BOCK HG4 GEA Semi Hermertic Compressor

Product Information

The product is a compressor manufactured by BOCK, a company
based in Germany. The specific model numbers include:

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

About these Instructions

These instructions provide guidelines for the assembly and use
of the compressor. It is important to read and understand these
instructions to avoid any misunderstandings and prevent damage.
Improper assembly and use can result in serious or fatal injury.
The safety instructions provided in these instructions must be
followed. These instructions should be passed on to the end
customer along with the compressor unit.

The manual covers various topics including safety instructions,
product description, areas of application, compressor assembly,
electrical connection, commissioning, maintenance, technical data,
dimensions and connections, and declaration of incorporation.

1. Safety

1.1 Identification of Safety Instructions

The safety instructions are categorized as follows:

DANGER! – Indicates a dangerous situation that
can cause immediate fatal or serious injury.
WARNING! – Indicates a dangerous situation
that can cause fatal or serious injury.
CAUTION! – Indicates a dangerous situation
that can cause fairly severe or minor injury.
ATTENTION! – Indicates a situation that can
cause property damage.
INFO! – Provides important information or tips
on simplifying work.

1.2 Qualifications Required of Personnel

Work on compressors should only be performed by personnel with
the following qualifications:

– Qualified refrigeration technician

– Qualified electrician

– Qualified mechanics engineer

Product Usage Instructions

1. Safety

Follow the safety instructions provided in the manual to ensure
safe operation and prevent any accidents or injuries.

2. Product Description

The manual provides a short description of the product,
including its name plate and type key. Familiarize yourself with
these details to understand the product better.

3. Areas of Application

Understand the recommended refrigerants, oil charge, and limits
of application for the compressor. Ensure you use the correct
materials and follow the guidelines provided.

4. Compressor Assembly

Follow the instructions for storage, transport, setting up, pipe
connections, laying suction and pressure lines, operating the
shut-off valves, and operating mode of the lockable service
connections.

5. Electrical Connection

Refer to the provided information for contactor and motor
contactor selection. Follow the appropriate circuit diagrams for
different motor types and understand the connection process. If
applicable, connect the trigger unit MP 10 and perform a functional
test. Additionally, connect the oil sump heater if it is included
as an accessory.

6. Commissioning

Before starting up the compressor, make necessary preparations
such as pressure strength test, leak test, evacuation, and
refrigerant charge. Follow the start-up procedure and ensure you
avoid slugging. Connect the oil level regulator if required.

7. Maintenance

Prepare for maintenance work and follow the recommended
procedures. Make use of recommended spare parts and accessories.
Use the specified lubricants or oil for proper functioning. When
decommissioning, follow the instructions provided.

8. Technical Data

Refer to the technical data section for detailed specifications
and information about the compressor.

9. Dimensions and Connections

Find the dimensions and connections details of the compressor in
this section. Use this information for installation purposes.

10. Declaration of Incorporation

Review the declaration of incorporation for any additional
information or requirements related to the use of the
compressor.

View Fullscreen

BOCK B72o6ck36GFmribckHe,nBheanuzssetrn.,7Germany

BOCK® HG4

Operating guide

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

Translation of the original instructions

AQ452034894212en-000201

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.
D GB F E I Ru

2 | AQ452034894212en-000201

Contents
1 Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use
2 Product description 2.1 Short description 2.2 Name plate 2.3 Type key
3 Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application 4 Compressor assembly 4.1 Storage and transport 4.2 Setting up 4.3 Pipe connections 4.4 Pipes 4.5 Laying suction and pressure lines 4.6 Operating the shut-off valves 4.7 Operating mode of the lockable service connections
5 Electrical connection
5.1 Information for contactor and motor contactor selection 5.2 Standard motor, design for direct or part winding start 5.3 Basic circuit diagram for part winding start with standard motor 5.4 Special motor: design for direct or star-delta start 5.5 Basic circuit diagram for star-delta start with special motor 5.6 Electronic trigger unit MP 10 5.7 Connecting the trigger unit MP 10 5.8 Functional test of the trigger unit MP 10 5.9 Oil sump heater (accessories)
6 Commissioning 6.1 Preparations for start-up 6.2 Pressure strength test 6.3 Leak test 6.4 Evacuation 6.5 Refrigerant charge 6.6 Start-up 6.7 Avoiding slugging 6.8 Connection of oil level regulator
7 Maintenance 7.1 Preparation 7.2 Work to be carried out 7.3 Spare parts recommendation/accessories 7.4 Lubricants / oil 7.5 Decommissioning
8 Technical data
9 Dimensions and connections
10 Declaration of incorporation

Page 4
6
8 10
D 13 GB
F E I Ru 23
25
27 28 30

AQ452034894212en-000201 | 3

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!

