GEA FK20 User manual

GEA Compressor FK20
Assembly instructions
09740-06.2016-Gb
Translation of the original instructions
FK20/120 N FK20/145 N FK20/170 N
FK20/120 K FK20/145 K FK20/170 K
FK20/120 TK FK20/145 TK FK20/170 TK
FKX20/120 N FKX20/145 N FKX20/170 N
FKX20/120 K FKX20/145 K FKX20/170 K
FKX20/120 TK FKX20/145 TK FKX20/170 TK

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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 [phone]
Fax [phone]
[email protected]
www.gea.com

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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 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 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
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 Shaft seal
5.6.1 Notes on replacing the shaft seal
  5.7 Avoidingliquidshocks
6 Maintenance 18
6.1 Preparation
6.2 Work to be carried out
6.3 Recommended spare parts
6.4 Extract from the lubricants table
6.5 Decommissioning
6.6 Valve plate, TK version
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

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1.1 Identicationofsafetyinstructions:
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.
1|Safety
1.2 Qualicationsrequiredofpersonnel
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.

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1|Safety
These assembly instructions describe the standard version of the FK20 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, 97/23/EC 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
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.

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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 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
Suction shut-off
valve
Cylinder cover
Name plate
Shaft end
Shaft seal
Valve plate
Oil pump
Dimension and connection values can be found in Chapter 9
Discharge
shut-off valve

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2|Product description
/
FK 02 170 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
1
2
3
4
5
AS12345A020
19/28bar
Observe the limits of application
diagrams!
}
FKX20/170N
14,8
GEA Bock GmbH
72636 Frickenhausen, Germany

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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
compressor 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
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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. FKX20/170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 6.4.

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3|Areas of application
Designforotherrangesonrequest
Max. permissible
operatingpressure(g)high-
pressureside(HP):28bar
Max. permissible
operatingpressure(g)high-
pressureside(HP):28bar
Unrestricted
application range
Unrestricted
application range
Reduced suction gas
temperature
Reduced suction gas
temperature
Evaporationtemperature(°C)
Evaporationtemperature(°C)
Condensingtemperature(°C)
Condensingtemperaturee(°C)
Suctiongassuperheat(K)
Suctiongassuperheat(K)
Suctiongastemperature(°C)
Suctiongastemperature(°C)
Fig. 4
Fig. 5
20
30
50
70
80
-20 -10 10
020 30 t (°C)
o
t (°C)
c
82
-30
40
60
90
t + 25 °C
oh
<
?
t
oh
20 K
R134a
20
30
50
-20 -10 10
020 t (°C)
o
t (°C)
c
61
-30
40
60
-25
<
?
toh 20 K
t + 25 °C
oh
R407C
3.4.1LimitsofapplicationR134a(NandKversions)
3.4 N and K versions
Models available:
• FKX20/120 N • FKX20/145 N • FKX20/170 N
• FKX20/120 K • FKX20/145 K • FKX20/170 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

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3|Areas of application
3.5 TK version
Models available:
• FK20/120 TK • FK20/145 TK • FK20/170 TK
• FKX20/120 TK • FKX20/145 TK • FKX20/170 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
FK
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
Dtoh<20K
t +20°C
oh
58
-45
R404A/R507
R404A/R507 TK
t
c
t
0
toh
Dt
oh
Verdampfungstemperatur (°C)
Verflüssigungstemperatur (°C)
Sauggasüberhitzung (K)
Sauggastemperatur (°C)
Uneingeschränkter
Anwendungsbereich
reduzierte Sauggastemperatur
FK
R22
t
c
t
0
toh
Dt
oh
Verdampfungstemperatur (°C)
Verflüssigungstemperatur (°C)
Sauggasüberhitzung (K)
Sauggastemperatur (°C)
Uneingeschränkter
Anwendungsbereich
reduzierte Sauggastemperatur
R22 TK
10
0
-10
-20
-30
-40
-50
20
30
40
50
60
70
t (°C)
o
t (°C)
c
Dtoh<20K
t +25°C
oh
66
-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

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4|Compressor assembly
4.1 Setting up
4.2 Maximum permissible inclination
Amax. 30°,
max. 2 minutes
amax. 15°,
continuous
operation
ATTENTION! Poor lubrication can damage the compressor.
Respect the stated values.
INFO! Newcompressorsarefactory-lledwithinertgas(3barnitrogen).
Leave this service 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.
Fig. 8
AA
aa
AA
aa
 Fittings(e.g.pipeholders,additionalunitsetc.)onthecompressorarepermissibleonly
following consultation with GEA.
 Setuponanevensurfaceorframewithsufcientload-bearingcapacity.Thecompressorcan
be fastened as follows:
- using the 4 drill holes on the baseplate
- using the 3 side M10 tapped blind holes on the left or right of the compressor housing
- using the 4 M10 tapped blind holes on the front of the compressor housing.
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.

