ba hg3 (gb) - bock.de2 connection for oil level regulator 3 oil sump heating / oil drain plug 4 oil...

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ROperating instructions for motor compressor Series HG 3

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for suction-gas cooled hermetic motor compressorSeries HG 3

Types: HG 3/155 - 4 HG 3/155 - 4 S HGX 3/155 - 4 HGX 3/155 - 4 S HG 3/190 - 4 HG 3/190 - 4 S HGX 3/190 - 4 HGX 3/190 - 4 S HG 3/235 - 4 HG 3/235 - 4 S HGX 3/235 - 4 HGX 3/235 - 4 S HG 3/275 - 4 HG 3/275 - 4 S HGX 3/275 - 4 HGX 3/275 - 4 S HG 3/325 - 4 HG 3/325 - 4 S HGX 3/325 - 4 HGX 3/325 - 4 S

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OPERATING INSTRUCTIONS

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- Subject to modications -

Dear Customer,Bock compressors are top-quality, reliable, service-friendly quality products. Please comply with thefollowing operating and maintenance instructions so that you can benet from all advantages to thefull and use your refrigerating system throughout its entire service life. If you have any questionsabout installation, operation and accessories, please contact our technical service departmentor your refrigerating system wholesale dealer or our representative. The Bock service team isavailable by phone under +49 7022 9454-0, by e-mail under [email protected] or on the internet underwww.bock.de. In addition, for German speaking countries we have set up a toll-free Bock hotlineunder 00 800 / 800 00 88 from Monday to Saturday between 8 a.m. and 9 p.m. Any suggestions youmay have regarding the on-going development of our compressor, equipment and parts programmeare welcome at any time.

Bock Kältemaschinen GmbHPostfach 11 61D-72632 FrickenhausenBenzstr. 7D-72636 FrickenhausenFon: +49 7022 9454-0Fax: +49 7022 [email protected]

Please read the information summarised for you inthis manual before starting work.It contains important instructions for safety, installation,initial commissioning and handling. In addition you will nd information on maintenance, spare parts and acces-sories.Some instructions are identied by special symbols withthe following meaning:

WARNING This symbol is used to indicatethat inaccurate compliance or total failureto comply with the instructions couldcause injury to persons or damage to thecompressor or refrigerating machineThis symbol indicates important additionalinstructions which you should observeduring your work.

The high quality standard of Bock compressors isguaranteed also by on-going further development ofmachine, features and accessories. This could possiblyresult in nonconformities between this present manualand your compressor. Please understand that it is notpossible for any claims to be derived from the details,illustrations and descriptions.

Your team atBock Kältemaschinen GmbH

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Contents Safety 4Product description 5Main function parts 5Nameplate 6Type code 6Limits of application 7Installation instructions 8 General 8 Pipe connections / pipes 8 Pipe installation 9 Shut-off valves 9 Versions of discharge shut-off valves 10 Suction shut-off valve 10Electrical connection 11 General instructions 11 Direct start 11 Main line diagram for direct start 12 Star delta starting 13 Main line diagram for star delta starting 13 Electronic trigger MP 10 14 Connection MP 10 14 Function test MP 10 14 Recommended circuit contactors and motor contactors 15 Oil sump heating 16Initial commissioning 16 Leak test, evacuation 16 Filling with coolant 16 Operation checks 17 Liquid shocks 17 Lubrication / oil check 17 Connection of the oil level controller 18 Lubricants 18Maintenance 18 Safety instructions 18 Service intervals 18 Maintenance and servicing kits 19 Screwed unions 19Accessories 19Technical specications 20Connections 21Dimensions 21Declaration of conformity CE 96 22Manufacturer declaration 22

Contents

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SafetyThe Bock refrigerating compressors named in the title are intended for installation in machines(within the EU according to EU directive 98/37/EC Machinery Directive, 97/23/EC Pressure Equip-ment Directive and 73/23/EC Low Voltage Directive). Initial commissioning is only allowed when thecompressor has been installed according to these instructions and the whole machine in which it isintegrated has been tested and accepted according to the statutory regulations.Bock refrigerating compressors have been designed to state-of-the-art engineering. Safety for theuser is given particular priority during the design stage. However, it is always possible for therefrigerating machine and operation thereof to pose unavoidable residual risks. This is why theseinstructions must be observed carefully by every person working at the compressor.Work on the compressor may only be carried out by persons whose technical training, skills andexperience together with their knowledge of pertinent regulations and documentation means thatthey are capable of assessing the work to be carried out and detecting any possible dangers (trainedstaff as per DIN 31000).

