BOCK FK30 Bedienungsanleitung

FK30/235 N FK30/275 N FK30/325 N

FK30/235 K FK30/275 K FK30/325 K

FK30/235 TK FK30/275 TK FK30/325 TK

FKX30/235 N FKX30/275 N FKX30/325 N

FKX30/235 K FKX30/275 K FKX30/325 K

FKX30/235 TK FKX30/275 TK FKX30/325 TK

BOCK FK3

Assembly instructions

09705-06.2021-Gb

Translation of the original instructions

colour the world

of tomorrow

BOCK®

09705-06.2021-DGbFITrRu

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 lead to

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.

The safety advice, which is contained in these instructions for assembly, and which is relevant for

regular operation and maintenance, must be forwarded by the manufacturer in his own documents

to the operator of the entire system. It must also be ensured, that personnel working in daily

operation with the compressor have access to important information such as safety and warning

advice about the compressor. Such persons must read the safety advice and have understood it.

Bock assumes no liability for any damage arising from non-compliance.

Bock GmbH

72636 Frickenhausen

Manufacturer

Contact

Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Phone +49 7022 9454-0

Fax +49 7022 9454-137

www.bock.de

[email protected]

09705-06.2021-DGbFITrRu

Contents Page

1 Safety 4

1.1 Identication of safety instructions

1.2 Qualications required of personnel

1.3 Danger to life and limb in the event of faults during operation

1.4 General safety instructions

1.5 Intended use

2 Product description 6

2.1 Brief 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 9

4.1 Setting up

4.2 Maximum permissible inclination

4.3 V-belt drive

4.4 Main bearing load

4.5 Installation of electromagnetic clutch assembly

4.6 Pipe connections

4.7 Pipes

4.8 Operating the shut-off valves

4.9 Operating mode of the lockable service connections

4.10 Suction pipe lter

5 Commissioning 13

5.1 Preparations for start-up

5.2 Pressure strength test

5.3 Leak test

5.4 Evacuation

5.5 Refrigerant charge

5.6 Oil level check

5.7 Shaft seal

5.8 Avoiding liquid shocks

6 Maintenance 15

6.1 Preparation

6.2 Work to be carried out

6.3 Shaft seal, emptying the oil reservoir

6.4 Recommended spare parts/accessories

6.5 Integrated decompression valve

6.6 Lubricants / Oils

6.7 Decommissioning

7 Accessories 18

7.1 Thermal protection thermostat

8 Technical Data 19

9 Dimensions and connections 20

10 Declaration of incorporation 22

11 Service 23

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1|Safety

1.2 Qualicationsrequiredofpersonnel

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.

WARNING Inadequatelyqualiedpersonnelposes theriskofaccidents,the

consequencebeingseriousorfatalinjury.Workon compressors

isthereforereservedforpersonnelwhichisqualiedtoworkon

pressurized refrigerant systems:

• For example, a refrigeration technician, refrigeration mechatronic

engineer. As well as professions with comparable training, which

enables personnel to assemble, install, maintain and repair refrigeration

and air-conditioning systems. Personnel must be capable of assessing

the work to be carried out and recognising any potential dangers.

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

1.3 Danger to life and limb in the event of faults during operation

WARNING If a compressor continues to be operated during extreme running

noise and/or a sharp reduction in refrigerating capacity, there is

the danger of further events occurring, such as the fracture of the

housing wall. If people are standing in the immediate surroundings,

there is the risk of severe injury or even death from flying parts.•In

the event of extreme running noise, switch the compressor off

immediately.

• If there is a sharp reduction in refrigerating capacity, switch the

compressor off immediately.

• Secure the compressor against being switched on again.

• In such cases do not continue to operate the compressor under any

circumstances.

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1.4 General safety instructions

1|Safety

These assembly instructions describe the standard version of the FK30 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 installation in a machine (within

the EU according to the EU Directives 2006/42/EC Machinery Directive, 2014/68/EU Pressure

Equipment Directive).

Commissioning is permissible only 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.

1.5 Intended use

WARNING Risk of accidents.

Refrigerating compressors are pressurised machines and as such

call for heightened caution and care in handling.

The maximum permissible overpressure must not be exceeded,

even for testing purposes.

Risk of burns!

- Depending on the operating conditions, surface temperatures of

over 60°C on the discharge side or below 0°C on the suction side

can be reached.

- Avoid contact with refrigerant necessarily.

Contact with refrigerant can cause severe burns and skin

damage.

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2|Product description

Three different designs are available for various ranges of application:

> for air-conditioning the K Design

> for air-conditioning or normal cooling the N Design

> for deep freezing the TK Design

The differences lie mainly in the valve plate tooling which is adapted to each applica-

tion range where operational safety and efficiency are concerned.

