GEA FK40 Series Manuel utilisateur

GEA Compressor FK40

Assembly instructions

09716-06.2016-Gb

Translation of the original instructions

FK40/390 N FK40/390 K FK40/390 TK

FK40/470 N FK40/470 K FK40/470 TK

FK40/560 N FK40/560 K FK40/560 TK

FK40/655 N FK40/655 K FK40/655 TK

FK40/755 K

FKX40/390 N FKX40/390 K FKX40/390 TK

FKX40/470 N FKX40/470 K FKX40/470 TK

FKX40/560 N FKX40/560 K FKX40/560 TK

FKX40/655 N FKX40/655 K FKX40/655 TK

FKX40/755 K

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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

GEA Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Phone +49 7022 9454 0

Fax +49 7022 9454-137

[email protected]

www.gea.com

Manufacturer

Contact

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Contents Page

1 Safety 4

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

  1.2 Qualicationsrequiredofpersonnel

1.3 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 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 the oil reservoir

  5.9 Avoidingliquidshocks

6 Maintenance 18

6.1 Preparation

6.2 Work to be carried out

6.3 Recommended spare parts

6.4 Integrated decompression valve

6.5 Extract from the lubricants table

6.6 Decommissioning

7 Accessories 20

7.1 Capacity regulator

7.2 Thermal protection thermostat

8 Technical data 21

9 Dimensions and connections 22

 10 Installationcerticate 24

11 Service 25

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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:

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1|Safety

These assembly instructions describe the standard version of the FK40 manufactured by GEA. The

compressor is intended for use in refrigeration systems in compliance with the operating limits.

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 (with-

in 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 as-

sembly 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 Safety instructions

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.

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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

application range where operational 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 sight glass

Valve plate

Cylinder cover

Discharge shut-off valve

Shaft end

Shaft seal

Suction shut-off valve

Oil pump

Dimension and connection values can be found in Chapter 9

Eyebolt

Oil sight glass

Leak oil trapping device

with oil reservoir

Leak oil drain hose

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2|Product description

FK 04 655 NX

1 Type designation

2 Displacement at 1450 rpm

3 LP: Max. permissible operating pressure

(g)Lowpressureside

HP: Max. permissible operating pressure

(g)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charge(HFCrefrigerant,e.g.R134a,R407C)

Designs ¹)

Swept volume

Size

Ester oil charge ²)

Series

AS12345A020

19/28bar

Observe the limits of

application diagrams!

}

GEA Bock GmbH

72636 Frickenhausen, Germany

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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).

For operation with capacity regulator:

- Continuous operation, when the capacity regulator is activated,

is not permissible 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suf-

cient oil is transported back to the compressor.

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|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. FKX40/655N).

3.1 Refrigerants

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

• (H)FCKW/(H)CFC: R22

3.2 Oil charge

3.3 Limits of application

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

see lubricants table, Chapter 6.5.

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3|Areas of application

Designforotherrangesonrequest

Max. permissible operating

pressure(g)onthehigh-

pressureside(HP):28bar

Max. permissible operating

pressure(g)onthehigh-

pressureside(HP):28bar

Unrestricted

application range

Unrestricted

application range

reduced suction gas temperature

Evaporating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:

• FKX40/390 N • FKX40/470 N • FKX40/560 N • FKX40/655 N

• FKX40/390 K • FKX40/470 K • FKX40/560 K • FKX40/655 K • FKX40/755 K

Permissible rotation speeds:

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

K Design: 500 - 3500 rpm

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

Permissible rotation speeds:

N Design: 500 - 2600 rpm

K Design: 500 - 3500 rpm

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3|Areas of application

3.5 TK version

Models available:

• FK40/390 TK • FK40/470 TK • FK40/560 TK • FK40/655 TK

• FKX40/390 TK • FKX40/470 TK • FKX40/560 TK • FKX40/655 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 rpm

Permissible rotation speeds:

TK design: 500 - 2600 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)onthehigh-

pressureside(HP):28bar

Unrestricted

application range

reduced suction gas temperature

Evaporatingtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Fig. 6

R404A/R507

R22

Max. permissible operating

pressure(g)onthehigh-

pressureside(HP):28bar

Unrestricted

application range

reduced suction gas temperature

Evaporatingtemperature(°C)

Condensingtemperature(°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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