Danfoss BOCK FK20 Bedienungsanleitung

AQ451838788471en-000201

BOCK®FK

Operating guide

FK20/120 N FK20/145 N FK20/170 N

FK20/120 K FK20/145 K FK20/170 K

FK20/120 TK FK20/145 TK FK20/170 TK

FKX20/120 N FKX20/145 N FKX20/170 N

FKX20/120 K FKX20/145 K FKX20/170 K

FKX20/120 TK FKX20/145 TK FKX20/170 TK

Translation of the original instructions

2 | AQ451838788471en-000201 © Danfoss | Climate Solutions | 2023.07

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.

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 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 Shaft seal

5.6.1 Notes on replacing the shaft seal

  5.7 Avoidingliquidshocks

6 Maintenance 16

6.1 Preparation

6.2 Work to be carried out

6.3 Recommended spare parts/accessories

6.4 Lubricants / Oils

6.5 Decommissioning

6.6 Valve plate, TK version

7 Accessories 18

7.1 Thermal protection thermostat

8 Technical Data 19

9 Dimensions and Connections 20

10 Declaration of incorporation 22

4 | AQ451838788471en-000201 © Danfoss | Climate Solutions | 2023.07

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

1.2 Qualicationsrequiredofpersonnel

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 with the

 qualicationslistedbelow:

• 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|Safety

These assembly instructions describe the standard version of the FK20 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 (with-

in 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 as-

sembly instructions and the entire system into which it is integrated has been inspected and approved

in accordance with legal regulations.

1.5 Intended use

1.4 General 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

 ying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.

DANGER! • 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.

WARNING! • 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.

6 | AQ451838788471en-000201 © Danfoss | Climate Solutions | 2023.07

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

Suction shut-off

valve

Cylinder cover

Name plate

Shaft end

Shaft seal

Valve plate

Oil pump

Dimension and connection values can be found in Chapter 9

Discharge

shut-off valve

Sight glass

2|Product description

FK 02 170 NX

1 Type designation

2 Displacement at 1450 rpm

3 LP:

Max. permissible operating pressure

  (g)Lowpressureside

HP:

Max. permissible operating pressure

  (g)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

BB12345A020

19/28bar

Observe the limits of application

diagrams!

}

FKX20/170N

14,8

Bock GmbH, Benzstr. 7

72636 Frickenhausen, Germany

BOCK

Öl: BOCK lub E55

8 | AQ451838788471en-000201 © Danfoss | Climate Solutions | 2023.07

Max.permissibleoperatingpressure(g)high-pressureside(HP):

28 bar

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.

    -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

compressor 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

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factory-lled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.

FKX20/170N).

3.1 Refrigerants

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

• HFCKW / HCFC: R22

3.2 Oil charge

3.3 Limits of application

INFO! For recharging, we recommend the above oil types. See chapter 6.4.

4|Compressor assembly

4.1 Setting up

4.2 Maximum permissible inclination

Amax. 30°,

max. 2 minutes

amax. 15°,

continuous

operation

ATTENTION! Poor lubrication can damage the compressor.

Respect the stated values.

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.

Fig. 4

Storageat(-40°C)-(+100°C),maximumpermissiblerelativeHumidity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capacity.Thecompressorcan

be fastened as follows:

- using the 4 drill holes on the baseplate

- using the 3 side M10 tapped blind holes on the left or right of the compressor housing

- using the 4 M10 tapped blind holes on the front of the compressor housing.

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.

10 | AQ451838788471en-000201 © Danfoss | Climate Solutions | 2023.07

4|Compressor assembly

4.3 V-belt drive

4.4 Main bearing load

4.5 Electromagnetic clutch assembly

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.

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

Toabsorbthemagneticeldoftheelectromagneticclutch,theslidingringlidhas

asnugtØ38h8(seeFig.6).

Toconnectthemagneticeld,removethemarkedAllenheadscrewsoftheslidingringlid

(seeFig.7).

Slidethemagneticeldtoasnug-tandfastenusingthethreeM5x20cheesehead

screwsprovided(Fig.7).Screwtorque=9Nm.

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

Fig. 6

Sliding ring lid

Magneticeld

Fig. 7

To prevent the belt drive overloading the compressor main bearing,

ensure that:

Theengagementforceappliedbythebelttension(seeFig.5)

must not exceed Fmax per.=600N.

If the force engagement point shifts to the right (see Fig. 5,

smallpoint),theforceFmax per. reduces as per the following

formula:

Fmax per.= 30 kNmm

(50mm+L1[mm])

Fmax= 600 N

Mbmax= 30kNmm

(mm)

Fig. 5

Snugt

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