GEA FK40/560 N Assembly Instructions Manual

Text of GEA FK40/560 N User Guide:

• 6 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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

• GEA FK40/560 N, 13 09716-01.2013-DGbFEITrCn D GB F E I TR CN 4| Compressor assembly 4.7 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. ATTENTION! Ov

• GEA FK40/560 N, 24 09716-01.2013-DGbFEITrCn D GB F E I TR CN 10| Installation certificate INSTALLATION CERTIFICATE forusingthecompressorswithintheEuropeanUnion (inaccordancewithMachineryDirective2006/42/EC) Themanufacturer: GEABockGmbH,Benzstraße7   D-72636Frickenhausen,Tel.:07022/9454-0 herebydeclaresthattherefrigeratingcompressor FK40conformstotheessentialrequirements ofAnnexII1BoftheMachineryDirective2006/42/EC. Thefollowingharmonisedstandardshavebe

• GEA FK40/560 N, 26 09716-01.2013-DGbFEITrCn D GB F E I TR CN Excellence Passion Integrity Responsibility GEA-versity GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index. GEA Refrigeration Technologies GEA Bock GmbH Benzstraße 7, 72636 Frickenhausen, Germany Telephone: +49 7022 9454-0, Fax: +49 7022 9454-137 [email protected]

• GEA FK40/560 N, 22 09716-01.2013-DGbFEITrCn D GB F E I TR CN 9| Dimensions and connections Dimensionsin () =K-Design Shaft end Centreof gravity Dimensionsinmm Dimensionsinmm Fig.20 Fig.21 169 ca.110 ca.170 M SV A SV1 A1 C/E G 13 232 210 145 329 ca.370 4x ca.320 (325) F DV B B1 L H K D Y 109 130 1704xM10 LK 253 344 ca.385 Leakoildrainhose

• GEA FK40/560 N, 19 09716-01.2013-DGbFEITrCn D GB F E I TR CN 6.6 Decommissioning Closetheshut-offvalveonthecompressor.Draintherefrigerant(itmustnotbedischargeddirectly intotheenvironment)anddisposeofitaccordingtotheregulations.Whenthecompressorisdepres- surised,undothefasteningscrewsoftheshut-offvalves.Removethecompressorusinganappropri- atehoist.Disposeoftheoilinsideinaccordancewiththevalidnationalregulations. 6| Maintenance 6.5 Extract from the lubric

• GEA FK40/560 N, 3 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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 Lim

• GEA FK40/560 N, 21 09716-01.2013-DGbFEITrCn D GB F E I TR CN 8| Technical data Type Nr. of Cyl. Displace- ment cm 3 Swept volume (1450 rpm) m 3 /h Weight kg Discharge line DV mm/inch Suction line SV mm/inch Oil charge Ltr. Inertia moment of the driving unit [kgm 2 ] Lubri- cation Oil pump FK40/390 4 385 33.5 34.0 22 / 7 / 8 28 /1 1 / 8 2.0 0.0043 Forced lubrication Rotation- independent FK40/470 466 40.5 33.0 28 /1 1 / 8 35 /1 3 / 8 FK40/560 554 48.3 33.0 28 /1 1 / 8 35 /1 3 / 8 FK40/655 650 56.6 31.0

• GEA FK40/560 N, 15 09716-01.2013-DGbFEITrCn D GB F E I TR CN 5| Commissioning 5.1 Preparations for start-up 5.4 Evacuation  Firstevacuatethesystem andthenincludethe compressor in the evacuation process.  Relievethecompressorpressure.  Openthesuctionanddischargelinevalves.  Evacuatethesuctionanddischargepressuresidesusingthevacuumpump.  Attheendoftheevacuationprocess,thevacuumshouldbe<1.5mbarwhenthepumpisswitchedoff.  Repeattheprocessasoftenasi

• GEA FK40/560 N, 8 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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

• GEA FK40/560 N, 23 09716-01.2013-DGbFEITrCn D GB F E I TR CN 9| Dimensions and connections 1) =Noconnectionavailableasstandard. Availableonrequest(ConnectionM22x1,5) SV DV Suctionline Dischargeline seetechnicaldata,Chapter8 A Connectionsuctionside,notlockable 1 / 8 "NPTF A1 Connectionsuctionside,lockable 7 / 16 "UNF B Connectiondischargeside,notlockable 1 / 8 &qu