SAFETY INSTRUCTIONSCaution! Refrigerating compressors are pressurised machines and therefore require particu-larly careful and meticulous handling.

Only qualied staff are allowed to handle refrigerating compressors.National safety regulations, accident prevention regulations, technical rules and otherspeci cations (incl. EN 378 etc.) must be observedThe compressor may only be operated in refrigerating systems, and only withcoolants approved for this compressor by Bock.The maximum tolerable operating overpressure may not be exceeded (not even fortest purposes).Pressure switches are required to safeguard the machine from excess pressures.New compressors are provided with an inert gas lling in the factory (approx. 3 barnitrogen) The pressure in the compressor must be relieved before connecting up therefrigerating system.Before starting the compressor, check for any signs of transport damage.Before starting up, check that all components mounted by the user have been pro-perly tted and are connected pressure-tight with the compressor (e.g. pipelines,bungs, union nuts, replaced parts, etc.)Before starting up, evacuate the refrigerating machine carefully with the compressorand then ll with coolant.Before starting the compressor, open the discharge shut-off valve and suction shut-offvalve.Do not start the compressor in a vacuum. Only operate the compressor when thewhole system has been lled.Surface temperatures of more than 100°C are possible on the pressure side respec-tively below 0°C on the suction side, depending on operating conditions.

Safety

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GBTerminal box

Product descriptionHermetic four-cylinder reciprocating compressor with suction-gas cooled drive motorDrive motor anged to the compressor housingThe stream of coolant sucked out of the evaporator ows over the motor and cools itintensively. In this way, the motor can be kept at a relatively low temperature level, particularlyunder high loads.Preferred application range: normal refrigerating and air-conditioning.

1 Suction shut-off valve2 Discharge shut-off valve3 Oil pump4 Oil sump heating5 Oil drain plug / oil lter6 Oil sight glass

7 Oil ller plug8 Connection for oil level controller9 Connection for heat protection thermostat10 Valve plate11 Connection for capacity regulator12 Transport eyelets

Main function parts

Compressor section

Motor section

Terminal box

Main parts

1

2

9

8765

4

3 10

12

11

Function parts

two-

1

23

4

5

6

789

10

1 Discharge shut-off valve2 Connection for oil level regulator3 Oil sump heating / Oil drain plug4 Oil pump5 Connection for heat protection thermostat

6 Valve plate7 Transport eyelets8 Oil ller plug9 Oil sight glass10 Suction shut-off valve

Compressor section

Motor section

Product descriptionHermetic four-cylinder reciprocating compressor with suction-gas cooled drive motorDrive motor anged to the compressor housingThe stream of coolant sucked out of the evaporator ows over the motor and cools itintensively. In this way, the motor can be kept at a relatively low temperature level, particularlyunder high loads.Preferred application range: normal refrigerating and air-conditioning.

Product description

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Type code

HG 4 / 650 - 4 SMotor version air-conditioning

No. of polesCode for capacity size

Series

Size

Compressors which have been fi lled with ester oil in the factory (e.g. for use withchlorine-free coolants such as R404A, R407C) are identifi ed accordingly

in the type designation by the suffi x X (e.g. HGX 4/650-4).

