GEA FK40/560 N User manual

1
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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

2
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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

3
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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

4
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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.

5
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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

6
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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

7
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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

8
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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.

9
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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

10
09716-01.2013-DGbFEITrCn
D
GB
F
E
I
TR
CN
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