GEA FK50/460 N User manual

GEA Compressor FK50
Assembly instructions
09704-06.2016-Gb
Translation of the original instructions
FK50/460 N FK50/555 N FK50/660 N FK50/775 N FK50/830 N FK50/980 N
FK50/460 K FK50/555 K FK50/660 K FK50/775 K FK50/830 K FK50/980 K
FK50/460 TK FK50/555 TK FK50/660 TK FK50/775 TK
FKX50/460 N FKX50/555 N FKX50/660 N FKX50/775 N FKX50/830 N FKX50/980 N
FKX50/460 K FKX50/555 K FKX50/660 K FKX50/775 K FKX50/830 K FKX50/980 K
FKX50/460 TK FKX50/555 TK FKX50/660 TK FKX50/775 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
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Telephone [phone]
Fax [phone]
[email protected]
www.gea.com
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 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 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 valves
6.5 Extract from the lubricants table
6.6 Decommissioning
7 Accessories 20
7.1 Capacity regulator
7.2 Thermi 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 FK50 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 six cylinder compressor in W design.
Six capacity ranges.
Lightweight aluminum design.
Lubricating oil pump with oil pressure relief valve independent of rotational direction.
Variable arrangement of the shut-off valves.
Fig. 1
2.1 Brief description
Fig. 2
Valve plate
Cylinder cover
Shaft end
Shaft seal
Suction shut-off valve
Suction line valve
Oil pump
Dimension and connection values can be found in Chapter 9
Eyebolt
Leak oil trapping
device with oil
reservoir
Name plate
Eyebolt
Oil sight glass
Oil sightglass
Discharge shut-off valve
Leak oil drain hose

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2|Product description
/
FK 05 775 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
AT12345A029
19/28bar
Observe the limits of application
diagrams!
}
FKX50/775N
67,4
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).
   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ci-
ent oil is transported back to the compressor.
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. FKX50/775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) 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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:
• FKX50/460 N • FKX50/555 N • FKX50/660 N • FKX50/775 N
• FKX50/460 K • FKX50/555 K • FKX50/660 K • FKX50/775 K
• FKX50/830 N • FKX50/980 N
• FKX50/830 K • FKX50/980 K
Permissible rotation speeds:
N Design: 500 – 3000 rpm (maxrotationspeed3500rpm)
K Design: 500 – 3500 rpm
3.4.2 Limits of application R407C (N and K versions)
Permissible rotation speeds:
N Design: 500 – 2600 rpm
K Design: 500 – 3500 rpm

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3|Areas of application
3.5 TK version
Models available:
•FK50/460 TK •FK50/555 TK •FK50/660 TK •FK50/775 TK
•FKX50/460 TK •FKX50/555 TK •FKX50/660 TK •FKX50/775 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 rpm
Permissible rotation speeds:
TK design: 500 – 2600 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 tempera-
ture
Evaporationtemperature(°C)
Condensingtemperature(°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 tempera-
ture
Evaporationtemperature(°C)
Condensingtemperature(°C)
Suctiongassuperheat(K)
Suctiongastemperature(°C)
Designforotherrangesonrequest
Fig. 7