GEA FK40/560 N Bedienungsanleitung

09716-01.2013-DGbFEITrCn

FK40/390 N FK40/470 N FK40/560 N FK40/655 N

FK40/390 K FK40/470 K FK40/560 K FK40/655 K

FK40/390 TK FK40/470 TK FK40/560 TK FK40/655 TK

FKX40/390 N FKX40/470 N FKX40/560 N FKX40/655 N

FKX40/390 K FKX40/470 K FKX40/560 K FKX40/655 K

FKX40/390 TK FKX40/470 TK FKX40/560 TK FKX40/655 TK

engineering for a better world GEA Refrigeration Technologies

Bock Compressor FK40

Assembly instructions

09716-01.2013-DGbFEITrCn

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coupling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 Oillevelcheck

  5.7 Shaftseal

  5.8 Shaftseal,emptyingtheoilreservoir

  5.9 Avoidingliquidshocks

6 Maintenance 18

  6.1 Preparation

  6.2 Worktobecarriedout

  6.3 Recommendedspareparts

  6.4 Integrateddecompressionvalve

  6.5 Extractfromthelubricantstable

  6.6 Decommissioning

7 Accessories 20

  7.1 Capacityregulator

  7.2 Thermalprotectionthermostat

8 Technical data 21

9 Dimensions and connections 22

 10 Installationcerticate 24

11 Service 25

About these instructions

Readtheseinstructionsbeforeassemblyandbeforeusingthecompressor.Thiswillavoidmisunder-

standings 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compres-

sorisinstalled.

GEABockGmbH

72636Frickenhausen

GEABockGmbH

Benzstraße7

72636Frickenhausen

Germany

Telephone +49702294540

Fax +4970229454-137

[email protected]

www.bock.de

Manufacturer

Contact

09716-01.2013-DGbFEITrCn

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coupling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 Oillevelcheck

  5.7 Shaftseal

  5.8 Shaftseal,emptyingtheoilreservoir

  5.9 Avoidingliquidshocks

6 Maintenance 18

  6.1 Preparation

  6.2 Worktobecarriedout

  6.3 Recommendedspareparts

  6.4 Integrateddecompressionvalve

  6.5 Extractfromthelubricantstable

  6.6 Decommissioning

7 Accessories 20

  7.1 Capacityregulator

  7.2 Thermalprotectionthermostat

8 Technical data 21

9 Dimensions and connections 22

 10 Installationcerticate 24

11 Service 25

09716-01.2013-DGbFEITrCn

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

DANGER!

WARNING!

CAUTION!

ATTENTION!

INFO!

Indicates a dangerous situation which, if not avoided,

will cause immediate fatal or serious injury.

Indicates a dangerous situation which, if not avoided,

may cause fatal or serious injury.

Indicates a dangerous situation which, if not avoided,

may cause fairly severe or minor injury.

Indicates a situation which, if not avoided,

may cause property damage.

Important information or tips on simplifying work.

1|Safety

1.2 Qualicationsrequiredofpersonnel

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.

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.

09716-01.2013-DGbFEITrCn

1|Safety

These assembly instructions describe the standard version of the FK40 manufac-

tured by Bock. The compressor is intended for use in refrigeration systems in compliance

with the operating limits. 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,97/23/EC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.

1.4 Intended use

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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

applicationrangewhereoperationalsafetyandefficiencyareconcerned.

 CompactfourcylindercompressorinVdesign.

 Fourcapacityranges.

 Lightweightaluminumdesign.

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

 Variablearrangementoftheshut-offvalves.

Nameplate

Fig.1

2.1 Brief description

Fig.2

Oilsightglass

Valveplate

Cylindercover

Discharge

shut-offvalve

Shaftend

Shaftseal

Suction

shut-offvalve

Oilpump

DimensionandconnectionvaluescanbefoundinChapter9

Eyebolt

Oilsightglass

Leakoiltrapping

devicewithoil

reservoir

Leakoil

drainhose

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2|Product description

FK 04 655 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!

}

GEA Bock GmbH

72636 Frickenhausen, Germany

09716-01.2013-DGbFEITrCn

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 com-

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

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

When capacity regulators are used, the limits of application can

move.

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!

 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.FKX40/655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 6.5.

09716-01.2013-DGbFEITrCn

3|Areas of application

Designforotherrangesonrequest

Max. permissible operating

pressure(g)onthehigh-

pressureside(HP):28bar

Max. permissible operating

pressure(g)onthehigh-

pressureside(HP):28bar

Unrestricted

applicationrange

Unrestricted

applicationrange

reducedsuctiongastemperature

Evaporatingtemperature(°C)

Condensingtemperature(°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:

•FKX40/390N •FKX40/470N •FKX40/560N•FKX40/655N

•FKX40/390K •FKX40/470K •FKX40/560K•FKX40/655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

09716-01.2013-DGbFEITrCn

3|Areas of application

3.5 TK version

Modelsavailable:

•FK40/390TK •FK40/470TK •FK40/560TK •FK40/655TK

•FKX40/390TK •FKX40/470TK •FKX40/560TK •FKX40/655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)onthehigh-

pressureside(HP):28bar

Unrestricted

applicationrange

reducedsuctiongastemperature

Evaporatingtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Fig.6

R404A/R507

R22

Max. permissible operating

pressure(g)onthehigh-

pressureside(HP):28bar

Unrestricted

applicationrange

reducedsuctiongastemperature

Evaporatingtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Designforotherrangesonrequest

Fig.7

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