6 7 8 9 10 11 12 13

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Bock Compressor HG4 Assembly instructions

HG4/310-4 HG4/385-4 HG4/465-4 HG4/555-4 HG4/650-4 HG4/310-4 S HG4/385-4 S HG4/465-4 S HG4/555-4 S HG4/650-4 S HGX4/310-4 HGX4/385-4 HGX4/465-4 HGX4/555-4 HGX4/650-4 HGX4/310-4 S HGX4/385-4 S HGX4/465-4 S HGX4/555-4 S HGX4/650-4 S

09958-05.2012-DGbFEI

engineering for a better world

GEA Refrigeration Technologies

1

About these instructions

Read these instructions before assembly and before using the compressor. This will avoid misunderstandings 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 compressor is installed. Manufacturer GEA Bock GmbH 72636 Frickenhausen Contact GEA Bock GmbH Benzstrae 7 72636 Frickenhausen Germany Telephone +49 7022 9454 0 Fax +49 7022 9454 137 bock@gea.com www.bock.de

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09958-05.2012-DGbFEI

Contents
1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 7 7.1 7.2 7.3 7.4 7.5 7.6 8 9 10 11 Safety Identification of safety instructions Qualifications required of personnel General safety instructions Intended use Product description Short description Name plate Type key Areas of application Refrigerants Oil charge Limits of application Compressor assembly Setting up Pipe connections Pipes Laying suction and pressure lines Operating the shut-off valves Operating mode of the lockable service connections Electrical connection Information for contactor and motor contactor selection Standard motor, design for direct or partial winding start Basic circuit diagram for partial winding start with standard motor Special motor: design for direct or star-delta start Circuit diagram for direct start 230 V / 400 V Y Electronic trigger unit MP 10 Connecting the trigger unit MP 10 Functional test of the trigger unit MP 10 Oil sump heater Commissioning Preparations for start-up Pressure strength test Leak test Evacuation Refrigerant charge Start-up Avoiding slugging Connection of oil level regulator Maintenance Preparation Work to be carried out Spare parts recommendation Accessories Extract from the lubricants table Decommissioning Technical data Dimensions and connections Declaration of conformity and installation Service

Page 4

10

13

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23

25

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27 28 30 31

1| Safety
1.1 Identification of safety instructions: DANGER! Indicates a dangerous situation which, if not avoided, will cause immediate fatal or serious injury. WARNING! CAUTION! Indicates a dangerous situation which, if not avoided, may cause fatal or serious injury. Indicates a dangerous situation which, if not avoided, may cause fairly severe or minor injury. Indicates a situation which, if not avoided, may cause property damage. Important information or tips on simplifying work.

ATTENTION!

INFO!

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1.2 Qualifications required of personnel WARNING! nadequately qualified personnel poses the risk of accidents, the I consequence being serious or fatal injury. Work on compressors must therefore only be performed by personnel with the qualifications listed below: or example, a refrigeration technician, refrigeration mechatronF ics engineer. As well as professions with comparable training, which enable personnel to assemble, install, maintain and repair refrigeration and air-conditioning systems. Personnel must be capable of assessing thework to be carried out and recognising any potential dangers. 1.3 General safety instructions WARNING! efrigerating compressors are pressurised machines and R t herefore require particular caution and care in handling. isk of burns! Depending on the operating conditions, surface R temperatures of over 60 C on the pressure side or below 0 C on the suction side can be reached. The maximum permissible overpressure must not be exceeded, even for testing purposes.

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1| Safety
1.4 Intended use These assembly instructions describe the standard version of the HG4 manufactured by Bock. The compressor is 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! WARNING! The compressor may not be used in potentially explosive environments! The Bock refrigerating compressor named in the title is intended for installing in a machine (within the EU according to the EU Directives 2006/42/EC Machinery Directive, 97/23/EC Pressure Equipment Directive and 2006/95/EC Low Voltage Directive). Commissioning is only permissible if the compressor has been installed in accordance with these assembly instructions and the entire system into which it is integrated has been inspected and approved in accordance with legal regulations.

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2| Product description
2.1 Short description Semi-hermetic four-cylinder reciprocating compressor with suction-gas cooled drive motor. Flange-mounted drive motor on the compressor case. Preferred application range: normal refrigerating and air-conditioning.

Terminal box Suction shutoff valve Transport eyelet Valve plate

Motor section Cylinder cover

6 7 8 9 10 11 12 13

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Discharge shut-off valve Oil pump

1 2

Name plate Drive section Oil sight glass

Fig. 1

Dimension and connection values can be found in Chapter 9

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2| Product description
2.2 Name plate (example)
GEA Bock GmbH 72636 Frickenhausen, Germany

1 2 3 4 5

HGX4/310-4 AS35830A006 17,0A 57 A 75 A

27,1 32,5 SE 55

6 7 8 9 10 11 12 13

Fig. 2 1 2 3 4 5 Type designation Machine number maximum operating current Starting current (rotor blocked) Y: Part winding 1 YY: Part windings 1 and 2 ND (LP): max. admissible operating pressure (g) Low pressure side HD (HP): max. admissible operating pressure (g) High pressure side Observe the limits of application diagrams! 6 7 8 9 10 11 12 13 Voltage, circuit, frequency Nominal rotation speed 50 Hz Displacement Voltage, circuit, frequency 60 Hz Nominal rotation speed Displacement Oil type filled at the factory Terminal box protection type Electrical accessories can change the IP protection class!