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4|Compressor assembly
4.3 V-belt drive
4.4 Main bearing load
4.5 Electromagnetic clutch assembly
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.
The following description applies for an electromagnetic clutch secured to a shaft.
Toabsorbthemagneticeldoftheelectromagneticclutch,theslidingringlidhas
asnugtØ38h8(seeFig.10).
Toconnectthemagneticeld,removethemarkedAllenheadscrewsoftheslidingringlid
(seeFig.11).
Slidethemagneticeldtoasnug-tandfastenusingthethreeM5x18cheesehead
screwsprovided(Fig.11).Screwtorque=9Nm.
Further assembly of the electromagnetic clutch according to the clutch manufacturer.
Fig. 10
Sliding ring lid
Magneticeld
Fig. 11
To prevent the belt drive overloading the compressor main bearing,
ensure that:
Theengagementforceappliedbythebelttension(seeFig.9)
must not exceed Fmax per.=600N.
If the force engagement point shifts to the right (see Fig. 9,
smallpoint),theforceFmax per. reduces as per the following
formula:
Fmax per.= 30 kNmm
(50 mm + L1[mm])
Fmax= 600 N
Mbmax= 30kNmm
L
1
(mm)
Fig. 9
Snugt

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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.
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. 13 Fig. 14
ATTENTION! Overheating can damage the valve.
Solder only using inert gas to inhibit oxidation products.
Release
Tighten
The pipe connections have graduated inside diameters so that pipes
in the common millimeter 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. 12: Stepped
internal diameters

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4|Compressor assembly
4.9 Operating mode of the lockable service connections
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. 15
Fig. 16
1
1
3
3
Pipe connection
Pipe connection
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.
3
3
2
2
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.

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5|Commissioning
5.1 Preparations for start-up
5.4 Evacuation
First evacuate the system and then includethe 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.
INFO! To protect the compressor against inadmissible operating
conditions, high-pressure and low-pressure pressostats are
mandatory on the installation side.
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!
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.
5.3 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.
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
CAUTION! Wear personal protective clothing such as goggles and
protective gloves!
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.
ATTENTION! Avoidoverllingthesystemwithrefrigerant!
To avoid shifts in concentration, zeotropic refrigerant blends
    (e.g.R407C)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.
5.5 Refrigerant charge
5.6 Shaft seal
As changing the seal involves opening the refrigerant circuit, this is recommended only if the seal is
losing refrigerant. Replacing the seal is described in the spare part kit concerned.
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).
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.
5.6.1 Notes on replacing the shaft seal

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5|Commissioning
5.7 Avoidingliquidshocks
ATTENTION! Slugging can damage the compressor and cause refrigerant to
leak.
Topreventliquidshocks:
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.

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6.1 Preparation
6.2 Work to be carried out
6|Maintenance
FK20 / ... 120 N
145 N
170 N 120 TK
145 TK
170 TK 120 K
145 K
170 K
Designation Ref. No. Ref. No. Ref. No. Ref. No. Ref. No.
Set of gaskets 80200 80515
Valve plate kit 80240 80242 80201 80202 80514
Set of shaft seals 08002
Oil SP 46, 1 litre 02279
Oil SE 55, 1 litre 02282
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.
Annualchecks: Check the tightness of the compressor, running noise, pressures, temperatures,
function of auxiliary devices.
Only use genuine GEA spare parts!
6.3 Recommended spare parts
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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6.5 Decommissioning
6.6 Valve plate, TK version
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
depressurised, undo the fastening screws of the shut-off valves. Remove the compressor using an
appropriate hoist. Dispose of the oil inside in accordance with the valid national regulations.
Based on the tried-and-tested N valve plate system, a valve plate with reduced dead space
hasbeenadaptedtotheFK20TKspecicallyforapplicationsinthedeep-freezearea.Thesystemis
equippedwithanon-interchangesafeguardtoavoidconfusingitwithNvalveplate.
6|Maintenance
6.4 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.
Refrigerants GEA standard oil types 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
Non-interchangesafeguardfortheFK20valveplate,TKversion:
Fig. 17

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7|Accessories
Aspecialintermediateange,locatedbelowthedischargelinevalve,isusedtoattachthesensor
element(Partno.04175).Wire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
7.1 Thermalprotectionthermostat(ItemNo.07595)