Danfoss BOCK HG4 User manual

AQ452034894212en-000201

HG4/310-4 HG4/310-4S HGX4/310-4 HGX4/310-4S

HG4/385-4 HG4/385-4S HGX4/385-4 HGX4/385-4S

HG4/465-4 HG4/465-4S HGX4/465-4 HGX4/465-4S

HG4/555-4 HG4/555-4S HGX4/555-4 HGX4/555-4S

HG4/650-4 HG4/650-4S HGX4/650-4 HGX4/650-4S

BOCK®HG4

Operating guide

BockGmbH, Benzstr. 7

72636Frickenhausen, Germany

BOCK

Translation of the original instructions

2 | AQ452034894212en-000201 © Danfoss | Climate Solutions | 2023.06

About these instructions

Read these instructions before assembly and before using the compressor. This will avoid misunder-

standings 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 compres-

sor is installed.

Contents Page

1 Safety 4

 1.1 Identicationofsafetyinstructions

 1.2 Qualicationsrequiredofpersonnel

1.3 General safety instructions

1.4 Intended use

2 Product description 6

2.1 Short description

2.2 Name plate

2.3 Type key

3 Areas of application 8

3.1 Refrigerants

3.2 Oil charge

3.3 Limits of application

4Compressor assembly 10

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 13

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 23

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 25

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 27

9 Dimensions and connections 28

10 Declaration of incorporation 30

4 | AQ452034894212en-000201 © Danfoss | Climate Solutions | 2023.06

1|Safety

1.2 Qualicationsrequiredofpersonnel

1.3 General safety instructions

WARNING! Inadequately qualied 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qualica-

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.

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.

1.1 Identication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|Safety

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speciedintheseinstructionsmaybeused.

Any other use of the compressor is prohibited!

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.

1.4 Intended use

WARNING! The compressor may not be used in potentially

explosive environments!

6 | AQ452034894212en-000201 © Danfoss | Climate Solutions | 2023.06

2|Product 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.

2.1 Short description

Dimension and connection values can be found in Chapter 9

Name plate

Fig. 1

Valve plate

Cylinder cover

Terminal box

Transport eyelet

Discharge

shut-off valve

Oil pump

Suction shut-

off valve

Oil sight glass

Drive section

Motor section

BockGmbH, Benzstr. 7

72636Frickenhausen, Germany

BOCK

AS35830A006

HGX4/310-4

17,0A

57 A 75 A

27,1

32,5

SE 55

2|Product description

Fig. 2

2.3 Typekey(example)

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

Motor variant 3)

Number of poles

Swept volume

Size

Oil charge ²)

Series ¹)

1 Typedesignation 6 Voltage,circuit,frequency

2 Machine number 7 Nominal rotation speed

3 maximum operating current 8 Displacement

4 Startingcurrent(rotorblocked) 9 Voltage,circuit,frequency

Y: Part winding 1 10 Nominal rotation speed

YY: Part windings 1 and 2 11 Displacement

5 ND (LP):

max. admissible operating

 12 Oiltypelledatthefactory

pressur

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

HD (HP):

max. admissible operating

Electrical accessories can change

pressur

e(g) High pressure side the IP protection class!

Observe the limits of application

diagrams!

50 Hz

}

60 Hz

}

HG 4650-4

2.2 Name plate(example)

Bock GmbH, Benzstr. 7

72636 Frickenhausen, Germany

BOCK

BOCK lub E55

8 | AQ452034894212en-000201 © Danfoss | Climate Solutions | 2023.06

3|Areas 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

sufcient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!

 Thecompressorsarelled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).

3.2 Oil charge

3.3 Limits of application

INFO! Forrefilling,werecommendtheaboveoiltypes.

Alternatives: see chapter 7.4

The oil level must be in the

visible part of the sight

glass; damage to the com-

pressor is possible if over-

filled or underfilled!

ATTENTION!max.

min.

1,8 Ltr.

oil level

Fig. 3

3.1 Refrigerants

• HFKW / HFC: R134a, R404A/R507, R407C • (H)FCKW / (H)CFC: R22

Evaporation temperature (°C)

Condensing temperature (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

3|Areas of application

Design for other

areasonrequest

R134a

R407C

R404A/R507

R22

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Unlimited application range

Supplementary cooling or

reduced suction gas temperature

Supplementary cooling and

reduced suction gas temperature

Motor version S

(more powerful motor)

Max. permissible operating

pressure(LP/HP)1): 19/28 bar

1) LP = Low pressure

HP = High pressure

10 | AQ452034894212en-000201 © Danfoss | Climate Solutions | 2023.06

4|Compressor assembly

 Setuponanevensurfaceorframewithsufcientload-

bearing capacity.

Single compressor preferably on vibration damper.

Duplex and parallel circuits always rigid.

 Provideadequateclearanceformaintenancework.

 Ensureadequatecompressorventilation.

Do not use in a corrosive, dusty, damp atmosphere or a

combustible environment.

Fig. 10

Fig. 11

Fig. 12

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).

4.3 Pipe connections

INFO! New compressors are factory-lled 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.

4.2 Setting up

4.1 Storage and transport

Use transport eyelet.

Do not lift manually!

Use lifting gear!

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 com-

bustible environment.

Fig. 9

Fig. 8

ATTENTION! Attachments(e.g.pipeholders,additionalunits,fasteningparts,

etc.)directlytothecompressorarenotpermissible!

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