Indicates a dangerous situation which, if not avoided, may cause fatal or serious injury.

CAUTION!

Indicates a dangerous situation which, if not avoided, may cause fairly severe or minor injury.

ATTENTION!

Indicates a situation which, if not avoided, may cause property damage.

INFO!

Important information or tips on simplifying work.

1.2 Qualifications required of personnel

WARNING! Inadequately qualified personnel poses the risk of accidents, the

consequence being serious or fatal injury. Work on compressors must therefore only be performed by personnel with the qualifica-

tions listed below:

· For example, a refrigeration technician, refrigeration mechatron-

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!

· Refrigerating compressors are pressurised machines and therefore require particular caution and care in handling.
· Risk of burns! Depending on the operating conditions, surface
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.

4 | AQ452034894212en-000201

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 and 2014/68/EU Pressure Equipment 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.
D GB F E I Ru

AQ452034894212en-000201 | 5

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

Transport eyelet

Valve plate

Discharge

shut-off valve

Oil pump

BOCK B72o6ck36GFmribckHe,nBheanuzssetrn.,7Germany
Fig. 1

Dimension and connection values can be found in Chapter 9

Suction shutoff valve
Motor section Cylinder cover
Name plate Drive section Oil sight glass

6 | AQ452034894212en-000201

2| Product description

2.2 Name plate(example)

BOCK Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany

HGX4/310-4

AS35830A006

17,0A

57 A 75 A

27,1

32,5

SBEO5C5K lub E55

12 13

Fig. 2

1 Type designation 2 Machine number

6 Voltage, circuit, frequency

} 7 Nominal rotation speed

50 Hz

3 maximum operating current

8 Displacement

4 Starting current (rotor blocked) Y: Part winding 1

9 Voltage, circuit, frequency

} 10 Nominal rotation speed

60 Hz

YY: Part windings 1 and 2

11 Displacement

5 ND (LP): max. admissible operating

12 Oil type filled at the factory

pressure (g) Low pressure side 13 Terminal box protection type

HD (HP): max. admissible operating

Electrical accessories can change

pressure (g) High pressure side

the IP protection class!

Observe the limits of application

diagrams!

2.3 Type key(example)

HG X 4 / 650-4 S

Motor variant 3) Number of poles Swept volume Size Oil charge ²) Series ¹)
¹) HG – Hermetic Gas-cooled (suction gas-cooled) ²) X – Ester oil charge (HFC refrigerant, e.g. R134a, R404A/R507, R407C) 3) S – More powerful motor, e.g. for air-conditioning applications

AQ452034894212en-000201 | 7

3| Areas of application

3.1 Refrigerants · HFKW / HFC: R134a, R404A/R507, R407C

· (H)FCKW / (H)CFC: R22

3.2 Oil charge

The compressors are filled at the factory with the following oil type:

– for R134a, R404A/R507, R407C

BOCK lub E55

– for R22

BOCK lub A46

Compressors with ester oil charge (BOCK lub E55) 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 chapter 7.4

ATTENTION!

The oil level must be in the visible part of the sight glass; damage to the compressor is possible if overfilled or underfilled!

max. oil level min.

~~ 1,8 Ltr. Fig. 3

3.3 Limits of application

ATTENTION! Compressor operation is possible within the operating limits.

These can be found in Bock compressor selection tool (VAP)

under vap.bock.de. Observe the information given there.

– Permissible ambient temperature (-20°C) – (+60°C)

– 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: – Continuous operation, when the capacity regulator is activated,

is not permissible and can cause damage to the compressor.