Compact two-cylinder compressor in single row.

Three capacity ranges.

Lightweight aluminum design.

Lubricating oil pump with oil pressure relief valve independent of rotational direction.

Variable connection and fixing options.

Fig. 1

2.1 Brief description

Fig. 2

Oil sight glass

Valve plate

Cylinder cover

Shaft end

Shaft seal

Suction

shut-off valve

Oil pump

Dimension and connection values can be found in Chapter 9

Leak oil trapping

device with oil

reservoir Discharge

shut-off valve

Suction Suction

shut-off valve

(option)

Leak oil drain hose

Name plate

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2|Product description

FK 03 325 NX

1 Type designation

2 Displacement at 1450 rpm

3 ND (LP): max.

permissible operating pressure

Low pressure side

HD (HP): max.

permissible operating pressure

High pressure side

4 Machine number

5 Factory-lled oil type

Fig. 3

2.2 Name plate (example)

2.3 Type key (example)

¹) K - specially for air-conditioning

N - specially for air-conditioning or normal cooling

TK - specially for deep freezing

²) X - Ester oil charging (HFC refrigerant, e.g. R134a, R407C)

Designs ¹)

Swept volume

Size

Ester oil charging ²)

Series

AS12345A020

19/28bar

Observe the limits of application

diagrams!

}

FKX30/325N

28,3

Bock GmbH, Benzstr. 7

72636 Frickenhausen, Germany

BOCK

Öl: BOCKlub E55

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3|Areas of application

The compressors are factory-lled with the following oil type:

- for R134a, R404A/R507, R407C, R513A 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.

FKX30/325 N).

3.1 Refrigerants

• HFKW / HFC: R134a, R404A/R507, R407C, R514A,

R452A

• HFCKW / HCFC: R22

3.2 Oil charge

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.

- Max. permissible discharge end temperature: 140°C

- Permissible ambient temperature: (-20°C) - (+100°C)

-Max.permissibleswitchingfrequency:12x/h

-A minimum running time of 2 min. at equilibrium (continuous

operation) must be achieved.

Avoid continuous operation near the threshold. Should the com-

pressor happen to be used near the thresholds, we recommend the

use of a thermal protection thermostat (Accessories, Chap. 7).

When operating in the vacuum range, there is a danger of air en-

tering 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!

3.3 Limits of application

INFO For recharging, we recommend the above oil types. See lubricants

table, Chapter 6.6.

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4|Compressor assembly

4.1 Setting up

4.2 Maximum permissible inclination

Fig. 4

Fig. 5

Storage at (-40°C) - (+100°C), maximum permissible relative Humid-

ity 10% - 95%, no condensation

Fittings (e.g. pipe holders, additional units etc.) on the compressor are

permissible only following consultation with Bock.

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

ity. Use all 4 fastening points.

Correct setup of the compressor and mounting of the belt drive are

decisive for running comfort, operating safety and the service life of

the compressor.

In the condition on delivery the compressor is provided with installa-

tion feet (see Fig. 4). Alternatively the compressor can also be bolted

directly, without installation feet, on the substructure.

Amax. 30°,

max. 2 minutes

amax. 15°,

continuous

operation

INFO Newcompressorsarefactory-lledwithinertgas.Leavethisser-

vice 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.

ATTENTION Poor lubrication can damage the compressor. Respect the stated

values.

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4|Compressor assembly

4.3 V-belt drive

4.4 Main bearing load

4.5 Installation of electromagnetic clutch assembly

To prevent the belt drive overloading the compressor main bearing,

ensure that:

The force applied at the force engagement force by the belt

tension (see Fig. 6) must not exceed Fmax = 2750 N.

If the force engagement point shifts forwards (see Fig.6, small

point), the force Fmax reduces as per the following formula:

Fmax zul. = 245 kNmm

(90 mm + L1 [mm])

The following description applies for an electromagnetic clutch secured to a shaft.

To absorb the magnetic eld of the electromagnetic clutch, the front bearing ange has a

snug t Ø 95 f7 (see Fig. 7).

For the installation push the magnetic eld on snugly and fasten with 2 cheese head screws

M6 x 16 (see Fig. 8). Screw tightening torque = 15 Nm.

Further assembly of the electromagnetic clutch according to the clutch manufacturer.

Bearing ange, front

Magnetic eld

Fig. 8

Fmax = 2750 N

(Mbmax = 245 kNmm)

Fmax

(mm)

Fig. 6

95 f7

Fig. 7

ATTENTION Inappropriately designed belt drives, especially belt knocking

(offsets, inclinations) or excessive tensioning forces can cause

compressor damage! Make sure that the drive belt is designed

correctly,e.g.byusingtensionersandselectingthebeltproleand

the belt length.

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