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2.3 Type key (example)

HG X 4 / 650-4 S
Motor variant 3) Number of poles Swept volume Size Oil charge ) 09958-05.2012-DGbFEI Series ) ) HG - Hermetic Gas-cooled (suction gas-cooled) ) X - Ester oil charge (HFC refrigerant, e.g. R134a, R404A/R507, R407C)
3)

S - More powerful motor, e.g. for air-conditioning applications

3| Areas of application
3.1 Refrigerants HFKW / HFC: (H)FCKW / (H)CFC: 3.2 Oil charge The compressors are filled at the factory with the following oil type: - for R134a, R404A/R507, R407C FUCHS Reniso Triton SE 55 - for R22 FUCHS Reniso SP 46 Compressors with ester oil charge (FUCHS Reniso Triton SE 55) are marked with an X in the type designation (e.g. HGX4/650-4). INFO! For refilling, we recommend the above oil types. Alternatives: see lubricants table, Chapter 7.5. R134a, R404A/R507, R407C R22

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3.3 Limits of application ATTENTION! Compressor operation is possible within the operating limits shown in the diagrams. Please note the significance of the shaded areas. Thresholds should not be selected as design or continuous operation points. - 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: - The suction gas superheat temperature may need to be reduced or set individually when operating near to the threshold. or operation with frequency converter: F - 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. hen operating in the vacuum range, there is a danger of air W e ntering 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! 09958-05.2012-DGbFEI 8

3| Areas of application

R134a

Fig. 3

R407C
D GB
Fig. 4
Unlimited application range Supplementary cooling or reduced suction gas temperature

F E

R404A/R507

Supplementary cooling and reduced suction gas temperature Motor version S (more powerful motor) Evaporation temperature (C) Condensing temperature (C) Suction gas superheat (K) Suction gas temperature (C)

Fig. 5

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R22

Max. permissible operating pressure (LP/HP)1): 19/28 bar

1)

LP = Low pressure HP = High pressure Design for other areas on request

Fig. 6

4| Compressor assembly
INFO! New compressors are factory-filled with inert gas (3 bar nitrogen). Leave this service charge in the compressor for as long as possible and prevent the ingress of air. Check the compressor for transport damage before starting any work.

4.1 Setting up Use transport eyelet. Do not lift manually! Use lifting gear!

Fig. 7
3

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Fig. 8

Fig. 9

Fig. 10 4.2 Pipe connections

ung

Zeichn.-Nr.

Fig. 11: graduated Blatt: internal diameter Teile-Nr.

Zone Mastab:

x.xxxx-xxxxx.x 1/x 1:1

Benennung: 400 1000 0.8

Bearb. Gepr. nderungs-Nr. Datum Ausgangsteil, bzw. Rohteil: Werkstoff: Lieferantenzeichnung Alternativbezug: Baumustergeprft Entwicklungsstand

10

Wasserwaage
fr Indesign

09958-05.2012-DGbFEI

1 Provide adequate clearance for maintenance work. Ensure adequate compressor ventilation. F

Do not use in a corrosive, dusty, damp atmosphere or a combustible environment.

Setup on an even surface or frame with sufficient loadbearing capacity. Single compressor preferably on vibration damper. Duplex and parallel circuits always rigid.
D

ATTENTION! Superheating can damage the valve. Remove the pipe supports from the valve for soldering. Only solder using inert gas to inhibit oxidation products (scale). The pipe connections have graduated inside diameters so that pipes with C standart millimetre and inch dimansions can be used. The connection diameters of the shut-off valves are rated for maximum compressor output. The actual required pipe cross section must be matched to the output. The same applies for non-return valves.

4| Compressor assembly
4.3 Pipes Pipes and system components must be clean and dry inside and free of scale, swarf and layers of rust and phosphate. Only use air-tight parts. Lay pipes correctly. Suitable vibration compensators must be provided to prevent pipes being cracked and broken by severe vibrations. Ensure a proper oil return. Keep pressure losses to an absolute minimum. 4.4 Laying suction and pressure lines INFO! Proper layout of the suction and pressure lines directly after the compressor is integral to the smooth running and vibration behaviour of the system.

ATTENTION! mproperly installed pipes can cause cracks and tears which can I result in a loss of refrigerant, A rule of thumb: Always lay the first pipe section starting from the shut-off valve downwards and parallel to the drive shaft.

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67 67 89 10 11 12 13 89 10 11 12 13

1 1 2

Rigid fixed point As short as possible Fig. 12

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11

4| Compressor assembly
4.5 Operating the shut-off valves Before opening or closing the shut-off valve, release the valve spindle seal by approx. of a turn counter-clockwise. After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise.

Release

Tighten

Valve spindle seal Fig. 13 Fig. 14

4.6 Operating mode of the lockable service connections

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Service connection closed

Connection cannot be shut off

Spindle

Connection blocked Compressor

Pipe connection

Opening the shut-off valve: Spindle: turn to the left (counter-clockwise) as far as it will go. > Shut-off valve completely opened / service connection closed. The connection which cannot be shut off is intended for safety devices.
Service connection opened

Fig. 15

Connection cannot be shut off

Spindle

Opening the service connection Compressor Spindle: Turn - 1 turn to the right clockwise. > Service connection opened / shut-off valve opened. The connection which cannot be shut off is intended for safety devices. 12

Fig. 16

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Connection open

Pipe connection

5| Electrical connection
5 Electrical connection DANGER! INFO! H igh voltage! Risk of electric shock! Only carry out work when the electrical system is disconnected from the power supply! Connect the compressor motor in accordance with the circuit diagram (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.

5.1 Information for contactor and motor contactor selection All protection equipment, switching and monitoring devices must comply with the local safety regulations and established specifications (e.g. VDE) and regulations as well as the manufacturers specifications. Motor protection switch is required! Motor contactors, feed lines, fuses and motor protection switches must be rated according to the maximum operating current (see name plate). Set the short circuit trigger current at max. 7 times the permissible operating current according to the compressor name plate. 5.2 Standard motor, design for direct or partial winding start Designation on the name plate Sticker on the terminal box

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Y/YY
Compressors with this marking are suitable for direct or partial winding start. The motor winding is subdivided into two parts: Partial winding 1 = 66% and part winding 2 = 33%. This winding division reduces the start-up current needed for a part winding start to approx. 65% of that for a direct start. INFO! A mechanical unloaded start with bypass solenoid valve is not required.

