Bock Compressor HA5 Assembly Instructions

5 Electrical connection5Electrical connectionDANGER! igh voltage! Risk of electric shock! Only carry out work when theHelectrical system is disconnected from the power supply!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.C ompare the voltage and frequency values with the data for the mainspower supply.Only connect the motor if these values are the same.5.1 Information for contactor and motor contactor selectionAll protection equipment, switching and monitoring devices must comply with the local safety regulations and established specifications (e.g. VDE) and regulations as well as the manufacturer’s specifications. Motor protection switch is required! Motor contactors, feed lines, fuses and motor protectionswitches must be rated according to the maximum operating current (see name plate).Use the following overload protection device:A current-dependent time-delayed overload protection device for monitoring of all three phases, notset higher than the rated current of the machine, which must respond at 1.2 times the set currentwithin 2 hours and must not have responded at 1.05 times the set current within 2 hours, or anothercomparable device.DGBFE5.2 Standard motor, design for direct or part winding startDesignation on the name plateSticker on the terminal boxY/YYCompressors with this marking are suitable for direct or partial winding start. The motor winding issubdivided into two parts: Partial winding 1 66% and part winding 2 33%. This winding divisionreduces the start-up current needed for a part winding start to approx. 65% of that for a direct start.A mechanical unloaded start with bypass solenoid valve isnot required.09911-09.2013-DGbFEIINFO!13

5.3 Basic circuit diagram for part winding start with standard motor0 1 2 F1.1F1.2I 66%I 33%3 4 F24AS1Q1135246K1135246F1.1K2F1.2X 1X1 L1 L1 NLN 43 43 11X2 14S12M14R1235MP106R214R1Cold conductor (PTC sensor) motor windingDatum 02.Feb.2009R2Thermal protection thermostat(PTC sensor)Bearb. KelichF1.1 /1.2 2 motor protection switches(66% / 33% of I A total)Gepr. 10.Feb.2010Name NormUrspr.F2 nderungControlDatumpower circuitfuseF3High pressure safety monitorF4Safety chain (high/low pressure monitoring)F5Oil differential pressure monitorC1Fan operating capacitorB1Release switch (thermostat)Ers. .09911-09.2013-DGbFEIFig. 16Anschlu asten VerdichterCompressorterminal boxErs. d.

5 6 7 9 8 L1.1L2.1L3.1L1.2K1K1K1K1TK1910111213K214P PF3F4K1T1516NPE17181920P DB1GBFEX31234E1F5C1T2NLMSM1 09911-09.2013-DGbFEIM1.1PW MP10P lQ1M1M1.1K1K2K1TS1E1Main switch Compressor motor Fan motorB CK C MPRESS RSMains contactor (part winding 1)Mains contactor (part winding 2)Delay relay max. 1sControl voltage switchOil sump heater1Bl.1Bl.15

5 Electrical connectionThe motor is wired for direct start (YY) at the factory. For part winding start Y / YY, the bridges must beremoved and the motor feed line connected according to the circuit diagram:400 VDirectstart YYYYDirektstartPart winding start 1U11V11W11U11V11W1L1L2L3L1L2L3ATTENTION! F ailure to do this results in opposed rotary fields and results indamage to the motor. After the motor starts up via partial winding1, partial winding 2 must be switched on after a maximum delay ofone second . Failure to comply can adversely affect the service lifeof the motor.DGBF09911-09.2013-DGbFEIE16

5 Electrical hör)erforderlich.A(Zubehör)mechanicalunloaded start with bypass solenoid valve (accessories) is required for theerforderlich.star-delta ufkleberDesignation on the name plateSticker on the terminal box //YY /YStern-Dreieck-Anlaufistist nurimimSpannungsbereichSpannungsbereich (230(230 V)möglich.möglich. Beispiel:Stern-Dreieck-AnlaufStar-deltastart-up is onlynurpossiblefor 230 V power supply.V)Example: Beispiel:230230VVV 0Star-delta 2L3L3Directstart onlynurDirektstartDirektstartnurU2W2 U2W2V2V2U2W2 U2W2V2V2W2 U2U2 V2V2W2U1 V1V1U1W1W1V1U1 V1U1W1W1U1U1V1 1-09.2013-DGbFEIE17

5.5 Basic circuit diagram for star-delta start with special motor0 1 2 3 4 .2F1.2X SSDL1L2L3NPEPE78Net 400V 50 GBFEU1V1M1M3 W1W2U2X1 L1 L1 NLN 43 43 11X2 14S12M14V2R12356MP10R218R1R2F1.1 /1.2F2F3F4F5 nderungC1B1Q1Anschlu asten VerdichterCompressorterminal boxCold conductor (PTC sensor) motor windingThermal protection thermostat (PTC sensor)2 motor protection switchesControl power circuit fuseHigh pressure safety20.Feb.2009Datum monitorBearb. KelichSafety chain (high/lowpressure monitoring)Gepr. 10.Feb.2010Oil differentialmonitorDatumName pressureNormUrspr.Fan operating capacitorEnabling switch (thermostat)Main switchErs. .Ers. d.09911-09.2013-DGbFEIFig. 17

5 6 7 8 9 K4T1314AL15P PF3F4K5T1617NPE18192021P DB1GBFX3123E4E1F5C1T2NLMSM1 09911-09.2013-DGbFEIM1.1D/SMP10P lM1M1.1K1K2K3K4TK5TS1ALE1Compressor motorFan motorMains contactorΔ-contactor Y-contactor Delay relay S/D changeoverB CK C MPRESS RSDelay relay, start unloaderControl voltage switchStart unloaderOil sump heater1Bl.1Bl.19

5 Electrical connection5.6 Electronic trigger unit MP 10The compressor motor is fitted with cold conductor temperature sensors (PTC) connected to theelectronic 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, theunit 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 thermalprotection 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 remedythe cause.INFO! The unit has a restart prevention device. After you have rectified thefault, interrupt the mains voltage. This unlocks the restart preventiondevice and the LEDs H1 and H2 go out.5.7 Connection of the trigger unit MP10INFO! Connect the trigger unit MP10 in accordance with the circuit diagram. Protect the trigger unit with a delayed-action fuse (F) of max.4 A. In order to guarantee the protection function, install the triggerunit as the first element in the control power circuit.GBTemperature monitoring connections:Motor winding:Thermal protection thermostat:Restart prevention:FETerminals 1 - 2Terminals 3 - 4Terminals 5 - 6ATTENTION!Terminals 1 - 6 on the triggerunit MP 10 and terminals PTC1 and PTC 2 on the compressor terminal board must notcome into contact with mainsvoltage. This would destroy thetrigger unit and PTC sensors.The supply voltage at L1-N( /- for DC 24 V version) mustbe identical to the voltage atterminals 11, 12, 14 and 43.Terminal boardFig. 182009911-09.2013-DGbFEID

5 Electrical connection5.8 Function test of the trigger unit MP 10Before start-up, troubleshooting or making changes to the control power circuit, check the functionalityof the trigger unit:PosProcedure1 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)2 Restore the power supply (L1 or S1) Function check of motor temperature sensor: operational Function check of hot gas temperature sensor: operationalLED H1 LED H2 LED H3redredgreenOFFOFFOFFONONON3 Interrupt power supply again (L1 or S1) Reconnect terminals 1 or 2 and/or 3 or 4OFFOFFOFF4 Restore the power supply (L1 or S1): MP 10 is operational againOFFOFFONThe compressor and the trigger unit MP10 are operational when the H3 LED (green) lights.DGBF09911-09.2013-DGbFEIE21

5 Electrical connection5.9 Oil sump heater (accessories)During compressor standstill and depending on the pressure and ambient temperature, refrigerantdiffuses 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.09983- 10.01-DGBFConnection: Connect the oil sump heater via an auxiliary contact (or parallel-wired auxiliaryD Anschlussschema für Ölsumpfheizung contactor) of thecompressor contactor to a separate current path.GB Connection diagramm for oil sump heaterElectrical data: 230 V - 1 - 50/60 Hz, 140 W.F Plan de raccordement pour résistance de carter d‘huileDGBFEFig. 19ATTENTION! Connection to the current path of the safety control chain is notpermitted5.10 Fan motor09911-09.2013-DGbFEIThe fan motor for cooling the compressor is already wired in the terminal box. The power supply aswell as triggering of the compressor contactor should be made in accordance with the basic circuitdiagram (in the terminal box). The fan motor is protected by an internal temperature monitor.Electrical data: 230 V - 1 - 50/60 Hz, 170 W - 0,71 A, IP4422

6 Commissioning6.1 Preparations for start-upINFO! In order to protect the compressor against inadmissible operatingconditions, high-pressure and low-pressure pressostats controls aremandatory on the installation side.The compressor has undergone trials in the factory and all functions have been tested. There aretherefore no special running-in instructions.Check the compressor for transport damage!6.2 Pressure strength testDANGER! 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 notbe exceeded at any time during the testing process (see name platedata)! Do not mix any refrigerant with the nitrogen as this couldcause the ignition limit to shift into the critical range.The compressor has been factory-tested for pressure resistance. The following must be observed ifthe entire plant is subjected to an additional pressure strength test:Test the refrigeration circuit according to EN 378-2 or a corresponding safety standard.DGB6.3 Leak testFDANGER! Bursting! Do not mix any refrigerant with the nitrogen (N2) as this could causethe ignition limit to shift into the critical range.ECarry out the leak test of the refrigerating system in accordance with EN 378-2 or a correspondingsafety standard without including the compressor.6.4 Evacuation09911-09.2013-DGbFEIATTENTION! Do not start the compressor if it is under vacuum. Do not applyany voltage - even for test purposes (must only be operated with refrigerant).Under vacuum, the spark-over and creepage current distances of theterminal board connection bolts shorten; this can result in winding andterminal 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.23

