GEA FK40/560 N Manual de usuario

09716-01.2013-DGbFEITrCn

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

09716-01.2013-DGbFEITrCn

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

09716-01.2013-DGbFEITrCn

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

09716-01.2013-DGbFEITrCn

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.

09716-01.2013-DGbFEITrCn

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

09716-01.2013-DGbFEITrCn

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

09716-01.2013-DGbFEITrCn

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

AS12345A020

19/28bar

Observe the limits of

application diagrams!

}

GEA Bock GmbH

72636 Frickenhausen, Germany

09716-01.2013-DGbFEITrCn

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.

09716-01.2013-DGbFEITrCn

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

Evaporatingtemperature(°C)

Condensingtemperature(°C)

Suctiongassuperheat(K)

Suctiongastemperature(°C)

Fig.4

Fig.5

-20 -10 10

020 30 t (°C)

t (°C)

-30

t + 25 °C

20 K

R134a

-20 -10 10

020 t (°C)

t (°C)

-30

-25

toh 20 K

t + 25 °C

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

09716-01.2013-DGbFEITrCn

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

-10

-20

-30

-40

-50

t (°C)

Dtoh<20K

t +20°C

-45

R404A/R507

R404A/R507 TK

toh

Verdampfungstemperatur (°C)

Verflüssigungstemperatur (°C)

Sauggasüberhitzung (K)

Sauggastemperatur (°C)

Uneingeschränkter

Anwendungsbereich

reduzierte Sauggastemperatur

R22

toh

Verdampfungstemperatur (°C)

Verflüssigungstemperatur (°C)

Sauggasüberhitzung (K)

Sauggastemperatur (°C)

Uneingeschränkter

Anwendungsbereich

reduzierte Sauggastemperatur

R22 TK

-10

-20

-30

-40

-50

t (°C)

Dtoh<20K

t +25°C

-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

Este manual sirve para los siguientes modelos

Tabla de contenidos

Otros manuales de Compresor de aire de GEA

GEA

GEA HG22e/160-4 Manual de usuario

GEA

GEA HG34e Manual de usuario

GEA

GEA HGX4 R134a Manual de usuario

GEA

GEA Grasso M-Series Manual de usuario

GEA

GEA HG76e/1620-4 Manual de usuario

GEA

GEA HA22P/125-4 Manual de usuario

GEA

GEA Bock HG8 Series Manual de usuario

GEA

GEA Bock HGX46 CO2 T Series Manual de usuario

GEA

GEA HG44e Manual de usuario

GEA

GEA FK40 Series Manual de usuario

GEA

GEA HG22e/125-4 Manual de usuario

GEA

GEA HGX12P CO2 Manual de usuario

GEA

GEA Bock HG22P A Manual de usuario

GEA

GEA HGX5/725-4 R134a Manual de usuario

GEA

GEA HGX4 CO2 Series Manual de usuario

GEA

GEA HGX46/280-4 ML CO2T Manual de usuario

GEA

GEA Bock HGX2/70-4 CO2 T Manual de usuario

GEA

GEA HG4 Manual de usuario

GEA

GEA Bock F76 Series Manual de usuario

GEA

GEA HGX34/110-4 ML CO2 T Manual de usuario

GEA

GEA FK50/460 N Manual de usuario

GEA

GEA HGX34/130-4 ML CO2 T Manual de usuario

GEA

GEA HGX12e S CO2 Manual de usuario

GEA

GEA HG34P/215-4 Manual de usuario

Manuales populares de Compresor de aire de otras marcas

Sparmax

Sparmax DC-25XR Manual de usuario

KAESER

KAESER M122 Manual de usuario

GMC

GMC GAC1500 Manual de usuario

Briggs & Stratton

Briggs & Stratton Air Compressor Manual de usuario

Fini

Fini F3GST2TK Manual de usuario

Industrial Air

Industrial Air CP1580325 Manual de programación

Campbell Hausfeld

Campbell Hausfeld RP3300 Guía de inicio rápido

Ingersoll-Rand

Ingersoll-Rand UP6 20 HP Manual de usuario

Hitachi

Hitachi EC99S Manual del operador

Parkside

Parkside PKO 270 A1 Manual de usuario

Sullair

Sullair 185 Manual de usuario

Clas Ohlson

Clas Ohlson QIE-ZTH-15 Manual de usuario

Ferm

Ferm CRM1046 Manual de usuario

BE AC153 Manual de usuario

RIDGID

RIDGID OF25150A Manual de usuario

Johnson Controls

Johnson Controls QUANTUM LX Manual

Sears

Sears Craftsman 919.167463 Manual de usuario

Ring Automotive

Ring Automotive RAC700 Manual de usuario