BOCK FK40/390 K1 Assembly Instructions Manual

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BOCK FK 4

Assembly instructions

09716-03.2025-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

FKX40/470 N

FKX40/470 K

FKX40/560 N

FKX40/560 K

FKX40/655 N

FKX40/655 K

FKX40/755 K

BOCK

FK40/390 K1

FK40/470 K1

FK40/560 K1

FK40/655 K1

FK40/755 K1

FKX40/390 K1

FKX40/470 K1

FKX40/560 K1

FKX40/655 K1

FKX40/755 K1

FK40/390 TK

FK40/470 TK

FK40/560 TK

FK40/655 TK

FKX40/390 TK

FKX40/470 TK

FKX40/560 TK

FKX40/655 TK

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Page 1 BOCK FK 4 Assembly instructions 09716-03.2025-Gb Translation of the original instructions FK40/390 N FK40/390 K FK40/390 K1 FK40/390 TK FK40/470 N FK40/470 K FK40/470 K1 FK40/470 TK FK40/560 N FK40/560 K FK40/560 K1 FK40/560 TK FK40/655 N FK40/655 K FK40/655 K1...
Page 2: About These Instructions
It must also be ensured, that personnel working in daily opera- tion with the compressor have access to important information such as safety and warning advice about the compressor. Such persons must read the safety advice and have understood it. Bock assumes no liability for any damage arising from non-compliance.
Page 3: Table Of Contents
Contents Page Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 Danger to life and limb in the event of faults during operation 1.4 Safety instructions 1.5 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...
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 Bock 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) BOCK AS12345A020 Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany Öl: BOCK lub E55 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...
Page 8: Areas Of Application
See chapter 6.6. 3.3 Limits of application ATTENTION Compressor operation is possible within the operating limits. These can be found in Bock compressor selection tool (VAP) under vap.bock.de. Observe the information given there. - Max. permissible discharge end temperature: 140 °C - Permissible ambient temperature: (-20 °C) - (+100 °C)
Page 9: Compressor Assembly
Fig. 4 Storage at (-40 °C) - (+100 °C), maximum permissible relative humidity 10 % - 95 %, no condensation. Fittings (e.g. pipe holders, additional units etc.) on the compressor are permissible only following consultation with Bock. 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 10: V-Belt Drive
4| Compressor assembly 4.3 V-belt drive ATTENTION Inappropriately designed belt drives, especially belt knocking (offsets, inclinations) 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 regulator (Accessories, Chap. 7), the changing load can cause increased running noises and belt drive vibrations.
Page 11: Pipe Connections
4| Compressor assembly 4.6 Pipe connections The pipe connections, if installed, 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 12: Operating Mode Of The Lockable Service Connections
4| Compressor assembly 4.9 Operating mode of the lockable service connections Fig. 13 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. 14 Pipe connection Opening the service connection (2): b) Spindle 1: Turn ½...
Page 13: Characteristics For K1 Special Housing
Opt. Anschlussmöglichkeit Saugabsperrventil 108,5 Opt. connection suction line valve (L)* = Lötanschluss / brazing connection 4| Compressor assembly 1) = Nur ab Werk möglich / ony possible ex factory 168,5 4.11 Characteristics for K1 special housing nur bei K1 Ausführung only for K1 version 167,8 3xM10...
Page 14: Preparations For Start-Up Pt
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 15: Oil Level Check Ru
5| Commissioning ATTENTION Avoid overfilling the system with refrigerant! To avoid shifts in concentration, zeotropic refrigerant blends 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. 5.6 Oil level check After starting, check the compressor's oil level. Drive motor in operating condition "High idle". Compressor run time min.
Page 16: Avoiding Liquid Shocks
5| Commissioning 5.8 Avoiding liquid shocks ATTENTION Slugging can damage the compressor and cause refrigerant to leak. To avoid liquid shocks, the following points should be observed: The complete refrigeration plant must be correctly designed and executed. The capacities of all components must be compatible (particularly evaporator and expansion valve). Suction gas superheating at the evaporator output should be at least 7 – 10 K (check setting of the expansion valve).
Page 17: Shaft Seal, Emptying The Oil Reservoir
6| Maintenance Where requirements are higher during use (frequent operation at the limits of application, or in hotlands with over +40 °C ambient temperature, or in the case of deep freezing), the following requirements must be observed: • Initial oil change during the first maintenance of the vehicle (at the latest after one year) • Then an oil change after every 2,000 operating hours, at the latest however after two years. Also clean the oil filter. Preventive maintenance The above requirements for higher use applications also apply in the case of preventive maintenance. The shaft seal must also be changed after 3 years. Regular inspections (at least annually): Checks to be carried out on oil level in the oil sight glass, oil fill level of the shaft seal in the oil drain hose, absence of leaks in the compressor, running noise, vibrations, pressures, temperatures, and functioning of auxiliary devices such as the capacity control.
Page 18: Recommended Spare Parts/Accessories
It is for this reason, that we only recommend the use of oil from Bock! Bock assumes no liability for any damage arising from alternative oil types.
Page 19: 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...
Page 20: Thermal Protection Thermostat
7| Accessories 7.2 Thermal protection thermostat (Item No. 07595) A screw-in option is provided for the sensor element on the hot gas side of the compressor housing (see Chap. 9). Connect the thermal protection thermostat in series with the control line. Technical Data: Switching voltage max. : 24 V DC Switching current max. : 2.5 A at 24 V DC Switch-off temperature : 145 °C ±...
Page 21: Technical Data
8| Technical data Oil pump Rotation-independent Lubri cation Forced lubrication Mass moment of inertia Oil charge Weight Displacement (1450 rpm) Displacement Rotation speed Swept volume No. of cylinders Type FK40/...
Page 22: Dimensions And Connections
9| Dimensions and connections Anschlüsse / FK(X)40/470 FK(X)40/390 FK(X)40/655 FK(X)40/755 Connections FK(X)40/560 Saugabsperrventil, Rohr (L)* mm / Zoll 28 – 1 1/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “ DV B B1 mm / inch Suction line valve, tube (L)* Anschlüsse / 319 (326)
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 "...
Page 24: Declaration Of Incorporation
10| Declaration of incorporation Declaration of incorporation for incomplete machinery in accordance with EC Machinery Directive 2006/42/EC, Annex II 1. B Manufacturer: Bock GmbH Benzstraße 7 72636 Frickenhausen, Germany We, as manufacturer, declare in sole responsibility that the incomplete machinery...
Page 25 Declaration of incorporation of partly completed machinery in accordance with UK Statutory Instrument Supply of Machinery (Safety) Regulations 2008, Annex II 1. B Manufacturer: Bock GmbH Benzstraße 7 72636 Frickenhausen, Germany We, as manufacturer, declare in sole responsibility that the partly completed machinery...
Page 26: Service
11| Service Dear customer, 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, +49 (0)7022 9454-0 or via bock.info@danfoss.com. Yours faithfully Bock GmbH...

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Fk40/390 n Fk40/390 k Fk40 Fk40/390 tk Fk40/470 n Fk40/470 k ... Show all

BOCK FK40/390 K1 Assembly Instructions Manual

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