Bock EX-HG44e (HC), EX-HG56e (HC), EX-HG66e (HC)
Bock EX-HG44e (HC), EX-HG56e (HC), EX-HG66e (HC)
Bock EX-HG44e (HC), EX-HG56e (HC), EX-HG66e (HC)
Maintenance manual
96530-08.2023-Gb
BOCK
® colour the world
of tomorrow
About these instructions
Read these instructions before assembly and before using the com- Liability and warranty
pressor. This will avoid misunderstandings and prevent damage.
Improper assembly and use of the compressor can result Manufacturer‘s liability and warranty are excluded if
in serious or fatal injury. • Alterations and functional modifications have been carried out
Observe the safety instructions contained in these instructions. • No original replacement parts have been used
Contact
Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
2
1 I Safety
Safety instructions
• Work on the compressor may only be carried out by persons whose technical training, skills and experience
along with their knowledge of pertinent regulations and documentation means that they are capable
of assessing the work to be carried out and detecting any possible dangers.
• Specialist can mean a refrigeration technician for example. Note that electrical work may only be carried
out by a qualified electrician. Alternatively, on a country-specific basis, persons who have undergone elec-
trotechnical instruction and who have proof of their qualification are also permitted to carry out the work.
This symbol indicates that parts with refrigerating machine oil (type of oil see compressor name plate) must
be lubricated before assembly.
This symbol indicates that parts must be wetted with a suitable adhesive before assembly.
60 Nm This symbol indicates the permitted tightening torque for the relevant screw.
96530-08.2023-Gb
≤100Ω
Ω This symbol indicates the permissible electrical resistance for the resistance measurement of the thermal
protection thermostats.
3
1 I Safety
WARNING • Any handling of the compressor is only permitted by personnel who have the necessary
specialist knowledge (qualified person) due to their vocational training, professional experience
and their timely professional activity.
• Observe national safety regulations, accident prevention regulations, generally recognized
technical rules and specific regulations (EN 378, EN 60204, EN 60335, EN 60079-14, EN 60079-17,
EN 60079-19, EG Directive 1999/92/EG, Operational Safety Ordinance etc.).
• No work may be performed when an explosive atmosphere is present!
• Smoking, fire and open flame are strictly prohibited! Mobile telephones must be switched off!
• Strongly charge-generating processes must be excluded within 2 meters. The contact of
rapidly moving particles with the surface of the compressor must be avoided with certainty.
• Only transport compressors with lifting gear of sufficient capacity.
• Operate compressor only in refrigeration systems with approved refrigerants and refrigeration
oils.
• Hydrocarbons (combustible refrigerants) may be used in the compressors only if all relevant
and applicable regulations, standards and technical rules are followed. National safety
regulations must be observed.
In addition, we refer to the following applicable standards and regulations:
EN 378, EC Directives 1999/92/EC and 2014/34/EU.
Please also see the section "Important notes when using hydrocarbons" in the assembly
instructions of the compressor.
• Maximum permissible overpressure – even for testing purposes – must not be exceeded.
• Perform reconnection of the compressor only if no damage, leaks and/or appearances of
corrosion can be recognized.
• Before commissioning, evacuate the refrigerant systems carefully including the compressor
and afterwards charge refrigerant.
• Never put the safety switch out of action!
• Depending on the operating conditions, surface temperatures of over 100 °C occur on the
pressure side and below 0 °C on the suction side.
• Observe work safety rules! e.g. TRGS 727; protective shoes, clothing etc.).
96530-08.2023-Gb
4
1 I Safety
ATTENTION Refrigerating compressors are pressurised machines and therefore require particular caution
and care in handling.
Before starting any work on the compressor:
• Obtain written work release.
• Use only tools permitted for explosion-protected systems.
• When working on electrical circuits, these must be disconnected and secured against reclosing.
Determine the absence of voltage before starting any work.
• Close the pressure and suction shut-off valves.
CAUTION • Relieve pressure of compressor before repairs. Avoid possible injuries to skin and eyes.
Wear goggles!
• Extract the refrigerant and dispose environmentally.
• Only use original Bock spare parts.
Important notes
work.
