BOCK FK40 Series User manual

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
BOCK FK40
Assembly instructions
09716-01.2021-Gb
Translation of the original instructions
colour the world
of tomorrow
BOCK®

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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.
Bock GmbH
72636 Frickenhausen
Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Phone [phone]
Fax [phone]
www.bock.de
[email protected]
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
4Compressor assembly 9
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
  4.10Suctionpipelter
4.11 Characteristics for K1 special housing
5 Commissioning 14
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 17
6.1 Preparation
6.2 Work to be carried out
6.3 Shaft seal, emptying the oil reservoir
6.4 Recommended spare parts/accessories
6.5 Integrated decompression valve
6.6 Extract from the lubricants table
6.7 Decommissioning
7 Accessories 19
7.1 Capacity regulator
7.2 Thermal protection thermostat
8 Technical data 21
9 Dimensions and connections 22
10 Declaration of incorporation 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 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 (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(5atKDesign).
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
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
Valve plate

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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
1
2
3
4
5
AS12345A020
19/28bar
Observe the limits of
application diagrams!
}
Bock GmbH, Benzstr. 7
72636 Frickenhausen, Germany
BOCK

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ATTENTION Compressor operation is possible within the operating limits.
These can be found in Bock compressor selection tool (VAP)
under vap.bock.de. Observe the information given there.
- Max. permissible discharge end temperature: 140°C
- Permissible ambient temperature: (-20°C) - (+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 6.6.
Maximum admissible
operating pressure (g)
(LP/HP)1): 19/28 bar
1) LP = Low pressure
HP = High pressure

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AA
aa
AA
aa
4|Compressor assembly
4.1 Setting up
4.2 Maximum permissible inclination
Amax. 30°,
max. 2 minutes
amax. 15°,
continuous
operation
Fig. 4 Fig. 5
 Transportandsuspensionunitontheeyebolt(Fig.4)ordirectonthedischargelinevalve
(Fig.5).
Storage at (-40°C) - (+100°C), maximum permissible relative humidity 10% - 95%, no
condensation.
 Fittings (e.g. pipe holders, additional units etc.) on the compressor are permissible only
following consultation with Bock.
 Setuponanevensurfaceorframewithsufcientload-bearingcapacity.Useall4fastening
points.
Correct setup of the compressor and mounting of the belt drive are decisive for running comfort,
operating safety and the service life of the compressor.
Fig. 6
INFO Newcompressorsarefactory-lledwithinertgas.Leavethisser-
vice charge in the compressor for as long as possible and prevent
the ingress of air.
Check the compressor for transport damage before starting any
work.
ATTENTION Poor lubrication can damage the compressor. Respect the stated
values.
WARNING Movecompressorsonlywithhoiststhathaveadequateload-bear-
ing capacity.

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4|Compressor assembly
 Duringoperation with capacitycontrollers(Accessories, Chap.7),the changing loadcan cause
increased running noises and belt drive vibrations.
4.3 V-belt drive
4.4 Main bearing load
4.5 Electromagnetic clutch assembly
The following description applies for an electromagnetic clutch secured to a shaft.
Toabsorbthemagneticeldoftheelectromagneticclutch,thefrontbearingangehasa
snugtØ148h8(seeFig.8).
Toconnectthemagneticeld,loosenthe4cheeseheadscrewsM8onthebearingange
(seeFig.8).
Slidethemagneticeldtoasnugtandre-attachusingthefourcheeseheadscrewsM8
(Fig.9).Screwtorque=37Nm.
Further assembly of the electromagnetic clutch according to the clutch manufacturer.
To prevent the belt drive overloading the compressor main bearing,
ensure that:
The force applied at the force engagement force by the belt
tension(seeFig.7)mustnotexceedFmax = 2750 N.
If the force engagement point shifts forwards (see Fig.11, small
point),theforceFmax reduces as per the following formula:
Fmax = 245 kNmm
(90 mm + L1[mm])
Fmax= 2750N
Mbmax= 245kNmm
L
1
(mm)
Fig. 7
ATTENTION Inappropriately designed belt drives, especially belt knocking
or excessive tensioning forces can cause compressor damage!
Make sure that the drive belt is designed correctly, e.g. by using
tensionersandselectingthebeltproleandthebeltlength.
Fig. 8
Bearingange,front
Magneticeld
Fig. 9
148 h8