– The suction gas superheat temperature may need to be reduced

or set individually when operating near to the threshold. – When the capacity regulator is activated, the gas velocity in

the system can not under certain circumstances ensure that sufficient oil is transported back to the compressor. For operation with frequency converter:

– 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.
When operating in the vacuum range, there is a danger of air entering 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!

8 | AQ452034894212en-000201

3| Areas of application R134a
Fig. 4

R407C
Fig. 5
R404A/R507
Fig. 6
R22
Fig. 7
© Danfoss | Climate Solutions | 2023.06

Unlimited application range

Supplementary cooling or

reduced suction gas temperature

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)
Max. permissible operating pressure (LP/HP)1): 19/28 bar 1) LP = Low pressure HP = High pressure
Design for other areas on request

AQ452034894212en-000201 | 9

4| Compressor assembly

INFO!

New compressors are factory-filled with inert gas.
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 Storage and transport

?Fig. 8

Storage at (-30°C) – (+70°C), maximum permissible relative humidity 10% – 95%, no condensation Do not store in a corrosive, dusty, vaporous atmosphere or in a combustible environment.

Fig. 9

Use transport eyelet. Do not lift manually! Use lifting gear!

4.2 Setting up

ATTENTION! Attachments (e.g. pipe holders, additional units, fastening parts, etc.) directly to the compressor are not permissible!

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

Fig. 10

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

Fig. 11 Fig. 12

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

4.3 Pipe connections
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).

10 | AQ452034894212en-000201

4| Compressor assembly

Fig. 13: graduated internal diameter

The pipe connections have graduated inside diameters so that pipes with
standart millimetre and inch dimensions 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.

4.4 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.

4.5 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! Improperly installed pipes can cause cracks and tears which can

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.

BOCK B72o6ck36GFmribckHe,nBheanuzssetrn.,7Germany
As short as possible

Rigid fixed point

BOCK B72o6ck36GFmribckHe,nBheanuzssetrn.,7Germany
Fig. 14
AQ452034894212en-000201 | 11

4| Compressor assembly
4.6 Operating the shut-off valves Before opening or closing the shut-off valve, release the valve spindle seal by approx. ¼ 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. 15

Fig. 16

4.7 Operating mode of the lockable service connections

Service connec-

Connection cannot be

tion closed

shut off

Spindle

Connection blocked

Pipe connection

Ru Opening the shut-off valve:

Compressor

Fig. 17

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

Connection cannot be shut off

Spindle

Connection open

Pipe connection

Opening the service connection

Compressor

Spindle: Turn ½ – 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.

Fig. 18

After activating the spindle, generally fit the spindle protection cap again and tighten with 14-16 Nm. This serves as a second sealing feature during operation.

12 | AQ452034894212en-000201

5| Electrical connection

5 Electrical connection

DANGER! High voltage! Risk of electric shock! Only carry out work when the electrical system is disconnected from the power supply!
ATTENTION! When attaching accessories with an electrical cable, a minimum bending radius of 3 x the cable diameter must be maintained for laying the cable.

INFO!

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 devices and switching or monitoring units must be fitted in accordance with the local safety regulations and established specifications (e.g. VDE) as well as with the manufacturer’s infor-

mation. Motor protection switches are required! Motor contactors, feed lines, fuses and motor GB

protection switches must be rated on the basis of the maximum working current (see name plate).

For motor protection use a current-dependent and time-delayed overload protection device for moni-

toring all three phases. Set the overload protection device so that it must be actuated within 2 hours,

if there is 1.2 times the max. working current.

5.2 Standard motor, design for direct or part winding start

Designation on the name plate

Sticker on the terminal box

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.

AQ452034894212en-000201 | 13

5.3 Basic circuit diagram for part winding start with standard motor

F1.1
I=66%

F1.2
I=33%

F2
4A
S1

1 3 5 F1.1

F1.2

D GB F E I Ru

XSS

L1 L2 L3 N

PE 1

10 11

1U1 1V1 1W1

M1 M
Y/YY
R1

2U1 2V1 2W1

X1 L1 L1 N N 43 43 11 12 14

X2 1 2 3 4 5 6

MP10

Fig. 19

CAonmsprcehssloruteárkmainsaltbeoxnVerdichter

Cold conductor (PTC sensor) motor winding

Thermal protection thermostat (PTC sensor)

F1.1 /1.2 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)

nderung Datum

Datum 20.Feb.2009 Bearb. Kelich Gepr. 09.M,,r.2010 Name Norm

Urspr.

