GEA FK20, Assembly Instructions Manual

Page 1: ... Gb Translation of the original instructions FK20 120 N FK20 145 N FK20 170 N FK20 120 K FK20 145 K FK20 170 K FK20 120 TK FK20 145 TK FK20 170 TK FKX20 120 N FKX20 145 N FKX20 170 N FKX20 120 K FKX20 145 K FKX20 170 K FKX20 120 TK FKX20 145 TK FKX20 170 TK ...

Page 2: ...se 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 Manufacturer Contact GEA Bock GmbH Benzstrasse 7 72636 Frickenhausen Germany Phone 49 7022 9454 0 Fax 49 7022 9454 137 info gea com ...

Page 3: ...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 5 Commissioning 15 5 1 Preparations for start up 5 2 Pressure strength test 5 3 Leak test 5 4 Evacuation 5 5 Refrigerant charge 5 6 Shaft seal 5 6 1 Notes on replacin...

Page 4: ...damage INFO Important information or tips on simplifying work 1 Safety 1 2 Qualifications required of personnel WARNING Inadequately qualified personnel poses the risk of accidents the consequence being serious or fatal injury Work on compressors is therefore reserved for personnel with the qualifications listed below For example a refrigeration technician refrigeration mechatronic engineer As wel...

Page 5: ...inery Directive 97 23 EC 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 DANGER Refrigerating compressors are pressurised machines an...

Page 6: ...pted to each applica tion range where operational safety and efficiency are concerned Compact two cylinder compressor in single row Three capacity ranges Lightweight aluminum design Lubricating oil pump with oil pressure relief valve independent of rotational direction Variable connection and fixing options Fig 1 2 1 Brief description Fig 2 Suction shut off valve Cylinder cover Name plate Shaft en...

Page 7: ...Machine number 5 Factory filled oil type Fig 3 2 2 Name plate example 2 3 Type key example K specially for air conditioning N specially for air conditioning or normal cooling TK specially for deep freezing X Ester oil charging HFC refrigerant e g R134a R407C Designs Swept volume Size Ester oil charging Series 1 2 3 4 5 AS12345A020 19 28bar Observe the limits of application diagrams FKX20 170N 14 8...

Page 8: ... happen to be used near the thresholds we recommend the use of a thermal protection thermostat Accessories Chap 7 When operating in the vacuum range there is a danger of air entering 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 The compressors are factory filled with the fol...

Page 9: ... Suction gas superheat K Suction gas superheat K Suction gas temperature C Suction gas temperature C Fig 4 Fig 5 20 30 50 70 80 20 10 10 0 20 30 t C o t C c 82 30 40 60 90 t 25 C oh toh 20 K R134a 20 30 50 20 10 10 0 20 t C o t C c 61 30 40 60 25 toh 20 K t 25 C oh R407C 3 4 1 Limits of application R134a N and K versions 3 4 N and K versions Models available FKX20 120 N FKX20 145 N FKX20 170 N FKX...

Page 10: ...duzierte Sauggastemperatur FK R22 tc t0 toh Dtoh Verdampfungstemperatur C Verflüssigungstemperatur C Sauggasüberhitzung K Sauggastemperatur C Uneingeschränkter Anwendungsbereich reduzierte Sauggastemperatur R22 TK 10 0 10 20 30 40 50 20 30 40 50 60 70 t C o t C c Dtoh 20K t 25 C oh 66 45 Max permissible operating pressure g high pressure side HP 28 bar Unrestricted application range Reduced suctio...

Page 11: ...ort damage before starting any work Fig 8 A A a a A A a a 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 The compressor can be fastened as follows using the 4 drill holes on the baseplate using the 3 side M10 tapped blind holes on the left or right of the c...

Page 12: ...s a snug fit Ø 38 h8 see Fig 10 To connect the magnetic field remove the marked Allen head screws of the sliding ring lid see Fig 11 Slide the magnetic field to a snug fit and fasten using the three M5 x 18 cheese head screws provided Fig 11 Screw torque 9 Nm Further assembly of the electromagnetic clutch according to the clutch manufacturer Fig 10 Sliding ring lid Magnetic field Fig 11 To prevent...

