Operating instructions for motor compressor Series HG 3 R

OPERATING INSTRUCTIONS
for suction-gas cooled hermetic motor compressor
Series 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 GB
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
09972-07.02-DGBFEI

-1-
 Operating instructions for motor compressor Series HG 3 R

Dear Customer,
Bock compressors are top-quality, reliable, service-friendly quality products. Please comply with the
following operating and maintenance instructions so that you can benet from all advantages to the
full and use your refrigerating system throughout its entire service life. If you have any questions
about installation, operation and accessories, please contact our technical service department
or your refrigerating system wholesale dealer or our representative. The Bock service team is
available by phone under +49 7022 9454-0, by e-mail under [email protected] or on the internet under
www.bock.de. In addition, for German speaking countries we have set up a toll-free Bock hotline
under 00 800 / 800 00 88 from Monday to Saturday between 8 a.m. and 9 p.m. Any suggestions you
may have regarding the on-going development of our compressor, equipment and parts programme
are welcome at any time.
GB Please read the information summarised for you in
this 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 identied by special symbols with
the following meaning:
WARNING This symbol is used to indicate
that inaccurate compliance or total failure
to comply with the instructions could
cause injury to persons or damage to the
compressor or refrigerating machine
This symbol indicates important additional
i instructions which you should observe
during your work.

The high quality standard of Bock compressors is

guaranteed also by on-going further development of
machine, features and accessories. This could possibly
result in nonconformities between this present manual
and your compressor. Please understand that it is not
possible for any claims to be derived from the details,
illustrations and descriptions.
09972-07.02-DGBFEI

Bock Kältemaschinen GmbH

Postfach 11 61 Your team at
D-72632 Frickenhausen Bock Kältemaschinen GmbH
Benzstr. 7
D-72636 Frickenhausen
Fon: +49 7022 9454-0
Fax: +49 7022 9454-137
[email protected]
-2- www.bock.de - Subject to modications -
 Operating instructions for motor compressor Series HG 3 R
Contents

Contents
Safety 4
Product description 5
Main function parts 5
Nameplate 6
Type code 6
Limits of application 7
Installation instructions 8
General 8
Pipe connections / pipes 8
Pipe installation 9 GB
Shut-off valves 9
Versions of discharge shut-off valves 10
Suction shut-off valve 10
Electrical 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 16
Initial 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 18
Maintenance 18
Safety instructions 18
Service intervals 18
09972-07.02-DGBFEI

Maintenance and servicing kits 19

Screwed unions 19
Accessories 19
Technical specications 20
Connections 21
Dimensions 21
Declaration of conformity CE 96 22
Manufacturer declaration 22
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 Operating instructions for motor compressor Series HG 3 R
Safety

Safety
The 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 the
compressor has been installed according to these instructions and the whole machine in which it is
integrated has been tested and accepted according to the statutory regulations.
Bock refrigerating compressors have been designed to state-of-the-art engineering. Safety for the
user is given particular priority during the design stage. However, it is always possible for the
refrigerating machine and operation thereof to pose unavoidable residual risks. This is why these
instructions must be observed carefully by every person working at the compressor.
GB
Work on the compressor may only be carried out by persons whose technical training, skills and
experience together with their knowledge of pertinent regulations and documentation means that
they are capable of assessing the work to be carried out and detecting any possible dangers (trained
staff as per DIN 31000).

SAFETY INSTRUCTIONS
Caution! Refrigerating compressors are pressurised machines and therefore require particu-
larly careful and meticulous handling.
Only qualied staff are allowed to handle refrigerating compressors.
National safety regulations, accident prevention regulations, technical rules and other
specications (incl. EN 378 etc.) must be observed
The compressor may only be operated in refrigerating systems, and only with
coolants approved for this compressor by Bock.
The maximum tolerable operating overpressure may not be exceeded (not even for
test 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 bar
nitrogen) The pressure in the compressor must be relieved before connecting up the
refrigerating 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.)
09972-07.02-DGBFEI