Ers.f.

Ers.d.

14 | AQ452034894212en-000201

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

K1T

12 13 14 15 16

17 18 19

20 21 22

23 24 25 26

T2 N

PTMl

P> F3

D GB F E I Ru

Main switch

Compressor motor

Mains contactor (part winding 1)

Mains contactor (part winding 2)

K1T Delay relay max. 1s

Control voltage switch

Oil sump heater

PWMP10
© Danfoss | Climate Solutions | 2023.06

= +
BOCKCOMPRESSORS

Bl.

1 1 Bl.

AQ452034894212en-000201 | 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

DDiirreeckttstaarrttYYYY

TPeairlwt wiciknlduingsssttaarrttYY//YYYY

L1 L2 L3

2U1 2V1 2W1

1U1 1V1 1W1
L1 L2 L3

ATTENTION! Failure to do this results in opposed rotary fields and results in

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 | AQ452034894212en-000201

5| Electrical connection

5.4 Special motor: design for direct or star-delta start
A mechanical unloaded start with bypass solenoid valve (accessories) is required for the star-delta start.

Designation on the name plate

Sticker on the terminal box

/ Y

Star-delta start-up is only possible for 230 V power supply. Example:

Direct start

230 V Star-delta start

400 V Y Direct start only

L1 L2 L3

W2 U2 V2 U1 V1 W1 L1 L2 L3

W2 U2 V2

U1 V1 W1

L1 L2 L3

AQ452034894212en-000201 | 17

5.5 Basic circuit diagram for star-delta start with special motor

F1.1

F2
4A
S1

F1.1

1 3 5 F1.2

F1.2

D GB F E I Ru

XSS

L1 L2 L3 N

PE 1

10 11

X1 L1 L1 N N 43 43 11 12 14

X2 1 2 3 4 5 6

MP10

R2
CAonmsprceshsloruteármkianasl tboexnVerdichter
Fig. 20

Cold conductor (PTC sensor) motor winding

Thermal protection thermostat (PTC sensor)

F1.1 /1.2 2 motor protection switches

Control power circuit fuse

High pressure safety monitor

Safety chain (high/low pressure monitoring)

Oil differential pressure monitor

Enabling switcDhat(tuhmerm20o.sFteabt.)2009

Main switch Bearb. Kelich

Gepr. 09.M,,r.2010

nderung Datum

Name Norm

18 | AQ452034894212en-000201

Urspr.

Ers.f.

Ers.d.

5
K1

K1 K3 K4T K4T

K5T

9
L1.1 L2.1 L3.1 L1.2
K1

K3 K2

K2 K3

K4T AL

K5T

12 13 14 15 16

T2 N

PTMl

P> F3

17 18 19

20 21 22

23 24 25 26

D GB F E I Ru

Compressor motor

Mains contactor

-contactor

Y-contactor

K4T Delay relay for contactor changeover

K5T Delay relay for start unloader

Control voltage switch

D/S

MP10 E1

Start unloader Oil sump heater

BOCKCOMPRESSORS

Bl.

1 1 Bl.

AQ452034894212en-000201 | 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 pre-
vention 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 dia-

gram. 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. GB

Temperature monitoring connections:

Motor winding:

Terminals 1 – 2

Thermal protection thermostat:

Terminals 3 – 4

Restart prevention:

Terminals 5 – 6

ATTENTION!

Terminals 1 – 6 on the trigger

unit MP 10 and terminals PTC

1 and PTC 2 on the compres-

sor 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

Terminal board

be identical to the voltage at terminals 11, 12, 14 and 43.

