GEA Bock FK30 Manuel utilisateur

GEA Bock FK30

Assembly instructions

09705-01.2018-Gb

Translation of the original instructions

FK30/235 N FK30/275 N FK30/325 N

FK30/235 K FK30/275 K FK30/325 K

FK30/235 TK FK30/275 TK FK30/325 TK

FKX30/235 N FKX30/275 N FKX30/325 N

FKX30/235 K FKX30/275 K FKX30/325 K

FKX30/235 TK FKX30/275 TK FKX30/325 TK

09705-01.2018-DGbFITrRu

About these instructions

Read these instructions before assembly and before using the compressor. This will avoid

misunderstandings and prevent damage. Improper assembly and 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

Manufacturer

Contact

GEA Bock GmbH

Benzstrasse 7

72636 Frickenhausen

Germany

Phone +49 7022 9454 0

Fax +49 7022 9454 137

[email protected]

www.gea.com

09705-01.2018-DGbFITrRu

Contents Page

1 Safety 4

1.1 Identication of safety instructions

1.2 Qualications required of personnel

1.3 General safety instructions

1.4 Intended use

2 Product description 6

2.1 Brief description

2.2 Name plate

2.3 Type key

3 Areas of application 8

3.1 Refrigerants

3.2 Oil charge

3.3 Limits of application

3.4 N and K versions

3.4.1 Limits of application R134a

3.4.2 Limits of application R407C

3.5 TK version

3.5.1 Limits of application R404A/R507

3.5.2 Limits of application R22

4Compressor assembly 11

4.1 Setting up

4.2 Maximum permissible inclination

4.3 V-belt drive

4.4 Main bearing load

4.5 Installation of 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

4.10 Suction pipe lter

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 Avoiding liquid shocks

6 Maintenance 18

6.1 Preparation

6.2 Work to be carried out

6.3 Shaft seal, emptying the oil reservoir

6.4 Recommended spare parts

6.5 Integrated decompression valve

6.6 Extract from the lubricants table

6.7 Decommissioning

7 Accessories 20

7.1 Thermal protection thermostat

8 Technical Data 21

9 Dimensions and connections 22

 10 Installationcerticate 24

11 Service 25

09705-01.2018-DGbFITrRu

1|Safety

1.2 Qualicationsrequiredofpersonnel

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.

ATTENTION Indicates a situation which, if not avoided,

may cause property damage.

INFO Important information or tips on simplifying work.

WARNING Inadequatelyqualied personnelposesthe riskof accidents, the

consequencebeingseriousorfatalinjury.Workon compressors

isthereforereservedforpersonnelwhichisqualiedtoworkon

pressurized refrigerant systems:

• For example, a refrigeration technician, refrigeration mechatronic

engineer. As well as professions with comparable 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.

1.1 Identicationofsafetyinstructions:

09705-01.2018-DGbFITrRu

1.3 General safety instructions

1|Safety

These assembly instructions describe the standard version of the FK30 manufactured by GEA.

The compressor is intended for use in refrigeration systems in compliance with the limits of

application. Only the refrigerant specied in these instructions may be used.

Any other use of the compressor is prohibited!

The GEA 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, 2014/68/EU 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

WARNING Risk of accidents.

Refrigerating compressors are pressurised machines and as such

call for heightened caution and care in handling.

The maximum permissible overpressure must not be exceeded,

even for testing purposes.

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.

- Avoid contact with refrigerant necessarily.

Contact with refrigerant can cause severe burns and skin

damage.

09705-01.2018-DGbFITrRu

2|Product 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 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

Oil sight glass

Valve plate

Cylinder cover

Shaft end

Shaft seal

Suction

shut-off valve

Oil pump

Dimension and connection values can be found in Chapter 9

Leak oil trapping

device with oil

reservoir Discharge

shut-off valve

Suction Suction

shut-off valve

(option)

Leak oil drain hose

Name plate

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2|Product description

FK 03 325 NX

1 Type designation

2 Displacement at 1450 rpm

3 ND (LP): max.

permissible operating pressure

Low pressure side

HD (HP): max.

permissible operating pressure

High pressure side

4 Machine number

5 Factory-lled oil type

Fig. 3

2.2 Name plate (example)

2.3 Type key (example)

¹) K - specially for air-conditioning

N - specially for air-conditioning or normal cooling

TK - specially for deep freezing

²) X - Ester oil charging (HFC refrigerant, e.g. R134a, R407C)

Designs ¹)

Swept volume

Size

Ester oil charging ²)

Series

AS12345A020

19/28bar

Observe the limits of application

diagrams!