Before starting up, evacuate the refrigerating machine carefully with the compressor
and then ll with coolant.
Before starting the compressor, open the discharge shut-off valve and suction shut-off
valve.
Do not start the compressor in a vacuum. Only operate the compressor when the
whole 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.
-4-
 Operating instructions for motor compressor Series HG 3 R
Product description
Product description
Product description
Hermetic four-cylinder reciprocating compressor with suction-gas cooled drive motor
Drive motor
Hermetic two-anged to reciprocating
four-cylinder the compressor housing with suction-gas cooled drive motor
compressor
The stream
Drive motor of coolant
anged to sucked out of thehousing
the compressor evaporator ows over the motor and cools it
intensively.
The stream In of this way,sucked
coolant the motor
out can beevaporator
of the kept at a relatively
ows overlowthe
temperature
motor and level,
cools particularly
it
under high loads.
intensively. In this way, the motor can be kept at a relatively low temperature level, particularly
Preferred
under highapplication
loads. range: normal refrigerating and air-conditioning.
Preferred application range: normal refrigerating and air-conditioning.
Main function parts
Terminal box
Compressor section GB
Terminal box

Compressor
section
Main10parts

Motor section

Motor section
1
9 8 7

12
2 6
11

5
3
10

1 Function parts
4 4
9
09972-07.02-DGBFEI

5
6 7 8
1 Suction shut-off valve 72 Oil ller plug
2 Discharge shut-off valve 8 Connection for oil level controller 3
31 Oil pump shut-off valve 9 Connection for6 heat
Discharge protection
Valve plate thermostat
42 Oil sump heating
Connection 10 Valve plate 7 Transport eyelets
for oil level regulator
53 Oil drain
sumpplug / oil /lter
heating Oil drain 11
plugConnection for8 capacity
Oil ller regulator
plug
64 Oil sight
pumpglass 12 Transport eyelets
9 Oil sight glass
5 Connection for heat protection thermostat 10 Suction shut-off valve -5-
 Operating instructions for motor compressor Series HG 3 R
Product description
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Type code

HG 34 / 325
650 - 4 S
Series Motor version air-conditioning
Size No. of poles
Code for capacity size
Compressors which have been filled with ester oil in the factory (e.g. for use with
chlorine-free coolants such as R404A, R407C) are identified accordingly
in the type designation by the suffix X (e.g. HGX 3/325-4
4/650-4).
09972-07.02-DGBFEI

-6-
 Operating instructions for motor compressor Series HG 3 R
Product description

Limits of application
Compressor operating mode: to - evaporation temperature
L = deep-freeze range t - condensing temperature
in normal operating mode M = normal refrigeration range tc - suction gas temperature 20°C
H = air-conditioning oh
with additional cooling ∆toh - suction gas overheating 10 K

GB
09972-07.02-DGBFEI

-7-
 Operating instructions for motor compressor Series HG 3 R
Installation instructions
Explanations of the limits of application diagrams
Operation of the compressor is only possible within the limits shown in the diagrams. The limits must
Explanations
be observed. Theof the limits of
maximum application
discharge end diagrams
temperature of 140°C may not be exceeded. In the dark
grey area, of
Operation compressor operation
the compressor is only
is only possible
possible with
within theadditional
limits shown cooling.
in the diagrams. The limits must
be observed.
Additional The maximum
cooling discharge
solutions can consistend temperature
of additional fansof(accessories)
140°C may not be exceeded.cylinder
or water-cooled In the dark
grey area,
covers compressorWe
(accessories). operation is onlyheat
advise using possible with additional
protection thermostats cooling.
(accessories).
Additional
As cooling
a general rule:solutions can consist of additional fans (accessories) or water-cooled cylinder
covers (accessories).
Only use thermallyWehighly
advise usingoils
stable heat protection
(see lubricantthermostats (accessories).
table)! Recommendation:
As a for R22 rule:
general Bock standard oil FUCHS Reniso SP 46
for R134a,
Only R404A, highly
use thermally R407C,stableR507oils (see Bock standard
lubricant oil FUCHS
table)! Reniso Triton SE 55
Recommendation:
When
for R22operating with capacity regulators, the standard
Bock suction gas overheating
oil FUCHS must
Reniso SPbe46adjusted accor-
dingly.
for R134a, R404A, R407C, R507 Bock standard oil FUCHS Reniso Triton SE 55
GB When operating
using frequency transformers,
with capacity please
regulators, thenote thatgas
suction the overheating
limits of application
must becan be restricted
adjusted accor-
on reaching the maximum tolerable power consumption of the drive motor.
dingly.
Continuous
When using operation
frequencyintransformers,
the limit zoneplease
is not note
recommended.
that the limits of application can be restricted
Maximum
on reachingpermissible
the maximum ON/OFF switching
tolerable powerfrequency
consumption of the
of drive motor:
the drive 12 switching cycles per
motor.
hour. The whole
Continuous machine
operation in themust
limitreach
zoneaisstate of equilibrium (constant operating conditions).
not recommended.
Maximum permissible ON/OFF
Rating switching
values frequency
for operating of the on
ranges drive motor: 12 switching cycles per
request.
hour. The whole machine must reach a state of equilibrium (constant operating conditions).
Rating values for operating ranges on request.
Installation instructions
Transport eyelet
General
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 air
must be guaranteed. Do not operate the compressor in a corrosive atmosphere, dust, steam
or 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 before
mounting the compressor in a slanting position!
Direct erection on bundle pipe condensers only with anti-vibration pads. Risk of vibration
cracks and breakage with rigid installation!
In addition, we recommend the installation of pipeline vibration compensators.
Pipe connections / pipes
Caution! 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 inch
09972-07.02-DGBFEI