HG 3 / 325 - 4 S

HGX 3/325-4

Product description

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Limits of applicationto - evaporation temperaturetc - condensing temperaturetoh - suction gas temperature 20°C∆toh - suction gas overheating 10 K

L = deep-freeze rangeM = normal refrigeration rangeH = air-conditioning

Compressor operating mode:in normal operating modewith additional cooling

Product description

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Explanations of the limits of application diagramsOperation of the compressor is only possible within the limits shown in the diagrams. The limits mustbe observed. The maximum discharge end temperature of 140°C may not be exceeded. In the darkgrey area, compressor operation is only possible with additional cooling.Additional cooling solutions can consist of additional fans (accessories) or water-cooled cylindercovers (accessories). We advise using heat protection thermostats (accessories).As a general rule:

Only use thermally highly stable oils (see lubricant table)! Recommendation: for R22 Bock standard oil FUCHS Reniso SP 46 for R134a, R404A, R407C, R507 Bock standard oil FUCHS Reniso Triton SE 55

When operating with capacity regulators, the suction gas overheating must be adjusted accor-dingly.When using frequency transformers, please note that the limits of application can be restrictedon reaching the maximum tolerable power consumption of the drive motor.Continuous operation in the limit zone is not recommended.Maximum permissible ON/OFF switching frequency of the drive motor: 12 switching cycles perhour. The whole machine must reach a state of equilibrium (constant operating conditions).

Rating values for operating ranges on request.Installation instructionsGeneral

Only lift the compressor at the transport eyelet.The hoisting gear must be suitable for the compressor weight.When erecting the compressor in a closed room, suf cient ventilation of the machine room airmust be guaranteed. Do not operate the compressor in a corrosive atmosphere, dust, steamor ammable environment. Allow suf cient space for performing maintenance work.The compressor must be erected horizontally on anti-vibration pads or if necessary rigidly.Avoid any distortion in the compressor housing. Always consult the manufacturer beforemounting the compressor in a slanting position!Direct erection on bundle pipe condensers only with anti-vibration pads. Risk of vibrationcracks and breakage with rigid installation!In addition, we recommend the installation of pipeline vibration compensators.

Transport eyelet

Pipe connections / pipesCaution! Compressor is pressurised. Leave the inert gas lling in the compressor until initial commissioning. The shut-off valves should remain closed until evacuated.The pipe connections are suitable for all pipes of normal metric and inchdimensions. The solder connections of the shut-off valves are to be removed from theshut-off valves when soldering the pipes.Pipes and machine components should always be clean and dry on the inside, and freeof cinders, metal chips, rust and phosphate coats. In addition, all parts to be tted to thecompressor and to the whole machine must be delivered sealed air-tight.

Explanations of the limits of application diagramsOperation of the compressor is only possible within the limits shown in the diagrams. The limits mustbe observed. The maximum discharge end temperature of 140°C may not be exceeded. In the darkgrey area, compressor operation is only possible with additional cooling.Additional cooling solutions can consist of additional fans (accessories) or water-cooled cylindercovers (accessories). We advise using heat protection thermostats (accessories).As a general rule:

Only use thermally highly stable oils (see lubricant table)! Recommendation: for R22 Bock standard oil FUCHS Reniso SP 46 for R134a, R404A, R407C, R507 Bock standard oil FUCHS Reniso Triton SE 55

When operating with capacity regulators, the suction gas overheating must be adjusted accor-dingly.When using frequency transformers, please note that the limits of application can be restrictedon reaching the maximum tolerable power consumption of the drive motor.Continuous operation in the limit zone is not recommended.Maximum permissible ON/OFF switching frequency of the drive motor: 12 switching cycles perhour. The whole machine must reach a state of equilibrium (constant operating conditions).

Rating values for operating ranges on request.

Installation instructions

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Pipe installationEnsure there is provision for proper oil re uxPipes and non-return valves must be dimensioned according to the operating points.Pressure losses must be kept to a minimum.Fix the pipes with fastening clips with rubber sleeves.Provide suitable vibration compensators for the pipes, ensuring they are mounted in thecorrect position. Prevent any vibration in the pipes, as these can cause cracks or breaks(caution! Risk of coolant leaks). Check the whole machine regularly.

Shut-off valvesWarning! Both shut-off valves - the suction and the discharge shut-off valve - must be opened before starting the compressor!Before opening or closing the shut-off valve, turn the valve spindle seal approx. 1⁄4 of a turn counter-clockwise. After activating the shut-off valve, tighten the valve spindle seal again clockwise.

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Connection 3 is intended for safeguard systems and cannot be shut-off.

Opening the shut-off valveOpen spindle 1 turning to the left(counter-clockwise) as far as itwill go.Shut-off valve is fully open / ser-vice connection 2 closed(setting A).