5
2 I Disassembly of the compressor
- Extract the refrigerant from the system into a container which may be used for this refrigerant
- Evacuate the systems including the compressor
- Cut off the vacuum with nitrogen, humid air should not get into the system
- Close the shut-off valves on the suction and discharge side, remove the compressor
- Close the suction and discharge line connection points on the system
Removal of the compressor from the system, shut-off valves for compressor remaining at the system
Disassembly of compressor
The disassembly of the compressor is explained in separate steps on the following pages. The indicated parts list positions refer to the
spare parts lists, repair set lists, special accessories part lists and are available online at www.bock.de.
You can also find exploded drawings on the Internet at www.bock.de.
6
2 I Disassembly of the compressor
7
2 I Disassembly of the compressor
96530-08.2023-Gb
8
2 I Disassembly of the compressor
EX-HG44e
96530-08.2023-Gb
EX-HG56e, EX-HG66e
9
2 I Disassembly of the compressor
EX-HG44e
EX-HG56e, EX-HG66e
96530-08.2023-Gb
10
2 I Disassembly of the compressor
2.5 Stator
Position in Tools: Allen key 6 mm
parts list
Before starting any work on the compressor observe the safety instructions page 3-5!
2130
Working course
2280 - Loosen and remove the threaded pin for axial stator securing. For easier disassembly, heat the threaded pin for
axial stator securing with a hot air blower - Attention, protect electrical cables from heating!
- Pull out the stator and pay attention to the tracking of the cables, avoid jamming.
- Attention, observe the weight!
1179 - Remove feather key.
Feather key
stator fuse
96530-08.2023-Gb
11
2 I Disassembly of the compressor
2.6 Rotor
Position in Tools: Spanner SW 19
parts list
Before starting any work on the compressor observe the safety instructions page 3-5!
2130
Working course
800, 810, 820 - Loosen and remove rotor screw with disc and spring washer.
800, 810, 1177 - Remove groove nut, safety sheet und spacer sleeve if available.
- Pull off rotor from crankshaft. In case of sluggishness, use a puller.
1179 - Take off feather key from crankshaft. Remove spacer sleeve if available.
EX-HG44e, EX-HG66e
96530-08.2023-Gb
EX-HG56e
12
2 I Disassembly of the compressor
13
2 I Disassembly of the compressor
96530-08.2023-Gb
CAUTION Carry out soldering work only under exclusion of explosive atmosphere. Observe important
information on the use of hydrocarbons (combustible refrigerants ) in the assembly inst-
ructions compressor
220, 221, - Release the flange screw connection of the shut-off valve. Remove the shut-off valve and gaskets.
210
- Carefully clean the sealing surfaces old flat gasket material and make sure that no gasket residues get into the
compressor.
EX-HG44e
96530-08.2023-Gb
EX-HG56e, EX-HG66e
15
2 I Disassembly of the compressor
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16
2 I Disassembly of the compressor
17
2 I Disassembly of the compressor
INFO Mark the matching connecting rods and connecting rod shells clearly and indelibly,
including the bearing shell assignment (top/bottom) in the case of the HC version, in order
to prevent confusion later when reassembling!
2100 - Unscrew the hexagon head screws from the lower connecting rod shell.
- Remove lower connecting rod shell.
- Same procedure for the remaining connecting rods.
- Detach the remaining connecting rod parts from the crankshaft journals and push them into the cylinder bore
2030
as far as possible. All piston rings must now protrude from the cylinder bore on the cylinder cover side.
96530-08.2023-Gb
18
2 I Disassembly of the compressor
2.13 Crankshaft
Position in Tools: -
parts list
Before starting any work on the compressor observe the safety instructions page 3-5!
2050
Working course
- Carefully pull out the crankshaft in the axial direction.
96530-08.2023-Gb
19
2 I Disassembly of the compressor
INFO Mark the matching pistons to the cylinder bore clearly and indelibly to prevent confusion
when reassembling later!
290, 295, 300 - Remove piston rings. Spread piston rings only as far as necessary (risk of deformation or breakage).
- Remove the piston in the direction of the crankcase.
280 - Remove circlips of the piston pins with circlet pliers.