}

FKX30/325N

28,3

GEA Bock GmbH

72636 Frickenhausen, Germany

09705-01.2018-DGbFITrRu

3|Areas of application

The compressors are factory-lled with the following oil type:

- for R134a, R404A/R507, R407C FUCHS Reniso Triton SE 55

- for R22 FUCHS Reniso SP 46

Compressors with ester oil charge (FUCHS Reniso Triton SE 55) are marked with an X in the type

designation (e.g. FKX30/325 N).

3.1 Refrigerants

• HFKW / HFC: R134a, R404A/R507, R407C

• (H)FCKW / (H)CFC: R22

3.2 Oil charge

ATTENTION Compressor operation is possible within the limits of application

showninthediagrams.Pleasenotethesignicanceoftheshaded

areas. The limits of application must be observed. Thresholds

should not be selected as design or continuous operating points.

- Max. permissible discharge end temperature: 140°C

- Max. permissible ambient temperature: 100°C

-Max.permissibleswitchingfrequency:12x/h

-A minimum running time of 2 min. at equilibrium (continuous

operation) must be achieved.

Avoid continuous operation near the threshold. Should the com-

pressor 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 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!

3.3 Limits of application

INFO For recharging, we recommend the above oil types. Alternatives are:

see lubricants table, Chapter 6.6.

09705-01.2018-DGbFITrRu

3|Areas of application

Designforotherrangesonrequest

Max. permissible

operating pressure high-

pressureside(HP):28bar

Unrestricted

application range

Unrestricted

application range

Reduced suction gas

temperature

Reduced suction gas

temperature

Evaporation temperature (°C)

Condensing temperature (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

Fig. 4

Fig. 5

-20 -10 10

020 30 t (°C)

t (°C)

-30

t + 25 °C

20 K

R134a

-20 -10 10

020 t (°C)

t (°C)

-30

-25

toh 20 K

t + 25 °C

R407C

3.4.1LimitsofapplicationR134a(NandKversions)

3.4 N and K versions

Models available:

•FKX30/235 N • FKX30/275 N • FKX30/325 N

•FKX30/235 K • FKX30/275 K • FKX30/325 K

Permissible rotation speeds:

N-Design: 500 - 3000 ¹/rpm (max rotation speed 3500 rpm)

K-Design: 500 - 3500 ¹/rpm

3.4.2LimitsofapplicationR407C(NandKversions)

Permissible rotation speeds:

N-Design: 500 - 2600 ¹/rpm

K-Design: 500 - 3500 ¹/rpm

Max. permissible

operating pressure high-

pressureside(HP):28bar

09705-01.2018-DGbFITrRu

3|Areas of application

3.5 TK version

Models available:

• FK30/235 TK • FK30/275 TK • FK30/325 TK

• FKX30/235 TK • FKX30/275 TK • FKX30/325 TK

3.5.1LimitsofapplicationR404A/R507(TKversion)

3.5.2LimitsofapplicationR22(TKversion)

Permissible rotation speeds:

TK design: 500 – 2600 ¹/rpm

Permissible rotation speeds:

TK design: 500 – 2600 ¹/rpm

-10

-20

-30

-40

-50

t (°C)

Dtoh<20K

t +20°C

-45

R404A/R507

R404A/R507 TK

toh

Verdampfungstemperatur (°C)

Verflüssigungstemperatur (°C)

Sauggasüberhitzung (K)

Sauggastemperatur (°C)

Uneingeschränkter

Anwendungsbereich

reduzierte Sauggastemperatur

R22

toh

Verdampfungstemperatur (°C)

Verflüssigungstemperatur (°C)

Sauggasüberhitzung (K)

Sauggastemperatur (°C)

Uneingeschränkter

Anwendungsbereich

reduzierte Sauggastemperatur

R22 TK

-10

-20

-30

-40

-50

t (°C)

Dtoh<20K

t +25°C

-45

Max. permissible

operatingpressure(g)high-

pressureside(HP):28bar

Unrestricted

application range

Reduced suction gas

temperature

Evaporation temperature (°C)

Condensing temperaturee (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

Fig. 6

R404A/R507

R22

Max. permissible

operatingpressure(g)high-

pressureside(HP):28bar

Unrestricted

application range

Reduced suction gas

temperature

Evaporation temperature (°C)

Condensing temperaturee (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

Designforotherrangesonrequest

Fig. 7

Ce manuel convient aux modèles suivants

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