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4|Compressor assembly
4.7 Pipes
Pipes and system components must be clean and dry inside and free of scale, swarf and layers of
rust and phosphate. Only use air-tight parts.
Lay pipes correctly. Suitable vibration compensators must be provided to prevent pipes being cracked
and broken by severe vibrations.
Ensure a proper oil return.
Keep pressure losses to an absolute minimum.
The pipe connections have stepped internal diameters so that pipes
with standard millimetre and inch dimensions can be used.
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. 10: Stepped
internal diameters
4.6 Pipe connections
Valve spindle seal
4.8 Operating the shut-off valves
Before opening or closing the shut-off valve, release the valve spindle seal by approx. ¼ of a turn
counter-clockwise.
After activating the shut-off valve, re-tighten the adjustable valve spindle seal clockwise.
Fig. 11 Fig. 12
Release
Tighten
ATTENTION Overheating can damage the valve.
Therefore, remove the pipe supports from the valve before
soldering.
Solder only using inert gas to inhibit oxidation products (scale).

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4|Compressor assembly
4.9 Operating mode of the lockable service connections
1
1
3
3
Pipe connection
Pipe connection
2
2
Fig. 13
Opening the shut-off valve:
a) Spindle1:turntotheleft(counter-clockwise)asfarasitwillgo.
—> Shut-off valve fully opened / service connection 2 closed.
Fig. 14
Opening the service connection (2):
b) Spindle 1: Turn ½ - 1 rotation to the right.
—> Service connection 2 opened / shut-off valve opened.
Connection 3 is provided for safety devices and is not lockable.
Afteractivatingthespindle,generallytthespindleprotectioncapagainandtightenwith14-16Nm.
This serves as a second sealing feature during operation.
For systems with long pipes and higher degree of contamination, a lter on the suction-side is
recommended.Thelterhastobebereneweddependingonthedegreeofcontamination(reduced
pressureloss).
4.10Suctionpipelter

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Fig. 15
The M10 threads in the housing can be used for screwing on attachments and bracing the
compressor.
• Maximum load on the screw connection = 6 g-force
•Maximumtighteningtorqueofthescrews=60Nmwithminimumscrew-indepth=20mm
andfrictioncoefcient=µ0,15.
• Maximum screw-in depth 25 mm.
• Usable screws up to strength class 10.9.
Incaseofscrew-indepthslessthan15mmorlowerfrictioncoefcientsthanµ=0.15,thetightening
torquesandmaximumloadmustbereduced.
168,5 ±0,6 130 ±0,2
LK 170 M10 (4x)
Nur zur Information!
210 ±0,2
30°
54 ±0,2
Passung / Clearance
Werkstoff (Zeile 2+3 alternativ) /
All rights reserved in the event of the grant of a patent, utility model or
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Base part, Raw part:
13
088833
Layh
Maß / Measure
Baumustergeprüft / Tested for type examination:
Layh
Zust. / Rev.
Oberflächenangaben /
The supplier has to ensure the delivery of parts in proper c onditions
Part-No.
bis / up to
2
über / above
Extranet:
--
Alt.bezug / Alt.supply:
zyxw
Freigabe / Approved
tus
Kunde / Customer:
Evobus
3.0851 -K - FKX40/655 K1 *R134a .310182
frei (CAD)
-
-
Status:
Rz 12,5 Rz 6,3
Rz 63
6,3 Rz 16
21,6 0,7 0,3 Rz 1,6 0,05
Nein / No
25 Rz 25
Der Lieferant muß sicherstellen, dass die Ware in einwandfreiem Zustand
(corrosion prevention, packaging for safe trans portation).
Teile-Nr. / Scale:
±0.1
Gewicht / Weight: (kg)
K - FKX40/655 K1 *R134a
09.03.13
Ra Rz
%
Maßstab /
Indication of surface texture
Drawing-No.
±0.2
Rz 160
120
±0.3
32,5
6 30 1000
±0.8
angeliefert wird (Korrosionsschutz, V erpackung für sicheren Transport).
30
Zeichnungs-Nr. /
DIN EN ISO 1302
Page:
-
1/1
Büttner
GneitingGeprüft / Verified
Benennung / Description:
Oberfläche nbehandlung, Härte / Treatm ent of surface, H ardness:
400
Workpiece edges
09.03.13
09.03.13
Blatt /
Datum / Date
Geprüft / Appr.
Erstellt / Drawn
DIN ISO 137 15
-
-
Ausgangsteil, Rohteil /
Material (Line 2+3 alternative):
Änd.-Nr. / Mod-No.
Werkstückkanten /
Gußtoleranze n / Rough castings-genera l tolerances:
Dok-ID:
Projektleiter / Project leader:
--
K.-Auftrag/ C.-Task:
120
Unbemaßte Radien / Undefined radius:
Name
Bearb. / EditedDatum / Date
design.
-
-
-
-
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany
6
0.5
±0.5
400
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwer tung und
Mitteilung seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rec hte für den Fall
der Patent-, Gebrauchsmuster- oder Geschmack smustereintragung
vorbehalten.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without express author ization is
prohibited. Offenders will be held liable for the payment of damages.
Tol.-Ang. / Dim. without individual tolerance
indications DIN ISO 2768-mK
H
D
K
1517
211
F
800,810,
820
1517 340,355,370,
400,410
X
ca.440
108,5
391
151,5
±0,4
253
46
4x 13 ±0,1
46
A
211 221
LC/E
M
SV
A1
220, 210
199
Y
376
232
ca.325
145
ca.415DIM>
167,8 ±0,6 78 ±0,2
±0,2
26
M10x26/31 (3x)
DV
B1 B
221
220,
340,350,360,
380,390
±0,2
150123,5 ±0,6
60 ±0,2
±0,2
150
±0,2
60
123,5 ±0,6
M10x21/25 (4x)
168,5 ±0,6 130 ±0,2
LK 170 M10 (4x)
Nur zur Information!
210 ±0,2
30°
54
±0,2
Passung / Clearance
Werkstoff (Zeile 2+3 alternativ) /
All rights reserved in the event of the grant of a patent, utility model or
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11 10 98
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131415
16
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7654
Base part, Raw part:
13
088833
Layh
Maß / Measure
Baumustergeprüft / Tested for type examination:
Layh
Zust. / Rev.
Oberflächenangaben /
The supplier has to ensure the delivery of parts in proper c onditions
Part-No.
bis / up to
2
über / above
Extranet:
--
Alt.bezug / Alt.supply:
zyxw
Freigabe / Approved
tus
Kunde / Customer:
Evobus
3.0851 -K - FKX40/655 K1 *R134a .310182
frei (CAD)
-
-
Status:
Rz 12,5 Rz 6,3
Rz 63
6,3 Rz 16
21,6 0,7 0,3 Rz 1,6 0,05
Nein / No
25 Rz 25
Der Lieferant muß sicherstellen, dass die Ware in einwandfreiem Zustand
(corrosion prevention, packaging for safe trans portation).
Teile-Nr. / Scale:
±0.1
Gewicht / Weight: (kg)
K - FKX40/655 K1 *R134a
09.03.13
Ra Rz
%
Maßstab /
Indication of surface texture
Drawing-No.
±0.2
Rz 160
120
±0.3
32,5
6 30 1000
±0.8
angeliefert wird (Korrosionsschutz, V erpackung für sicheren Transport).
30
Zeichnungs-Nr. /
DIN EN ISO 1302
Page:
-
1/1
Büttner
GneitingGeprüft / Verified