- Push the piston pins out of the piston.
2
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20
2 I Disassembly of the compressor
EX-HG44e, EX-HG56e
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EX-HG66e
21
3 I Assembly of compressor
520 29 Nm
510 38 Nm
520 29 Nm
EX-HG44e, EX-HG56e
590 580 15 Nm
2080
EX-HG66e
520 29 Nm
520 29 Nm
520 29 Nm
510 38 Nm
590 580 15 Nm
96530-08.2023-Gb
2080
3 I Assembly of compressor
F
W W
Installation location:
Mount the butt joint of the
bearing bush at 12 o‘clock.
X
C
Dimensions
Gußtoleranzen / General casting tolerances: X
W
Zeichnungs-Nr. /
XTeile-Nr. /
Y
X
Blatt / Maßstab /
X
W Werkstoff (Zeile 2+3 alternativ) /
XY
Compressor - Drawing-No. Contact
Part-No. surface Page: A Scale: Material (Line 2+3 alternative):
A B B
x. xxxx -xxxxx .x 1/x 1:2
Baumustergeprüft / Type examination: -
- -
EX-HG44e 0,5 ±Gewicht
0,3 mm / Weight: 0
(kg)mm
- 2) -
Allgemeintoleranzen / General tolerances
DIN ISO 2768-mK Benennung / Description:
EX-HG56e
Y 0,5 ±über
0,3 /mm
above
bis / up to
-1)
0.5 6 30 120 400
6 30 120 400 1000
X X Y HG44e
EX-HG66e 0,5 ±0,3 mm 0 mm 2)
±0.1 ±0.2 ±0.3 ±0.5 ±0.8
A B
MA Lagerwechsel HH
Unbemaßte Radien / Undimensioned radii: - Oberflächenangaben / Oberflächenbehandlung, Härte / Treatment of surface, Hardness: Ausgangsteil, Rohteil /
1) Bearing bush not available Indication of surface texture -
DIN EN ISO 1302 -
-
-
Base part, Raw part:
Y
Ra Rz -
25 Rz 160 6,3 Rz 63 2 Rz 25 1,6 Rz 16 0,7 Rz 12,5 0,3 Rz 6,3 2120
0,05 Rz 1,6 2120
Status: -
s t u w
Bx y z Ersatz für / replacement for:
- A
Werkstückkanten / K.-Auftrag / C.-Task: - Kunde / Customer:
Y
Z
Workpiece edges
Projektleiter / Project leader: - -
DIN ISO 13715
Y Z
Datum / Date Name
B ZZ
Erstellt / Drawn
Geprüft / Verified
Nr. / Mod-No. Datum / Date Bearb. / Edited Geprüft / Appr. Maß / Dimension Passung / Clearance GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de Freigabe / Approved
5 4 3 2 1
Flush
1,8 -0,2
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Coating
23
3 I Assembly of compressor
96530-08.2023-Gb
24
500
Darstellung illustrativ:
Kabelbinder auf Kontakt
zugezogen /
only illustration: 182
cable tie close-drawn 15Nm
ÖWE D
to contact 566
3 I Assembly of compressor
550,
560
13Nm
183
184 540
3.3 Pistons and connecting rods
29Nm
566
anschießend
Y
ausrichten /
Position in afterwards
Tools: Piston ring plier, needle nose pliers
turn to position
parts list
D-D 35°
2030
Before starting any work on the compressor observe the safety instructions page 3-5!
182 520
(2 : 1) Working course15Nm
566
29Nm
566
- Apply a little oil to the cylinder bores.
0,2 - For HC version,550, bearing shell into the connecting rod, see chapter 3.5. D
insert the upper 505
560
- Insert pistons/connecting 100Nm
rods from below into the cylinder liners up to the stop.
13Nm
784 --> Pay attention to the correct assembly position (suction fin grooves).
540 500
ift mit - Note the assembly
29Nm view of the piston rings. Spread the piston rings carefully and only as far as necessary (risk
zeug of deformation566 or breakage).
