GEA Bock FK50 Series User manual

GEA Bock FK50
Assembly instructions
09704-10.2019-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
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

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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
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 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
  4.10Suctionpipelter
5 Commissioning 13
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 16
6.1 Preparation
6.2 Work to be carried out
6.3 Shaft seal, emptying the oil reservoir
6.4 Recommended spare parts
6.5 Integrated decompression valves
6.6 Extract from the lubricants table
6.7 Decommissioning
7 Accessories 18
7.1 Capacity regulator
7.2 Thermi protection thermostat
8 Technical Data 19
9 Dimensions and Connections 20
 10 Installationcerticate 22
11 Service 23

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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 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 and 2014/68/EU 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
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
Two different designs are available for various ranges of application:
> for air-conditioning the K Design
> for air-conditioning or normal cooling the N 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
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
BB12345A029
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
 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
ATTENTION Compressor operation is possible within the operating limits.
These can be found in GEA Bock compressor selection tool (VAP)
under vap.gea.com. Observe the information given there.
- 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).
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!
INFO For recharging, we recommend the above oil types. Alternatives are:
see lubricants table, Chapter 6.6.

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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
Fig. 4
 Transportandsuspensionunitonbotheyebolts(Fig.4).
 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.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.
AA
aa
AA
aa
Fig. 5
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
4.5 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148h8(seeFig.7).
Toconnectthemagneticeld,loosenthe4cheeseheadscrewsM8onthebearingange
(seeFig.7).
Slidethemagneticeldtoasnugtandre-attachusingthefourcheeseheadscrewsM8
(Fig.8).Screwtorque=37Nm.
Further assembly of the electromagnetic clutch according to the clutch manufacturer.
Fig. 7
Bearingange,front
Magneticeld
Fig. 8
148 h8
4.4 Main bearing load
To prevent the belt drive overloading the compressor main bearing,
ensure that:
The engagement force applied by the belt tension (centre of
shafttaper,seeFig.10)mustnotexceedFmax per.=2750N.
If the force engagement point shifts to the right (see Fig.6,
smallpoint),theforceFmax per. reduces as per the following
formula:
Fmax per.= 245 kNmm
(90 mm + L1[mm])
Fmax= 2750 N
Mbmax= 245kNmm
L
1
(mm)
Fig. 6
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.