GEA Bock FF-NH3 User Manual

Bock Compressors F/F-NH

Assembly instructions

F2, F3 F4, F5 F14/1166, F14/1366 F16/1751, F16/2051

FX2, FX3 FX4, FX5 FX14/1166, FX14/1366 FX16/1751, FX16/2051

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engineering for a better world GEA Refrigeration Technologies

F2 NH3, F3 NH F4 NH3, F5 NH F14/1166 NH3, F14/1366 NH F16/1751 NH3, F16/2051 NH

3 3

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.

Manufacturer

GEA Bock GmbH 72636 Frickenhausen

Contact

GEA Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Telephone +49 7022 9454 0

Fax +49 7022 9454-137

bock@gea.com

www.bock.de

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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

1.5

2 Product description 6

2.1 Short description

2.2 Name plate

2.3 Type code

3 Areas of application F 9

3.1 Refrigerants F, F-NH

3.2 Oil charge

3.3 Operating limits

4 Areas of application F-NH3 11

4.1 Oil charge NH

4.2 Operating limits NH 5 Compressor assembly 12

5.1 Setting up

5.2 Maximum permissible inclination

5.3 Pipe connections

5.4 Pipes

5.5 Laying suction and discharge lines

5.6 Operating the shut-off valves

5.7 Operating mode of the lockable service connections

5.8 Drive

5.9 Oil sump heating (standard by F4, F5, F14 and F16)

6 Commissioning 18

6.1 Preparations for start-up

6.2 Pressure resistance test

6.3 Leak test

6.4 Evacuation

6.5 Refrigerant charge

6.6 Shaft seal

6.7 Shaft seal change

6.8 Start-up

6.9 Avoiding slugging

7 Maintenance 21

7.1 Preparation

7.2 Work to be carried out

7.3 Spare parts recommendation

7.4 Spare parts recommendation NH

7.5 Accessories

7.6 Excerpt from the lubricant table

7.7 Decommissioning

8 Technical data F2-F16 23 9 Technical data F2 NH3-F16 NH

10 Dimensions and connections F 25 11 Dimensions and connections F-NH3 33

12 Declaration of installation 41 13 Service 42

1.4 Additional safety instructions NH Intended use

1 | Safety

1.1 Identication of safety instructions:

DANGER!

WARNING!

CAUTION!

ATTENTION!

INFO!

1.2 Qualications required of personnel

INFO! This operating manual describes compressors that are suitable

Specic information and characteristics for using NH3 are

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

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.

for both F-gases and for NH3.

indicated at the corresponding location with the following symbols:

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

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.

1.4 Additional safety instructions NH

1.5 Intended use

These assembly instructions describe the standard version of the compressor named in the title and NH3 manufactured by Bock. The Bock refrigerating compressor are 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.

Only the refrigerant specied in these instructions may be used.

Any other use of the compressor is prohibited!

ATTENTION! • High toxicity, intense odour (MAK 50 ppm)

• Explosive between 15 and 30 vol. % in the air. Due to the high

ignition energy and temperature, the risk of explosion, however, is rated as low. So there are no special explosion protection

measures are required.

• However, the national safety regulations, accident prevention

regulations, technical regulations as well as specific regulations (EN 378 etc.) must be observed.

• NH3 steam is lighter than air and therefore disperses upwards.

• All key directives are summarised in the area for the AiF research

project 9404B "Safety of ammonia refrigeration systems".

• NH3 corrodes copper materials and non-ferrous metals and is

incompatible with a number of plastics.

• Proof of personnel's specific expertise for installation,

commissioning, operation and service.

WARNING! The compressor may not be used in potentially explosive environments!

2 | Product description

2.1 Short description

Open type compressors for external drive (V-belt or coupling) with oil pump lubrication

Short description NH

Based on the F compressor series, a specially modied selection of compressors is available for use with the refrigerant R 717.

Important differences from the basic compressor F:

Pistons with three-ring assembly Con-rod with additional oil supply oil to the small end Valve plate with optimised pressure unit Shut-off valve with steel connector for welded joints All connections are designed as compression joints for steel pipes F14 NH3 and F16 NH3 with increased oil volume due to the higher base plate Special oil lling for NH3: Fuchs Reniso KC 68

F2, F3

Cylinder cover

Suction shut-off valve

Discharge shut-off valve

Valve plate

Oil sightglass

Fig. 1

Dimension and connection values can be found in Chapter 10

Shaft seal

Shaft end

Compressor housing

Base plate

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2 | Product description

F4, F5

Cylinder cover

Suction shut-off valve

Name plate

Fig. 2

F14, F16

Discharge

shut-off valve

Valve plate

Shaft seal

Shaft end

Compressor housing

Base plate

Discharge shut-off valve

Transport eyelet

Cylinder cover

Valve plate

Compressor housing

Base plate

Dimension and connection values can be found in Chapter 10

F16

Suction

shut-off valve

Transport eyelet

Shaft seal

Shaft end

Leak oil drain hose

Fig. 3

2 | Product description

2.2 Name plate (example)

GEA Bock GmbH 72636 Frickenhausen, Germany

1 2 3 4

5 6

1 Type designation 2 Machine number 3 Rotation speed minimum with a corresponding displacement 4 Rotation speed maximum with a corresponding displacement

5 ND(LP): Max. admissible operating pressure Suction side HD(HP): Max. admissible operating pressure

High-pressure side

6 Oil type charged at factory

2.3 Type code (example)

FX16/2 051

19/28

SE55

Fig. 4

Observe the limit of

application diagrams!