/ with the „TOP“ marking facing upwards, in the direction of the piston crown. D
esst / anschießend
n with
sed-in
- Fit the piston
- The butt
rings
ausrichten
afterwards
turn joints ÖWE
of the piston rings have to be installed 30° twisted to each other and may not be lying upon each
to position
D782 35° other.
520
(2 : 1)
Y
29Nm
566
1,8 -0,2 EX-HG66e
0,2 505
EX-HG44e, EX-HG56e 100Nm
Einbauansicht Kolbenringe
500 /
assembly view piston rings
(2:1) ÖWE
90° 510 Y 520 570, 590
1,8 -0,2 38Nm 29Nm
566 566
Einbauansicht Kolbenringe /
assembly view piston rings
(2:1)
Assembly views piston rings 510 520 570, 590 580 Stüc
Teile-N
quan
38Nm 29Nm 15Nm
part-n
X
566 566 1
Plain compression ring Piston ring
295 Einbauansicht Kolbenringe /
1
290ring
Piston assembly view piston rings Oil scraper ring 1720 1
260 (2:1) 1720
270
Stossfugen der Kolbenringe um Double bevel oil
je ca. 90° versetzt montiert 510/ content
520ring
X (5 : 1)
570, 590 580
Teile-Nr. /
986 part-no. 1721
1721
1
1
280 joints of the
Xstaggered every 90° piston rings 38Nm 29Nm
TOP566oben bei allen Kolben /
15Nm
1721
LB
566
hrung / marking "TOP" on top for all pistons 17208 EX-HG6 1721 1
295
rsion 17209 EX-HG6
1721
290 240
Stossfugen der Kolbenringe um
je ca. 90° versetzt montiert /
X (5 : 1)
“TOP“ at the top of all pistons
17210 EX-HG6
1721
17211 EX-HG6
260 241
joints of the piston rings
hrung / nur bei HC-Ausführung / staggered every 90° TOP oben bei allen Kolben / 17212 1723
EX-HG6
96530-08.2023-Gb
241 29Nm
rings ofstaggered
joints the pistonevery
rings 90°. gelber Streifen
TOP oben bei allen Kolben /
links
yellow von
stripe left der
17211
of Stossfuge
theEX-HG66e/1540-4
joint / S 1723317220
17212 EX-HG66e/1750-4 17234
17219
1723
EX-HG6EX
EX
alternative EX-HG6
on top for all identification for "TOP" marking:
staggered every 90° alternative Kennzeichnung für TOP: 25
ur bei HC-Ausführung / marking "TOP" pistons 17213 EX-HG66e/1750-4 S 17235172211723 EX
nly at the HC-version yellow gelber
strip Streifen
left of links
the von
jointder Stossfuge /
17214 EX-HG66e/2070-4
EX-HG6
17222 EX
3 I Assembly of compressor
3.4 Crankshaft
Position in Tools: -
parts list
Before starting any work on the compressor observe the safety instructions page 3-5!
2050
Working course
- Coat the running surfaces for connecting rods with oil. Oil bearing surfaces of crankshaft.
2050 - Insert crankshaft.
96530-08.2023-Gb
26
3 I Assembly of compressor
2030 - Compress the piston rings on the piston with the piston ring pliers and push them back into the cylinder bore.
- Mount the connecting rods on the crankpins by hand and align them in parallel.
241, 242 - Insert lower bearing shells in connecting rod shells (for HC version).
2100 - Place the marked lower connecting rod shell on the corresponding connecting rods.
- Tighten connecting rod screws.
2050 - Turn the crankshaft by hand. In case of sluggishness, check the fit of the connecting rods, if necessary,
dismantle the connecting rods and carry out the work step again.
Assembly view
HC version
241
242
96530-08.2023-Gb
27
4 3 2 1
3 I Assembly of compressor F
B-B (1 : 2)
D
X X
Installation location:
Mount the butt joint of the
bearing bush at 12 o‘clock.
