GEA Bock F76 Series, Assembly Instructions Manual

Page 1: ...GEA Bock F76 F76 1570 FX76 1570 F76 1800 FX76 1800 F76 2050 FX76 2050 F76 2425 FX76 2425 Assembly instructions 96438 02 2020 Gb Translation of the original instructions ...

Page 2: ...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 gea com gea com contact Manufactu...

Page 3: ...al 4 7 Laying suction and discharge lines 4 8 Operating the shut off valves 4 9 Operating mode of the lockable service connections 4 10 Drive 5 Commissioning 16 5 1 Preparations for start up 5 2 Pressure resistance test 5 3 Leak test 5 4 Evacuation 5 5 Refrigerant charge 5 6 Shaft seal 5 7 Start up 5 8 Avoiding slugging 5 9 Oil separator 6 Maintenance 19 6 1 Preparation 6 2 Work to be carried out ...

Page 4: ...mparable 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 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 c...

Page 5: ...tended for use in refrigeration systems in compliance with the limits of application Only the refrigerant specified in these instructions may be used Any other use of the compressor is prohibited 1 4 Intended use 1 3 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 o...

Page 6: ...elt or coupling with oil pump lubrication 2 1 Short description Fig 1 Fig 2 Transport eyelet Discharge shut off valve Cylinder cover Valve plate Suction shut off valve Leak oil drain hose Shaft end Shaft seal Base plate Dimension and connection values can be found in Chapter 9 Name plate Oil pump Sight glass ...

Page 7: ... BC12756A001 SE55 19 28 GEA Bock GmbH 72636 Frickenhausen Germany Observe the limit of application diagrams 1 Type designation 2 Machine number 3 Rotation speed minimum with a corresponding displacement 4 Rotation speed maximum with a corresponding displacement 5 ND LP Max admissible operating pressure Suction side HD HP Max admissible operating pressure High pressure side 6 Oil type charged at fa...

Page 8: ...hown in the diagrams Please note the significance of the shaded areas Thresholds should not be selected as design or continuous operat ing points Permissible ambient temperature 20 C 60 C Max permissible discharge end temperature 140 C Max permissible switching frequency Please refer to the instructions of the engine manufacturer A minimum running time of 3 min steady state condition continuous op...

Page 9: ...tion range Reduced suction gas temperature Evaporating temperature C Condensing temperature C Suction gas superheat K Suction gas temperature C Permissible rotation speeds 500 1800 rpm Maximum permissible operating pressure LP HP 1 19 28 bar Design for other areas on request 1 LP Low pressure HP High pressure 3 Areas of application ...

Page 10: ...r Check the compressor for transport damage before starting any work 4 1 Storage and transport Use transport eyelet Do not lift manually Use lifting gear with sufficient load capacity Transport and suspension unit on the eyebolt Fig 11 Storage at 30 C 70 C maximum permissible relative humidity 10 95 no condensation Do not store in a corrosive dusty vaporous atmosphere or in a com bustible environm...

Page 11: ...tab 1 1 Wasserwaage für Indesign Der Lieferant muß sicherstellen dass die Ware in einwandfreiem Zustand angeliefert wird Korrosions schutz Verpackung für sicheren Transport Rz 25 Rz 160 s 25 z y x w u t 0 05 Rz 1 6 0 3 0 7 1 6 2 Rz 16 6 3 Rz 63 Rz 6 3 Rz 12 5 4 3 Maximum permissible inclination Fig 15 A A a a A A a a ATTENTION Risk of compressor damage Poor lubrication can damage the compressor Re...

Page 12: ...ischarge and suction line At the same time a non return valve in the discharge line closes and prevents a backflow of refrigerant from the condenser Fig 17 The compressor is now short circuited and delivers from the outflow directly into the intake The pressure differential consequently decreases substantially As a result the torque on the drive shaft of the compressor is considerably diminished T...

Page 13: ...ing and vibration behaviour Important Start unloader may only be employed during the starting phase Check the solenoid valve and the non return valve regularly for tightness In addition we recommend to use a heat protection thermostat on the discharge side of the com pressor This protects the compressor against thermal overloading Connect the heat protection thermostat in series on the safety chai...

Page 14: ...as far as it will go The shut off valve is then fully open and the service connection is closed Fig 23 Opening the service connection Spindle 1 2 1 rotation to the right clockwise The service connection is then open and the shut off valve is also open Spindle Spindle Valve spindle seal loosen tighten After activating the spindle generally fit the spindle protection cap again and tighten with 14 16...

Page 15: ...GEA Bock recommends the direct drive with centring a coupling housing accessory ATTENTION Faulty alignment results in premature failure of the coupling and bearing damage CAUTION Risk of injury Mount suitable safeguards when driving the compressor by means of V belts or shaft couplings Fig 24 schematical Fig 25 schematical D GB F E 15 96246 09 2012 DGb Betriebsweise Ölsumpfheizung EIN bei Stillsta...

Page 16: ...r the compressor DANGER Risk of bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The maximum permissible overpressure of the compressor must not be exceeded at any time during the testing process see name plate data Do not mix any refrigerant with the nitrogen as this could cause the ignition limit to shift into the critical range 5 Com...

Page 17: ...inter Therefore run the system every 4 weeks for 10 minutes CAUTION Risk of injury Contact with refrigerant can cause severe burns and skin damage Avoid contact with refrigerant and 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 must always only be filled i...

Page 18: ...ticularly in critical systems e g several evaporator points measures are recommended such as replacement of liquid traps solenoid valve in the liquid line etc There should be no movement of coolant whatsoever while the compressor is at a standstill WARNING Ensure that both shut off valves are open before starting the compressor ATTENTION If larger quantities of oil have to be topped up there is a ...

Page 19: ...Kit capacity regulator 80879 81414 80889 80879 Oil pump kit 80116 Kit shaft seal 80897 Oil SP 46 1 litre 02279 Oil SE 55 1 litre 02282 6 3 Spare parts recommendation Only use genuine GEA Bock spare parts 6 Maintenance 6 1 Preparation 6 2 Work to be carried out To guarantee optimum operating safety and service life of the compressor we recommend perform ing service and checking work at regular inte...

Page 20: ...tional regulations 7 Accessories When the compressor is at a standstill refrigerant diffuses into the lubrication oil of the compressor housing depending on pressure and ambient temperature This reduces the lubrication capacity of the oil When the compressor starts up the refrigerant contained in the oil evaporates out through the reduction in pressure The consequences can be lack of lubrication f...

Page 21: ...it pilot valve with sealing ring and tight with 15 Nm Wet thread sides with ester oil Insert magnetic coil fasten it with knurled nut and connect it Fig 29 Before start up remove the cover at the capacity regulator and replace it with the enclosed control unit pilot valve Caution The compressor is under pressure Depressurize the compressor first Delivery status 2 ex works Capacity regulator assemb...

Page 22: ...TION Capacity regulated operation alters the gas speeds and pressure ratios of the refrigerating plant Adjust the suction line routing and dimensioningaccordingly donotsetthecontrolintervalstoocloseand 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 permitted We recommend switchi...

Page 23: ...op edge Oil charge sight glass centre Rotation speed range Oil sump heater Flywheel belt pulley Shaft coupling Discharge line DV Suction line SV m 3 h kg mm inch mm inch Ltr Ltr rpm W Ø WK F76 1570 6 137 164 214 42 1 5 8 54 2 1 8 5 3 4 4 500 1800 200 406 9 x SPB 190 63 F76 1800 157 188 211 F76 2050 178 214 208 F76 2425 211 253 203 for soldering joint ...

Page 24: ...en Transport 4 3 2 5 6 2 3 4 5 6 Zeichn Nr Drawing no Wir behalten uns alle Rechte gemäß DIN ISO 16016 Numéro de plan Tol Ang DIN ISO 2768 mK Ra Rz Maß Passung 120 400 0 5 über 0 5 bis 6 GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Ge Rz 63 6 3 Rz 16 2 1 6 0 7 Unbemaßte Radien an dieser Zeichnung vor Bearb Datum Änderungs Nr Gepr Zone 1 3 Oberflächenbeha Blatt 400 Benennung 0 8 1000 30 6 0 3 120...

Page 25: ...ssure safety switch LP 7 16 UNF D1 Connection oil return from oil separator 5 8 UNF E Connection oil pressure gauge 7 16 UNF F Oil drain plug M22x1 5 H Oil charge plug M22x1 5 J Connection oil sump heater M22x1 5 K Sight glass 3 x M6 L Connection thermal protection thermostat 1 8 NPTF ÖV Connection oil service valve 1 4 NPTF P Connection oil pressure differential sensor M20x1 5 Q Connection oil te...

Page 26: ... 1 3 1 1 5 1 3 2 1 3 3 1 3 7 1 5 1 1 5 2 1 5 13 and 1 7 1 to 1 7 4 excepted 1 7 4 f are fulfilled Applied harmonised standards in particular EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction EN 12693 2008 Refrigerating systems and heat pumps Safety and environmental requirements Positive displacement refrigerant compressors Remarks We also decla...

Page 27: ...ny questions about installation operation and accessories please contact our technical service or specialist wholesaler and or our representative The GEA Bock service team can be contacted by phone with a toll free hotline 00 800 800 000 88 or via gea com contact Yours faithfully GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany 11 Service ...

Page 28: ... 49 0 7022 9454 0 Fax 49 0 7022 9454 137 gea com gea com contact 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 ...