F 14

)

X - Ester oil charge (HFC refrigerant R134a, R404A/R507, R407C)

)

Indication only at F14, F16

1166

NH3 version

Swept volume

Size

)

Oil charge

Series

)

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3 | Areas of application F, F-NH

3.1 Refrigerants

• HFKW: R134a, R404A/R507, R407C

• (H)FCKW: R22

NH3:

3.2 Oil charge

The compressors are lled with the following oil type at the factory:

- 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. FX16/2051).

R7 17

INFO! Alternatives: see lubricants table, Chapter 7.6

ATTENTION!

3.3 Operating limits ATTENTION! Compressor operation is possible within the operating

limits shown in the diagrams. Please note the signicance of the shaded areas. Thresholds should not be selected as design or continuous operating points.

- Max. permissible discharge end temperature: 140°C

- Max. permissible switching frequency: 12x /h

- A minimum running time of 3 min. steady-state condition

Avoid continuous operation near the threshold. For operation with supplementary cooling:

- Use only oils with high thermal stability. For operation with capacity regulator:

- The suction gas superheat temperature may need to be reduced

When operating in the vacuum range, there is a danger of air

For refilling, we recommend the above oil types.

The oil level must be in the visible part of the sight glass; damage to the compressor is possible if overfilled or underfilled!

(continuous operation) must be achieved.

or set individuallywhen operating near to the threshold.

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!

max. oil level

min. oil level

Fig. 5

3| Areas of application F

3.3 Operating limits

R134a

Fig. 6

R404A/R507

Fig. 7

Unlimited application range

Reduced suction gas temperature

Evaporating temperature (°C)

Condensing temperature (°C)

Suction gas superheat (K)

Suction gas temperature (°C)

Permissible rotation speeds:

F2, F3: 960 - 1800 rpm F4, F5: 500 - 1800 rpm

F14, F16: 700 - 1800 rpm

Fig. 8

Fig. 9

R407C

R22

Maximum admissible

operating pressure (g)

High pressure side (LP/HP)1):

19/28 bar

LP = Low pressure

HP = High pressure

Design for other

areas on request

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4| Areas of application F-NH

The compressors are lled with the following oil type at the factory:

- for R717: Fuchs Reniso KC 68

4.1 Oil charge NH

4.2 Operating limits NH

Fig. 10

Permissible rotation speeds:

F2 NH

, F3 NH3: 960 - 1500 rpm

F4 NH

, F5 NH3: 500 - 1500 rpm

F14 NH

, F16 NH3: 700 - 1500 rpm

Supplementary cooling necessary

(e.g. water-cooled

cylinder covers)

Unlimited application range

Evaporating temperature (°C)

Condensing temperature (°C)

Suction gas superheat (K)

Design for other

areas on request

Max. permissible operating

pressure (LP/HP)1): 19/25 bar

LP = Low pressure

HP = High pressure

Nh3

-30 -20 0-10 10

t (°C)

-40

t (°C)

5| Compressor assembly

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.

5.1 Setting up

WARNING! Move compressors only with hoists that have adequate load-bearing

capacity.

Transport and suspension unit on the eyebolt (Fig. 12, F14 to F16) or direct on the discharge

line valve (Fig. 11, F2 to F5).

Fig. 11

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.

Fig. 12

Fig. 13

Fig. 14

Fig. 15

Provide adequate clearance for maintenance work. Provide adequate ventilation for the drive motor.

Do not use in a dusty, damp atmosphere or a combustible

environment.

Set up on an even surface or frame with sufcient load-bearing

capacity.

Compressors and drive motors are basically rigid and should be

mounted together on a base frame.

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5| Compressor assembly

5.2 Maximum permissible inclination

ATTENTION! Poor lubrication can damage the compressor. Respect the stated values.

A A

Fig. 16

5.3 Pipe connections

ATTENTION! Overheating can damage the valve.

Remove the pipe supports from the valve for soldering. Only solder using inert gas to inhibit oxidation products (scale).

Fig. 17: Stepped internal diameters

A A

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.

The required tightening torque for the ange connection is 60 Nm.

max. 30°,

max. 2 minutes

max. 15°,

continuous operation

5.4 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.

5| Compressor assembly

5.5 Laying suction and discharge lines INFO! Proper layout of the suction and discharge lines directly after

the compressor is integral to the system’s smooth running and vibration behaviour.

ATTENTION! Improperly installed pipes can cause cracks and tears, the result

being a loss of refrigerant.

A rule of thumb: Always lay the rst pipe section starting from the shut-off valve downwards and parallel to the drive shaft.

As shor t as possible

Rigid Fixed point

Fig. 18

5.6 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.

loosen

tighten

Valve spindle seal

Fig. 19 Fig. 20

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GEA Bock FF-NH3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual