corresponding seals.

Connections on terminal board HG8 and HG88e standard part winding (PW Y / YY)

Connections on terminal board HG8 and HG88e star delta circuit Y/∆

Connections on terminal board HR40 star delta circuit Y/∆

Danfoss A/S
Climate Solutions • danfoss.com • +45 7488 2222.

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