Opening the serviceconnection (2)Turn spindle 1 approx. 1⁄2 to 1 turnto the right (clockwise)Service connection 2 is nowopen, the shut-off valve is alsoopen (setting B).

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Setting A

Setting B Pipe connection

Pipe connection

Compressor

Compressor

Valve spindle seal loosen

tighten


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Versions of discharge shut-off valvesa) HG 3/155-4, HG 3/155-4S

HG 3/190-4, HG 3/190-4SHG 3/235-4, HG 3/235-4S

b) HG 3/275-4, HG 3/275-4SHG 3/325-4, HG 3/325-4S

Valve spindle

Connection B1(can be shut of)

Connection B (cannot be shut of)

Suction shut-off valves

Valve spindle

Connection A1 (can be shut of)

Connection A (cannot be shut of)


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Electrical connectionGeneral instructions

The electrical connection of the motor is to be completed according to the main line circuitdiagram (on the inside of the terminal box). When connecting up the compressor, alwayscomply with the local electricity regulations (VDE 0100 for Germany).Use suitable screwed cable glands with protection class IP 54 for the cable leadthroughs atthe terminal box. Use strain relief elements. Avoid any chafe marks on the cables.Motor contactors (see table), feed lines and fuses are to be rated according to the maximumoperating current (see compressor nameplate). Compare the details for voltage and fre-quency on the nameplate with the details for the electricity mains supply. The motor may onlybe connected up when these details correspond.

Main line diagram for direct start 230 V ∆ / 400 V Y

ConnectionThe motor is connected in ∆ / Y in series.

Designation on the nameplate: ∆ / YDesignation on the yellow label on the terminal box (see gur):

In the factory, the motor is switched for direct starting (Y).Direct start (Example for motor 230 V ∆ / 400 V Y)Terminal box with bridges inserted for direct start: a) at low voltage (230 V ∆ / 3~): b) at high voltage (400 V Y/ 3~):

1-2 Connections for PTC sensorR1 PTC sensor motor windingR2 Heat protection thermostat (PTC sensor)F1 Safety device load stabilisation circuitF2 Fuse control power circuitF3 Safety chain (high/low pressure monitoring)

B1 Enable switch(thermostat)Q1 Main switchS1 Switch control voltageM1 Compressor motorK1 Mains contactorA1 Electronic trigger MP 10

Electrical connections

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Main line diagram for direct start 230 V ∆ / 400 V Y

ConnectionThe motor is connected in ∆ / Y in series.

Designation on the nameplate: ∆ / YDesignation on the yellow label on the terminal box (see gur):

In the factory, the motor is switched for direct starting (Y).Direct start (Example for motor 230 V ∆ / 400 V Y)Terminal box with bridges inserted for direct start: a) at low voltage (230 V ∆ / 3~): b) at high voltage (400 V Y/ 3~):

1-2 Connections for PTC sensorR1 PTC sensor motor windingR2 Heat protection thermostat (PTC sensor)F1 Safety device load stabilisation circuitF2 Fuse control power circuitF3 Safety chain (high/low pressure monitoring)

B1 Enable switch(thermostat)Q1 Main switchS1 Switch control voltageM1 Compressor motorK1 Mains contactorA1 Electronic trigger MP 10


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Star delta startingMechanical start unloader with bypass solenoid(accessories) is required for star delta starting!

For star delta starting (only in voltage range 230 V ∆) the bridges are to be inserted according to thecircuit diagram in the lid of the terminal box. Delay time on switching over max. 2 seconds.

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Main line diagram for star delta starting at 230 V ∆

1-2 Connections for PTC sensorR1 PTC sensor motor windingR2 Heat protection thermostat (PTC sensor)F1 Safety device load stabilisation circuitF2 Fuse control power circuitF3 Safety chain (high/low pressure monitoring)B1 Enable switch(thermostat)Q1 Main switchM1 Compressor motor

K1 Mains contactorK2 ∆ contactorK3 Y-contactorK4T Time relay for contactor changeoverK5T Time relay for start unloaderAL Magnetic coil for start unloaderA1 Electronic trigger MP 10S1 Switch control voltageY1 MV start unloader


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Electronic trigger MP 10The compressor motor is equipped with posistor temperature sensors (PTC) which are wired to theelectronic trigger MP 10 in the terminal box. The stand-by mode is indicated by the light diode H3(green) when mains voltage is applied. In the event of overtemperature in the motor winding, thedevice switches the compressor off and signal lamp H1 lights up red.In addition, the hot gas side of the compressor can be protected from overheating by heat protectionthermostats (accessories).