6 Commissioning6.5 Refrigerant fillingCAUTION! Wear personal protective clothing such as goggles and protectivegloves!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 vapourform on the suction side, or, taking suitable precautions, also in liquid form at the inlet to theevaporator.INFO!DAvoid overfilling the system with refrigerant! In order to prevent shifts in concentration, zeotropic refrigerantblends (e.g. R407C) must always only be added to the refrigeratingsystem in liquid form. Do not pour liquid refrigerant through the suction line shut-offvalve on the compressor. It is not permissible to mix additives with the oil and refrigerant.6.6 CommissioningGBFEWARNING! Ensure that both shut-off valves are open before starting the compressor!Check that the safety and protection devices (pressure switch, motor protection, electrical contact 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 oilimpact effects. If this is the case, check the oil return!6.7 Avoid slugging24To prevent slugging:The complete refrigeration plant must be properly designed.All components must be compatibly rated with each other with regard to output (particularly theevaporator and expansion valves).Suction gas superheating at the compressor input should be min. 7 - 10 K (check the setting ofthe 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 liquidtraps, 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.09911-09.2013-DGbFEIATTENTION! Slugging can result in damage to the compressor and causerefrigerant to leak.

6 Commissioning6.8 Connection of oil level regulator124o124 oo412Oil 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). Allcommon oil level regulators from AC&R, ESK and Carly as well as the OM3 TraxOil oil level regulationsystem from Alco can be connected directly without adapters (see Fig. 19). A sight glass on the oillevel regulator is not required.Anschluss Ölspiegelregulator124 oBei Verbundschaltungen von mehreren Verdichtern haben sichÖlstandsregulierungssysteme bewährt. Für die Montage eines ÖlspieM6 x 10gelregulators ist der Anschluss „O“ vorgesehen (siehe Maßzeichnung).3 timesje3 maleachAlle gängigen Ölspiegelregulatoren von AC&R, ESK sowie das elektronische Reglersystem TRAXOIL S1A1 von SPORLAN können direktohne Adapter angeschlossen werden (s. Abb.). Ein Schauglas amÖlspiegelregulator ist nicht erforderlich.47,6Fig. 20Mechanical oil level regulatorat the "O" connection33-Loch-Anschlussbildhole connection diagrammfür ssbildhole diagramm for TraxOilfür TraxOilahr vonDGBF7 MaintenanceE7.1 PreparationWARNING! 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.09911-09.2013-DGbFEI7.2 Work to be carried outIn order to guarantee optimum operational reliability and service life of the compressor, we recommendcarrying 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 100to 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.25

7 Maintenance7.3 Recommended spare partsHA5 / .Designation725-4830-4925-4Ref. No.Ref. No.Ref. No.Set of gaskets08961Valve plate kit08851Oil pump kitOil sump heater kit230 V Only use genuine Bock spare parts!08384084267.4 AccessoriesAvailable accessories can be found on the Internet at www.bock.de.7.5 Extract from the lubricants tableThe oil type filled as standard in the factory is marked on the name plate . This oil type should beused as a preference. Alternatives are stated in the extract from our lubricants table below.DGBRefrigerantsFEHFC(e.g. R404A/R507)HCFC (e.g. R22)Bock standard oil typesRecommended alternativesFuchs Reniso Triton SE 55Fuchs Reniso Triton SEZ 32Esso/Mobil EAL Arctic 46Sunoco Suniso SL 46Texaco Capella HFC 55Fuchs Reniso SP 46Fuchs Reniso SP 32BP Energol LPT 46Sunoco Suniso 3,5 GSTexaco Capella WF 467.6 Decommissioning09911-09.2013-DGbFEIClose the shut-off valves on the compressor. Drain the refrigerant (it must not be discharged into theenvironment) 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

4No. ofcylinders82,2 / 98,672,2 / 86,762,9 / 75,5m3 /hrpm)Displacement50 / 60 Hz(1450 / 17401Voltage380-420 V Y/YY - 3 - 50 Hz PW440-480 V Y/YY - 3 - 60 Hz PWPW Part WindingWinding ratio : 66% / 33%262626APW 1 umptionElectrical data 3kg204207205A107 / 140126 / 160126 / 160PW 1 / PW 1 2(rotor locked)StartingcurrentWeightSuctionlineSV28 (1 1/8)42 (1 5 /8)mm (inch) mm (inch)DischargelineDVConnections 44,5Ltr.Oilcharge73 / 7173 / 7172 / 70dB(A)L/M 5Soundpressurelevel3 All specifications are based on the average of the

D GB F E 1 09911-09.2013-DGbFEI engineering for a better world GEA Refrigeration Technologies Bock Compressor HA5