GEA Bock FF-NH3 User Manual

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09702-09.2013-DGbF

Bock Compressors F/F-NH3

Assembly instructions

F2, F3	F2 NH3, F3 NH3
F4, F5	F4 NH3, F5 NH3
F14/1166, F14/1366	F14/1166 NH3, F14/1366 NH3
F16/1751, F16/2051	F16/1751 NH3, F16/2051 NH3
FX2, FX3
FX4, FX5
FX14/1166, FX14/1366
FX16/1751, FX16/2051
engineering for a better world		GEA Refrigeration Technologies

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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.

Manufacturer

GEA Bock GmbH

72636 Frickenhausen

Contact

GEA Bock GmbH

Benzstraße 7

72636 Frickenhausen

Germany

Telephone [phone]

Fax

[phone]

[e-mail]

www.bock.de

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Contents		Page
	1 Safety	4

1.1Identification of safety instructions

1.2Qualifications required of personnel

1.3General safety instructions

1.4Additional safety instructions NH3

1.5Intended use

	2	Product description	6
	2.1	Short description
	2.2	Name plate
	2.3	Type code
	3	Areas of application F	9

3.1Refrigerants F, F-NH3

3.2Oil charge

3.3Operating limits

4	Areas of application F-NH3	11
4.1	Oil charge NH3
4.2	Operating limits NH3
5	Compressor assembly	12

5.1Setting up

5.2Maximum permissible inclination

5.3Pipe connections

5.4Pipes

5.5Laying suction and discharge lines

5.6Operating the shut-off valves

5.7Operating mode of the lockable service connections

5.8Drive

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

6 Commissioning

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6.1Preparations for start-up

6.2Pressure resistance test

6.3Leak test

6.4Evacuation

6.5Refrigerant charge

6.6Shaft seal

6.7Shaft seal change

6.8Start-up

6.9Avoiding slugging

7 Maintenance

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7.1Preparation

7.2Work to be carried out

7.3Spare parts recommendation

7.4Spare parts recommendation NH3

7.5Accessories

7.6Excerpt from the lubricant table

7.7Decommissioning

8	Technical data F2-F16	23
9	Technical data F2 NH3-F16 NH3	24
10	Dimensions and connections F	25
11	Dimensions and connections F-NH3	33
12	Declaration of installation	41
13	Service	42

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1 | Safety

1.1 Identification 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.
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				NH3	INFO!	This operating manual describes compressors that are suitable
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						for both F-gases and for NH3.
E						Specific information and characteristics for using NH3 are
						indicated at the corresponding location with the following
						symbols:	NH3

1.2 Qualifications required of personnel

WARNING! Inadequately qualified personnel poses the risk of accidents, the consequence being serious or fatal injury. Work on compressors is therefore reserved for personnel with the qualifications listed below:

•For example, a refrigeration technician, refrigeration mechatronic engineer. As well as professions with comparable training, which enablespersonneltoassemble,install,maintainandrepairrefrigeration 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 NH3

NH3	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.

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 specified in these instructions may be used.

Any other use of the compressor is prohibited!

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

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2 |Product description

2.1 Short description

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

Short description NH3

Based on the F compressor series, a specially modified 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 filling for NH3: Fuchs Reniso KC 68

F2, F3

F2

Discharge shut-off valve

Cylinder cover

Valve plate

Suction shut-off valve

Shaft seal

Shaft end

Oil sightglass

Compressor housing

Base plate

Fig. 1

Dimension and connection values can be found in Chapter 10

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2 |Product description

F4, F5

F5

Discharge

shut-off valve

Cylinder cover

Suction shut-off valve

Valve plate

Shaft seal

Shaft end

Compressor housing

Name plate

Base plate

Fig. 2

F14, F16

F16

Discharge shut-off valve

Suction

shut-off valve

Transport eyelet

Cylinder cover

Transport eyelet

Valve plate

Shaft seal

Shaft end

Compressor housing

Base plate

Fig. 3

Leak oil drain hose

Dimension and connection values can be found in Chapter 10

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2 |Product description

2.2 Name plate (example)

			GEA Bock GmbH
			72636 Frickenhausen, Germany
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			FX16/2051
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5						19/28
6			SE55

Fig. 4

1Type designation

2Machine number

3Rotation speed minimum with a corresponding displacement

4Rotation speed maximum with a corresponding displacement

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

	HD(HP): Max. admissible operating pressure	Observe the limit of
		application diagrams!
	High-pressure side

6Oil type charged at factory

2.3Type code (example)

F X 14 / 1166 NH3

NH3 version

Swept volume ²)

Size

Oil charge ¹)

Series

¹) X - Ester oil charge (HFC refrigerant R134a, R404A/R507, R407C) ²) Indication only at F14, F16

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3 |Areas of application F, F-NH3

3.1 Refrigerants
•	HFKW:	R134a, R404A/R507, R407C
•	(H)FCKW:	R22
	NH3:	R717
3.2 Oil charge
	The compressors are filled 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).

		INFO!	For refilling, we recommend the above oil types.
			Alternatives: see lubricants table, Chapter 7.6
		ATTENTION!	The oil level must be in the visible
			part of the sight glass; damage
				max. oil level
			to the compressor is possible if
				min. oil level
			overfilled or underfilled!
				Fig. 5
3.3 Operating limits
		ATTENTION!	Compressor operation is possible within			the operating
			limits shown in the diagrams. Please note			the significance
			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 (continuous operation) must be achieved.

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 or set individuallywhen operating near to the threshold.

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!

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3|Areas of application F

3.3 Operating limits

R134a

Fig. 6

R404A/R507

Fig. 7

R407C

Fig. 8

R22

Fig. 9

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Unlimited application range

Reducedsuctiongas temperature

Evaporatingtemperature(°C)

Condensingtemperature (°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

Maximum admissible operating pressure (g)

High pressure side (LP/HP)1): 19/28 bar

1)LP = Low pressure HP = High pressure

Design for other areas on request

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4|Areas of application F-NH3

4.1 Oil charge NH3

The compressors are filled with the following oil type at the factory: - for R717: Fuchs Reniso KC 68

NH3

4.2	Operating limits			NH3
tc	(°C)
60									Unlimited
55
									application range
50
									Supplementary cooling
40					NH3				necessary (e.g. water-cooled
30									cylinder covers)
					? tOh 5K				Evaporating temperature (°C)
20
									Condensing temperature (°C)
10									Suction gas superheat (K)
0	-40	-30	-20	-10	0	10	15	20	to (°C)

Fig. 10				D
Permissible rotation speeds:
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F2 NH3, F3 NH3:	960 - 1500 rpm
				F
F4 NH3, F5 NH3:	500 - 1500 rpm			E
F14 NH3, F16 NH3:	700 - 1500 rpm
		Design for other
Max. permissible operating
pressure (LP/HP)1): 19/25 bar		areas on request

1)LP = Low pressure HP = High pressure

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5|Compressor assembly

INFO! New compressors are factory-filled 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

Fig. 12

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 sufficient 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.

Provide adequate clearance for maintenance work.

Provide adequate ventilation for the drive motor.

	Fig. 13
		Do not use in a dusty, damp atmosphere or a combustible
		environment.
			-DGbF
	Fig. 14		-09.2013
		Set up on an even surface or frame with sufficient load-bearing
		capacity.
			09702
		Compressors and drive motors are basically rigid and should be
	Fig. 15	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	A	A
a	a		a	a

A	max. 30°,
	max. 2 minutes
a	max. 15°,
	continuous
Fig. 16	operation

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

5.4 Pipes

The pipe connections have stepped internaldiameters­ so that pipes with standard millimetre and inch dimensions can be used.

Theconnectiondiametersoftheshut-offvalvesaredesignedformaximum­ compressor output.Therequiredpipecross-sectionmustbematched to the capacity. The same applies for non-return valves.

The required tightening torque for the flange connection is 60 Nm.

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.

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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 first pipe section starting from the shut-off valve downwards and parallel to the drive shaft.

	As short as	Rigid
		Fixed point	Fig. 18
	possible

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	DGbF-
Valve spindle seal
Fig. 19	Fig. 20	09702-09.2013

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