Benennung / Description:
Oberfläche nbehandlung, Härte / Treatm ent of surface, H ardness:
400
Workpiece edges
09.03.13
09.03.13
Blatt /
Datum / Date
Geprüft / Appr.
Erstellt / Drawn
DIN ISO 137 15
-
-
Ausgangsteil, Rohteil /
Material (Line 2+3 alternative):
Änd.-Nr. / Mod-No.
Werkstückkanten /
Gußtoleranze n / Rough castings-genera l tolerances:
Dok-ID:
Projektleiter / Project leader:
--
K.-Auftrag/ C.-Task:
120
Unbemaßte Radien / Undefined radius:
Name
Bearb. / EditedDatum / Date
design.
-
-
-
-
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany
6
0.5
±0.5
400
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwer tung und
Mitteilung seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. A lleRec hte für den Fall
der Patent-, Gebrauchsmuster- oder Geschmack smustereintragung
vorbehalten.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without express author ization is
prohibited. Offenders will be held liable for the payment of damages.
Tol.-Ang. / Dim. without individual tolerance
indications DIN ISO 2768-mK
H
D
K
1517
211
F
800,810,
820
1517 340,355,370,
400,410
X
ca.440
108,5
391
151,5
±0,4
253
46
4x 13 ±0,1
46
A
211 221
LC/E
M
SV
A1
220, 210
199
Y
376
232
ca.325
145
ca.415DIM>
167,8 ±0,6 78 ±0,2
±0,2
26
M10x26/31 (3x)
DV
B1 B
221
220,
340,350,360,
380,390
±0,2
150123,5 ±0,6
60 ±0,2
±0,2
150
±0,2
60
123,5 ±0,6
M10x21/25 (4x)
168,5 ±0,6 130 ±0,2
LK 170 M10 (4x)
Nur zur Information!
210 ±0,2
30°
54 ±0,2
Passung / Clearance
Werkstoff (Zeile 2+3 alternativ) /
All rights reserved in the event of the grant of a patent, utility model or
F
E
D
C
B
A
12
34
F
E
D
C
A
B
5
6
7
8
16 15 14 13 12
G
H
G
H
9
101112
11 10 98
I
J
K
L
131415
16
I
J
K
L
7654
Base part, Raw part:
13
088833
Layh
Maß / Measure
Baumustergeprüft / Tested for type examination:
Layh
Zust. / Rev.
Oberflächenangaben /
The supplier has to ensure the delivery of parts in proper c onditions
Part-No.
bis / up to
2
über / above
Extranet:
--
Alt.bezug / Alt.supply:
zyxw
Freigabe / Approved
tus
Kunde / Customer:
Evobus
3.0851 -K - FKX40/655 K1 *R134a .310182
frei (CAD)
-
-
Status:
Rz 12,5 Rz6 ,3
Rz 63
6,3 Rz 16
21,6 0,7 0,3 Rz 1,6 0,05
Nein / No
25 Rz 25
Der Lieferant muß sicherstellen, dass die Ware in einwandfreiem Zustand
(corrosion prevention, packaging for safe trans portation).
Teile-Nr. / Scale:
±0.1
Gewicht / Weight: (kg)
K - FKX40/655 K1 *R134a
09.03.13
Ra Rz
%
Maßstab /
Indication of surface textur e
Drawing-No.
±0.2
Rz 160
120
±0.3
32,5
6 30 1000
±0.8
angeliefert wird (Korrosionsschutz, V erpackung für sicheren Transport).
30
Zeichnungs-Nr. /
DIN EN ISO 1302
Page:
-
1/1
Büttner
GneitingGeprüft / Verified
Benennung / Description:
Oberfläche nbehandlung, Härte / Trea tment of surface , Hardness:
400
Workpiece edges
09.03.13
09.03.13
Blatt /
Datum / Date
Geprüft / Appr.
Erstellt / Drawn
DIN ISO 137 15
-
-
Ausgangsteil, Rohteil /
Material (Line 2+3 alternative):
Änd.-Nr. / Mod-No.
Werkstückkanten /
Gußtoleranze n / Rough castings-gener al tolerances:
Dok-ID:
Projektleiter / Project leader:
--
K.-Auftrag / C.-Task:
120
Unbemaßte Radien / Undefined radius:
Name
Bearb. / EditedDatum / Date
design.
-
-
-
-
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany
6
0.5
±0.5
400
Weitergabe sowie Vervielfältigung dieses Dokuments, Ver wertung und
Mitteilung seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet.
Zuwiderhandlungen verpflichten zu Schadenersatz. A lleRec hte für den Fall
der Patent-, Gebrauchsmuster- oder Geschmac ksmustereintragung
vorbehalten.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without express authorization is
prohibited. Offenders will be held liable for the payment of damages.
Tol.-Ang. / Dim. without individual tolerance
indications DIN ISO 2768-mK
H
D
K
1517
211
F
800,810,
820
1517 340,355,370,
400,410
X
ca.440
108,5
391
151,5
±0,4
253
46
4x 13 ±0,1
46
A
211 221
LC/E
M
SV
A1
220, 210
199
Y
376
232
ca.325
145
ca.415DIM>
167,8 ±0,6 78 ±0,2
±0,2
26
M10x26/31 (3x)
DV
B1 B
221
220,
340,350,360,
380,390
±0,2
150123,5 ±0,6
60 ±0,2
±0,2
150
±0,2
60
123,5 ±0,6
M10x21/25 (4x)
X
X
INFO If the M10 threads are used as additional bracing, installation is
overdetermined. It must be ensured that the compressor housing is not
distorted during installation. The specifications of the motor / chassis
manufacturer are mandatory.
Mounting thread only on this side of the compressor available.
4.11 Characteristics for K1 special housing
4|Compressor assembly