When the device has triggered, this indicates an overload or intolerable operating conditions. Ascertain and eliminate the cause.

The device has a reclosure preventing feature. After eliminating the fault, the device is quit byinterrupting the mains power with the external alarm reset switch S1 (see main-line wiring diagram).The reclosure preventing feature is unlocked and LEDs H1 or H2 go off again.

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Connection of the electronic trigger MP 10The electrical connection of MP 10 is to be completedaccording to the circuit diagram. The trigger is to beprotected with a fuse (F) of max. 4 A, slow-acting. Toguarantee the protection function, the electronic triggeris mounted as rst element in the control power circuit.

Connections temperature monitoring:motor winding: terminals 1-2hot gas side: terminals 3 - 4

WARNING! Terminals 1 - 6 on the electronic trigger MP 10 and terminals PTC 1 and PTC 2 on the compressor terminal board (see dia-gram) may not come into contact with mains voltage. This would destroy the electronic trigger and the PTC sensors.

Terminalboard

Function test of the electronic trigger MP 10Before starting up and after any faults or changes to the control power circuit of the machine, checkthe electronic trigger to ensure that it functions properly:

Procedure LED H1 LED H2 LED H3 red red green

1 Interrupt the power supply OFF OFF OFFDisconnect the motor temperature sensor connection (terminal 1 or 2)

Disconnect the hot gas temperature sensor (if installed) (terminal 3 or 4) 2 Switch the power supply on again. ON

Function check motor temperature sensor: stand-by ONFunction check hot gas temperature sensor: stand-by ON

3 Interrupt mains voltage again OFF OFF OFFConnect terminals 1 or 2 respectively 3 or 4 again

4 Switch the power supply on again: MP in stand-by mode OFF OFF ON


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Oil sump heatingWhen the compressor is at a standstill, coolant diffuses into the lubricating oil of the compressorhousing, depending on pressure and ambient temperature. This reduces the lubricating capacity ofthe oil. When the compressor starts up, the coolant contained in the oil evaporates out through thereduction in pressure. The consequences can be foaming and migration of the oil, causing oil shocksunder certain circumstances.In order to avoid damage to the compressor, the compressor is equipped with an oil sump heating asa standard feature. The oil sump heating should always be connected up and operated.Operation: The oil sump heating operates when the compressor is at a standstill. When the

compressor starts up, the oil sump heating switches off again automatically.Connection: The oil sump heating must be connected via an auxiliary contact (or parallel wiredauxiliary contact) of the compressor contactor to a separate electric circuit. El. data: 230 V ~ / 80 W

WARNING! The oil sump heating must not be connected to the electrical circuit of thesafety control chain.

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Initial commissioningThe compressor has undergone trials in the factory and all functions have been tested. There aretherefore no special running-in instructions.

Before starting up, check the compressor for any signs of transport damage!To protect the compressor from intolerable operating conditions, high- and low-pressure pressostats. Comply with the accident prevention regulations!

Leak test, evacuationCheck the refrigerating system for leaks without including the compressor (preferablywith dried N2)In the following evacuation process, evacuate the machine rst, then include the compres-sor as follows:- Release the pressure in the compressor using the suction and pressure shut-off valves at service connection A1/B1.- Open the suction and discharge shut-off valves- Evacuate the suction and high-pressure wide with the vacuum pump.- Vacuum 1.5 mbar while the pump is switched off.- Repeat the procedure several times.The refrigerating machine is then dry and tight when the pressure increase in the refrigera-ting system is < 0.5 mbar/24h.WARNING! Do not start the compressor in vacuum. Do not apply voltage,not even for test purpose (may only run after lling with coolant).The spark-over and leakage current distances of the terminal board connection bolts arereduced in a vacuum, this can cause damage to the winding and to the terminal board.