• GEA FK40/560 N, 17 09716-01.2013-DGbFEITrCn D GB F E I TR CN 5| Commissioning Aschangingtheshaftsealinvolvesopeningtherefrigerant circuit,thisisrecommendedonlyifthesealislosingrefriger- ant.Replacingtheshaftsealisdescribedinthesparepart kitconcerned. Emptyingtheoilreservoir:Theoilreservoircanbeemptied verysimplewithouthavingtodismantlethecouplingand/or beltdrive.Itisrecommendedthatthi

• GEA FK40/560 N, 1 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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

• GEA FK40/560 N, 7 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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�

• GEA FK40/560 N, 25 09716-01.2013-DGbFEITrCn D GB F E I TR CN - Änderungen vorbehalten - Sehr geehrter Kunde, Bock-Verdichter sind hochwertige, zuverlässige und servicefreundliche Qualitätsprodukte. Um alle Vorteile in vollem Umfange und über den gesamten Einsatzzeitraum Ihrer Kälteanlage nutzen zu können, beachten Sie unbedingt die folgenden Bedienungs- und Wartungshinweise. Bei Fragen zu Montage, Betrieb und Zubehör wenden Sie sich bitte an unsere Anwendungstechnik oder an den Kältefachgroßhandel bzw. unsere Vertretung. Das Bock-Serviceteam erreichen Sie direkt unter Tel.: +49 7022 9454-0, via e-mail: mail@boc

• GEA FK40/560 N, 18 09716-01.2013-DGbFEITrCn D GB F E I TR CN 6.1 Preparation 6.2 Work to be carried out 6| Maintenance Oilchange:Inprinciple,anoilchangeisnotmandatoryifthesystemiscorrectlymanufactured andoperated. However,based on decadesofexperiencewe recommend that the following oil change/serviceworkiscarriedout:  - Firstoilchangeduringtherstmaintenanceofthevehicle. �

• GEA FK40/560 N, 11 09716-01.2013-DGbFEITrCn D GB F E I TR CN 4| Compressor assembly 4.1 Setting up 4.2 Maximum permissible inclination A max.30°, max.2minutes a max.15°, continuous operation ATTENTION! Poor lubrication can damage the compressor. Respect the stated values. 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 d

• GEA FK40/560 N, 12 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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 4.4 Main bearing load 4.5 Electromagnetic clutch assembly ATTENTION! Inappropriately designed belt drives, especially belt knocking or excessive tensioning forces can cause compressor damage! Make sure

• GEA FK40/560 N, 4 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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 DANGE

• GEA FK40/560 N, 14 09716-01.2013-DGbFEITrCn D GB F E I TR CN 4| Compressor assembly 4.9 Operating mode of the lockable service connections 1 1 3 3 Pipeconnection Pipeconnection 2 2 Fig.17 Openingtheshut-offvalve: a) Spindle1:turntotheleft(counter-clockwise)asfarasitwillgo.  —>Shut-offvalvefullyopened/serviceconnection2closed. Fig.18 Openingtheserviceconnection(2): b) Spindle1:Turn½-1rotationtotheright.  —>Serviceconnection2opened/shut-offvalveopened.  Connection3isprovidedforsa

• GEA FK40/560 N, 10 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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�

• 5 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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

• GEA FK40/560 N, 9 09716-01.2013-DGbFEITrCn D GB F E I TR CN 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 reducedsuctiongastemperature Evaporatingtemperature(°C) Evaporatingtemperature(°C) Condensingtemperature(°C) Condensingtemperature

• 20 09716-01.2013-DGbFEITrCn D GB F E I TR CN 7| Accessories 7.1 Capacity regulation Foradescription,seetechnicalinformation"Capacityregulation"(ItemNo.09900) Ifthecapacityregulatorisfactory-tted,itisintegratedintoanextra,dedicatedcylindercover.For retrots,itissupplied

• 16 09716-01.2013-DGbFEITrCn D GB F E I TR CN 5| Commissioning CAUTION! Wear personal protective clothing such as goggles and protective gloves! Makesurethatthesuctionanddischargelinevalvesareopen.  Withthecompressorswitchedoff,addtheliquidrefrigerantdirectlytothecondenserorreceiver, breaki

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