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13

5.3 Basic circuit diagram for part winding start with standard motor
0 1 2 3 4

F1.1
I=66%

F1.2
I=33%

F2
4A

S1

3 4

3 4

5 6

Q1

K1
2 6

K2
2

F1.1

F1.2

XSS

L1

L2

L3

PE

PE

10

11

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M1
1U1 1V1 1W1

M
Y/YY

2U1 2V1 2W1 X1 L1 L1 N

L N 43 43 11

S 12

M 14

R1
X2 1 2 3 4 5 6

MP10

R2

Fig. 17 R1 R2 F1.1 /1.2 F2 F3 F4 F5 B1

AnschluastenVerdichter Compressor terminal box

Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) 2 motor protection switches (66% / 33% of I A total) Control power circuit fuse High pressure safety monitor Safety chain (high/low pressure monitoring) Oil differential pressure monitor Release switch (thermostat)

Datum

20.Feb.2009

Bearb. Kelich Gepr. 09.Mr.2010 Urspr. Ers..

14

nderung

Datum

Name

Norm

Ers.d.

09958-05.2012-DGbFEI

L1.1 L2.1 L3.1 L1.2

K1

K1

K1

K1T

K1

K2

K1T

N PE

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

D
F5
T2 N L M S

GB
P> F3
Pl

P F4

P< B1

F E
E1

09958-05.2012-DGbFEI

Q1 M1 K1 K2 K1T S1 E1

Main switch Compressor motor Mains contactor (part winding 1) Mains contactor (part winding 2) Delay relay max. 1s Control voltage switch Oil sump heater

PWMP10

= +

BKMPRESSRS

Bl.

1 1
Bl.

15

5| 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 Direct start YY Direktstart YY Part winding start Y/YY TeilwicklungsstartY/YY L1
2U1 2V1 2W1 2U1

L2
2V1

L3
2W1

1U1

1V1

1W1

1U1

1V1

1W1

L1

L2

L3

L1

L2

L3

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ATTENTION! ailure to do this results in opposed rotary fields and results in F 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.

16

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5| Electrical connection
5.4 Sondermotor: Ausfhrung fr Direkt- oder Stern-Dreieck-Anlauf 5.4 Sondermotor: Ausfhrung fr Direkt- oder Stern-Dreieck-Anlauf 5.4 den Stern-Dreieck-Anlauf ist eine mechanische start Fr Special motor: design for direct mechanische Anlaufentlastung mit Bypass-Magnetventil Fr den Stern-Dreieck-Anlauf ist eineor star-delta Anlaufentlastung mit Bypass-Magnetventil (Zubehr) erforderlich. A mechanical unloaded start with bypass solenoid valve (accessories) is required for the (Zubehr) erforderlich. star-delta start. Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Bezeichnung auf dem Typschild Aufkleber auf Klemmenkasten Designation on the name plate Sticker on the terminal box

Y //Y /Y
Stern-Dreieck-Anlauf ist nur im Spannungsbereich (230 V) mglich. Stern-Dreieck-Anlauf ist nur im Spannungsbereich supply. Example: Beispiel: Star-delta start-up is only possible for 230 V power (230 V) mglich. Beispiel: 230 V 230 230 VV Direct start Direktstart Direktstart Star-delta start Stern-Dreieck-Start Stern-Dreieck-Start L1 L1 W2 U2 W2 U2 U1 V1 U1 V1 L1 L1 L2 L2 V2 V2 W1 W1 L3 L3 L2 L2 L3 L3 V2 V2 W1 W1 L3 L3 W2 U2 V2 W2 U2 V2 U1 U1 L1 L1 V1 W1 V1 W1 L2 L2 L3 L3 400 VVYY 400 400 V Y DirectDirektstart nur start only nur Direktstart

W2 U2 W2 U2 U1 V1 U1 V1 L1 L1 L2 L2

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17

5.5 Circuit diagram for direct start 230 V / 400 V Y

0 1 2 3 4

F2 F1.1
4A

S1

Q1
1 3 4 5 1 3 4 5 1 3 4 5 6

F1.1

K1
2 6

K3
Y 2 6

K2
D 2

F1.2

F1.2

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U1 XSS L1 L2 L3 N PE 1 2 3 PE 4 5 6 7 8 9 10 11

M1

W2

V1

M
3

U2 X1 L1 L1 N V2

L N 43 43 11

S 12

M 14

W1

R1
X2 1 2 3 4 5 6

MP10

R2

Fig. 18 R1 R2 F1.1 /1.2 F2 F3 F4 F5 B1 Q1 18

nderung

AnschluastenVerdichter Compressor terminal box

Cold conductor (PTC sensor) motor winding Thermal protection thermostat (PTC sensor) 2 motor protection switches Control power circuit fuse High pressure safety monitor Safety chain (high/low pressure monitoring) Oil differential pressure monitor Enabling switch (thermostat) Datum 20.Feb.2009 Main switch Bearb. Kelich
Gepr. Datum Name Norm 09.Mr.2010 Urspr. Ers.. Ers.d.

09958-05.2012-DGbFEI

L1.1 L2.1 L3.1 L1.2

K1 K1 K3 K4T

K4T

K1 K5T

K3

K2

K1

K2

K3

K4T

AL

K5T

N PE

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12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

F5
T2 N L M S

P> F3
Pl

P F4

P< B1

E1

D/S MP10

M1 K1 K2 K3 K4T K5T S1 AL E1

Compressor motor Mains contactor -contactor Y-contactor Delay relay for contactor changeover Delay relay for start unloader Control voltage switch Start unloader Oil sump heater

09958-05.2012-DGbFEI

= + Bl.

