ha4 bock operating instructions

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Operating instructionsHermetic motor compressorSeries HA 4

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Operating instructionsfor air-cooled hermetic motor compressors

SERIES HA 4

Types:

HA 4/310 - 4HA 4/385 - 4HA 4/465 - 4HA 4/555 - 4HA 4/650 - 4

HA 4

Betriebsanleitung HA 4Operating instructions HA 4Instructions de service HA 4Instrucciones de servicio HA 4Istruzioni per l’uso HA 4

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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 9Electrical connection 10 General instructions 10 Standard motor 10 Main line wiring diagram for part winding start 11 Special motor 11 Main line diagram for star delta starting 12 Electronic trigger MP 10 13 Connection MP 10 13 Function test MP 10 13 Recommended circuit contactors and motor contactors 14 Oil sump heating 14 Ventilator motor 14Initial commissioning 15 Leak test, evacuation 15 Filling with coolant 15 Operation checks 15 Liquid shocks 16 Lubrication / oil check 16 Connection of the oil level controller 16 Lubricants 17Maintenance 17 Safety instructions 17 Service intervals 17 Maintenance and servicing kits 18 Screwed unions 18Accessories 19Technical specifications 19Connections 20Dimensions 21Declaration of conformity CE 96 22Manufacturer declaration 22

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

7 Oil fi 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

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3 10

12

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Function parts

Compressor section

Terminal box

Motor section

Air deflection hood

Product description Hermetic four-cylinder self-reciprocating compressor with air-cooled drive motor. The suction gas is sucked straight into the compressor housing. The drive motor is outside the suction gas fl ow. The drive motor is fl anged to the compressor housing. The motor is cooled by a current of air generated by the ventilator. The fl ow of cooling air

is guided deliberately over the motor. The discharged cooling air also lowers the operating temperature in the compressor housing.

Preferred range of application: normal refrigeration and deep freezing.

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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).

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).

310 = 27.1 m³/h theoretical volume flow rate at 50 Hz385 = 33.5 m³/h theoretical volume flow rate at 50 Hz465 = 40.5 m³/h theoretical volume flow rate at 50 Hz555 = 48.2 m³/h theoretical volume flow rate at 50 Hz650 = 56.6 m³/h theoretical volume flow rate at 50 Hz

HA 4 / 650 - 4

HAX

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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, suffi cient ventilation of the machine room air

must be guaranteed. Do not operate the compressor in a corrosive atmosphere, dust, steam or fl ammable environment. Allow suffi 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.

Transport eyelet

Pipe connections / pipesCaution! Compressor is pressurised. Leave the inert gas fi 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 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 fi tted to the compressor 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 must be observed. The maximum discharge end temperature of 140°C may not be exceeded. In the dark grey area, compressor operation is only possible with additional cooling.Additional cooling solutions can consist of water-cooled cylinder covers (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 restricted

on 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 per

hour. The whole machine must reach a state of equilibrium (constant operating conditions).Rating values for operating ranges on request.

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Pipe installation Ensure there is provision for proper oil refl 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 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.i

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 it will 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 turn to the right (clockwise) Service connection 2 is now open, the shut-off valve is also open (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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Standard motor, designed for direct or part winding startFeatures:

Designation on the nameplate: Y / YY Designation on the yellow label on the terminal box (see fi gur):

Compressors marked in this way are suitable for direct or part winding start.The motor winding is divided into two parts: part winding 1 = 60% and part winding 2 = 40%. This winding division reduces the start-up current during a part winding start to approx. 65% of the value for a direct start.

Mechanical start unloader with bypass solenoid is not required

In the factory, the motor is switched for direct starting (YY) (see photo).For part winding start Y/YY, remove the bridges and connect the motor feed cable according to the circuit diagram. right wrong

part winding 2 = 40%

part winding 1 = 60%

WARNING!Failure to comply results in reversed fi elds of rotation and can cause motor damage.After the motor has started up with part winding 1, part winding 2 must be switched on after max. 1 second delay. Failure to comply can be detrimental to the service life of the motor.