Gußtoleranzen / General casting tolerances: Zeichnungs-Nr. / Teile-Nr. / Blatt / Maßstab / Werkstoff (Zeile 2+3 alternativ) /
- Drawing-No. Part-No. Page: Scale: Material (Line 2+3 alternative):
B
X x. xxxx -xxxxx
Baumustergeprüft / Type examination: -
-
Gewicht / Weight: (kg) -
X .x
X 1/x 1:2 -
-
Compressor
Y Dimensions
Allgemeintoleranzen / General tolerances A Contact surface
DIN ISO 2768-mK Benennung / Description: A
über / above
bis / up to
0.5 6 30 120 400
6 30 120 400 1000 HG44e EX-HG44e 0,5 ±0,3 mm
±0.1 ±0.2 ±0.3 ±0.5 ±0.8 MA Lagerwechsel HH
Unbemaßte Radien / Undimensioned radii: - X
Oberflächenangaben / Y X
Oberflächenbehandlung, Härte / Treatment of surface, Hardness:
Indication of surface texture - -
EX-HG56e
Ausgangsteil, Rohteil0,5
Base part, Raw part:
/ ±0,3 mm
Y
DIN EN ISO 1302 -
A -
EX-HG66e
- 0,5 ±0,3 mm
Ra Rz -
25 Rz 160 6,3 Rz 63 2 Rz 25 1,6 Rz 16 0,7 Rz 12,5 0,3 Rz 6,3 0,05 Rz 1,6
Status: -
s t u w x y z Ersatz für / replacement for:
2125 Y - A
Werkstückkanten / K.-Auftrag / C.-Task: - Kunde / Customer:
B Workpiece edges
Projektleiter / Project leader: - -
DIN ISO 13715
Datum / Date Name
Erstellt / Drawn
Geprüft / Verified
m / Date Bearb. / Edited Geprüft / Appr. Maß / Dimension Passung / Clearance GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de Freigabe / Approved
4 3 B 2 1
96530-08.2023-Gb
28
3 I Assembly of compressor
15 Nm
517 516 45 Nm
2220
760
Tightening sequence:
1 9 11 3
2110
750 75 Nm
8 5
16 13
6 7
96530-08.2023-Gb
2020 - Pre-assemble spring steel sheet with excentric ring and outer rotor.
- Push the internal rotor on the crankshaft.
- Insert the preassembled excentric ring into the chamber so that it is flush with the bearing flange.
2020, 470, - Fill oil pump chamber with refrigeration machine oil (see compressor name plate). Mount the cover plate and
480 O-ring with the hexagon head screws. O-ring must be placed exactly in the annular groove of the cover plate.
ATTENTION Risk of damage compressor!
Check the oil differential pressure on recommissioning.
480 25 Nm
470
2020 15 Nm
220 75 Nm
221
380 75 Nm
210
EX-HG44e, EX-HG56e
220 100 Nm
380 90 Nm
360
210
96530-08.2023-Gb
EX-HG66e
31
3 I Assembly of compressor
186 45 Nm
11 10
9 3 2 6
Cylinder cover
96530-08.2023-Gb
Valve plate
32
3 I Assembly of compressor
Tightening sequence: 45 Nm
160
185
1st pass
6 12 14 3
180
165
45 Nm 8 9 45 Nm
Apply by 1 2 Apply by
hand hand
45 Nm 10 7 45 Nm
4 13 15 11 5
45 Nm
75 Nm 8 7 75 Nm
29 Nm 15 14 29 Nm
75 Nm 6 9 75 Nm
96530-08.2023-Gb
12 3 1 5 11
75 Nm
33
3 I Assembly of compressor
3.11 Stator
Position in Tools: Allen key 6 mm
parts list
Before starting any work on the compressor observe the safety instructions page 3-5!
2130
Working course
WARNING The heavy weight of the stator can potentially be dangerous; risk of falling, danger of
crushing!
1139 - Insert feather key to protect stator.
- Note the direction of the stator to feather key, you must align the parts in order to install them.
- Lead the winding connections through the terminal board opening after inserting the stator. Do not damage core
insulation when passing through, do not bend the core.
2130 - Push the stator into the housing and pre-align it according to the check dimension, see page 35.
2280 - Screw in threaded pin M8x20 for axial stator securing. The hardening time of the thread coating is 6 hours.
Use threaded pin for axial stator securing only once.