Fig. 21

20 | AQ452034894212en-000201

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 Procedure
1 · 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)

LED H1 LED H2 LED H3 red red green OFF OFF OFF

2 · Restore the power supply (L1 or S1) · Function check of motor temperature sensor: operational · Function check of hot gas temperature sensor: operational

ON ON
ON

3 · Interrupt power supply again (L1 or S1) · Reconnect terminals 1 or 2 and/or 3 or 4

OFF OFF OFF

4 · Restore the power supply (L1 or S1):

OFF OFF ON

· MP 10 is operational again

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

AQ452034894212en-000201 | 21

5| Electrical connection
5.9 Oil sump heater (accessories) 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.
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 contactor) of the compressor contactor to a separate current path. Electrical data: 230 V – 1 – 50/60 Hz, 80 W.

Fig. 22

ATTENTION! Connection to the current path of the safety control chain is not

permitted

22 | AQ452034894212en-000201

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

The compressor has been tested in the factory for pressure integrity. If however the entire system is to be subjected to a pressure integrity test, this should be carried out in accordance with EN 378-2 or a corresponding safety standard without the inclusion of the compressor.

6.3 Leak test

DANGER! Risk of bursting!

The compressor must only be pressurised using nitrogen (N2).

Never pressurise with oxygen or other gases!

The maximum permissible overpressure of the compressor must not

be exceeded at any time during the testing process (see name plate

data)! Do not mix any refrigerant with the nitrogen as this could

cause the ignition limit to shift into the critical range.

Carry out the leak test on the refrigerating plant in accordance with EN 378-2 or a corresponding

safety standard, while always observing the maximum permissible overpressure for the compressor.

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.

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.

AQ452034894212en-000201 | 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!

In order to prevent shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always only be added to the refrigerating system in liquid form.

Do not pour liquid refrigerant through the suction line shut-off

valve on the compressor.
It is not permissible to mix additives with the oil and refrigerant. D

GB 6.6 Start-up

WARNING! Ensure that both shut-off valves are open before starting the

compressor! E

Check that the safety and protection devices (pressure switch, motor protection, electrical con-

tact 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! If larger quantities of oil have to be topped up, there is a risk of oil 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.
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. Particularly in critical systems (e.g. several evaporator points), measures such as the use of liquid traps, solenoid valve in the liquid line, etc. are recommended. There should be no movement of refrigerant in the compressor while the system is at a standstill.

24 | AQ452034894212en-000201

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.
124 o
M6 x 10 3jet3immesaleach

124 o

124o

Fig. 23
Mechanical oil level regulator at the “O” connection

124o 47,6
3-hLoolcehc-oAnnnsecchtilounssdbiailgdrafümr mESfoKr, EASCK&, ARCu&nRdeCt ACARRLLYY 3-hLoolcehd-iAangrsacmhlmusfsobriTldrafxüOriTl raxOil

7| Maintenance

I 7.1 Preparation
Ru 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. – for 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.

AQ452034894212en-000201 | 25

7| Maintenance

7.3 Spare part recommendation/accessories
Available spare parts and accessories can be found on our compressor selection tool under vap.bock.de as well as at bockshop.bock.de. Only use genuine Bock spare parts!

7.4 Lubricants / oil
The oil type filled as standard in the factory is marked on the name plate, and this should always be used, even in the case of maintenance units. Alternative oil types can vary significantly in quality due to additives or inferior raw materials by the manufacturer. Validation within the compressors entire operating limits can not be guaranteed, if such alternative oil types are used. It is for this reason, that we only recommend the use of oil from Bock! Bock assumes no liability for any damage arising from alternative oil types..

Refrigerants

HFC

(e.g. R134a/R407C)

HCFC (e.g. R22)

Bock standard oil types BOCK lub E55 BOCK lub A46

7.5 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.