BKMPRESSRS

1 1
Bl.

19

5| Electrical connection
5.6 Electronic trigger unit MP 10 The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to the electronic trigger unit MP 10 in the terminal box. Readiness to operate is signalled by the H3 LED (green) after the power supply is applied. In the case of excess temperature in the motor winding, the unit switches off the compressor and the H1 LED lights red. The hot gas side of the compressor can also be protected against overtemperature using a thermal protection thermostat (accessory). The H2 LED (red) is provided for the protection function. The unit trips when an overload or inadmissible operating conditions occur. Find and remedy the cause. INFO! The unit has a restart prevention device. After you have rectified the fault, either interrupt the mains voltage. This unlocks the restart prevention device and the LEDs H1 and H2 go out.

5.7 Connection of the trigger unit MP10 INFO! Connect the trigger unit MP10 in accordance with the circuit diagram. Protect the trigger unit with a delayed-action fuse (F) of max. 4 A. In order to guarantee the protection function, install the trigger unit as the first element in the control power circuit. Terminals 1 - 2 Terminals 3 - 4 Terminals 5 - 6

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Temperature monitoring connections: Motor winding: Thermal protection thermostat: Restart prevention:

ATTENTION! Terminals 1 - 6 on the trigger unit MP 10 and terminals PTC 1 and PTC 2 on the compressor terminal board must not come into contact with mains voltage. This would destroy the trigger unit and PTC sensors. The supply voltage at L1-N (+/- for DC 24 V version) must be identical to the voltage at terminals 11, 12, 14 and 43.

Terminal board

Fig. 19

20

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5| Electrical connection
5.8 Function test of the trigger unit MP 10

Before start-up, troubleshooting or making changes to the control power circuit, check the functionality of the trigger unit: Pos
1

Procedure
Interrupt power supply (L1 or S1) Release the motor temperature sensor connection (1 or 2) Release the hot gas temperature sensor (if installed) (3 or 4) Restore the power supply (L1 or S1) Function check of motor temperature sensor: operational Function check of hot gas temperature sensor: operational Interrupt power supply again (L1 or S1) Reconnect terminals 1 or 2 and/or 3 or 4 Restore the power supply (L1 or S1): MP 10 is operational again

LED H1 LED H2 LED H3 red red green

OFF OFF OFF

ON ON ON

3 4

OFF OFF

OFF OFF

OFF ON

The compressor and the trigger unit MP10 are operational when the H3 LED (green) lights.

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21

5| Electrical connection
5.9 Oil sump heater

During compressor standstill and depending on the pressure and ambient temperature, refrigerant diffuses into the compressor's lubricating oil. This reduces the oil's lubricating ability. When the compressor is started, the refrigerant contained in the oil evaporates due to the decline in pressure. This can result in oil foaming and oil exodus which can result in oil hammer in certain circumstances. In order to prevent damage to the compressor, the compressor is equipped with an oil sump heater as standard. The oil sump heater must always be connected and operated. Operation mode: The oil sump heater operates when the compressor is shut down. The oil sump heater is switched off when the compressor starts. Connection: Connect the oil sump heater via an auxiliary contact (or parallel-wired auxiliary D Anschlussschema fr lsumpfheizung contactor) of the compressor contactor to a separate current path. GB Connection-diagramm for W. sump heater Electrical data: 230 V - 1 50/60 Hz, 80 oil F Plan de raccordement pour rsistance de carter dhuile

D GB E
09983- 10.01-DGBF

Fig. 20 ATTENTION! Connection to the current path of the safety control chain is not permitted

22

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6| Commissioning
6.1 Preparations for start-up INFO! In order to protect the compressor against inadmissible operating conditions, high-pressure and low-pressure pressostats controls are mandatory on the installation side.

The compressor has undergone trials in the factory and all functions have been tested. There are therefore no special running-in instructions. Check the compressor for transport damage! 6.2 Pressure strength test WARNING! The compressor must never be pressurised using oxygen or other technical gases! The maximum permissible overpressure of the compressor must not be exceeded at any time during the testing process (see name plate data)! The compressor has been factory-tested for pressure resistance. The following must be observed if the entire plant is subjected to an additional pressure strength test: Test the refrigeration circuit according to EN 378-2 or a corresponding safety standard. The pressure strength test is best carried out using dry nitrogen (N2). Do not mix any refrigerant with the testing medium (N2) as this could cause the ignition limit to shift into the critical range. 6.3 Leak test Carry out the leak test of the refrigerating system in accordance with EN 378-2 or a corresponding safety standard without including the compressor. Do not mix any refrigerant with the testing medium, as this could cause the ignition limit to shift into the critical range. 6.4 Evacuation ATTENTION! Do not start the compressor if it is under vacuum. Do not apply any voltage - even for test purposes (must only be operated with refrigerant). 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. 09958-05.2012-DGbFEI 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.

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23

6| Commissioning
6.5 Refrigerant charge CAUTION! Wear personal protective clothing such as goggles and protective gloves!

Make sure that the suction and pressure line shut-off valves are open. With the compressor switched off, add the liquid refrigerant directly to the condenser or receiver, breaking the vacuum. 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. INFO! Avoid overfilling the system with refrigerant! n order to prevent shifts in concentration, zeotropic refrigerant I blends (e.g. R407C) must always only be added to the refrigerating system in liquid form. o not pour liquid refrigerant through the suction line shut-off D valve on the compressor. It is not permissible to mix additives with the oil and refrigerant.

D GB F E

6.6 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 functioning properly. Switch on the compressor and let it run for at least 10 minutes. Check the oil level : The oil must be visible in the sight glass. ATTENTION! f larger quantities of oil have to be topped up, there is a risk of oil I impact effects. If this is the case, check the oil return!

