GEA FK40/390 K, Assembly Instructions Manual

Page 1: ...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 FKX40 560 K FKX40 655 K FKX40 390 TK FKX40 470 TK FKX40 560 TK FKX40 655 TK engineering for a better world GEA Refrigeration Technologies Bock Compressor FK40 Assembly instructions ...

Page 2: ... 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 GEA Bock GmbH 72636 Frickenhausen GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 bock gea com www bock de Man...

Page 3: ...le inclination 4 3 V belt drive 4 4 Main bearing load 4 5 Electromagnetic coupling 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 Oil level check 5 7 Shaft seal 5 8 Shaft seal emptying t...

Page 4: ...chines and as such call for heightened caution and care in handling The maximum permissible overpressure must not be exceeded even for testing purposes WARNING Risk of burns Depending on the operating conditions surface temperatures of over 60 C on the discharge side or below 0 C on the suction side can be reached WARNING Inadequately qualified personnel poses the risk of accidents the consequence...

Page 5: ... 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 Directive Commissioning is permissible only if the compressor has been installed in accordance with these as sembly instructions and the entire system int...

Page 6: ... 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 Name plate Fig 1 2 1 Brief description Fig 2 Oil sightglass Valve plate Cylinder cover Discharge shut off valve Shaft end Shaft seal Suct...

Page 7: ...sure side 4 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 GEA...

Page 8: ... we recommend the use of a thermal protection thermostat Accessories Chap 7 When capacity regulators are used the limits of application can move When operating in the vacuum range there is a danger of air en tering 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...

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 FKX40 390 N FKX40 470 N FKX40 560 N FKX4...

Page 10: ...sbereich reduzierte 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 on the high pressure side HP 28 bar Unrestricted application ra...

Page 11: ...ressor for transport damage before starting any work Fig 8 Fig 9 Transport and suspension unit on the eyebolt Fig 8 or direct on the discharge line valve Fig 9 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 c...

Page 12: ... the magnetic field of the electromagnetic clutch the front bearing flange has a snug fit Ø 148 h8 see Fig 12 To connect the magnetic field loosen the 4 cheese head screws M8 on the bearing flange see Fig 12 Slide the magnetic field to a snug fit and re attach using the four cheese head screws M8 Fig 13 Screw torque 34 Nm Further assembly of the electromagnetic clutch according to the clutch manuf...

Page 13: ... inhibit oxidation products scale 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 The same applies for non return valves Fig 14 Stepped internal diameters 4 6 Pipe conne...

Page 14: ...ion 2 2 Fig 17 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 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 ...

Page 15: ...e compressor for transport damage 5 2 Pressure strength test DANGER 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...

Page 16: ...ses The oil level must be visible in at least one sightglass 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 ...

Page 17: ...s 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 The 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 reser...

Page 18: ...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 In this case check the valve and replace as necessary 6 4 Integrated decompression valve Only use genuine Bock spare parts 6 3 Recommended spare parts WARNING Before starting any work on the compressor Swi...

Page 19: ...ith the valid national regulations 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 HFC e g R134a R407 R 404A Fuchs Reniso Triton SE 55 see also...

Page 20: ...ity 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 recommended as the gas velocity in the p...

Page 21: ...nt of the driving unit kgm 2 Lubri cation Oil pump FK40 390 4 385 33 5 34 0 22 7 8 28 1 1 8 2 0 0 0043 Forced lubrication Rotation independent FK40 470 466 40 5 33 0 28 1 1 8 35 1 3 8 FK40 560 554 48 3 33 0 28 1 1 8 35 1 3 8 FK40 655 650 56 6 31 0 35 1 3 8 35 1 3 8 Connections The technical data for the different designs K N and TK are identical The compressor type data therefore do not mention th...

Page 22: ...connections Dimensions in K Design Shaft end Centre of gravity Dimensions in mm Dimensions in mm Fig 20 Fig 21 169 ca 110 ca 170 M SV A SV1 A1 C E G 13 232 210 145 329 ca 370 4x ca 320 325 F DV B B1 L H K D Y 109 130 170 4xM10 LK 253 344 ca 385 Leak oil drain hose ...

Page 23: ...ckable 7 16 UNF B Connection discharge side not lockable 1 8 NPTF B1 Connection discharge side lockable 7 16 UNF C Connection oil pressure safety switch OIL 1 8 NPTF D Connection oil pressure safety switch LP 1 8 NPTF E Connection oil pressure gauge 1 8 NPTF F Oil drain 1 4 NPTF G Opt connection for oil sump heating 1 H Oil charge plug 1 4 NPTF K Sightglass 2 x 1 1 8 18 UNEF L Connection thermal p...

Page 24: ... 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...

Page 25: ...nzeichnet WARNUNG Dieses Symbol weist darauf hi dass ungenaues Befolgen oder Nichtbefolg von Anweisungen zu Schäden an Personen am Verdichter oder an der Kälteanlage füh kann GEFAHR Dieses Symbol weist auf Anweis gen hin um unmittelbare schwere Gefährd gen von Personen zu vermeiden GEFAHR Dieses Symbol weist auf Anweis gen hin um unmittelbare schwere Gefähr dungen von Personen oder Anlagen durch e...

Page 26: ...ore 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 GEA Refrigeration Technologies GEA Bock GmbH Benzstraße 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 bock gea com www bock de 09716 01 2013 DGbFEITrCn GEA Group AG All rights reserved ...