26 | AQ452034894212en-000201

8| Technical data
Oil charge

Weight D GB F E I Ru
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%
No. of cylinders

Type

Displace-

Electrical data 3

Connections 4

Sound

ment 50 / 60 Hz (1450 / 1740
rpm)

Voltage 1

Max. Operating current
2
PW 1 + 2

Max. power consumption
2

Starting current
(rotor locked) PW 1 / PW 1 + 2

Dis-
charge
line DV

Suction
line SV

pressure level
L/M/H 5

m3/h

kg mm (inch) mm (inch) Ltr.

dB(A)

HG4/310-4 HG4/310-4 S HG4/385-4 HG4/385-4 S

27,1 / 32,5 27,1 / 32,5 33,5 / 40,2 33,5 / 40,2

8,5

50 / 65

147

9,0

57 / 75

149

9,5

57 / 75

149

22 (7/8) 28 (1 5/8)

12,5

82 / 107

152

59 / 60 / 60 61 / 61 / 60

HG4/465-4 4
HG4/465-4 S
HG4/555-4
HG4/555-4 S

40,5 / 48,6 40,5 / 48,6 48,2 / 57,8 48,2 / 57,8

11,0

57 / 75

148

2,7 64 / 63 / 62

13,0

82 / 107

151

12,9

82 / 107

150

35 (1 3/8)

28 (1 1/8)

15,2

107 / 140 153

66 / 64 / 62

AQ452034894212en-000201 | 27

HG4/650-4 HG4/650-4 S

56,6 / 67,9 56,6 / 67,9

15,7

82 / 107

152

18,4

107 / 140 155

42 (1 5/8)

69 / 66 / 63

1 Tolerance (± 10%) relative to the mean value of the voltage range. Other voltages and types of current on request.
2 – The specifications for max. power consumption apply for 50Hz operation. For 60Hz operation, the specifications have to be multiplied by the factor
1.2. The max. working current remains unchanged.
– Take account of the max. operating current / max. power consumption for
design of fuses, supply lines and safety devices. Fuse: Consumption
category AC3

3 All specifications are based on the average of the voltage range
4 For solder connections
5 L = low temperature (-35 / 40 °C), M = normal cooling (-10 / 45 °C), H = air conditioning (5 / 50°C) sound pressure level measured in low reflection measuring area, measuring distance 1m. Compressor operation at 50 Hz (1450 rpm), refrigerant R404A. Values stated are average values, tolerance ± 2 dB(A).

9| Dimensions and connections

D GB F E I Ru

DV L A N

Centre of gravity

73 ca.245

112

436

550 (535)

ca.725 (690)

ca.370 306
B B1

ca.180 ca.405
278 170

1)
SV A1

F J

4x 11 ÖV
280
330

30 20
30 20

M10 40
Ansicht HG(X)4/310-555 -4 (S) View HG(X)4/310-555 -4 (S) Vue HG(X)4/310-555 -4 (S)
SV A A1

Schwingungsdämpfer Vibration absorbers Amortisseurs de vibration

Anschlüsse

Connections

SV Saugabsperrventil, Rohr (L)*

Suction line valve,

DV Druckabsperrventil, Rohr (L)*

Discharge line valve,

A Anschluß Saugseite, nicht absperrbar

Connection suct

A1 Anschluß Saugseite, absperrbar

Connection suct

Vibration B Anschluß Druckseite, nicht absperrbar M10 damper B1 Anschluß Druckseite, absperrbar
C Anschluß Öldrucksicherheitsschalter OIL D Anschluß Öldrucksicherheitsschalter LP

Connection di Connection di Connection oi Connection oi

40 D1 Anschluß Ölrückführung vom Ölabscheider Connection oil ret

E Anschluß Öldruckmanometer

Connection oil pressure gauge

F Ölablaß

Oil drain

H Stopfen Ölfüllung

Oil charge plug

J Anschluß Ölsumpfheizung

Connection oi

K Schauglas

Sight glass

L Anschluß Wärmeschutzthermostat

Connection therm

View HG(X)4/310-555 -4 (S)
1)
SV A
A1
1) SV 90° rotatable Dimensions in ( ) = HG(X)4/310-4 (S), HG(X)4/385-4 (S)
HG(X)4/465-4 (S), HG(X)4/555-4 (S)

Dimensions in mm Fig. 24

28 | AQ452034894212en-000201

9| Dimensions and connections

SV Suction line DV Discharge line

see technical data, Chapter 8

Connection suction side, not lockable

A1 Connection suction side, lockable

Connection discharge side, not lockable

B1 Connection discharge side, lockable

Connectoin oil pressure switch OIL

Connection oil pressure switch LP

D1 Connection oil return from oil separator

Connection oil pressure gauge

Oil drain

Oil charge plug

Oil sump heater (accessories)