6.7 Avoid slugging ATTENTION! Slugging can result in damage to the compressor and cause refrigerant to leak.

24

To prevent slugging: The complete refrigeration plant must be properly designed. All components must be compatibly rated with each other with regard to output (particularly the evaporator and expansion valves). Suction gas superheating at the compressor input should be min. 7 - 10 K (check the setting of the expansion valve). The system must reach a state of equilibrium. articularly in critical systems (e.g. several evaporator points), measures such as the use of liquid P traps, solenoid valve in the liquid line, etc. are recommended. There should be no movement of coolant whatsoever while the compressor is at a standstill.

09958-05.2012-DGbFEI

6| Commissioning
6.8 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. 21). A sight glass on the oil level regulator is not required. Anschluss lspiegelregulator 124 o Bei Verbundschaltungen von mehreren Verdichtern haben sich lstandsregulierungssysteme bewhrt. Fr die Montage eines lspieM6 x 10 gelregulators ist der Anschluss O vorgesehen (siehe Mazeichnung). je 3 mal 3 times each Alle gngigen lspiegelregulatoren von AC&R, ESK sowie das elektronische Reglersystem TRAXOIL S1A1 von SPORLAN knnen direkt ohne Adapter angeschlossen werden (s. Abb.). Ein Schauglas am lspiegelregulator ist nicht erforderlich. Fig. 21 47,6
12

124 o

Mechanical oil level regulator at the "O" connection

3 hole connection diagramm for 3-Loch-Anschlussbild fr ESK, ESK, AC&R et CARLY AC&R und CARLY 3 hole diagramm for TraxOil 3-Loch-Anschlussbild fr TraxOil

ahr von

12

4o

o 4

D GB F E

7| Maintenance
7.1 Preparation WARNING! Before starting any work on the compressor: Switch off the compressor and secure it to prevent a restart. Relieve compressor of system pressure. Prevent air from infiltrating the system! After maintenance has been performed: Connect safety switch. Evacuate compressor. Release switch-on lock. 7.2 Work to be carried out In order to guarantee optimum operational reliability and service life of the compressor, we recommend carrying out servicing and inspection work at regular intervals: Oil change: not mandatory for factory-produced series systems. - f or field installations or when operating near the application limit: for the first time after 100 to 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 auxiliary devices such as oil sump heater, pressure switch. 25

09958-05.2012-DGbFEI

7| Maintenance
7.3 Spare part recommendation
HG4 / ... Designation Set of gaskets Valve plate kit 08888 Oil pump kit Oil sump heater kit 230 V ~ Only use genuine Bock spare parts! 310-4 (S) Ref. No. 385-4 (S) 465-4 (S) Ref. No. 08913 08247 08384 08425 08248 555-4 (S) 650-4 (S) Ref. No.

7.4 Accessories Available accessories can be found on the Internet at www.bock.de. 7.5 Extract from the lubricants table

D GB F E

The oil type filled as standard in the factory is marked on the name plate . This oil type should be used as a preference. Alternatives are stated in the extract from our lubricants table below.
Refrigerants Bock standard oil types Recommended alternatives Fuchs SEZ 32 ICI Emkarate RL 46 S Mobil Arctic AL 46 Shell Clavus R 46 Mobil SHC 425 Shell Clavus SD 22-12 Sunoil Suniso 4GS Texaco Capella WF 46

HFC Fuchs Reniso Triton SE 55 (e.g. R134a/R407C)

HCFC (e.g. R22)

Fuchs Reniso SP 46

7.6 Decommissioning Close the shut-off valves on the compressor. Drain the refrigerant (it must not be discharged into the environment) and dispose of it according to the regulations. When the compressor is depressurised, undo the fastening screws of the shut-off valves. Remove the compressor using an appropriate hoist. Dispose of the oil inside in accordance with the applicable national regulations. 09958-05.2012-DGbFEI 26

09958-05.2012-DGbFEI
Electrical data 3 Weight Starting current
(rotor locked) PW 1 / PW 1 + 2

Type Suction line SV L/M/H 5 Ltr. dB(A) 59 / 60 / 60 22 (7/8) 28 (1 5 /8) 61 / 61 / 60

Connections 4 Oil charge Sound pressure level

No. of cylinders Discharge line DV kg 147 149 149 152 148 151 150 153 152 155 28 (1 1/8) 42 (1 5 /8) 35 (1 3 /8) 66 / 64 / 62 2,7 mm (inch) mm (inch)

Displacement 50 / 60 Hz (1450 / 1740 1 A 16 18 18 27 18 27 27 34 27 34 18,4 15,7 82 / 107 107 / 140 15,2 107 / 140 12,9 82 / 107 13,0 82 / 107 11,0 57 / 75 12,5 82 / 107 9,5 57 / 75 9,0 57 / 75 8,5 50 / 65 kW A
Max. Max. power Operating current consumption 2 2 PW 1 + 2

Voltage

rpm)

m3 /h

HG4/310-4

27,1 / 32,5

8| Technical data

HG4/310-4 S

27,1 / 32,5

HG4/385-4

33,5 / 40,2

HG4/385-4 S

33,5 / 40,2

HG4/465-4

HG4/465-4 S

40,5 / 48,6

40,5 / 48,6

64 / 63 / 62

HG4/555-4

48,2 / 57,8

380-420 V Y/YY - 3 - 50 Hz PW 440-480 V Y/YY - 3 - 60 Hz PW PW = Part Winding Winding ratio : 66% / 33%

