GEA Bock FK30 User Manual

0 (0)

09705-09.2013-DGbFITr

Bock Compressor FK30

Assembly instructions

FK30/235 N	FK30/275 N	FK30/325 N
FK30/235 K	FK30/275 K	FK30/325 K
FK30/235 TK	FK30/275 TK	FK30/325 TK
FKX30/235 N	FKX30/275 N	FKX30/325 N
FKX30/235 K	FKX30/275 K	FKX30/325 K
FKX30/235 TK	FKX30/275 TK	FKX30/325 TK

engineering for a better world GEA Refrigeration Technologies

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

09705-09.2013-DGbFITr

Contents

1Safety

1.1Identification of safety instructions

1.2Qualifications required of personnel

1.3General safety instructions

1.4Intended use

2Product description

2.1Brief description

2.2Name plate

2.3Type key

3Areas of application

3.1Refrigerants

3.2Oil charge

3.3Limits of application

3.4N and K versions

3.4.1Limits of application R134a

3.4.2Limits of application R407C

3.5TK version

3.5.1Limits of application R404A/R507

3.5.2Limits of application R22

4Compressor assembly

4.1Setting up

4.2Maximum permissible inclination

4.3V-belt drive

4.4Main bearing load

4.5Installation of electromagnetic clutch assembly

4.6Pipe connections

4.7Pipes

4.8Operating the shut-off valves

4.9Operating mode of the lockable service connections

5Commissioning

5.1Preparations for start-up

5.2Pressure strength test

5.3Leak test

5.4Evacuation

5.5Refrigerant charge

5.6Oil level check

5.7Shaft seal

5.8Shaft seal, emptying the oil reservoir

5.9Avoiding liquid shocks

6Maintenance

6.1Preparation

6.2Work to be carried out

6.3Recommended spare parts

6.4Integrated decompression valve

6.5Extract from the lubricants table

6.6Decommissioning

7Accessories

7.1Thermal protection thermostat

8Technical Data

9Dimensions and connections

10Installation certificate

11Service

Page

1| Safety

1.1 Identification of safety instructions:

	DANGER!	Indicates a dangerous situation which, if not avoided, will cause
	DANGER!	immediate fatal or serious injury.
		immediate fatal or serious injury.

Indicates a dangerous situation which, if not avoided,

WARNING! may cause fatal or serious injury.

Indicates a dangerous situation which, if not

CAUTION! 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.

1.2 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 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.

1.3General 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.

09705-09.2013-DGbFITr

1| Safety

1.4 Intended use

These assembly instructions describe the standard version of the FK30 manufactured by Bock.The compressor is intended for use in refrigeration systems in compliance with the limits of application. Only the refrigerant specified 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 assembly instructions and the entire system into which it is integrated has been inspected and approved in accordance with legal regulations.

09705-09.2013-DGbFITr

2 |Product description

2.1 Brief 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 two-cylinder compressor in single row.

Three capacity ranges.

Lightweight aluminum design.

Lubricating oil pump with oil pressure relief valve independent of rotational direction. Variable connection and fixing options.

Leak oil trapping

Name plate

device with oil

Discharge

reservoir

shut-off valve

Shaft seal

Leak oil drain hose

Shaft end

Oil sight glass

Fig. 1

Cylinder cover

Valve plate

Suction Suction

Suction

shut-off valve

(option)

Oil pump

Fig. 2 Dimension and connection values can be found in Chapter 9

09705-09.2013-DGbFITr

2 |Product description

2.2 Name plate (example)

72636 Frickenhausen, Germany

AS12345A020

GEA Bock GmbH

FKX30/325N

28,3

19/28bar

Fig. 3

Type designation

Machine number

Displacement at 1450 rpm

Factory-filled oil type

3 ND (LP): max. permissible operating pressure

}

Observe the limits of application

Low pressure side

diagrams!

HD (HP): max. permissible operating pressure

High pressure side

2.3

Type key (example)

FK X 3 0 / 325 N

Designs ¹) Swept volume

Size

Ester oil charging ²) Series

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)

3 |Areas of application

3.1 Refrigerants
•	HFKW / HFC:	R134a, R404A/R507, R407C
•	(H)FCKW / (H)CFC:	R22

3.2 Oil charge
	The compressors are factory-filled 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. FKX30/325 N).

		INFO!	For recharging,we recommend the above oil types.Alternatives are:
			see lubricants table , Chapter 6.5.

3.3 Limits of application

ATTENTION! Compressor operation is possible within the limits of application shown in the diagrams. Please note the significance

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).

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 compressedgas temperature. Prevent the ingress of air at all costs!

09705-09.2013-DGbFITr

+ 18 hidden pages