D GB F E Bock Compressor F18 Assembly instructions 96246-07.
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.
96246-07.2014-DGbRu Contents 1 Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 Safety instructions 1.4 Intended use 2 Product description 2.1 Short description 2.2 Name plate 2.3 Type code 3 Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Operating limits 4 Compressor assembly 4.1 Setting up 4.2 Maximum permissible inclination 4.3 Pipe connections 4.4 Pipes 4.5 Laying suction and discharge lines 4.6 Operating the shut-off valves 4.
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.
1 | Safety 1.3 Safety instructions WARNING Risk of accidents. 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. 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. - Avoid contact with refrigerant necessarily.
2 | Product description 2.1 Short description 8-cylinder open type compressor for external drive (V-belt or coupling) with oil pump lubrication Discharge shut-off valve Transport eyelet Suction shut-off valve Valve plate Cylinder cover Leak oil drain hose Shaft end Shaft seal D Sight glass GB Base plate F E Fig. 1 Name plate Fig. 2 Dimension and connection values can be found in Chapter 8. 6 96246-07.
2 | Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany 1 2 3 4 5 6 FX18/3235 AU12756A001 SE55 135,8 349,3 19/28 Fig. 3 1 2 3 4 5 6 Type designation Machine number Rotation speed minimum with a corresponding displacement Rotation speed maximum with a corresponding displacement ND(LP): Max. admissible operating pressure Suction side HD(HP): Max.
3 | Areas of application 3.1 Refrigerants • HFKW / HFC: • (H)FCKW / (H)CFC: R134a, R404A/R507, R407C R22 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. FX18/3235). INFO For refilling, we recommend the above oil types. Alternatives: see lubricants table, Chapter 6.
3| Areas of application 3.3 Operating limits R134a Unlimited application range Fig. 5 Reduced suction gas temperature Evaporating temperature (°C) Condensing temperature (°C) R404A/R507 Suction gas superheat (K) D Suction gas temperature (°C) GB Permissible rotation speeds: 700 - 1800 rpm F E Fig. 6 Maximum permissible operating pressure (LP/HP)1): 19/28 bar R407C 1) 96246-07.2014-DGbRu Fig. 7 LP = Low pressure HP = High pressure Design for other areas on request R22 Fig.
4| 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. 4.1 Setting up WARNING Risk of injury. Move compressors only with hoists that have adequate loadbearing capacity. Transport and suspension unit on the eyebolt (Fig. 8). D GB Fig. 9 F Fittings (e.g. pipe holders, additional units etc.
4| Compressor assembly 4.2 Maximum permissible inclination ATTENTION Risk of compressor damage. Poor lubrication can damage the compressor. Respect the stated values. A A a Fig. 13 a A A a a A max. 30°, max. 2 minutes a max. 15°, continuous operation D GB F E 4.3 Pipe connections 96246-07.2014-DGbRu ATTENTION Risk of damages. 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.
4| Compressor assembly 4.5 Laying suction and discharge lines ATTENTION Improperly installed pipes can cause cracks and tears, the result being a loss of refrigerant. INFO Proper layout of the suction and discharge lines directly after the compressor is integral to the system’s smooth running and vibration behaviour. A rule of thumb: Always lay the first pipe section starting from the shut-off valve downwards and parallel to the drive shaft. D GB F E As short as possible Rigid Fixed point Fig. 15 4.
4| Compressor assembly 4.7 Operating mode of the lockable service connections Service connection closed Spindle Pipe connection Connection blocked Compressor Fig. 18 Opening the shut-off valve: Spindle: turn to the left (counter-clockwise) as far as it will go. —> The shut-off valve is then fully open and the service connection is closed. Service connection opened D GB Spindle Pipe connection F Connection open E Compressor Fig. 19 96246-07.
ACHTUNG Da die Ölsumpfheizung auch bei einer Anlagenstörung funktionieren muss, darf die Ölsumpfheizung nicht an den Strompfad der Sicherheits-Steuerkette angeschlossen werden. 4| Compressor assembly Betriebsweise: Ölsumpfheizung EIN bei Stillstand des Verdichters. 4.8 Drive Ölsumpfheizung AUS bei Betrieb des Verdichters Anschluss: Die Ölsumpfheizung über einen Hilfskontakt (oder parallel geschalteten CAUTION desRisk of injury. an einen getrennten Strompfad anschließen.
4| Compressor assembly 4.9 Oil sump heater (accessory) When the compressor is at a standstill, refrigerant diffuses into the lubrication oil of the compressor housing, depending on pressure and ambient temperature. This reduces the lubrication capacity of the oil. When the compressor starts up, the refrigerant contained in the oil evaporates out through the reduction in pressure. The consepuences can be lack of lubrication, foaming and migration of the oil, which can eventually lead to compressor damage.