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5|Commissioning
5.1 Preparations for start-up
5.4 Evacuation
First evacuate the system and then include the compressor in the evacuation process.
Relieve the compressor pressure.
Open the suction and discharge line valves.
Evacuate the suction and discharge pressure sides using the vacuum pump.
At the end of the evacuation process, the vacuum should be < 1.5 mbar when the pump is switched off.
 Repeattheprocessasoftenasisrequired.
The compressor has undergone trials in the factory and all functions have been tested. There are
therefore no special running-in instructions.
Check the compressor for transport damage!
INFO To protect the compressor against inadmissible operating condi-
tions, high-pressure and low-pressure pressostats are mandatory
on the installation side.
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 maximum permissible overpressure of the compressor must
not be exceeded at any time during the testing process (see name
plate data)! Do not mix any refrigerant with the nitrogen as this
could cause the ignition limit to shift into the critical range.
5.2 Pressure strength test
The compressor has been tested in the factory for pressure integrity. If however the entire system is
to be subjected to a pressure integrity test, this should be carried out in accordance with EN 378-2
or a corresponding safety standard without the inclusion of the compressor.

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5|Commissioning
Make sure that the suction and discharge line valves are open.
 Withthecompressorswitchedoff,addtheliquidrefrigerantdirectlytothecondenserorreceiver,
breaking the vacuum.
If the refrigerant needs topping up after starting the compressor, it can be topped up in vapour
formonthesuctionside,or,takingsuitableprecautions,alsoinliquidformattheinlettothe
evaporator.
After starting, check the compressor's oil level.
Drive motor in operating condition "High idle".
Compressor run time min. 10 minutes.
The system should have reached operating points.
 Checkoillevel.Astheinstallationlocationofthecompressorcandifferinpractice(inclinations),it
is recommended that the oil level is checked in both sight glasses. The oil level must be visible in
at least one sight glass.
5.5 Refrigerant charge
5.6 Oil level check
5.7 Shaft seal
CAUTION Wear personal protective clothing such as goggles and protective
gloves!
ATTENTION Avoidoverllingthesystemwithrefrigerant!
To avoid shifts in concentration, zeotropic refrigerant blends
 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.
ATTENTION After a compressor is replaced, the oil level must be checked again.
If the level is too high, oil must be drained off (risk of oil impact,
reduced performance of the air-conditioning system).
ATTENTION Failure to observe the following instructions can cause loss of
refrigerant and damage to the shaft seal!
INFO The shaft seal seals and lubricates with oil. An oil leakage of
0.05 ml per operating hour is therefore normal. This applies
particularly during the run-in phase (200 - 300 h).
Totrapandcollectleakedoil,theFK40isttedwithaninte-
grated leak oil trapping device with oil reservoir (P.6, Fig. 1).

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5|Commissioning
The compressor shaft is sealed to outside using a shaft seal. The sealing element rotates with the
shaft.
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 Avoidingliquidshocks
Toavoidliquidshocks,thefollowingpointsshouldbeobserved:
The complete refrigeration plant must be correctly designed and executed.
The capacities of all components must be compatible (particularly evaporator and expansion
valve).
Suction gas superheating at the evaporator output should be at least 7 – 10 K (check setting of
theexpansionvalve).
 Thesystemmustreachastateofequilibrium.
 Particularly in critical systems (e.g. several evaporator points), suitable measures, e.g. use of
liquidtraps,solenoidvalveintheliquidline,etc.arerecommended.
ATTENTION Slugging can damage the compressor and cause refrigerant to
leak.