Page 13: ...Before opening or closing the shut off valve release the valve spindle seal by approx of a turn counter clockwise After activating the shut off valve re tighten the adjustable valve spindle seal clockwise Fig 13 Fig 14 ATTENTION Overheating can damage the valve Solder only using inert gas to inhibit oxidation products Release Tighten The pipe connections have graduated inside diameters so that pip...

Page 14: ... service connection 2 closed Fig 15 Fig 16 1 1 3 3 Pipe connection Pipe connection Opening the service connection 2 b Spindle 1 Turn 1 rotation to the right Service connection 2 opened shut off valve opened Connection 3 is provided for safety devices and is not lockable 3 3 2 2 After activating the spindle generally fit the spindle protection cap again and tighten with 14 16 Nm This serves as a se...

Page 15: ...g in instructions Check the compressor for transport damage 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 l...

Page 16: ...efrigerant 5 5 Refrigerant charge 5 6 Shaft seal As changing the seal involves opening the refrigerant circuit this is recommended only if the seal is losing refrigerant Replacing the seal is described in the spare part kit concerned ATTENTION Failure to observe the following instructions can cause loss of refrigerant and damage to the shaft seal INFO The shaft seal seals and lubricates with oil A...

Page 17: ...esigned 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 The system must reach a state of equilibrium Particularly in critical systems e g several evaporator points suitable measures e g use of liquid traps solenoid valve in th...

Page 18: ... of experience we recommend that the following oil change service work is carried out First oil change during the first maintenance of the vehicle Then after every 5 000 operating hours though no more than 3 years Annual checks Check the tightness of the compressor running noise pressures temperatures function of auxiliary devices Only use genuine GEA spare parts 6 3 Recommended spare parts WARNIN...

Page 19: ...ted to the FK20 TK specifically for applications in the deep freeze area The system is equipped with a non interchange safeguard to avoid confusing it with N valve plate 6 Maintenance 6 4 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 lubricant...

Page 20: ...is used to attach the sensor element Part no 04175 Wire 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 5 K Switch on temperature approx 115 C 7 1 Thermal protection thermostat Item No 07595 ...

Page 21: ...nch Oil charge Ltr Inertia moment of the driving unti kgm 2 Lubrication Oil pump FK20 120 2 118 10 3 15 0 16 5 8 16 5 8 0 7 0 0013 Forced lubrication Independent of rotational direction FK20 145 143 12 4 14 0 FK20 170 170 14 8 14 0 Connections The technical data for the different designs K N and TK are identical The compressor type data therefore do not mention these additions ...

Page 22: ...m Dimensions in mm Fig 18 Fig 19 30 99 3 0 4x M10 LK 130 115 ca 135 ca 150 155 78 5 78 5 H B1 B 3xM10 beidseitig 125 60 73 ca 263 155 110 h8 58 SV DV A2 F G B X 4x 11 ca 215 ca 270 280 30 115 ca 135 B1 B 3xM10 beidseitig 125 60 3 55 M8x22 25 21 69 24 7 6x M5 49 1 4 A4x6 5 DIN 6888 1 5 38 0 05 34 3 36 3 60 55 1 A1 A View X both sides ...

Page 23: ...not lockable 1 8 NPTF B Connection discharge side not lockable 7 16 UNF B1 Connection discharge side lockable 7 16 UNF B2 Connection discharge side not lockable 1 8 NPTF F Oil drain plug G 1 8 G Opt connection for oil sump heating 1 H Oil charge plug 1 4 NPTF K Sightglass 2 1 No connection available as standard Available on request Connection M22 x 1 5 2 No connection available as standard without...

Page 24: ...ds referenced 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 Th...

Page 25: ...ny 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 72636 Frickenhausen Germany 11 Service ...

Page 26: ...one 49 0 7022 9454 0 Fax 49 0 7022 9454 137 info gea com gea com 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 ...