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GEA Compressor FK40
Assembly instructions
09716-06.2016-Gb
Translation of the original instructions
FK40/390 N
FK40/390 K
FK40/470 N
FK40/470 K
FK40/560 N
FK40/560 K
FK40/655 N
FK40/655 K
FK40/755 K
FKX40/390 N FKX40/390 K FKX40/390 TK
FKX40/470 N FKX40/470 K FKX40/470 TK
FKX40/560 N FKX40/560 K FKX40/560 TK
FKX40/655 N FKX40/655 K FKX40/655 TK
FKX40/755 K
FK40/390 TK
FK40/470 TK
FK40/560 TK
FK40/655 TK
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Table of Contents
Related Manuals for GEA FK40 Series
Summary of Contents for GEA FK40 Series
- Page 1 GEA Compressor FK40 Assembly instructions 09716-06.2016-Gb Translation of the original instructions FK40/390 N FK40/390 K FK40/390 TK FK40/470 N FK40/470 K FK40/470 TK FK40/560 N FK40/560 K FK40/560 TK FK40/655 N FK40/655 K FK40/655 TK FK40/755 K FKX40/390 N FKX40/390 K FKX40/390 TK...
- Page 2 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...
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Page 3: Table Of Contents
Contents Page Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 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... -
Page 4: Safety
1| Safety 1.1 Identification 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. -
Page 5: Safety Instructions
Only the refrigerant specified 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 (with- in the EU according to the EU Directives 2006/42/EC Machinery Directive, 2014/68/EU Pressure Equipment Directive). -
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 application range where operational safety and efficiency are concerned. -
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. permissible operating pressure Observe the limits of (g) Low pressure side application diagrams! HP: Max. permissible operating pressure (g) High pressure side 2.3 Type key (example) -
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. -
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 • FKX40/755 K 3.4.1 Limits of application R134a (N and K versions) Permissible rotation speeds: Max. -
Page 10: Tk Version
3| Areas of application 3.5 TK version Models available: • FK40/390 TK • FK40/470 TK • FK40/560 TK • FK40/655 TK R404A/R507 • 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. -
Page 11: Compressor Assembly
(Fig. 9). Fig. 8 Fig. 9 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 sufficient 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. -
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 The pipe connections have stepped internal diameters so that pipes with standard millimetre and inch dimensions can be used. The connection diameters of the shut-off valves are designed for maximum compressor output. The required pipe cross-section must be matched to the capacity. -
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 condi- tions, 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. -
Page 16: Refrigerant Charge
5| Commissioning 5.5 Refrigerant charge CAUTION Wear personal protective clothing such as goggles and protective gloves! 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. -
Page 18: Maintenance
Oil SP 46, 1 Ltr. 02279 Oil SE 55, 1 Ltr. 02282 Only use genuine GEA spare parts! 6.4 Integrated decompression valve The valve is maintenance free. However, constant leakage can occur after blowing off due to abnormal operating conditions. This leads to reduced performance and increases the compressed gas temperature. -
Page 19: 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 GEA standard oil grade Recommended alternatives Fuchs Reniso Triton SE 55... -
Page 20: Accessories
7| Accessories 7.1 Capacity regulation ATTENTION Capacity-regulated operation alters the gas speeds and pressure ratios 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 No. of cylinders... -
Page 22: Dimensions And Connections
Zeichn.-Nr. / Drawing no. / prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event GEA Bock GmbH - Benzstraße 7 - 72 Teile Nr. / part no. 168,5 Zust. / Rev. - 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 "...
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Page 24: 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. Applied harmonised standard:... -
Page 25: Service
11| Service Dear customer, GEA 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 GEA service team can be contacted by phone with a toll-free hotline 00 800 / 800 000 88 or via e-mail: info@gea.com Yours faithfully GEA Bock GmbH Benzstraße 7... - Page 26 • • 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 ®...
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