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As changing the shaft seal involves opening the refrigerant
circuit, this is recommended only if the seal is losing refriger-
ant. Replacing the shaft seal is described in the spare part
kit concerned.
Emptying the oil reservoir: The oil reservoir can be emptied
very simple without having to dismantle the coupling and/or
belt drive. It is recommended that this is done at the same
time as the air-conditioning maintenance and motor service.
To proceed, detach the oil hose from the bracket, remove the
sealing plug and drain the oil into a collecting vessel. After
emptying, reseal the oil hose and clamp it into the bracket.
Dispose of the used oil in accordance with national
regulations.
6.3 Shaft seal, emptying the oil reservoir
Fig. 16
6.1 Preparation
6.2 Work to be carried out
6|Maintenance
Oil change: In principle, an oil change is not mandatory if the system is correctly manufactured
and operated. However, based on decades of experience we recommend that the following oil
change/service work is carried out:
 - Firstoilchangeduringtherstmaintenanceofthevehicle.
- Then after every 5,000 operating hours, though no more than 3 years, clean the 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.
WARNING Before starting any work on the compressor:
Switch off the compressor and secure it to prevent a restart.
Relieve compressor of system pressure.
 Preventairfrominltratingthesystem!
After maintenance has been performed:
Connect safety switch.
Evacuate compressor.
Release switch lock.

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The valve is maintenance free.
However, constant leakage can occur after blowing off due to abnormal operating conditions. This
leads to reduced performance and increases the compressed gas temperature. In this case check the
valve and replace as necessary.
6.5 Integrated decompression valve
6.4 Recommended spare parts/accessories
6.7 Decommissioning
Close the shut-off valve on the compressor. Drain the refrigerant (it must not be discharged directly
intotheenvironment)anddisposeofitaccordingtotheregulations.Whenthecompressorisdepres-
surised, undo the fastening screws of the shut-off valves. Remove the compressor using an appropri-
ate hoist. Dispose of the oil inside in accordance with the valid national regulations.
6.6 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.
Refrigerant Bock standard oil grade Recommended alternatives
HFC
(e.g. R134a, R407,
R404A)
Fuchs Reniso Triton SE 55
(seealsochap.6.3)
Fuchs SEZ 32/68/80
Esso/Mobil EAL Arctic 46
HCFC(e.g.R22) Fuchs Reniso SP 46
(seealsochap.6.3)
BP Energol LPT 46
Sunoco Suniso 3.5GS
Texaco Capella WF 46
6|Maintenance
Available spare parts and accessories can be found on our compressor selection tool under
vap.bock.de as well as at bockshop.bock.de.
Only use genuine Bock spare parts!

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7|Accessories
7.1 Capacity regulation
Foradescription,seetechnicalinformation"Capacityregulation"(ItemNo.09900)
Ifthecapacityregulatorisfactory-tted,itisintegratedintoanextra,dedicatedcylindercover.For
retrots,itissuppliedwiththecylindercover.Theregulatorclosesonecylinderbank(capacityregula-
tionapprox.50%).
FK40 / ... ... N + TK ... K
Designation Ref. No. Ref. No.
Special accessory 12 V 08703 08708
Special accessory 24 V 08704 08709
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 recommended as the gas
velocity in the plant system under certain circumstances does not
guaranteesufcientoilreturntothecompressorwithactivated
capacity regulator for a compressor speed below 1200 - 1500 rpm.
We recommend switching to unregulated operation (100% capacity)
for at least 5 minutes per capacity-regulated operating hour. An
assuredoilreturncanalsoberealisedbya100%capacityrequire-
ment after each compressor restart as otherwise the compressor
can also be shut down in the regulated operating time by the
thermostat.
Electrical actuation of the solenoid valve: Normally open, (cor-
responds to 100 % compressor capacity).
Cylinder covers for capacity regulation are marked with the
designation "CR" (Capacity Regulator).

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7|Accessories
A screw-in option is provided for the sensor element on the hot gas side of the compressor
housing(seeChap.9).Connectthethermalprotectionthermostatinserieswiththecontrolline.
Technical Data:
Switching voltage max. : 24 V DC
Switching current max. : 2.5 A at 24 V DC
Switch-off temperature : 145 °C ± 5 K
Switch-on temperature : approx. 115 °C
7.2 Thermal protection thermostat (Item No. 07595)