GEA Bock FK50 Series Bedienungsanleitung

GEA Bock FK50

Assembly instructions

09704-10.2019-Gb

Translation of the original instructions

FK50/460 N FK50/555 N FK50/660 N FK50/775 N FK50/830 N FK50/980 N

FK50/460 K FK50/555 K FK50/660 K FK50/775 K FK50/830 K FK50/980 K

FKX50/460 N FKX50/555 N FKX50/660 N FKX50/775 N FKX50/830 N FKX50/980 N

FKX50/460 K FKX50/555 K FKX50/660 K FKX50/775 K FKX50/830 K FKX50/980 K

09704-10.2019-DGbFPtITr

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

GEA Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Telephone +49 7022 9454 0

Fax +49 7022 9454 137

[email protected]

www.gea.com

Manufacturer

Contact

09704-10.2019-DGbFPtITr

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

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 Oil level check

5.7 Shaft seal

  5.8 Avoidingliquidshocks

6 Maintenance 16

6.1 Preparation

6.2 Work to be carried out

6.3 Shaft seal, emptying the oil reservoir

6.4 Recommended spare parts

6.5 Integrated decompression valves

6.6 Extract from the lubricants table

6.7 Decommissioning

7 Accessories 18

7.1 Capacity regulator

7.2 Thermi protection thermostat

8 Technical Data 19

9 Dimensions and Connections 20

 10 Installationcerticate 22

11 Service 23

09704-10.2019-DGbFPtITr

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:

09704-10.2019-DGbFPtITr

1|Safety

These assembly instructions describe the standard version of the FK50 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 and 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.

1.4 Intended use

1.3 General safety instructions

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.

09704-10.2019-DGbFPtITr

2|Product description

Two different designs are available for various ranges of application:

> for air-conditioning the K Design

> for air-conditioning or normal cooling the N 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 six cylinder compressor in W design.

Six capacity ranges.

Lightweight aluminum design.

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

Variable arrangement of the shut-off valves.

Fig. 1

2.1 Brief description

Fig. 2

Valve plate

Cylinder cover

Shaft end

Shaft seal

Suction shut-off valve

Suction line valve

Oil pump

Dimension and connection values can be found in Chapter 9

Eyebolt

Leak oil trapping

device with oil

reservoir

Name plate

Eyebolt

Oil sight glass

Oil sightglass

Discharge shut-off valve

Leak oil drain hose

09704-10.2019-DGbFPtITr

2|Product description

FK 05 775 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

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

Designs ¹)

Swept volume

Size

Ester oil charging ²)

Series

BB12345A029

19/28bar

Observe the limits of application

diagrams!

}

FKX50/775N

67,4

GEA Bock GmbH

72636 Frickenhausen, Germany

09704-10.2019-DGbFPtITr

3|Areas of application

 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. FKX50/775N).

3.1 Refrigerants

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

• (H)FCKW/(H)CFC: R22

3.2 Oil charge

3.3 Limits of application

ATTENTION Compressor operation is possible within the operating limits.

These can be found in GEA Bock compressor selection tool (VAP)

under vap.gea.com. Observe the information given there.

- 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).

For operation with capacity regulator:

- Continuous operation, when the capacity regulator is activated,

is not permissible and can cause damage to the compressor.

- The suction gas superheat temperature may need to be reduced

or set individually when operating near to the threshold.

- When the capacity regulator is activated, the gas velocity in the

systemcannotundercertaincircumstancesensurethatsuf-

cient oil is transported back to the compressor.

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!

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

see lubricants table, Chapter 6.6.

09704-10.2019-DGbFPtITr

4|Compressor assembly

4.1 Setting up

4.2 Maximum permissible inclination

Amax. 30°,

max. 2 minutes

amax. 15°,

continuous

operation

Fig. 4

 Transportandsuspensionunitonbotheyebolts(Fig.4).

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

following consultation with GEA.

 Setuponanevensurfaceorframewithsufcientload-bearingcapacity.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.

Fig. 5

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.

WARNING Movecompressorsonlywithhoiststhathaveadequateload-bear-

ing capacity.

09704-10.2019-DGbFPtITr

4|Compressor assembly

 During operation with capacity controllers (Accessories, Chap. 7), the changing load can cause

increased running noises and belt drive vibrations.

4.3 V-belt drive

4.5 Electromagnetic clutch assembly

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148h8(seeFig.7).

Toconnectthemagneticeld,loosenthe4cheeseheadscrewsM8onthebearingange

(seeFig.7).

Slidethemagneticeldtoasnugtandre-attachusingthefourcheeseheadscrewsM8

(Fig.8).Screwtorque=37Nm.

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

Fig. 7

Bearingange,front

Magneticeld

Fig. 8

148 h8

4.4 Main bearing load

To prevent the belt drive overloading the compressor main bearing,

ensure that:

The engagement force applied by the belt tension (centre of

shafttaper,seeFig.10)mustnotexceedFmax per.=2750N.

If the force engagement point shifts to the right (see Fig.6,

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

formula:

Fmax per.= 245 kNmm

(90 mm + L1[mm])

Fmax= 2750 N

Mbmax= 245kNmm

(mm)

Fig. 6

ATTENTION Inappropriately designed belt drives, especially belt knocking

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.

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere GEA Kompressor Handbücher

GEA

GEA Bock EX-HG88e Series Bedienungsanleitung

GEA

GEA HGZ7 Series Bedienungsanleitung

GEA

GEA HAX2 CO2 T Bedienungsanleitung

GEA

GEA HG34P Series Bedienungsanleitung

GEA

GEA HGX46/250-4 S CO2T Bedienungsanleitung

GEA

GEA InTouch HAX12P/60-4 Bedienungsanleitung

GEA

GEA ATEX Bedienungsanleitung

GEA

GEA Grasso V Series Bedienungsanleitung

GEA

GEA HG Series Bedienungsanleitung

GEA

GEA HG34P Series Bedienungsanleitung

GEA

GEA HG22e Series Bedienungsanleitung

GEA

GEA HG44e/475-4 S Bedienungsanleitung

GEA

GEA HGX34P Series Bedienungsanleitung

GEA

GEA HGX22e/85-4 S CO2 Bedienungsanleitung

Beliebte Kompressor Handbücher anderer Marken

Panasonic

Panasonic Matsushita QA91K22CAU6 Bedienungsanleitung

EKOM

EKOM DK50 B Bedienungsanleitung

Challenge Xtreme

Challenge Xtreme CX 1500/1 Bedienungsanleitung

Conrad

Conrad 1719346 Bedienungsanleitung

Hanbell

Hanbell RC2-AV Series Bedienungsanleitung

PLASMATECH

PLASMATECH SHARK 25 Bedienungsanleitung

Emerson

Emerson Copeland Scroll Digital HLR Series Bedienungsanleitung

Drawmer

Drawmer 1968 MKII Bedienungsanleitung

Badger Air-Brush

Badger Air-Brush X-Air 80-8 Bedienungsanleitung

Omnitronic

Omnitronic CL-166 Bedienungsanleitung

Scheppach

Scheppach HC24V Montageanleitung

Ingersoll-Rand

Ingersoll-Rand centac C950 Technisches Handbuch

LG GVH282PAB Bedienungsanleitung

Kooper

Kooper 2196438 Bedienungsanleitung

American Eagle

American Eagle SHD-66DD Bedienungsanleitung

Frick

Frick 1510 Bedienungsanleitung

Sierra

Sierra Eagle 12 VX Handbuch

EUFAB

EUFAB 21083 Bedienungsanleitung