GEA FK40/560 N Manuel utilisateur

09716-01.2013-DGbFEITrCn

FK40/390 N FK40/470 N FK40/560 N FK40/655 N

FK40/390 K FK40/470 K FK40/560 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

09716-01.2013-DGbFEITrCn

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 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

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

Telephone +49702294540

Fax +4970229454-137

[email protected]

www.bock.de

Manufacturer

Contact

09716-01.2013-DGbFEITrCn

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 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

09716-01.2013-DGbFEITrCn

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.

1|Safety

1.2 Qualicationsrequiredofpersonnel

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.

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.

09716-01.2013-DGbFEITrCn

1|Safety

These assembly instructions describe the standard version of the FK40 manufac-

tured by Bock. 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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intowhichitisintegratedhasbeeninspectedandapproved

inaccordancewithlegalregulations.

1.4 Intended use

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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sightglass

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sightglass

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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!

}

GEA Bock GmbH

72636 Frickenhausen, Germany

09716-01.2013-DGbFEITrCn

3|Areas of application

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 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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

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

09716-01.2013-DGbFEITrCn

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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)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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GEA

GEA HA4 Manuel utilisateur

GEA

GEA HGX46/280-4 ML CO2T Manuel utilisateur

GEA

GEA Bock HG22P A Manuel utilisateur

GEA

GEA Bock HG8 Series Manuel utilisateur

GEA

GEA HGX34/130-4 ML CO2 T Manuel utilisateur

GEA

GEA HGX12P CO2 Manuel utilisateur

GEA

GEA HGX4 R134a Manuel utilisateur

GEA

GEA Searle NSQ Series Manuel utilisateur

GEA

GEA HGX4 CO2 Series Manuel utilisateur

GEA

GEA HA22P/125-4 Manuel utilisateur

GEA

GEA pluscom Bock EX-HG12P Manuel utilisateur

GEA

GEA HG44e Manuel utilisateur

GEA

GEA Grasso 5 Manuel utilisateur

GEA

GEA HGX34 CO2 T Series Manuel utilisateur

GEA

GEA HG22e/160-4 Manuel utilisateur

GEA

GEA Bock HGX2/70-4 CO2 T Manuel utilisateur

Manuels Compresseur d'air populaires d'autres marques

Sparmax

Sparmax DC-25XR Manuel utilisateur

KAESER

KAESER M122 Manuel utilisateur

GMC

GMC GAC1500 Manuel utilisateur

Briggs & Stratton

Briggs & Stratton Air Compressor Manuel utilisateur

Fini

Fini F3GST2TK Manuel utilisateur

Industrial Air

Industrial Air CP1580325 Manuel de programmation

Campbell Hausfeld

Campbell Hausfeld RP3300 Guide de démarrage rapide

Ingersoll-Rand

Ingersoll-Rand UP6 20 HP Manuel utilisateur

Hitachi

Hitachi EC99S Manuel de l'opérateur

Parkside

Parkside PKO 270 A1 Manuel utilisateur

Sullair

Sullair 185 Manuel utilisateur

Clas Ohlson

Clas Ohlson QIE-ZTH-15 Manuel utilisateur

Ferm

Ferm CRM1046 Manuel utilisateur

BE AC153 Manuel utilisateur

RIDGID

RIDGID OF25150A Manuel utilisateur

Johnson Controls

Johnson Controls QUANTUM LX Manuel

Sears

Sears Craftsman 919.167463 Manuel utilisateur

Ring Automotive

Ring Automotive RAC700 Manuel utilisateur