GEA F Series Manuel utilisateur

09702-09.2013-DGbF

F2, F3

F2 NH3, F3 NH3

F4, F5

F4 NH3, F5 NH3

F14/1166, F14/1366

F14/1166 NH3, F14/1366 NH3

F16/1751, F16/2051

F16/1751 NH3, F16/2051 NH3

FX2, FX3

FX4, FX5

FX14/1166, FX14/1366

FX16/1751, FX16/2051

engineering for a better world GEA Refrigeration Technologies

Bock Compressors F/F-NH3

Assembly instructions

09702-09.2013-DGbF

1 Safety 4

1.1 Identication of safety instructions

1.2 Qualications required of personnel

1.3 General safety instructions

1.4 Additional safety instructions NH3

1.5 Intended use

2 Product description 6

2.1 Short description

2.2 Name plate

2.3 Type code

3 Areas of application F 9

3.1 Refrigerants F, F-NH3

3.2 Oil charge

3.3 Operating limits

4 Areas of application F-NH311

4.1 Oil charge NH3

4.2 Operating limits NH3

5Compressor assembly 12

5.1 Setting up

5.2 Maximum permissible inclination

5.3 Pipe connections

5.4 Pipes

5.5 Laying suction and discharge lines

5.6 Operating the shut-off valves

5.7 Operating mode of the lockable service connections

5.8 Drive

5.9 Oil sump heating (standard by F4, F5, F14 and F16)

6 Commissioning 18

6.1 Preparations for start-up

6.2 Pressure resistance test

6.3 Leak test

6.4 Evacuation

6.5 Refrigerant charge

6.6 Shaft seal

6.7 Shaft seal change

6.8 Start-up

6.9 Avoiding slugging

7 Maintenance 21

7.1 Preparation

7.2 Work to be carried out

7.3 Spare parts recommendation

7.4 Spare parts recommendation NH3

7.5 Accessories

7.6 Excerpt from the lubricant table

7.7 Decommissioning

8 Technical data F2-F16 23

9 Technical data F2 NH3-F16 NH324

10 Dimensions and connections F 25

11 Dimensions and connections F-NH333

12 Declaration of installation 41

13 Service 42

About these instructions

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

standings 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 compres-

sor is installed.

GEA Bock GmbH

72636 Frickenhausen

Manufacturer

Contact

GEA Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Telephone +49 7022 9454 0

Fax +49 7022 9454-137

[email protected]

www.bock.de

09702-09.2013-DGbF

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 Additional safety instructions NH3

1.5 Intended use

2 Product description 6

2.1 Short description

2.2 Name plate

2.3 Type code

3 Areas of application F 9

3.1 Refrigerants F, F-NH3

3.2 Oil charge

3.3 Operating limits

4 Areas of application F-NH311

4.1 Oil charge NH3

4.2 Operating limits NH3

5Compressor assembly 12

5.1 Setting up

5.2 Maximum permissible inclination

5.3 Pipe connections

5.4 Pipes

5.5 Laying suction and discharge lines

5.6 Operating the shut-off valves

5.7 Operating mode of the lockable service connections

5.8 Drive

5.9 Oil sump heating (standard by F4, F5, F14 and F16)

6 Commissioning 18

6.1 Preparations for start-up

6.2 Pressure resistance test

6.3 Leak test

6.4 Evacuation

6.5 Refrigerant charge

6.6 Shaft seal

6.7 Shaft seal change

6.8 Start-up

6.9 Avoiding slugging

7 Maintenance 21

7.1 Preparation

7.2 Work to be carried out

7.3 Spare parts recommendation

7.4 Spare parts recommendation NH3

7.5 Accessories

7.6 Excerpt from the lubricant table

7.7 Decommissioning

8 Technical data F2-F16 23

9 Technical data F2 NH3-F16 NH324

10 Dimensions and connections F 25

11 Dimensions and connections F-NH333

12 Declaration of installation 41

13 Service 42

09702-09.2013-DGbF

1|Safety

1.2 Qualications required of personnel

INFO! This operating manual describes compressors that are suitable

for both F-gases and for NH3.

Specic information and characteristics for using NH3are

indicated at the corresponding location with the following

symbols:

NH3

1.1 Identication of safety instructions:

DANGER!

WARNING!

CAUTION!

ATTENTION!

INFO!

Indicates a dangerous situation which, if not avoided,

will cause immediate fatal or serious injury.

Indicates a dangerous situation which, if not avoided,

may cause fatal or serious injury.

Indicates a dangerous situation which, if not avoided,

may cause fairly severe or minor injury.

Indicates a situation which, if not avoided,

may cause property damage.

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 with the qualications listed

below:

• 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.

09702-09.2013-DGbF

1|Safety

These assembly instructions describe the standard version of the compressor named in the title

and NH3 manufactured by Bock. The Bock refrigerating compressor are 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 into which it is integrated has been inspected and approved

in accordance with legal regulations.

