GEA FK20 Bedienungsanleitung

GEA Compressor FK20

Assembly instructions

09740-06.2016-Gb

Translation of the original instructions

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

09740-06.2016-DGbFITr

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.

GEA Bock GmbH

72636 Frickenhausen

Manufacturer

Contact

GEA Bock GmbH

Benzstrasse 7

72636 Frickenhausen

Germany

Phone +49 7022 9454 0

Fax +49 7022 9454 137

[email protected]

www.gea.com

09740-06.2016-DGbFITr

Contents Page

1 Safety 4

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

  1.2 Qualicationsrequiredofpersonnel

1.3 General safety instructions

1.4 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

3.4 N and K versions

3.4.1 Limits of application R134a

3.4.2 Limits of application R407C

3.5 TK version

3.5.1 Limits of application R404A/R507

3.5.2 Limits of application R22

4Compressor assembly 11

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

5 Commissioning 15

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 18

6.1 Preparation

6.2 Work to be carried out

6.3 Recommended spare parts

6.4 Extract from the lubricants table

6.5 Decommissioning

6.6 Valve plate, TK version

7 Accessories 20

7.1 Thermal protection thermostat

8 Technical Data 21

9 Dimensions and Connections 22

 10 Installationcerticate 24

11 Service 25

09740-06.2016-DGbFITr

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.

09740-06.2016-DGbFITr

1|Safety

These assembly instructions describe the standard version of the FK20 manufactured by GEA. 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 GEA 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, 97/23/EC 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.

1.4 Intended use

1.3 General safety instructions

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.

09740-06.2016-DGbFITr

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

09740-06.2016-DGbFITr

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

AS12345A020

19/28bar

Observe the limits of application

diagrams!

}

FKX20/170N

14,8

GEA Bock GmbH

72636 Frickenhausen, Germany

09740-06.2016-DGbFITr

3|Areas of application

ATTENTION! Compressor operation is possible within the limits of application

    showninthediagrams.Pleasenotethesignicance

of the shaded areas. The limits of application must

be observed. Thresholds should not be selected as design

or continuous operating points.

    -Max.permissibledischargeendtemperature:140°C

    -Max.permissibleambienttemperature: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 FUCHS Reniso Triton SE 55

- for R22 FUCHS Reniso SP 46

Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXinthetypedesignation

(e.g. FKX20/170N).

3.1 Refrigerants

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

• (H)FCKW/(H)CFC: R22

3.2 Oil charge

3.3 Limits of application

INFO! Forrecharging,werecommendtheaboveoiltypes.Alternativesare:

see lubricants table , Chapter 6.4.

09740-06.2016-DGbFITr

3|Areas of application

Designforotherrangesonrequest

Max. permissible

operatingpressure(g)high-

pressureside(HP):28bar

Max. permissible

operatingpressure(g)high-

pressureside(HP):28bar

Unrestricted

application range

Unrestricted

application range

Reduced suction gas

temperature

Reduced suction gas

temperature

Evaporationtemperature(°C)

Condensingtemperature(°C)

Condensingtemperaturee(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Fig. 4

Fig. 5

-20 -10 10

020 30 t (°C)

t (°C)

-30

t + 25 °C

20 K

R134a

-20 -10 10

020 t (°C)

t (°C)

-30

-25

toh 20 K

t + 25 °C

R407C

3.4.1LimitsofapplicationR134a(NandKversions)

3.4 N and K versions

Models available:

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

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

Permissible rotation speeds:

N Design: 500 – 3000 ¹/rpm (maxrotationspeed3500rpm)

K Design: 500

–

3500 ¹/rpm

3.4.2LimitsofapplicationR407C(NandKversions)

Permissible rotation speeds:

N Design: 500 – 2600 ¹/rpm

K Design: 500

–

3500 ¹/rpm

09740-06.2016-DGbFITr

3|Areas of application

3.5 TK version

Models available:

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

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

3.5.1LimitsofapplicationR404A/R507(TKversion)

3.5.2LimitsofapplicationR22(TKversion)

Permissible rotation speeds:

TK design: 500 – 2600 ¹/rpm

Permissible rotation speeds:

TK design: 500 – 2600 ¹/rpm

-10

-20

-30

-40

-50

t (°C)

Dtoh<20K

t +20°C

-45

R404A/R507

R404A/R507 TK

toh

Verdampfungstemperatur (°C)

Verflüssigungstemperatur (°C)

Sauggasüberhitzung (K)

Sauggastemperatur (°C)

Uneingeschränkter

Anwendungsbereich

reduzierte Sauggastemperatur

R22

toh

Verdampfungstemperatur (°C)

Verflüssigungstemperatur (°C)

Sauggasüberhitzung (K)

Sauggastemperatur (°C)

Uneingeschränkter

Anwendungsbereich

reduzierte Sauggastemperatur

R22 TK

-10

-20

-30

-40

-50

t (°C)

Dtoh<20K

t +25°C

-45

Max. permissible

operatingpressure(g)high-

pressureside(HP):28bar

Unrestricted

application range

Reduced suction gas

temperature

Evaporationtemperature(°C)

Condensingtemperaturee(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Fig. 6

R404A/R507

R22

Max. permissible

operatingpressure(g)high-

pressureside(HP):28bar

Unrestricted

application range

Reduced suction gas

temperature

Evaporationtemperature(°C)

Condensingtemperaturee(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Designforotherrangesonrequest

Fig. 7

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