2280 15 Nm
Fmax 33 kg
Feather key
Stator protection
96530-08.2023-Gb
2130
1179
34
3 I Assembly of compressor
3.11 Stator
Position in Tools: -
parts list
Before starting any work on the compressor observe the safety instructions page 3-5!
2000
Working course
WARNING The heavy weight of the stator can potentially be dangerous; risk of falling, danger of
crushing!
- Control dimensions for stator alignment
Control dimension Y
3.12 Rotor
Position in Tools: Spanner SW 19, impact wrench / impulse wrench
parts list
Before starting any work on the compressor observe the safety instructions page 3-5!
2130
Working course
INFO Observe screw tightening torques!
1178 - Push the distance disc (if available) onto the crankshaft as far as it will go.
790, 2130 - Insert the feather key into the crankshaft and push the rotor onto the crankshaft.
EX-HG44e und EX-HG66e
800, 810, - Insert the feather key into the crankshaft and push the rotor onto the crankshaft. The safest rotor bolt assembly
820 is expediently carried out with an appropriately adjusted impact wrench / impulse wrench.
Then the rotor does not have to be secured against twisting.
- Alternatively tighten the rotor screw with disc and spring washer manually. It is to prevent rotation of the rotor
by blocking the driving unit.
EX-HG56e
1177 - Slide the spacer sleeve (if available) onto the crankshaft.
800, 810 - Slide the safety sheet onto the crankshaft and fit the groove nut.
- Tighten the groove nut with a suitable tool until the locking lug fits into the groove nut. Then bend the locking
lugs over. See figure X.
790
1178
EX-HG44e, EX-HG66e
790
1178 X
96530-08.2023-Gb
EX-HG56e
2130 1177
800 810 100 Nm
36
3 I Assembly of compressor
1017, 1010 - Position gasket on cover by using two of the screws. Note the positioning of the steel bead seal.
2300, 1010 - Place cover with gasket and secure with both screws, then screw in all other screws hand-tight.
1010 - Tighten the screws crosswise.
1010
75 Nm
1017
2300 1000
Positioning of steel bead gasket
37
3 I Assembly of compressor
1 2 3 4 5
F
3.13 Motor cover EX-HG56e
Position in Tools: Auxiliary thorn, spanner SW 10, 17
parts list
Before starting any work on the compressor observe the safety instructions page 3-5!
2300, 2122
Working course
E - Wet bearing bush on the circumference with oil. Pay attention to the installation location of the butt joint!
- Press in the bearing bush evenly, flush with a suitable tool (e.g. auxiliary thorn).
- Wet the circumference of the seal disc with adhesive, then press it in flush.
1190, 1191 - Screw the suction filter to the motor cover with screws. Note the installation position of the suction filter: The
sieve mesh must point in the direction of the motor cover.
1017 - Position the gasket on the compressor housing using two dowel pins. Note the positioning of the steel bead
seal.
2300, 1010 - Oil the bearing journals of the crankshaft. Carefully fit )the
2 bearing
: 1( Bpairing
-B crankshaft/motorcover into each other.
D 1010, 1015 - Tighten the screws crosswise.
X X
Installation location: Y Y
Mount the butt joint of
the bearing bush at 12 Flush
o‘clock.
B
2:1 x/1 x. xxxxx- xxxx .x
- :noitanimaxe epyT / tfürpegretsumuaB
- -
- - )gk( :thgieW / thciweG
secnarelot lareneG / neznarelotniemegllA
:noitpircseD / gnunneneB Km-8672 OSI NID
1 2 3 4 10155 75 Nm
15 Nm 1191
1190
1017
2122
1000
2300
2540 - Screw the suction filter to the motor cover with screws. Note the installation position of the suction filter: The
1017, 1119 sieve mesh must point in the direction of the motor cover.
2520, 1010 - Position the gasket on the compressor housing using dowel pin. Note the positioning of the steel bead seal.
1010, 1015 - Place the motor cover with the gasket and screw it in hand-tight with the screws.
- Tighten the screws crosswise.
1191 15 Nm
1015 75 Nm
1190
2540
1017
2520
1000
1010 75 Nm
39
3 I Assembly of compressor
2070 - Install shut-off valve mit new gasket and suction filter.