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

Any other use of the compressor is prohibited!

1.5 Intended use

WARNING! The compressor may not be used in potentially explosive

environments!

1.4 Additional safety instructions NH3

NH3ATTENTION! • High toxicity, intense odour (MAK 50 ppm)

• Explosive between 15 and 30 vol. % in the air. Due to the high

ignition energy and temperature, the risk of explosion, however,

is rated as low. So there are no special explosion protection

measures are required.

• However, the national safety regulations, accident prevention

regulations, technical regulations as well as specific regulations

(EN 378 etc.) must be observed.

• NH3steam is lighter than air and therefore disperses upwards.

• All key directives are summarised in the area for the AiF research

project 9404B "Safety of ammonia refrigeration systems".

• NH3corrodes copper materials and non-ferrous metals and is

incompatible with a number of plastics.

• Proof of personnel's specific expertise for installation,

commissioning, operation and service.

1.3 General safety instructions

DANGER! • 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.

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.

09702-09.2013-DGbF

2|Product description

Open type compressors for external drive (V-belt or coupling)

with oil pump lubrication

2.1 Short description

Dimension and connection values can be found in Chapter 10

Based on the F compressor series, a specially modied selection of compressors is

available for use with the refrigerant R 717.

Important differences from the basic compressor F:

Pistons with three-ring assembly

Con-rod with additional oil supply oil to the small end

Valve plate with optimised pressure unit

Shut-off valve with steel connector for welded joints

All connections are designed as compression joints for steel pipes

F14 NH3 and F16 NH3 with increased oil volume due to the higher base plate

Special oil lling for NH3: Fuchs Reniso KC 68

Short description NH3

F2, F3

Suction

shut-off valve

Cylinder cover

Valve plate

Shaft seal

Shaft end

Compressor housing

Base plate

Discharge shut-off valve

Fig. 1

Oil sightglass

09702-09.2013-DGbF

2|Product description

F4, F5

Dimension and connection values can be found in Chapter 10

F16

F14, F16

Fig. 2

Suction

shut-off valve

Valve plate

Base plate

Name plate

Cylinder cover

Discharge

shut-off valve

Shaft seal

Shaft end

Compressor housing

Fig. 3

Transport eyelet

Discharge shut-off valve

Cylinder cover

Compressor housing

Base plate

Valve plate

Suction

shut-off valve

Leak oil drain hose

Shaft seal

Shaft end

Transport eyelet

09702-09.2013-DGbF

2|Product description

F14 1166 NH3

Fig. 4

2.2 Name plate (example)

2.3 Type code (example)

¹) X - Ester oil charge (HFC refrigerant R134a, R404A/R507, R407C)

²)Indication only at F14, F16

NH3 version

Swept volume

²)

Size

Oil charge

¹)

Series

FX16/2051

SE55

19/28

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 factory

Observe the limit of

application diagrams!

GEA Bock GmbH

72636 Frickenhausen, Germany

09702-09.2013-DGbF

3|Areas of application F, F-NH3

ATTENTION! Compressor operation is possible within the operating

limits shown in the diagrams. Please note the signicance

of the shaded areas. Thresholds should not be selected as design

or continuous operating points.

- Max. permissible discharge end temperature: 140°C

- Max. permissible switching frequency: 12x /h

- A minimum running time of 3 min. steady-state condition

(continuous operation) must be achieved.

Avoid continuous operation near the threshold.

For operation with supplementary cooling:

- Use only oils with high thermal stability.

For operation with capacity regulator:

- The suction gas superheat temperature may need to be reduced

or set individuallywhen operating near to the threshold.

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 lled with the following oil type at the factory:

- 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. FX16/2051).

3.1 Refrigerants

• HFKW: R134a, R404A/R507, R407C

• (H)FCKW: R22

NH3:R717

3.2 Oil charge

3.3 Operating limits

INFO! For refilling, we recommend the above oil types.

Alternatives: see lubricants table, Chapter 7.6

The oil level must be in the visible

part of the sight glass; damage

to the compressor is possible if

overfilled or underfilled!

ATTENTION!

Fig. 5

max. oil level

min. oil level

09702-09.2013-DGbF

3|Areas of application F

Design for other

areas on request

Permissible rotation speeds:

F2, F3: 960 - 1800 rpm

F4, F5: 500 - 1800 rpm

F14, F16: 700 - 1800 rpm

3.3 Operating limits

R134a

Fig. 6

R404A/R507

Fig. 7

R407C

Fig. 8

R22

Fig. 9

Unlimited

application range

Reduced suction gas

temperature

Evaporating temperature (°C)

Condensing temperature (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

Maximum admissible

operating pressure (g)

High pressure side (LP/HP)1):

19/28 bar

1) LP = Low pressure

HP = High pressure

Ce manuel convient aux modèles suivants

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