GEA FK40/560 N Assembly Instructions Manual
Bock compressor
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- Assembly instructions manual (26 pages) ,
- Maintenance manual (62 pages)
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Bock Compressor FK40
Assembly
instructions
FK40/390 N
FK40/470 N
FK40/390 K
FK40/470 K
FK40/390 TK
FK40/470 TK
FKX40/390 N
FKX40/470 N
FKX40/390 K
FKX40/470 K
FKX40/390 TK FKX40/470 TK FKX40/560 TK FKX40/655 TK
engineering for a better world
FK40/560 N
FK40/655 N
FK40/560 K
FK40/655 K
FK40/560 TK
FK40/655 TK
FKX40/560 N
FKX40/655 N
FKX40/560 K
FKX40/655 K
GEA Refrigeration Technologies
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GB
F
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TR
CN
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Table of Contents
Related Manuals for GEA FK40/560 N
Summary of Contents for GEA FK40/560 N
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Page 1: Assembly Instructions
Bock Compressor FK40 Assembly instructions 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... -
Page 2: Safety 4
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. Manufacturer GEA Bock GmbH 72636 Frickenhausen Contact GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone +49 7022 9454 0 Fax +49 7022 9454-137 bock@gea.com www.bock.de... -
Page 3: Table Of Contents
Contents Page Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use Product description 2.1 Brief description 2.2 Name plate 2.3 Type key Areas of application 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 Compressor assembly 4.1 Setting up 4.2 Maximum permissible inclination... -
Page 4: Safety
1| Safety 1.1 Identification of safety instructions: Indicates a dangerous situation which, if not avoided, DANGER! will cause immediate fatal or serious injury. Indicates a dangerous situation which, if not avoided, WARNING! may cause fatal or serious injury. Indicates a dangerous situation which, if not avoided, CAUTION! may cause fairly severe or minor injury. -
Page 5: Intended Use
1| Safety 1.4 Intended use 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 specified 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... -
Page 6: Product Description
2| Product description 2.1 Brief 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 a pplication 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. Eyebolt Discharge shut-off valve Leak oil trapping device with oil reservoir... -
Page 7: Type Key
2| Product description 2.2 Name plate (example) GEA Bock GmbH AS12345A020 72636 Frickenhausen, Germany 19/28bar Fig. 3 Machine number Type designation Factory-filled oil type Displacement at 1450 rpm LP: Max. p ermissible operating pressure Observe the limits of (g) Low pressure side application diagrams! HP: Max. p ermissible operating pressure (g) High pressure side 2.3 Type key (example) 655 N Designs ¹... -
Page 8: Areas Of Application
3| Areas of application 3.1 Refrigerants • HFKW / HFC: R134a, R404A/R507, R407C • (H)FCKW / (H)CFC: 3.2 Oil charge The compressors are factory-filled 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). INFO! For recharging, we recommend the above oil types. Alternatives are: see lubricants table, Chapter 6.5. 3.3 Limits of application ATTENTION! Compressor operation is possible within the limits of application shown in the diagrams. Please note the significance of the shaded areas. -
Page 9: N And K Versions
3| Areas of application 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 3.4.1 Limits of application R134a (N and K versions) Permissible rotation speeds: Max. permissible operating N Design: 500 - 3000 ¹/ (max rotation speed 3500 rpm) rpm pressure (g) on the high- K Design: 500 - 3500 ¹/ pressure side (HP): 28 bar t (°C) Unrestricted application range < 20 K reduced suction gas temperature R134a Evaporating temperature (°C) Condensing temperature (°C) t + 25 °C Suction gas superheat (K) Suction gas temperature (°C) t (°C) -
Page 10: Tk Version
3| Areas of application 3.5 TK version R404A/R507 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) R404A/R507 TK Permissible rotation speeds: Max. permissible operating pressure (g) on the high- TK design: 500 - 2600 ¹/ pressure side (HP): 28 bar t (°C) Unrestricted Uneingeschränkter Anwendungsbereich application range reduzierte Sauggastemperatur reduced suction gas temperature Verdampfungstemperatur (°C) <20K Evaporating temperature (°C) Verflüssigungstemperatur (°C) R404A/R507 Condensing temperature (°C) -
Page 11: Compressor Assembly