Terminal box with bridges inserted for direct start

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ISpecial motor, version for direct or star delta startingExample for motor 230 V ∆ / 400 V YFeatures: Designation on the nameplate: ∆ / Y

Designation on the yellow label on the terminal box (fi gur).Compressors with this code are suitable in the voltage range ∆ for start delta starting

Note: Mechanical start unloader with bypass solenoid(accessories) is required for star delta starting

In the factory, the motor is switched for direct starting (400 V Y, see photo).For star delta starting in voltage range ∆, the bridges are to be inserted according to the circuit diagram in the lid of the terminal box.z

Note the position and designation of the connection screws on the terminal board!

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Photograph: Terminal box with inserted bridges for direct starting with 400 V Y

U1 V1 W1

U2 V2W2

CAUTION! Ensure that power is supplied via K1 to winding 1 (60%) (1U1 / 1V1 / 1W1) and via K2 to winding 2 (40%) (2U1 / 2V1 / 2W1). The motor contactors (K1/K2) are each to be rated for approx. 70% of the max. operating current.

1-2 Connections for PTC sensorR1 PTC sensor motor windingR2 Heat protection thermostat (PTC sensor)F1 2 motor safety switches (60%:40% of IA total)F2 Fuse control power circuitF3 Safety chain (high/low pressure monitoring)F4 Oil differential pressure controllerB1 Enabling switch (thermostat)

K1 Mains contactor (part winding 1)K2 Mains contactor (part winding 2)K1T Delay relay max. 1sA1 Trigger unit MP10Q1 Main switchS1 Switch control voltageM1 Compressor motorM2 Ventilator motor

Main line wiring diagram for part winding start with standard motor

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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)F4 Oil differential pressure controllerB1 Enable switch(thermostat)Q1 Main switchS1 Switch control voltage

M1 Compressor motorM2 Ventilator motorK1 Mains contactorK2 ∆ contactorK3 Y-contactorK4T Time relay for contactor changeoverK5T Time relay for start unloaderAL Magnetic coil for start unloaderA1 Electronic trigger MP 10Y1 MV start unloader

Main line diagram for star delta starting with special motor

Special motor, version for direct or star delta startingExample for motor 230 V ∆ / 400 V YFeatures: Designation on the nameplate: ∆ / Y

Designation on the yellow label on the terminal box (fi gur).Compressors with this code are suitable in the voltage range ∆ for start delta starting

Note: Mechanical start unloader with bypass solenoid(accessories) is required for star delta starting

In the factory, the motor is switched for direct starting (400 V Y, see photo).For star delta starting in voltage range ∆, the bridges are to be inserted according to the circuit diagram in the lid of the terminal box.z

Note the position and designation of the connection screws on the terminal board!

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Photograph: Terminal box with inserted bridges for direct starting with 400 V Y

U1 V1 W1

U2 V2W2

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Electronic trigger MP 10The 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 conditions. Ascertain and eliminate the cause.

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.

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Connection of the electronic trigger MP 10The 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 fi rst element in the control power circuit.

Connections temperature monitoring: motor winding: terminals 1-2 hot 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.

Terminal board

Function test of the electronic trigger MP 10Before 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:

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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Ventilator motorThe ventilator motor for cooling the compressor is already wired in the terminal box.Please consult the main-line wiring diagram in the terminal box for the power supply and triggering via the compressor contactor. The ventilator motor is protected by a pressure controller.Electrical data: 230 V / 1 / 50 … 60 Hz, 170 W, 0.71 A

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Mechanical oil level controller at connection „O“

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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 fl 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 lubricant tables, and can also be found under www.bock.de

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8.8* 10.9* M5 8,5 Nm - M6 15 Nm - M8 34 Nm 37 NmM10 60 Nm 75 NmM12 90 Nm -M16 220 Nm -

* = screw quality, see screw headNotes: fi 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 work must therefore be performed with strict compliance with the given safety instructions. The following torques must be used when re-assembling the compressor:

Connecting rod screws M 6 15 NmOil drain plug, oil filler plug, oil sump heating M 22 x 1,5 100 NmSight glass, connection oil level controller M 6 15 NmFlange connection, 7/16″ 13 Nmsoldered connection shut-off valves M 10 60 NmPlug screws, bungs, valve bodies AL-, LR-Stopfen: 100 Nm 1/8″ NPTF 25 NmLive connections M 6 3 NmRotor M 12 65 Nm

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

HA 4/310-4 HA 4/385-4 HA 4/555-4 HA 4/465-4 HA 4/650-4 Kit Art. no. Art. no. Art. no. Seal kit 08913 08913 08913 Valve plate kit 08888 08247 08248 Oil pump kit 08384 08384 08384 Oil sump heating kit, 230 V ~ 08425 08425 08425 Start unloader kit, complete 08821 08821 08821 230 V ~ / 50 ... 60 Hz Capacity regulator kit, complete 08419 08419 08419 230 V ~ / 50 ... 60 Hz Ventilator motor kit 08630 08630 08630 230 V ~ / 50 ... 60 Hz

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No. of cylinders 4Rated speed 1450 rpm bei 50 Hz 1750 rpm bei 60 HzLubrication/oil filling Oil pump independent of direction of rotation / 3.4 l Oil grade for R22: FUCHS Reniso SP 46 Oil grade for X versions (for coolant fillings e.g. R134a, R404A, R407C, R507): FUCHS Reniso Triton SE55Voltage/phases/frequency 380-420 V / 3 / 50 Hz 440-480 V / 3 / 60 Hzmax. tol. operating overpressure high pressure side: 25 bar low pressure side: 19 bar

HA 4/310-4 HA 4/385-4 HA 4/465-4 HA 4/555-4 HA 4/650-4Theoretical flow rate 50 Hz (m³/h) 27,1 33,5 40,5 48,2 56,6Theoretical flow rate 60 Hz (m³/h) 32,5 40,2 48,6 57,8 67,9max. operating current (A) 17 21 21 26 26Start-up current (rotor blocked) (A)PW/direct start 57 / 75 82 / 107 82 / 107 107 / 140 107 / 140Noise level (dBA), L / M *) 70 / 69 70 / 69 70 / 69 70 / 69 70 / 69Weight incl.oil filling (kg) 154 157 157 160 163*) Measuring conditions: low-reflection machine room, measuring distance: 1 m, compressor operating at rated speed 1450 rpm at 50 Hz, coolant R404A. When using other coolants the values are increased by approx. ± 2 dB(A). Application ranges: L = deep-freezing range, M = normal refrigerating range

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1/8″ NPTF7/16″ UNF1/8″ NPTF1/8″ NPTF7/16″ UNF7/16″ UNF7/16″ UNF1/4″ NPTF7/16″ UNFM 22 x 1,5M 22 x 1,5M 22 x 1,5 ---1/8″ NPTFM 48 x 1,53 x M 6

Dimensions

HA 4/310-4 HA 4/385-4 HA 4/465-4 HA 4/555-4 HA 4/650-4SV Suction shut-off valve,pipe Ø solder connection (mm (inch)) 28 (11/8) 28 (11/8) 35 (13/8) 35 (13/8) 35 (13/8)DV Discharge shut-off valve,pipe Ø solder connection (mm (inch)) 22 (7/8) 22 (7/8) 28 (11/8) 28 (11/8) 28 (11/8)

Anti-vibration pad

Connections

A Suction side connection, cannot be shut off (inch) A1 Suction side connection, can be shut off (inch) A2 Suction side connection, cannot be shut off (inch)

B Discharge side connection, cannot be shut off (inch)

B1 Discharge side connection, can be shut off (inch) C Oil pressure safety switch connection OIL (inch) D Oil pressure safety switch connection LP (inch) D1 Connection oil return from oil separator (inch)

E Oil pressure gauge connection (Schrader) (inch)

F Oil drain bung (oil filter) (mm) H Oil filling bung (mm) J Oil sump heating (mm)

K Sight glass

L Connection heat protection thermostat (inch) N Connection capacity regulator (mm) O Connection oil level controller (mm)

Height with vibration compensators: + 30 mm

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ha4 bock operating instructions

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