GEA FK50/460 K, Assembly Instructions Manual

Page 1: ... 775 N FK50 830 N FK50 980 N FK50 460 K FK50 555 K FK50 660 K FK50 775 K FK50 830 K FK50 980 K FK50 460 TK FK50 555 TK FK50 660 TK FK50 775 TK FKX50 460 N FKX50 555 N FKX50 660 N FKX50 775 N FKX50 830 N FKX50 980 N FKX50 460 K FKX50 555 K FKX50 660 K FKX50 775 K FKX50 830 K FKX50 980 K FKX50 460 TK FKX50 555 TK FKX50 660 TK FKX50 775 TK ...

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 compressor 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 info gea com www gea com Manuf...

Page 3: ...le 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 Oil level check 5 7 Shaft seal 5 8 Shaft seal emptying the...

Page 4: ...ty 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 ...

Page 5: ...achinery 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...

Page 6: ...ficiency are concerned Compact six cylinder compressor in W design Six capacity ranges Lightweight aluminum design Lubricating oil pump with oil pressure relief valve independent of rotational direction Variable arrangement of the shut off valves Fig 1 2 1 Brief description Fig 2 Valve plate Cylinder cover Shaft end Shaft seal Suction shut off valve Suction line valve Oil pump Dimension and connec...

Page 7: ...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 AT12345A029 19 28bar Observe the limits of application diagrams FKX50 775N 67...

Page 8: ...le and can cause damage to the compressor The suction gas superheat temperature may need to be reduced or set individually when operating near to the threshold When the capacity regulator is activated the gas velocity in the system can not under certain circumstances ensure that suffici ent oil is transported back to the compressor When operating in the vacuum range there is a danger of air enteri...

Page 9: ...as 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 FKX50 460 N FKX50 555 N FKX50 660 N FKX50 775 N FKX50 460 K FKX50 555 K F...

Page 10: ...dungsbereich 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 high pressure side HP 28 bar Unrestricted application range...

Page 11: ...s of air Check the compressor for transport damage before starting any work Fig 8 Transport and suspension unit on both eyebolts Fig 8 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 ...

Page 12: ...romagnetic clutch the front bearing flange has a snug fit 148 h8 see Fig 11 To connect the magnetic field loosen the 4 cheese head screws M8 on the bearing flange see Fig 11 Slide the magnetic field to a snug fit and re attach using the four cheese head screws M8 Fig 12 Screw torque 34 Nm Further assembly of the electromagnetic clutch according to the clutch manufacturer Fig 11 Bearing flange fron...

Page 13: ...epend on the dimension 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 13 Stepped internal diameters 4 6 Pipe connections 4 8 Operating the shut off valves Before opening or closing the shut off valve release the valve spindle seal by approx of a tur...

Page 14: ...will go Shut off valve fully opened service connection 2 closed Opening the service connection 2 Spindle 1 1 2 1 rotation to the right Service connection 2 opened shut off valve opened Connection 3 is provided for safety devices and is not lockable 1 1 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 second sealing featu...

Page 15: ...ning in instructions Check the compressor for transport damage 5 3 Leak test Carry out the leak test on the refrigerating plant in accordance with EN 378 2 or a corresponding safety standard while always observing the maximum permissible overpressure for the compressor DANGER Risk of bursting The compressor must only be pressurised using nitrogen N2 Never pressurise with oxygen or other gases The ...

Page 16: ...s 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 5 ...

Page 17: ... 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 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 emptyi...

Page 18: ...oil strainer at the same time If necessary also empty the oil reservoir at the shaft seal Annual checks Oil level tightness of the compressor running noise pressures temperatures function of auxiliary devices such as checking the capacity control The valves are fundamentally maintenance free However constant leakage can occur after repeated blowing off due to abnormal operating conditions This lea...

Page 19: ... inside in accordance with 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 Refrigerants GEA standard oil types Recommended alternatives HFC e g R134a R407 R 404A Fuchs Renis...

Page 20: ...hermostat Item No 07595 ATTENTION 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 r...

Page 21: ...0 6 459 40 1 44 0 28 1 1 8 35 1 3 8 2 5 0 0047 Forced lubrication Rotation direction independent FK50 555 556 48 3 43 0 28 1 1 8 35 1 3 8 FK50 660 662 57 6 42 0 35 1 3 8 2 x 35 1 3 8 FK50 775 776 67 6 41 0 35 1 3 8 2 x 35 1 3 8 FK50 830 831 72 3 43 0 35 1 3 8 2 x 35 1 3 8 0 0056 FK50 980 976 84 9 41 0 35 1 3 8 2 x 35 1 3 8 Connections The technical data for the different designs K N and TK are ide...

Page 22: ...age d huile Anschluß Wärmeschutzthermostat 1 Only possible ex factory Oil charge plug Raccord opt vanne d arrêt d aspiration Connection thermal protection thermostat H Ölsieb Schauglas Zoll 1 8 NPTF Oil filter Opt connection oil sump heater 1 M L Raccord à braser 1 Ne possible qu ex usine Opt connection suction line valve SV1 Opt Anschlußmöglichkeit Ölsumpfheizung 1 M22x1 5 L Raccord opt chauffage...

Page 23: ...scharge 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 heater 1 H Oil charge plug 1 4 NPTF K Sight glass 2 x 1 1 8 18 UNEF L Connection thermal protection thermostat 1 8 NPTF M Oil strainer M22 x 1 5 SV1 Opt connection for suct...

Page 24: ...dards 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...

Page 25: ... 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 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 ...