GEA FK40/560 N User manual

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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

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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

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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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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1.1 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.

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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
1
2
3
4
5
AS12345A020
19/28bar
Observe the limits of
application diagrams!
}
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 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
reducedsuctiongastemperature
Evaporatingtemperature(°C)
Evaporatingtemperature(°C)
Condensingtemperature(°C)
Condensingtemperature(°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:
•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

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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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)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

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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 Fig.9
 Transportandsuspensionunitontheeyebolt(Fig.8)ordirectonthedischargelinevalve
(Fig.9).
 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.
AaA
a
WARNING! Movecompressorsonlywithhoiststhathaveadequateload-bearing
capacity.
AaA
a
Fig.10

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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
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frontbearingangehasa
snugtØ148h8(seeFig.12).
Toconnectthemagneticeld,loosenthe4cheeseheadscrewsM8onthebearingange
(seeFig.12).
Slidethemagneticeldtoasnugtandre-attachusingthefourcheeseheadscrewsM8
(Fig.13).Screwtorque=34Nm.
Furtherassemblyoftheelectromagneticclutchaccordingtotheclutchmanufacturer.
Fig.12
Bearingange,front
Magneticeld
Fig.13
148h8
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.11)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.11

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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.
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).
 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.14: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.15 Fig.16
Release
Tighten
 Therequiredtighteningtorquefortheangeconnectionis60Nm.

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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.17
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.18
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.

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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.
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!
5.2 Pressure strength test
DANGER! 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.
Thecompressorhasbeenfactory-testedforpressureresistance.Thefollowingmustbeobservedif
theentireplantissubjectedtoanadditionalpressurestrengthtest:
 TesttherefrigerationcircuitaccordingtoEN378-2oracorrespondingsafetystandard.
5.3 Leak test
DANGER! Bursting!
Do not mix any refrigerant with the nitrogen (N2) as this could cause
the ignition limit to shift into the critical range.
CarryouttheleaktestoftherefrigeratingsysteminaccordancewithEN378-2oracorresponding
 safetystandardwithout including 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.
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sightglasses.Theoillevelmustbevisiblein
atleastonesightglass.
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 Oil level check
5.7 Shaft seal
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integrated
leakoiltrappingdevicewithoilreservoir(P.6,Fig.1).
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).

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5|Commissioning
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.
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 Shaft seal, emptying the oil reservoir
5.9 Avoidingliquidshocks
ATTENTION! Slugging can damage the compressor and cause refrigerant to
leak.
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.
Fig.19

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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.
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.
6.4 Integrated decompression valve
Only use genuine Bock 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.
FK40 / ... 390 N
470 N
560 N
655 N
390K
470K
560K
655K
390TK
470TK
560TK
655TK
Designation Art.-Nr. Art.-Nr. Art.-Nr. Art.-Nr. Art.-Nr.
Setofgaskets 80230 80001 80230
Valveplatekit 80240 80241 80010 80240 80241
Setofshaftseals 80023
OilSP46,1Ltr. 02279
OilSE55,1Ltr. 02282

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6.6 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|Maintenance
6.5 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
ICIEmkarateRL46S
MobilArcticEAL46
ShellClavusR46
HCFC(e.g.R22) Fuchs Reniso SP 46
(seealsochap.6.3)
MobilSHC425
ShellClavusSD22-12
SunoilSuniso4GS
TexacoCapellaWF46

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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%).
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)
FK40 / ... ... N + TK ... K
Designation Art.-Nr. Art.-Nr.
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
dimensioning accordingly, donotsetthe controlintervals too closeand
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,(corre-
spondsto100%compressorcapacity).
Cylinder covers for capacity regulation are marked with the
designation"CR"(CapacityRegulator).