Filling with coolantCaution! Wear personal safety gear!Check that the compressor suction and discharge shut-off valves are open.With the compressor switched off, ll the liquid coolant directly into the condenser or receiver, breaking the vacuum.Start the compressor. If the coolant 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 liquidform at the inlet to the evaporator.Avoid over lling the machine with coolant.To avoid shifts in concentration, zeotropic coolant blends (e.g. R407C) must alwaysonly be lled into the refrigerating system in liquid form

WARNING! Do not ll liquid coolant into the suction shut-off valve on the compres-sor. Do not mix additives with the oil and coolant.

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Initial commissioning

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GBOperation check

After initial commissioning has been completed, check that the machine complies with thetolerable operating conditions.

Liquid shocksWARNING! Liquid shocks can cause damage to the compressor and leakage of coolant.

To avoid liquid shocks, the following points should be observed: The whole plant must be properly designed. All components must be rated to be compatible with each other with regard to output

(particularly evaporator and expansion valve). Suction gas overheating at the evaporator output should be min. 7 - 10 K (check setting

of the expansion valve). The machine must reach a state of equilibrium. Particularly in critical systems (e.g. several evaporator points), measures are recommended

such as replacement of liquid traps, solenoid in the liquid line, etc. Coolant should not movein the compressor when the machine is at a standstill.

Filling with coolantCaution! Wear personal safety gear!Check that the compressor suction and discharge shut-off valves are open.With the compressor switched off, ll the liquid coolant directly into the condenser or receiver, breaking the vacuum.Start the compressor. If the coolant 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 liquidform at the inlet to the evaporator.Avoid over lling the machine with coolant.To avoid shifts in concentration, zeotropic coolant blends (e.g. R407C) must alwaysonly be lled into the refrigerating system in liquid form

WARNING! Do not ll liquid coolant into the suction shut-off valve on the compres-sor. Do not mix additives with the oil and coolant.

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Normal oil level

Lubrication / oil check After reaching equilibrium (constant operating conditions),

check the oil level in the compressor. It should be visible in the lower section of the sight glass (see diagram).

WARNING! If larger quantities of oil have to be topped up, there is a risk of oil shocks. In this case, the oil return has to be checked.


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MaintenanceSafety instructions

Caution! Comply with the safety instructions on page 4! Before any work is carried out on the compressor, switch the machine off and secure

it to prevent it being switched on again. Relieve the pressure in the system using anextraction device. Do not release coolant into the atmosphere!

After maintenance has been completed, check the safety switch and check func-tions. Evacuate the compressor. Remove the switching-on safeguard.

Service intervalsThe compressor is to be kept in a clean, orderly condition by suitable care. In order to guaranteeoptimum operating safety and service life of the compressor, we recommend that you carry out thefollowing servicing and checks at regular intervals:

Oil change - not mandatory in series machines produced in the factory - for eld installation or operation in the application limit range, rst oil change after approx. 100 - 200 operating hours, then approx. every 3 years or 10,000 - 12,000 operating hours. Dispose of used oil properly, comply with national regulations.

Function checks: leaks, running noises, pressures, temperatures, proper functioning of alladditional equipment such as oil sump heating, pressure switch: once per year.

LubricantsBock standard oil grade Recommended alternativesfor H-CFCs (e.g. R22)FUCHS Reniso SP 46 MOBIL SHC 425 SUNOIL Suniso 4 GS SHELL Clavus SD 22-12 TEXAKO Capella WF 46 SUNOIL Suniso 3 GSfor uorocarbons (e.g. R 134a, R404A, R407C)FUCHS Reniso Triton SE 55 FUCHS SEZ 32 MOBIL Arctic EAL 46 ICI Emkarate RL 46 S SHELL Clavus R 46Information about other suitable supplementary or substitute oils is available in the Bock lubricanttables, and can also be found under www.bock.de

Connection of the oil level controllerOil level controlling systems have proven useful in compound systems with several compressors.Connection O is provided for tting an oil level controller (see dimensioned drawing). All customaryoil level controllers make AC&R, ESK and the electronic controller system TRAXOIL S1A21 bySPORLAN can be connected up directly without needing an adapter (see diagram). The oil levelcontroller does not need a sight glass.