dimensions. The solder connections of the shut-off valves are to be removed from the
shut-off valves when soldering the pipes.
Pipes and machine components should always be clean and dry on the inside, and free
of cinders, metal chips, rust and phosphate coats. In addition, all parts to be tted to the
compressor and to the whole machine must be delivered sealed air-tight.

-8-
 Operating instructions for motor compressor Series HG 3 R
Installation instructions

Pipe installation
Ensure there is provision for proper oil reux
Pipes 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 the
correct 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 valves
Warning! Both shut-off valves - the suction and the discharge shut-off valve - must be
opened before starting the compressor! GB
Before opening or closing the shut-off valve, turn the valve spindle seal approx. 1⁄4 of
i a turn counter-clockwise. After activating the shut-off valve, tighten the valve spindle
seal again clockwise.

Valve spindle seal

loosen

tighten

Opening the shut-off valve Setting A Pipe connection

Open spindle 1 turning to the left
(counter-clockwise) as far as it
will go.
Shut-off valve is fully open / ser-
vice connection 2 closed
(setting A).
Compressor

Opening the service Setting B Pipe connection

09972-07.02-DGBFEI

connection (2)
Turn spindle 1 approx. 1⁄2 to 1 turn
to the right (clockwise)
Service connection 2 is now
open, the shut-off valve is also
open (setting B).
Compressor

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

-9-
 Operating instructions for motor compressor Series HG 3 R
Installation instructions

Versions of discharge shut-off valves

a) HG 3/155-4, HG 3/155-4S
HG 3/190-4, HG 3/190-4S
HG 3/235-4, HG 3/235-4S

Valve spindle
GB
Connection B1 Connection B (cannot be shut of)
(can be shut of)
b) HG 3/275-4, HG 3/275-4S
HG 3/325-4, HG 3/325-4S

Suction shut-off valves

Connection A (cannot be shut of)

Connection A1 (can be shut of)

09972-07.02-DGBFEI

Valve spindle

- 10 -
 Operating instructions for motor compressor Series HG 3 R
Electrical connections

Electrical connection
General instructions
The electrical connection of the motor is to be completed according to the main line circuit
diagram (on the inside of the terminal box). When connecting up the compressor, always
comply with the local electricity regulations (VDE 0100 for Germany).
Use suitable screwed cable glands with protection class IP 54 for the cable leadthroughs at
the 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 maximum
operating 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 only
be connected up when these details correspond. GB
Connection
The motor is connected in ∆ / Y in series.
Designation on the nameplate: ∆/Y
Designation 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~):

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

09972-07.02-DGBFEI

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 Operating instructions for motor compressor Series HG 3 R
Electrical connections

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

GB

1-2 Connections for PTC sensor B1 Enable switch(thermostat)