HG4/555-4 S

48,2 / 57,8

HG4/650-4

56,6 / 67,9

HG4/650-4 S

56,6 / 67,9

69 / 66 / 63

3 All specifications are based on the average of the voltage range 1 Tolerance ( 10%) relative to the mean value of the voltage range. Other voltages and types of current on request. 4 For solder connections 2 - The specifications for max. power consumption apply for 50Hz operation. 5 L = low temperature (-35 / 40 C), M = normal cooling (-10 / 45 C), For 60Hz operation, the specifications have to be multiplied by the factor H = air conditioning (5 / 50C) sound pressure level measured in 1.2. The max. working current remains unchanged. low reflection measuring area, measuring distance 1m. - Take account of the max. operating current / max. power consumption for Compressor operation at 50 Hz (1450 rpm), refrigerant R404A. design of fuses, supply lines and safety devices. Fuse: Consumption Values stated are average values, tolerance 2 dB(A). category AC3

27

GB E

9| Dimensions and connections

7

7
DV L A N

6
Centre of gravity

5 ca.370 306 ca.370

306B

Mae Zub

ca.405 278 170 ca.405

SV A1
ca.180

ca.405 278 170

SV A1
ca.180
Q
73 112 ca.245 436 550 (535) ca.725 (690)

30 20

25
(L)*

Q
D 436 GB 550 (535)

D P F J

SV A1

D P F J

E H C D1 EO

D P 4x F J

278 170

ca.180

11 V 280 330

25

HK D1 O K

Ansicht X: A View X: Pos Vue X : Rac

a.245

73 112

436 550 (535) ca.725 (690)

Ansicht HG(X)4/310-555 -4 (S) View HG(X)4/310-555 -4 (S) Vue HG(X)4/310-555 -4 (S)

280 330
B

Anschlsse

25

ca.245

4x M10 Vibration absorbers 11 Amortisseurs de 4x 4011 V vibration 280

SV Saugabsperrventil, Rohr (L)*

Schwingungsdmpfer

V
Connections
Suction line valve, tube

Ansicht View X Vue X :

330

DV Druckabsperrventil, Rohr (L)* A Anschlu Saugseite, nicht absperrbar A1 Anschlu Saugseite, absperrbar Anschlu Druckseite, nicht absperrbar

Discharge line valve, tube (L)* Connection suction side, not lockable Connection suction side, lockable

30 20

E
Mae in mm Dimensions in mm Cotes en mm nderungen vorbehalten Subject to change without notice Sous rserve de toutes modifications

M10 40

30 20

ca.725 (690) F

Connection discharge side, not lockable Schwingungsdmpfer Vibration Connection discharge side, lockable Vibration absorbers oil pressure C Anschlu ldrucksicherheitsschalter OIL Connection SV M10 ldrucksicherheitsschalter LP de vibration safety switch OIL damper SchwingungsdmpferAmortisseurs Connection oil pressure safety switch LP D Anschlu B1 Anschlu Druckseite, absperrbar

D1 Anschlu Vibration absorberslrckfhrung vom labscheider Connection oil return from oil separator 40 E Anschlu ldruckmanometer Connection oil pressure gauge A AmortisseursFde vibration Anschlsse Oil drain labla Connec

Mae in mm Dimensions in mm Cotes en mm nderungen vorbehalten Subject to change without notice 1) Sous rserve de toutes modifications

Connection suction side, not Connecti B1 Anschlu Druckseite, absperrbar valve lockable Mae in ( fr HG(X)4/310-555 A (S) -4 Anschlu Saugseite, nicht absperrbar V Anschlu lserviceventil Connection oil service Massenschwerpunkt View HG(X)4/310-555 )-4 (S) C Connecti A1 Anschlu Connection suction side, lockable Dimensions in ( ) for HG(X)4/310-555 -4 (S) Saugseite, absperrbar Anschlu ldrucksicherheitsschalter OIL Centre of gravity Q Anschlu ltemperatursensor Connection oil temperature sensor Vue D Anschlu ldrucksicherheitsschalter LP notConnecti Centre de gravitHG(X)4/310-555 -4 pour HG(X)4/310-555 -4 (S) Ctes en ( ) (S) B Anschlu Druckseite,Ltanschlu Connection discharge side, lockable (L)* = nicht absperrbar (L)* = Brazing connection D1 B1 Anschlu Druckseite, absperrbar Anschlu lrckfhrung vom labscheider Connecti Connection discharge side, lockable 1) E Anschlu ldruckmanometer C Anschlu ldrucksicherheitsschalter OIL Connection oil pressure safety Connecti switch O Typ Teile Nr. Typ Teile Nr. TypAnschlu ldrucksicherheitsschalter LP Teile Nr. oil pressure safety Oil drain Teile Nr. Typ F labla Connection D switch L H Stopfen lfllung Oil charg HG4/310-4 13790* HGX4/310-4 13795* D1 Anschlu S 13760* HGX4/310-4 S 13775* HG4/310-4 lrckfhrung vom labscheider Connection oil return from oil separator J Anschlu lsumpfheizung Connecti E Anschlu ldruckmanometer Connection oil pressure gauge HG4/385-4 13791* HGX4/385-4 13796* HG4/385-4 S 13761* HGX4/385-4 S 13776* K Schauglas Sight gla F labla Oil drain HG4/465-4 13792 HGX4/465-4 13797 HG4/465-4 S 13762 HGX4/465-4 S Wrmeschutzthermostat L Anschlu 13777 Connecti H Stopfen S 13763 HGX4/555-4 S Leistungsregler Oil charge plug N Anschlu 13778 Connecti HG4/555-4 13793 HGX4/555-4 13798 HG4/555-4lfllung

Ansicht HG(X)4/310-555 -4 (S)

Sight glass AnschlsseK Schauglas Connections (L)* DV Druckabsperrventil, Rohr Discharg Ansicht HG(X)4/310-555 Anschlu Wrmeschutzthermostat L -4 (S) Connection thermal protection thermostat A Anschlu Saugseite, nicht absperrbar Connecti Connection capacity View HG(X)4/310-555 N Anschlu Leistungsregler -4 (S) SV Saugabsperrventil, Rohr (L)* Anschlu Saugseite, absperrbar controller Connecti Suction line valve, tube (L)* A1 O Anschlu lspiegelregulator Connection oil level Vue HG(X)4/310-555 -4 (S) Rohr (L)* Anschlu Druckseite, nicht valve, regulator (L)* DV Druckabsperrventil, Discharge line absperrbar tube B Connecti P Anschlu l-Differenzdrucksensor Connection oil pressure differential sensor