124 o

124o

124 o

124o

47,6

M6 x 10je 3 mal

3 hole connection dia-gram for ESK and AC&R3 hole connection dia-gram for TraxOil

Mechanical oil level controller at connection „O“

Connection of the oil level controllerOil level controlling systems have proven useful in compound systems with several compressors. Connection O is provided for tting an oil level controller (see dimensioned drawing). All customary oil level controllers make AC&R and ESK can be connected up directly without needing an adapter (see diagram). For the electronic controller system TRAXOIL S1A1 by SPORLAN the intermediate adapter ref.n. 80070 is necessary. The oil level controller does not need a sight glass.

Maintenance

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Maintenance and servicing kitsCaution! Only use original BOCK spare parts!i

Kit Art.no Art.no. Seal kit Valve plate kit Oil sump hesting kit, 230 V ~

HG 3/155-4 HG 3/190-4 HG 3/275-4 HG 3/155-4S HG 3/190-4S HG 3/275-4S HG 3/235-4 HG 3/325-4 HG 3/235-4S HG 3/325-4S

80064 80064 80064 80050 80008 80009 08424 08424 08424

8.8* 10.9*M5 8,5 Nm -M6 15 Nm -M8 34 Nm 37 Nm

M10 60 Nm 75 NmM12 90 Nm -M16 220 Nm -

* = screw quality, see screw headNotes: t seals in dry state, do not oilCylinder head/valve plate: tighten screwsfrom the middle outwards crosswise in atleast two stages (torque 50/100%)

Screwed unionsVarious installation, maintenance and servicing work entails intervention in the compressor. All workmust therefore be performed with strict compliance with the given safety instructions. The followingtorques must be used when re-assembling the compressor:

Oil drain plug, oil sump heating M 22 x 1,5 100 NmStart unloader AL plug 100 NmLive connections M 6 3 NmRotor M 12 65 Nm

7/16″ 13 Nm 1/8″ 25 Nm

AccessoriesSpecial accessories are only premounted in the factory if ordered specially by the customer. Retrotting is possible in full compliance with the safety instructions and installation instructions enclosed with the kits. Information about the use, operation, maintenance and servicing of the components is available in the printed literature or on the internet under www.bock.deDesignation Kit article no. RemarksStart unloader 08527 Only necessary for ∆/Y startingHeat protection thermostat 08921 Connection provided as standard featureAdditional fan 80046 Extended limits of application as per diagram

Accessories

Service intervalsThe compressor is to be kept in a clean, orderly condition by suitable care. In order to guaranteeoptimum operating safety and service life of the compressor, we recommend that you carry out thefollowing servicing and checks at regular intervals:

Oil change - not mandatory in series machines produced in the factory - for eld installation or operation in the application limit range, rst oil change after approx. 100 - 200 operating hours, then approx. every 3 years or 10,000 - 12,000 operating hours. Dispose of used oil properly, comply with national regulations.

Function checks: leaks, running noises, pressures, temperatures, proper functioning of alladditional equipment such as oil sump heating, pressure switch: once per year.

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Technical speci cationsNo. of cylindersRated speed [1/min] at 50 Hz at 60 HzLubrication: Oil pump independent of direction of rotationOil grade for R22: / oil lling [l]:Oil grade for X versions (for coolant llings e.g.R134a, R404A, R407C, R507) / oil lling [l]:Voltage / phases / frequency [V/Ph/Hz]

max. tol. pressure high pressure side HP: low pressure side LP:

Theoretical ow rate 50 Hz [m³/h]Theoretical ow rate 60 Hz [m³/h]max. operating current [A]Start-up current (rotor blocked) [A]Noise level [dbA], L / M / H *)Weight incl.oil lling [kg]

Theoretical ow rate 50 Hz [m³/h]Theoretical ow rate 60 Hz [m³/h]max. operating current [A]Start-up current (rotor blocked) [A]Noise level [dbA], L / M / H *)Weight incl.oil lling [kg]*) Measuring conditions: low-re ection machine room, measuring distance: 1 m, compressor operating at ratedspeed 1450 rpm at 50 Hz, coolant R134a. When using other coolants the values are increased by approx. 1 - 1.5dB(A). Application ranges: L = deep-freezing range, M = normal refrigerating range, H = air-conditioning.