R1 PTC sensor motor winding Q1 Main switch
R2 Heat protection thermostat (PTC sensor) S1 Switch control voltage
F1 Safety device load stabilisation circuit M1 Compressor motor
F2 Fuse control power circuit K1 Mains contactor
F3 Safety chain (high/low pressure monitoring) A1 Electronic trigger MP 10

09972-07.02-DGBFEI

- 12 -
 Operating instructions for motor compressor Series HG 3 R
Electrical connections

Star delta starting

Mechanical start unloader with bypass solenoid
i (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 the
circuit diagram in the lid of the terminal box. Delay time on switching over max. 2 seconds.
Main line diagram for star delta starting at 230 V ∆

GB

1-2 Connections for PTC sensor K1 Mains contactor

R1 PTC sensor motor winding K2 ∆ contactor
R2 Heat protection thermostat (PTC sensor) K3 Y-contactor
F1 Safety device load stabilisation circuit K4T Time relay for contactor changeover
F2 Fuse control power circuit K5T Time relay for start unloader
F3 Safety chain (high/low pressure monitoring) AL Magnetic coil for start unloader
B1 Enable switch(thermostat) A1 Electronic trigger MP 10
09972-07.02-DGBFEI

Q1 Main switch S1 Switch control voltage

M1 Compressor motor Y1 MV start unloader

- 13 -
 Operating instructions for motor compressor Series HG 3 R
Electrical connections

Electronic trigger MP 10
The compressor motor is equipped with posistor temperature sensors (PTC) which are wired to the
electronic 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, the
device 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 protection
thermostats (accessories).
When the device has triggered, this indicates an overload or intolerable operating
i conditions. Ascertain and eliminate the cause.
GB The device has a reclosure preventing feature. After eliminating the fault, the device is quit by
interrupting 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.
Connection of the electronic trigger MP 10
The electrical connection of MP 10 is to be completed
according to the circuit diagram. The trigger is to be
protected with a fuse (F) of max. 4 A, slow-acting. To
guarantee the protection function, the electronic trigger
is mounted as rst element in the control power circuit.
Connections temperature monitoring:
motor winding: terminals 1-2
hot gas side: terminals 3 - 4
WARNING! Terminal
board
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.
Function test of the electronic trigger MP 10
Before starting up and after any faults or changes to the control power circuit of the machine, check
the electronic trigger to ensure that it functions properly:
LED H1 LED H2 LED H3
Procedure
red red green
09972-07.02-DGBFEI

1 Interrupt the power supply OFF OFF OFF

Disconnect 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 ON
Function check hot gas temperature sensor: stand-by ON
3 Interrupt mains voltage again OFF OFF OFF
Connect terminals 1 or 2 respectively 3 or 4 again
- 14 - 4 Switch the power supply on again: MP in stand-by mode OFF OFF ON
 09972-07.02-DGBFEI

Recommended circuit contactors and motor contactors

The selected contactor types are make Moeller, but other comparable makes with equivalent performance data can also be used.
Compressor Motor Max. operating - Devices for direct starting Devices for Y / ∆ - start Rcold
type rated current (50 Hz) at 230 V - ∆ at 400 V - Y (only for voltage range ∆) at 20° C
power 230 V ∆ 400 V Y Circuit Motor Circuit Motor Circuit cont. Motor contactor
(KW) (A) (A) contactor contactor contactor contactor á 3 expl. (Imax=Ax0,57) Ω (Ohm)

HG 3/155-4 2,2 12 7 DIL-00AM PKZM0-16 DIL-00M PKZM0-10 DIL-EM Z0-10 2,15 - 2,48
HG 3/190-4 3 18 10 DIL-0AM PKZM0-16 DIL-00AM PKZM0-16 DIL-0M Z0-16 1,69 - 1,94
HG 3/235-4 3 18 10 DIL-0AM PKZM0-16 DIL-00AM PKZM0-16 DIL-0M Z0-16 1,69 - 1,94
Electrical connections

HG 3/275-4 4 23 13 DIL-1M PKZM0-25 DIL-0M PKZM0-16 DIL-0AM Z0-16 0,9 - 1,1

HG 3/325-4 4 23 13 DIL-1M PKZM0-25 DIL-0M PKZM0-16 DIL-0AM Z0-16 0,9 - 1,1
HG 3/155-4S 3 18 10 DIL-0AM PKZM0-20 DIL-00AM PKZM0-16 DIL-0M Z0-16 1,69 - 1,94
Operating instructions for motor compressor Series HG 3