Sight glass

Connection thermal protection thermostat

Connection capacity controller

Connection oil level regulator

ÖV Connection oil service valve

Connection oil differential pressure sensor

Connection oil temperature sensor

1/8″ NPTF 7/16″ UNF 1/8″ NPTF 7/16″ UNF 7/16″ UNF 7/16″ UNF 1/4″ NPTF 7/16″ UNF
M22 x 1,5

M22 x 1,5

–

1/8″ NPTF

M48 x 1,5

3 x M6

1/4″ NPTF

M20 x 1,5

1/8″ NPTF

AQ452034894212en-000201 | 29

10| Declaration of incorporation

Declaration of incorporation for incomplete machinery in accordance with EC Machinery Directive 2006/42/EC, Annex II 1. B

Manufacturer:

Bock GmbH Benzstraße 7 72636 Frickenhausen, Germany

We, as manufacturer, declare in sole responsibility that the incomplete machinery

Name: Types:

Semi-hermetic compressor HG(X)12P/60-4 S (HC) …………………… HG(X)88e/3235-4(S) (HC) UL-HGX12P/60 S 0,7……………………… UL-HGX66e/2070 S 60 HGX12P/60 S 0,7 LG …………………….. HGX88e/3235 (ML/S) 95 LG HG(X)22(P)(e)/125-4 A …………………… HG(X)34(P)(e)/380-4 (S) A HGX34(P)(e)/255-2 (A) ………………….. HGX34(P)(e)/380-2 (A)(K) HA(X)12P/60-4 ……………………………… HA(X)6/1410-4 HAX22e/125 LT 2 LG ……………………. HAX44e/665 LT 14 LG HGX12e/20-4 (ML/S) CO2 (LT) ……….. HGX44e/565-4 S CO2 UL-HGX12e/20 (S/ML) 0,7 CO2 (LT)… UL-HGX44e/565 S 31 CO2 HGX12/20-4 (ML/S/SH) CO2T………….. HGX46/440-4 (ML/S/SH) CO2 T UL-HGX12/20 ML(P) 2 CO2T…………. UL-HGX46/440 ML(P) 53 CO2T HGZ(X)7/1620-4 ……………………………. HGZ(X)7/2110-4 HGZ(X)66e/1340 LT 22…………………… HGZ(X)66e/2070 LT 35
HRX40-2 CO2 T H………………………….. HRX60-2 CO2 T H

Name:

Types:

Serial number:

Open type compressor F(X)2 …………………………………… F(X)88/3235 (NH3) FK(X)1………………………………….. FK(X)3 FK(X)20/120 (K/N/TK)…………….. FK(X)50/980 (K/N/TK)
BC00000A001 BN99999Z999

E
complies with the following provisions of the above-mentioned Directive:

According to Annex I, points 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.3, 1.3.7, 1.5.1, 1.5.2, 1.5.13 and

1.7.1 to 1.7.4 (excepted 1.7.4 f) are fulfilled.
Ru

Applied harmonised standards, in particular:

EN ISO 12100 :2010

EN 12693

:2008

Safety of machinery — General principles for design — Risk assessment and risk reduction Refrigerating systems and heat pumps — Safety and environmental requirements — Positive displacement refrigerant compressors

Remarks:

We also declare that the special technical documentation for this incomplete machine has been created in accordance with Annex VII, Part B and we obligate to provide these upon reasoned request from the individual national authorities by data transfer.
Commissioning is prohibited until it has been confirmed that the machinery into which the incomplete machine above is to be incorporated complies with the EC Machinery Directive and an EC Declaration of Conformity, Annex II. 1. A exists.

Authorized person for compiling and handing over technical documentation:

Bock GmbH Alexander Layh Benzstraße 7 72636 Frickenhausen, Germany

Frickenhausen, 04th of January 2021

i. A. Alexander Layh, Global Head of R&D

30 | AQ452034894212en-000201

D GB F E I Ru

AQ452034894212en-000201 | 31

32 | AQ452034894212en-000201