4| Compressor assembly INFO! N ew compressors are factory-filled with inert gas (3 bar nitrogen). 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. 4.1 Setting up WARNING! M ove compressors only with hoists that have adequate load-bearing capacity. -
Page 12: V-Belt Drive Gb
4| Compressor assembly 4.3 V-belt drive 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 t ensioners and selecting the belt profile and the belt length. During operation with capacity controllers (Accessories, Chap. 7), the changing load can cause increased running noises and belt drive vibrations. -
Page 13: Pipe Connections
4| Compressor assembly 4.6 Pipe connections T he pipe connections have stepped internal d iameters so that pipes with standard millimetre and inch dimensions can be used. T he connection diameters of the shut-off valves are designed for maximum compressor output. The required pipe cross-section must be matched to the capacity. The same applies for non-return valves. -
Page 14: Operating Mode Of The Lockable Service Connections Tr
4| Compressor assembly 4.9 Operating mode of the lockable service connections Fig. 17 Pipe connection Opening the shut-off valve: a) Spindle 1: turn to the left (counter-clockwise) as far as it will go. —> Shut-off valve fully opened / service connection 2 closed. Fig. 18 Pipe connection Opening the service connection (2): b) Spindle 1: Turn ½ - 1 rotation to the right. —> Service connection 2 opened / shut-off valve opened. Connection 3 is provided for safety devices and is not lockable. -
Page 15: Commissioning
5| Commissioning 5.1 Preparations for start-up INFO! To protect the compressor against inadmissible operating conditions, high-pressure and low-pressure pressostats are mandatory on the installation side. The compressor has undergone trials in the factory and all functions have been tested. There are therefore no special running-in instructions. Check the compressor for transport damage! 5.2 Pressure strength test DANGER! Bursting! The compressor must only be pressurised using nitrogen ). -
Page 16: Refrigerant Charge
5| Commissioning 5.5 Refrigerant charge CAUTION! Wear personal protective clothing such as goggles and protective gloves! ATTENTION! Avoid overfilling the system with refrigerant! To avoid shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always be added to the refrigerating plant in liquid form. Do not pour liquid refrigerant through the suction line valve on the compressor. It is not permissible to mix additives with the oil and refrigerant. Make sure that the suction and discharge line valves are open. With the compressor switched off, add the liquid refrigerant directly to the condenser or receiver, breaking the vacuum. If the refrigerant needs topping up after starting the compressor, it can be topped up in vapour form on the suction side, or, taking suitable precautions, also in liquid form at the inlet to the evaporator. -
Page 17: Shaft Seal, Emptying The Oil Reservoir
5| Commissioning The compressor shaft is sealed to outside using a shaft seal. The sealing element rotates with the shaft. The following is especially important to ensuring fault-free operation: The complete refrigerant circuit must be correctly executed and clean inside. Heavy shocks and vibrations to the shaft as well as continuous cyclic operation are to be avoided. T he sealing surfaces can stick together during prolonged downtimes (e.g. winter). Therefore, run the system every 4 weeks for 10 minutes. 5.8 Shaft seal, emptying the oil reservoir As changing the shaft seal involves opening the refrigerant circuit, this is recommended only if the seal is losing refriger- ant. Replacing the shaft seal is described in the spare part kit concerned. Emptying the oil reservoir: The oil reservoir can be emptied very simple without having to dismantle the coupling and/or belt drive. It is recommended that this is done at the same time as the air-conditioning maintenance and motor service. To proceed, detach the oil hose from the bracket, remove the sealing plug and drain the oil into a collecting vessel. After emptying, reseal the oil hose and clamp it into the bracket. Dispose of the used oil in accordance with national regulations. Fig. 19 5.9 Avoiding liquid shocks ATTENTION! Slugging can damage the compressor and cause refrigerant to leak. -
Page 18: Maintenance