HG 3/190-4S 4 23 13 DIL-1M PKZM0-25 DIL-0M PKZM0-16 DIL-0AM Z0-16 0,9 - 1,1

HG 3/235-4S 4 23 13 DIL-1M PKZM0-25 DIL-0M PKZM0-16 DIL-0AM Z0-16 0,9 - 1,1
HG 3/275-4S 5,5 33 19 DIL-1AM PKZ2-40 DIL-0AM PKZM0-20 DIL-1M Z0-24 0,78 - 0,9
HG 3/325-4S 5,5 33 19 DIL-1AM PKZ2-40 DIL-0AM PKZM0-20 DIL-1M Z0-24 0,78 - 0,9

HA 3/155-4 12 7 DIL-0AM PKZM0-16 DIL-00AM PKZM0-10 DIL-0M Z0-10 1,69 - 1,94

HA 3/190-4 18 10 DIL-1M PKZM0-20 DIL-0M PKZM0-10 DIL-0AM Z0-16 0,9 - 1,1
HA 3/235-4 18 10 DIL-1M PKZM0-20 DIL-0M PKZM0-16 DIL-0AM Z0-16 0,9 - 1,1
HA 3/275-4 18 10 DIL-1AM PKZM0-20 DIL-0AM PKZM0-16 DIL-1M Z0-10 0,78 - 0,9
HA 3/325-4 18 10 DIL-1AM PKZM0-20 DIL-0AM PKZM0-16 DIL-1M Z0-10 0,78 - 0,9
R

GB

- 15 -
 Operating instructions for motor compressor Series HG 3 R
Initial commissioning

Oil sump heating

When the compressor is at a standstill, coolant diffuses into the lubricating oil of the compressor
housing, depending on pressure and ambient temperature. This reduces the lubricating capacity of
the oil. When the compressor starts up, the coolant contained in the oil evaporates out through the
reduction in pressure. The consequences can be foaming and migration of the oil, causing oil shocks
under certain circumstances.
In order to avoid damage to the compressor, the compressor is equipped with an oil sump heating as
a 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.
GB
Connection: The oil sump heating must be connected via an auxiliary contact (or parallel wired
auxiliary contact) of the compressor contactor to a separate electric circuit. El. data: 230 V ~ / 60
80 W
WARNING! The oil sump heating must not be connected to the electrical circuit of the
safety control chain.
Initial commissioning
The compressor has undergone trials in the factory and all functions have been tested. There are
therefore no special running-in instructions.
i 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, evacuation
Check the refrigerating system for leaks without including the compressor (preferably
with 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.
09972-07.02-DGBFEI

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 are
reduced in a vacuum, this can cause damage to the winding and to the terminal board.
Filling with coolant
i Caution! 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
- 16 - 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 liquid
form at the inlet to the evaporator.
 Filling with coolant
i
Operating instructions
Caution! for motorsafety
Wear personal compressor
gear! Series HG 3 R
CheckInitial
that the commissioning
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 liquid
form 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 always
i only 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.
Operation check
After initial commissioning has been completed, check that the machine complies with the GB
tolerable operating conditions.

Liquid shocks
WARNING! 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 move
in the compressor when the machine is at a standstill.
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.

Normal oil level

09972-07.02-DGBFEI

- 17 -
 Operating instructions for motor compressor Series HG 3 R
Maintenance

Connection of the oil level controller

Oil 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
AC&R,and
oil level controllers make AC&R ESKESK
andcanthe be
electronic controller
connected system
up directly TRAXOIL
without S1A21
needing by
an adapter
SPORLAN
(see can For
diagram). be connected up directly
the electronic without
controller systemneeding
TRAXOILan adapter
S1A1 by(see diagram).
SPORLAN theThe oil level
intermediate
controllerref.n.
adapter does80070
not need a sight glass.
is necessary. The oil level controller does not need a sight glass.
124 o
3 hole connection dia-
gram for ESK and AC&R