5| Commissioning 5.1 Preparations for start-up INFO To protect the compressor against inadmissible operating conditions, high pressure and low pressure pressostats are mandatory on the installation side. The compressor has undergone trials in the factory and all functions have been tested. There are therefore no special running-in instructions.
5| Commissioning 5.5 Refrigerant charge CAUTION Risk of injury! Contact with refrigerant can cause severe burns and skin damage. Avoid contact with refrigerant and 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, breaking the vacuum.
5| Commissioning 5.7 Shaft seal change As changing the shaft seal involves opening the refrigerant circuit, this is recommended only if the seal is losing refrigerant. Replacing the shaft seal is described in the spare part kit concerned. 5.8 Start-up WARNING Ensure that both shut-off valves are open before starting the compressor! Check that the safety and protection devices (pressure switch, motor protection, electrical contact protection measures, etc.) are all functioning properly.
5| Commissioning 5.10 Oil separator ATTENTION Oil slugging can result in damage to the compressor. To prevent oil slugging: The oil return from the oil separator must be guided back at the intended connection (D1) on the compressor housing. A direct oil return into the suction line from the oil separator is not permissible. Ensure that the oil separator is properly dimensioned. D GB F 96246-07.
6| Maintenance 6.1 Preparation WARNING Before starting any work on the compressor: Switch off the compressor and secure it to prevent a restart. Relieve compressor of system pressure. Prevent air from infiltrating the system! After maintenance has been performed: Connect safety switch. Evacuate compressor. Release switch lock. 6.
6| Maintenance 6.5 Excerpt from the lubricant table The oil grade filled as standard in the factory is noted on the name plate. This oil grade should be used preferably. Alternatives to this are listed in the following excerpt from our lubricant table. Refrigerant HFKW (e.g. R134a, R404A/R507, R407C) HFCKW (e.g.
7| Accessories 7.1 Capacity regulator ATTENTION If the capacity regulator is mounted at the factory, the control component (pilot valve) is mounted and connected subsequently by the customer. If the control component is not connected, the cylinder bank is switched off permanently. Damage to the compressor is possible! LR 1 LR 2 LR 3 Cover D GB Delivery status (ex works): Capacity regulator assembled with cover (transport protection). Fig. 22 F E Fig.
7| Accessories ATTENTION apacity-regulated operation alters the gas speeds and pressure C ratios of the refrigerating plant: Adjust the suction line routing and dimensioning accordingly,do not set the control intervals too close and do not let the system switch more than 12 times per hour (refrigerating plant must have reached a state of equilibrium). Continuous operation in the control stage is not permitted.
7 Ölsumpfheizung Oil sump heater Chauffage du remplissag K Schauglas Sight glass Voyant L1 Wärmeschutzthermostat Thermal protection thermostat Thermostat de protection M ÖV1 P1 Q1 Ölsieb Ölserviceventil Öl-Differenzdrucksensor Öltemperatursensor Oil filter Oil service valve Oil pressure differential sensor Oil temperature sensor Filtre à huile Vanne de vidange d'huile Sonde de pressostat diff Sonde de température d 6 9| Dimensions and connections ca.355 149 5A1 6 ca.
9| Dimensions and connections SV DV Suction line Discharge line A Connection suction side, not lockable 1/ “ NPTF 8 A1 Connection suction side, lockable 7/ “ UNF 16 A2 Connection suction side, not lockable 1/ “ NPTF 8 B Connection discharge side, not lockable 1/ “ NPTF 8 B1 Connection discharge side, lockable 7/ “ UNF 16 B2 Connection discharge side, not lockable 7/ “ UNF 16 C Connection oil pressure safety switch OIL 7/ “ UNF 16 D Connection oil pressure safety switch LP 7/ “ UNF 1
10| Declaration of installation DECLARATION OF INSTALLATION 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.: +49 7022/9454-0 hereby declares that the refrigerating compressor F18 conforms to the essential requirements of Annex II 1B of the Machinery Directive 2006/42/EC.
11| Service Dear customer, Bock compressors are top-quality, reliable and service-friendly quality products. If you have any questions about installation, operation and accessories, please contact our technical service or specialist wholesaler and/or our representative. The Bock service team can be contacted by phone with a toll-free hotline 00 800 / 800 000 88 or via e-mail: bock@gea.com.
We live our values. Excellence • Passion • Integrity • Responsibility • GEA-versity D 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. GB F GEA Bock GmbH Benzstraße 7, 72636 Frickenhausen, Germany Telephone: +49 7022 9454-0, Fax: +49 7022 9454-137 bock@gea.com, www.bock.