6| Maintenance 6.1 Preparation WARNING! Before starting any work on the compressor: Switch off the compressor and secure it to prevent a restart. Relieve compressor of system pressure. Prevent air from infiltrating the system! After maintenance has been performed: Connect safety switch. Evacuate compressor. Release switch lock. 6.2 Work to be carried out Oil change: In principle, an oil change is not mandatory if the system is correctly manufactured and operated. However, based on decades of experience we recommend that the following oil change/service work is carried out: -... -
Page 19: Extract From The Lubricants Table
6| Maintenance 6.5 Extract from the lubricants table The oil type charged as standard in the factory is marked on the name plate. This oil type should be used as a preference. Alternatives are stated in the extract from our lubricants table below. Refrigerant Bock standard oil grade Recommended alternatives Fuchs Reniso Triton SE 55 Fuchs SEZ 32/68/80 ICI Emkarate RL 46 S (e.g. R134a, R407, (see also chap. 6.3) Mobil Arctic EAL 46 R 404A) Shell Clavus R 46 HCFC (e.g. R22) Fuchs Reniso SP 46 Mobil SHC 425 Shell Clavus SD 22-12 (see also chap. 6.3) -
Page 20: Accessories
7| Accessories 7.1 Capacity regulation ATTENTION! Capacity-regulated operation alters the gas speeds and pressure r atios of the refrigerating plant: Adjust the suction line routing and dimensioning accordingly, do not set the control intervals too close and do not let the system switch more than 12 times per hour (refriger- ating plant must have reached a state of equilibrium). Continuous operation in the control stage is not recommended as the gas velocity in the plant system under certain circumstances does not guarantee sufficient oil return to the compressor with activated capacity regulator for a compressor speed below 1200 - 1500 rpm. -
Page 21: Technical Data
8| Technical data... -
Page 22: Dimensions And Connections
9| Dimensions and connections ca.320 (325) Centre of DV B B1 gravity ca.110 ca.385 Dimensions in () = K - Design Dimensions in mm Fig. 20 Shaft end Leak oil drain hose Fig. 21 Dimensions in mm... - Page 23 9| Dimensions and connections Suction line see technical data, Chapter 8 Discharge line Connection suction side, not lockable 8 " NPTF Connection suction side, lockable 16 " UNF Connection discharge side, not lockable 8 " NPTF Connection discharge side, lockable 16 " UNF Connection oil pressure safety switch OIL 8 " NPTF Connection oil pressure safety switch LP 8 " NPTF Connection oil pressure gauge 8 " NPTF Oil drain 4 " NPTF 1) Opt. connection for oil sump heating Oil charge plug 4 " NPTF 2 x 1 1 / 8 "- 18 UNEF Sightglass Connection thermal protection thermostat 8 " NPTF...
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Page 24: Installation Certificate
10| Installation certificate INSTALLATION CERTIFICATE for using the compressors within the European Union (in accordance with Machinery Directive 2006/42/EC) The manufacturer: GEA Bock GmbH, Benzstraße 7 D-72636 Frickenhausen, Tel.: 07022/9454-0 hereby declares that the refrigerating compressor FK40 conforms to the essential requirements of Annex II 1B of the Machinery Directive 2006/42/EC. The following harmonised standards have been applied: EN ISO 12100-1 EN ISO 12100-2 EN 12693 EN 349 A partly completed machine may only be put into operation when it has been established that the machine, into which the partly completed machine is to be installed, conforms to the regulations of the Machinery Directive (2006/42/EC). The manufacturer undertakes to transmit electronically the special documentation required by individual states for partly completed machinery upon request. The special technical documentation required for partly completed machinery has been created in accordance with Annex VII Part B. Person responsible for documentation is: Wolfgang Sandkötter, Benzstraße 7, 72636 Frickenhausen. Frickenhausen, 01.11.2011 ppa. Wolfgang Sandkötter, Chief Development Officer... -
Page 25: Service
11| Service Dear customer, Bock compressors are top-quality, reliable and service-friendly quality products. If you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The Bock service team can be contacted by phone with a toll-free hotline 00 800 / 800 000 88 or via e-mail: bock@gea.com. Yours faithfully GEA Bock GmbH Benzstraße 7 Sehr geehrter Kunde, 72636 Frickenhausen Bock-Verdichter sind hochwertige, zuverlässige und servicefreundliche Qualitätsprodukte. Germany Vorteile in vollem Umfange und über den gesamten Einsatzzeitraum Ihrer Kälteanlage nutz können, beachten Sie unbedingt die folgenden Bedienungs- und Wartungshinweise. - Page 26 Responsibility GEA-versity GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index.