12
124 o

4
M6 x 10

o
je 3 mal 3 hole connection dia-
gram for TraxOil
GB

4o
Mechanical oil level controller at

12
47,6
connection „O“
Lubricants
Bock standard oil grade Recommended alternatives
for 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 GS
for 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 46
Information about other suitable supplementary or substitute oils is available in the Bock lubricant
tables, and can also be found under www.bock.de
Maintenance
Safety 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 an
extraction 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.
09972-07.02-DGBFEI

Service intervals
The compressor is to be kept in a clean, orderly condition by suitable care. In order to guarantee
optimum operating safety and service life of the compressor, we recommend that you carry out the
following 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.
- 18 - Dispose of used oil properly, comply with national regulations.
Function checks: leaks, running noises, pressures, temperatures, proper functioning of all
additional equipment such as oil sump heating, pressure switch: once per year.
 optimum operating safety and service life of the compressor, we recommend that you carry out the
following servicing and checks at regular intervals:
Oil change
Operating instructions for motor compressor Series HG 3 R
- not mandatory in series machines produced in the factory
- for Accessories
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 all
additional equipment such as oil sump heating, pressure switch: once per year.
Maintenance and servicing kits
i Caution! Only use original BOCK spare parts!

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
Kit Art.no Art.no.
Seal kit 80064 80064 80064 GB
Valve plate kit 80050 80008 80009
Oil sump hesting kit, 230 V ~ 08424 08424 08424
Screwed unions
Various installation, maintenance and servicing work entails intervention in the compressor. All work
must therefore be performed with strict compliance with the given safety instructions. The following
torques must be used when re-assembling the compressor:
8.8* 10.9*
M5 8,5 Nm - * = screw quality, see screw head
M6 15 Nm - Notes: t seals in dry state, do not oil
M8 34 Nm 37 Nm Cylinder head/valve plate: tighten screws
M10 60 Nm 75 Nm from the middle outwards crosswise in at
7/ ″ 13 Nm
M1216 90 Nm - least two stages (torque 50/100%)
1/ ″ 25
M168 220Nm
Nm -
Oil drain plug, oil sump heating M 22 x 1,5 100 Nm
Start unloader AL plug 100 Nm
Live connections M6 3 Nm
Rotor M 12 65 Nm

Accessories
Special accessories are only premounted in the factory if ordered specially by the customer.
Retrotting 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.de
09972-07.02-DGBFEI

Designation Kit article no. Remarks

Start unloader 08527 Only necessary for ∆/Y starting
Heat protection thermostat 08921 Connection provided as standard feature
Additional fan 80046 Extended limits of application as per diagram

- 19 -
 Operating instructions for motor compressor Series HG 3 R
Technical specications

Technical specications
No. of cylinders 2
Rated speed [1/min] at 50 Hz 1450
at 60 Hz 1740
Lubrication: Oil pump independent of direction of rotation
Oil grade for R22: / oil lling [l]: FUCHS Reniso SP 46 / 1,5
Oil grade for X versions (for coolant llings e.g.
R134a, R404A, R407C, R507) / oil lling [l]: FUCHS Reniso Triton SE 55 / 1,5
Voltage / phases / frequency [V/Ph/Hz] 220-240 ∆ / 380-420 Y / 3 / 50
265-290 ∆ / 440-480 Y / 3 / 60
GB max. tol. pressure high pressure side HP: 25
low pressure side LP: 19
HG 3/155-4 HG 3/190-4 HG 3/235-4 HG 3/275-4 HG 3/325-4
Theoretical ow rate 50 Hz [m³/h] 13,6 16,7 20,3 24,1 28,3
Theoretical ow rate 60 Hz [m³/h] 16,3 20,1 24,3 28,9 33,9
max. operating current [A] 12 / 7 16 / 9 18 / 10 21 / 12 24 / 14
Start-up current (rotor blocked) [A] 53 / 32 67 / 40 67 / 40 96 / 57 96 / 57
Noise level [dbA], L / M / H *) 62 / 61 / 60 63 / 62 / 61 64 / 63 / 62 65 / 64 / 63 66 / 65 / 64
Weight incl.oil lling [kg] 77 78 78 78 78