A1

H J

Stopfen lfllung

Oil charge plug

SV Saugabsperrventil, Rohr oil sump heater Anschlu lsumpfheizung Connection (L)*

Suction li

View HG(X)4/310-555 -4 (S)

Halbhermetischer Verdichter HG / Semi-hermetic compressor HG / Compresseur semi-h

SV A A1

SV A A1

HG4/650-4 13794
Massenschwerpunkt Centre of gravity Centre de gravit

HGX4/650-4 13799

J Anschlu lsumpfheizung Connection oil sump O Anschlu 13779 HG4/650-4 S 13764 HGX4/650-4 S lspiegelregulator heater K Schauglas
P

Connecti

* Keine Serie / No series / Pas de sries

Sight glass Anschlu l-Differenzdrucksensor

Connecti

notice difications

SV 90 rotatable Connection oil Dimensions in mmpressure differential sen Dimensions in ( ) = HG(X)4/310-4 (S), HG(X)4/385-4 (S) P Anschlu/ l-Differenzdrucksensor compressor HG / Com Semi-hermetic Connection oil service(kg) Gewicht: valve Mae inHalbhermetischer Verdichter Anschlu lserviceventil ( ) fr HG(X)4/310-555 -4 (S) V HG Massenschwerpunkt HG(X)4/465-4) (S), HG(X)4/555-4 (S) Q Anschlu Typ Fig. 22oil temperature sensor Dimensions in ( for HG(X)4/310-555 -4 (S) Centre of gravity Connection Typ Teile Nr. Typ Teile Nr. ltemperatursensor Teile Nr. Typ Teile Nr.
Centre de gravit Ctes en ( ) pour HG(X)4/310-555 -4 (S)

L Anschlu -4 (S) Connection thermal protection thermost Mae in ( ) fr HG(X)4/310-555Wrmeschutzthermostat Anschlu lserviceventil V Connecti N Anschlu Leistungsregler Connection capacity controller Connecti Dimensions in ( ) for HG(X)4/310-555 -4 (S) Q Anschlu ltemperatursensor Gutoleranzen: Ctes en ( ) pour HG(X)4/310-555 -4 (S) O Anschlu lspiegelregulator Connection oil level regulator (L)* = Bra (L)* = Ltanschlu

Revisionsdurchlauf: 2

f e d c b a

* Keine Serie / No series HG4/385-4 S HG4/385-4 13791* HGX4/385-4 13796* / Pas de sries HG4/465-4 13792 HGX4/465-4 13797 HG4/465-4 S Betrifft Blatt 2 HG4/555-4 13793 HGX4/555-4 13798 HG4/555-4 -S Alle Verdichterbaugren von Zeichnung 13762.0c aufgenommen HG4/650-4 13794 HGX4/650-4 13799 HG4/650-4 -S

13761* HGX4/385-4 S 13776* 13762 HGX4/465-4 S 13777 7635 13.01.10 Bttner Widm 13763 HGX4/555-4 S 13778 Layh 7626 13.11.09 Schni 13764 HGX4/650-4 S 13779
7609
7341,7368,7417,7431,7437

09958-05.2012-DGbFEI

(L)* = (L)* = Brazing connection HG4/310-4 13790* HGX4/310-4 13795*Ltanschlu HG4/310-4 S 13760* HGX4/310-4 S 13775* 6 30 ber 0.5 HG4/385-4 13791* HGX4/385-4 13796* HG4/385-4 S 30 bis 6 Halbhermetischer Verdichter HG / Semi-hermetic compressor 13761*/ Compresseur semi HG HGX4/385-4 S 13776* 120 HG4/465-4 13792 HGX4/465-4 13797 HG4/465-4 S 13762 HGX4/465-4 S 137770.3 0.1 0.2 Typ Teile Nr. Typ HG4/555-4 13793 Typ Teile Nr. Teile Nr. Typ Teile Nr. HGX4/555-4 13798 HG4/555-4 S 13763 HGX4/555-4 S 13778 Unbemate Radien: HG4/310-4 13790* HGX4/310-4 13795* HG4/310-4 S 13760* HGX4/310-4 S 13775* HG4/650-4 13794 HGX4/650-4 13799 HG4/650-4 S 13764 HGX4/650-4 S 13779

Tol.-Ang. DIN ISO 2768

Betrifft Bl.2

* Keine Serie / No series / Pas de sries

Zone

21.10.09 18.07.08 07.02.08 Datum

Schni Widm Buck

Layh Gr Keu

Massenschwerp. aufgen.;Pos.1089 entfernt,Betr. Bl.2;Stator als BS erhltl.,Zub. aufgen.,Betr. Bl.3

04.12.08 Franke

28 U-Scheiben, Pos.181+221, unter Zylinderdeckel und Ventilen eingefgt Betr. Bl.2+3

Pos.504,1086,1087,1088 hinzu., Esterlkleber entf., Gew.stift jetzt Klebst.besch.,Anschlsse Q u. V eingef.

7307,7283,7285,7342

7169 nderungs-Nr.

Zust. nderungsbeschreibung

Bearb. Gepr.