21450

1740

FUCHS Reniso SP 46 / 1,5

FUCHS Reniso Triton SE 55 / 1,5220-240 ∆ / 380-420 Y / 3 / 50

265-290 ∆ / 440-480 Y / 3 / 60 25 19

HG 3/155-4 HG 3/190-4 HG 3/235-4 HG 3/275-4 HG 3/325-413,6 16,7 20,3 24,1 28,316,3 20,1 24,3 28,9 33,912 / 7 16 / 9 18 / 10 21 / 12 24 / 1453 / 32 67 / 40 67 / 40 96 / 57 96 / 5762 / 61 / 60 63 / 62 / 61 64 / 63 / 62 65 / 64 / 63 66 / 65 / 6477 78 78 78 78

HG 3/155-4S HG 3/190-4S HG 3/235-4S HG 3/275-4S HG 3/325-4S13,6 16,7 20,3 24,1 28,316,3 20,1 24,3 28,9 33,916 / 9 21 / 12 23 / 13 28 / 16 33 / 1967 / 40 96 / 57 96 / 57 134 / 77 134 / 7762 / 61 / 60 63 / 62 / 61 64 / 63 / 62 65 / 64 / 63 66 / 65 / 6478 81 81 81 81

Technical specications

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Connections

SV Suction shut-off valve,pipe Ø solder connection (mm (inch))DV Discharge shut-off valve,pipe Ø solder connection (mm (inch))A Suction side connection,cannot be shut off (inch)A1 Suction side connection,can be shut off (inch)


Dimensions

Height with vibration compensators: + 30 mmAnti-vibration pad

Connections



HG 3/155-4 HG 3/190-4 HG 3/235-4 HG 3/275-4 HG 3/325-422 (7/8) 22 (7/8) 28 (11/8) 28 (11/8) 28 (11/8)

16 (5/8) 16 (5/8) 16 (5/8) 22 (7/8) 22 (7/8)

HG 3/155-4S HG 3/190-4S HG 3/235-4S HG 3/275-4S HG 3/325-4S22 (7/8) 22 (7/8) 28 (11/8) 28 (11/8) 28 (11/8)

16 (5/8) 16 (5/8) 16 (5/8) 22 (7/8) 22 (7/8)

7/16 UNF 7/16 UNF 7/16 UNF 7/16 UNF 1/8 NPTF M 22 x 1,5 M 22 x 1,5 M 22 x 1,5 - 1/8 NPTF 3 x M 6

A Suction side connection, cannot be shut off (inch)A1 Suction side connection, can be shut off (inch)B Discharge side connection, cannot be shut off (inch)B1 Discharge side connection, can be shut off (inch)D1 Connection oil return from oil separator (inch)F Oil drain bung (oil lter) (mm)H Oil lling bung (mm)J Oil sump heating (mm)K Sight glassL Connection heat protection thermostat (inch)O Connection oil level controller (mm)

Connections, dimensions

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DECLARATION OF CONFORMITY CE 96for use of the compressors within the European Union

(as per EU low voltage directive 73/23/EEC, in the version 93/68/EEC)

We herewith declare that the hermetic refrigerating compressors named in the titlecomply with the low voltage directive 73/23/EEC in the version 93/68/EEC.

Applied harmonised standardEN 60335-2-34

(HD 277 S1)

When installing our products in a machine,the following manufacturer declaration must be taken into consideration.

MANUFACTURER DECLARATIONfor use of the compressors within the European Union

(refering to the EU machinery directive 98/37/EEC, annex II B)

We herewith declare that the hermetic refrigerating compressors named in the titlein the version supplied by us are intended for installation in a machine

which complies with the machinery directive 98/37/EEC.

Applied harmonised standards EN 292-1 EN 349 EN 60529 EN 292-2 EN 60204-1

It is however not permitted to start up our products before the machine in which they areintegrated has been tested according to the corresponding statutory regulations and declaredto be conforming in all points.


ba hg3 (gb) - bock.de2 connection for oil level regulator 3 oil sump heating / oil drain plug 4 oil...

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