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

Theoretical ow rate 50 Hz [m³/h] 13,6 16,7 20,3 24,1 28,3
Theoretical ow rate 60 Hz [m³/h] 16,3 20,1 24,3 28,9 33,9
max. operating current [A] 16 / 9 21 / 12 23 / 13 28 / 16 33 / 19
Start-up current (rotor blocked) [A] 67 / 40 96 / 57 96 / 57 134 / 77 134 / 77
Noise level [dbA], L / M / H *) 62 / 61 / 60 63 / 62 / 61 64 / 63 / 62 65 / 64 / 63 66 / 65 / 64
Weight incl.oil lling [kg] 78 81 81 81 81
*) Measuring conditions: low-reection machine room, measuring distance: 1 m, compressor operating at rated
speed 1450 rpm at 50 Hz, coolant R134a. When using other coolants the values are increased by approx. 1 - 1.5
dB(A). Application ranges: L = deep-freezing range, M = normal refrigerating range, H = air-conditioning.
09972-07.02-DGBFEI

- 20 -
 Operating instructions for motor compressor Series HG 3 R
Connections
Connections, dimensions
SV Suction shut-off valve,
pipe Ø solder connection (mm (inch))
Connections
DV Discharge shut-off valve,
pipe Ø solder connection (mm (inch))
A HG 3/155-4 HG 3/190-4 HG 3/235-4 HG 3/275-4 HG 3/325-4
SVSuction
Suctionside connection,
shut-off valve,
7 22 (7/8) 28 (11/8) 28 (11/8) 28 (11/8)
pipe Ø solder connection (mm (inch)) ( /8)
cannot be shut off (inch) 22
A1 Suction side connection,
DV Discharge shut-off valve,
can
pipe be shut off
Ø solder (inch) (mm (inch)) 16 (5/8)
connection 16 (5/8) 16 (5/8) 22 (7/8) 22 (7/8)
A Suction side connection,
HG 3/155-4S HG 3/190-4S HG 3/235-4S HG 3/275-4S HG 3/325-4S
cannot be shut off (inch)
SV Suction shut-off valve, 22 (7/8) 22 (7/8) 28 (11/ 8) 28 (11/ 8) 28 (11/8)
A1 Suction side connection,
pipe Ø solder connection (mm (inch))
can be shut off (inch)
DV Discharge shut-off valve, 16 (5/8) 16 (5/8) 16 (5/8) 22 (7/8) 22 (7/8)
pipe Ø solder connection (mm (inch)) GB
A Suction
SV Suctionside connection,
shut-off valve,A Suction side connection, cannot be shut off (inch)
cannot be shut off (inch)(mm (inch))
7/16 UNF
pipe Ø solder connection A1 Suction side connection, can be shut off (inch) 7/16 UNF
A1
DV Suction sideshut-off
Discharge connection,
valve,
B Discharge side connection, cannot be shut off (inch)
can
7/16 UNF
pipe be shut off
Ø solder (inch) (mm (inch))
connection
B1 Discharge side connection, can be shut off (inch) 7/16 UNF
A Suction side connection,D1 Connection oil return from oil separator (inch) 1/8 NPTF
cannot be shut off (inch)
F Oil drain bung (oil lter) (mm) M 22 x 1,5
A1 Suction side connection,
H Oil lling bung (mm) M 22 x 1,5
can be shut off (inch)
J Oil sump heating (mm) M 22 x 1,5
K Sight glass -
L Connection heat protection thermostat (inch) 1/8 NPTF
O Connection oil level controller (mm) 3xM6
Dimensions
09972-07.02-DGBFEI

Height with vibration compensators: + 30 mm

Anti-vibration pad

- 21 -
 Operating instructions for motor compressor Series HG 3 R
Initial commissioning

DECLARATION OF CONFORMITY CE 96
for 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 title
comply with the low voltage directive 73/23/EEC in the version 93/68/EEC.

Applied harmonised standard

EN 60335-2-34
GB (HD 277 S1)

When installing our products in a machine,

the following manufacturer declaration must be taken into consideration.

MANUFACTURER DECLARATION
for 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 title
in 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 are
integrated has been tested according to the corresponding statutory regulations and declared
to be conforming in all points.
09972-07.02-DGBFEI

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