1270
90 Nm EX-HG44e/475-4 (S) + 565-4
1270
75 Nm
1260
1240 1260
2070
1240 2070
1210
1210 1190
1190 1230
1230 2070 1221
1220
EX-HG44e
37 Nm
75 Nm 1220
1220 75 Nm EX-HG56e
100 Nm EX-HG66e
1270
1270 150 Nm
1255
1260
1240
1210 2070
96530-08.2023-Gb
EX-HG56e, EX-HG66e
40
3 I Assembly of compressor
1270
Sequence of flat washers and adjusting washers
Gasket
Terminal box M6x12 (SW 10)
5 Nm Loctite 243
Flat washer
2170 B6,4-A2
DIN EN ISO 7090
Adjusting washer
6x12x1-A2 DIN988
1090
1100 15 Nm
Terminal assignment on the terminal board
1105 Part-winding 1
1
2
1070 45 Nm 3
Terminal board 9
8
7
Part-winding 2
Compressor
housing
41
3 I Assembly of compressor
15 Nm
96530-08.2023-Gb
42
3 I Assembly of compressor
EX-HG66e
EX-HG44e, EX-HG56e
Connection H Connection H
96530-08.2023-Gb
43
4 I Compressor accessories
3320
3320
3315
3340
3345
3311
180 3335
1270
186
3336 3311
3800
3330
3800
3322
3322
3325
3325
96530-04.2021-Gb
ATTENTION - For the installation, use heat-resistant lines with a temperature resistance of at least
140 °C.
- Wiring of the magnetic coil has to be static. The cable entry must be protected against
the effects of mechanical hazard.
INFO - To ensure a secure seal, the area of the sealing surface on the cylinder cover must be
carefully freed from paint residues before mounting the valve body.
- Do not allow contaminants to enter the compressor!
- Install cylinder cover for capacity regulator with new gasket. Note the positioning of the steel bead seal, see
3320, 3325 chapter 3.10.
- Tighten the cylinder cover screws in the order shown (see chapter 3.10).
- Mount the capacity regulator valve with O-ring/flat seal, observe the screw tightening torque.
- Place magnet coil with washers and gaskets in accordance with the enclosed documentation and secure with
3330 , knurled nut (if available).
3335, 3336 - Connect the magnet coil, paying attention to restore the IP protection level!
3320
ATTENTION In accordance with the EC Type Examination Certificate, each cylinder cover must be
monitored with a thermal protection thermostat.
- Install and check the thermal protection thermostats in the terminal box according to
the assembly instructions for the compressor (chapter electric) and chapter 3.16!
- Shrink the heat-shrinkable sleeve onto the PTC sensor lead.
- Carry out electrical installation of the magnet coil according to the enclosed documentation and the assembly
instructions for the compressor (chapter electric).
ATTENTION The „special conditions“ of the EC type-examination certificates must be observed!
INFO • Using the Norgren magnetic coil, ID no. 4280/4281 (Bock part no.: 70123, 70124, 70125, 70149)
effectively reduces the permissible ambient temperature of the compressor to (-20 °C) – (+50 °C).
Observe the type plate on the magnetic coil.
96530-04.2021-Gb
45
4 I Compressor accessories
Screw-in nipple
M22x1,5 (SW 27)
100 Nm
7 Nm 25 Nm
Cable gland
EX d M16x1,5 (SW 24)
96530-04.2021-Gb
46
4 I Compressor accessories
- Within the explosion-endangered area, the connection must be made in an external terminal box, which is
designed in a suitable type of protection!
INFO Please also observe the assembly instructions for the compressor.
47
4 I Compressor accessories
48
K
4 I Compressor accessories
5 5
3 F 3
m m
11 11
R
E
KF1 E KF2
KF1 (Response delay)
The setting shown corresponds to
a response delay of 90 seconds 3730 2020
KF2 (Drop-out delayed)
The setting shown corresponds to 3740
a drop-out delay of 90 seconds 2110
75 Nm
3720
D 10 Nm
3715
96530-04.2021-Gb
3710
49
BOCK
®
Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Tel +49 7022 9454-0
Fax +49 7022 9454-137
www.bock.de