Gutoleranzen: Schaich Ma

ca.455

DV L

A N

1)

C B1

ca.680ca.680

B1

B1 ca.370 306

Mae Z

C E H D O

Gu Ge To b Pa bi

9| Dimensions and connections

SV DV A A1 B B1 C D D1 E F H J K L N O V P Q Suction line Discharge line see technical data, Chapter 8 1/ NPTF 8 7/ UNF 16 1/ NPTF 8 7/ UNF 16 7/ UNF 16 7/ UNF 16 1/ NPTF 4 7/ UNF 16 M22 x 1,5 M22 x 1,5 M22 x 1,5 1/ NPTF 8 M48 x 1,5 3 x M6 1/ NPTF 4 M20 x 1,5 1/ NPTF 8

Connection suction side, not lockable Connection suction side, lockable Connection discharge side, not lockable Connection discharge side, lockable
Connectoin oil pressure switch OIL Connection oil pressure switch LP

Connection oil return from oil separator

Connection oil pressure gauge Oil drain Oil charge plug Oil sump heater Sight glass Connection thermal protection thermostat Connection capacity controller Connection oil level regulator Connection oil service valve Connection oil differential pressure sensor Connection oil temperature sensor

D GB F E

09958-05.2012-DGbFEI

29

10| Declaration of conformity and installation

DECLARATION OF CONFORMITY CE 96 for using the compressors within the European Union (in accordance with Low Voltage Directive 2006/95/EC) We hereby declare that the following refrigerating compressors Product designation: HG4 comply with the Low Voltage Directive 2006/95/EC. Applied harmonised standard: EN 60034-1, EN 60204-1 DECLARATION OF INSTALLATION for using the compressors within the European Union (in accordance with Machinery Directive 2006/42/EC) The manufacturer: GEA Bock GmbH, Benzstrae 7 72636 Frickenhausen, Tel.: 07022/9454-0

D GB F E

hereby declares that the refrigerating compressor HG4 complies with the basic requirements of Appendix II 1B of the Machinery Directive 2006/42/EC. The following harmonised standards have been applied: EN ISO 12100-1 EN ISO 12100-2 EN 12693 EN 349 A partly completed machine may only be put into operation when it has been established that the machine, into which the partly completed machine is to be installed, conforms to the regulations of the Machinery Directive (2006/42/EC). The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery on request. The special technical documentation required for partly completed machinery has been created in accordance with Appendix VII Part B. Person responsible for documentation is: Wolfgang Sandktter, Benzstrae 7, 72636 Frickenhausen. 09958-05.2012-DGbFEI

Frickenhausen, 01.11.2011 ppa. Wolfgang Sandktter, Chief Development Officer 30

11| Service
Dear customer,

Bock compressors are top-quality, reliable and service-friendly quality products. If you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The Bock service team can be contacted by phone: +49 7022 9454-0 via e-mail: bock@gea.com or on the Internet at: www.bock.de In addition, for German-speaking countries we have set up a toll-free Bock hotline 00 800 / 800 000 88 from Monday to Saturday between 8 am and 9 pm. Any suggestions you may have regarding the on-going development of our compressor, equipment Sehr geehrter Kunde, and parts programme are welcome at any time. Bock-Verdichter sind hochwertige, zuverlssige und servicefreundliche Qualittsprodukte. U Yours faithfully Vorteile in vollem Umfange und ber den gesamten Einsatzzeitraum Ihrer Klteanlage nutze knnen, beachten Sie unbedingt die folgenden Bedienungs- und Wartungshinweise. Bei Frag GEA Bock GmbH Montage, Betrieb und Zubehr wenden Sie sich bitte an unsere Anwendungstechnik oder an Benzstrae 7 Kltefachgrohandel bzw. unsere Vertretung. Das Bock-Serviceteam erreichen Sie direkt un +49 72636 Frickenhausen 7022 9454-0, via e-mail: mail@bock.de oder im Internet: www.bock.de. Fr den deuts chigen Raum steht darber hinaus die kostenlose Bock-Hotline 00 800 / 800 000 88 von mo Germany bis samstags zwischen 8 und 21 Uhr zur Verfgung. Fr Anregungen zur Weiterentwicklung D Verdichter-, Ausrstungs- und Ersatzteilprogramms sind wir Ihnen jederzeit sehr dankbar.

GB

We also provide information on the Internet at www.bock.de. F Lesen Sie vor Arbeitsbeginn die in dieser Betrieb For example, under the "Documentation" link you will find: tung fr Sie zusammengefassten Informationen. - Technical information - Product information - Product brochures - and much more

09958-05.2012-DGbFEI

E Es werden wichtige Hinweise zur Sicherheit, Montage triebnahme und Bedienung gegeben. Darber hinaus Sie Informationen zu Wartung, Ersatzteilen und Zube Einige Hinweise sind besonders gekennzeichnet: WARNUNG! Dieses Symbol weist darau dass ungenaues Befolgen oder Nichtb von Anweisungen zu Schden an Perso am Verdichter oder an der Klteanlage kann. GEFAHR! Dieses Symbol weist auf Anw gen hin, um unmittelbare schwere Gef gen von Personen zu vermeiden. GEFAHR! Dieses Symbol weist auf Anw gen hin, um unmittelbare schwere Gef dungen von Personen oder Anlagen du elektrischen Strom zu vermeiden. Dieses Symbol verweist auf wichtige Z hinweise, die bei der Arbeit unbedingt bercksichtigen sind.

Bock Kltemaschinen GmbH

Das hohe Qualittsniveau der Bock-Verdichter wird d stndige Weiterentwicklung der Konstruktion, der Aus 31 tung und des Zubehrs gewhrleistet. Daraus knnen Abweichungen zwischen der vorliegenden Betriebsan

Excellence

Passion

Integrity

Responsibility

GEA-versity

D GB F E

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index.

GEA Refrigeration Technologies

GEA Bock GmbH
Benzstrae 7, 72636 Frickenhausen, Germany Telephone: +49 7022 9454-0, Fax: +49 7022 9454-137 bock@gea.com, www.bock.de

32

09958-05.2012-DGbFEI GEA Group AG. All rights reserved.

09958-05.2012-DGbFEI