D GB F I TR Bock Compressor FK20 09740-09.
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.
Contents 1 09740-09.2013-DGbFITr Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 General safety instructions 1.4 Intended use 2 Product description 2.1 Brief description 2.2 Name plate 2.3 Type key 3 Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application 3.4 N and K versions 3.4.1 Limits of application R134a 3.4.2 Limits of application R407C 3.5 TK version 3.5.1 Limits of application R404A/R507 3.5.
1| Safety 1.1 Identification of safety instructions: DANGER! Indicates a dangerous situation which, if not avoided, will cause immediate fatal or serious injury. Indicates a dangerous situation which, if not avoided, WARNING! 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 1.4 Intended use These assembly instructions describe the standard version of the FK20 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.
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.
2| Product description 2.2 Name plate (example) AS12345A020 GEA Bock GmbH 72636 Frickenhausen, Germany 4 FKX20/170N 14,8 1 2 19/28bar 3 5 Fig. 3 1 2 3 Type designation Displacement at 1450 rpm LP: Max. permissible operating pressure (g) Low pressure side HP: Max. permissible operating pressure (g) High pressure side 4 5 Machine number Factory-filled oil type } Observe the limits of application diagrams! 2.
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 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. FKX20/170 N). INFO! For recharging, we recommend the above oil types.
3| Areas of application 3.4 N and K versions Models available: • FKX20/120 N • FKX20/120 K • FKX20/145 N • FKX20/145 K • FKX20/170 N • FKX20/170 K 3.4.
3| Areas of application 3.5 TK version R404A/R507 Models available: • FK20/120 TK • FK20/145 TK • FKX20/120 TK • FKX20/145 TK • FK20/170 TK • FKX20/170 TK 3.5.1 Limits of application R404A/R507 (TK version) FK R404A/R507 Permissible rotation speeds: TK Max.
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 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.
4| Compressor assembly 4.3 V-belt drive ATTENTION! Inappropriately designed belt drives, especially belt knocking or excessive tensioning forces can cause compressor damage! Make sure that the drive belt is designed correctly, e.g. by using tensioners and selecting the belt profile and the belt length. 4.4 Main bearing load To prevent the belt drive overloading the compressor main bearing, ensure that: The engagement force applied by the belt tension (see Fig. 9) must not exceed Fmax per. = 600 N.
4| Compressor assembly 4.6 Pipe connections The pipe connections have graduated inside diameters so that pipes in the common millimeter and inch dimensions can be used. Fig. 12: Stepped internal diameters 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. ATTENTION! Overheating can damage the valve. Solder only using inert gas to inhibit oxidation products.
4| Compressor assembly 4.9 Operating mode of the lockable service connections 3 3 2 Pipe connection 1 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. 15 3 3 2 D GB 1 I 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 safety devices and is not lockable.
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. Check the compressor for transport damage! 5.2 Pressure strength test DANGER! Bursting! The compressor must only be pressurised using nitrogen (N2).
5| Commissioning 5.5 Refrigerant charge CAUTION! Wear personal protective clothing such as goggles and protective gloves! ATTENTION! Avoid overfilling the system with refrigerant! To avoid shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always be added to the refrigerating plant in liquid form. Do not pour liquid refrigerant through the suction line valve on the compressor. It is not permissible to mix additives with the oil and refrigerant.
5| Commissioning 5.7 Avoiding liquid shocks ATTENTION! Slugging can damage the compressor and cause refrigerant to leak. To prevent liquid shocks: The complete refrigeration plant must be correctly designed and executed. The capacities of all components must be compatible (particularly evaporator and expansion valve). Suction gas superheating at the evaporator output should be at least 7 – 10 K (check setting of the expansion valve). The system must reach a state of equilibrium.
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. 6.2 Work to be carried out Oil change: In principle, an oil change is not mandatory if the system is correctly manufactured and operated.
6| Maintenance 6.4 Extract from the lubricants table The oil type charged as standard in the factory is marked on the name plate. This oil type should be used as a preference. Alternatives are stated in the extract from our lubricants table below. Refrigerants Bock standard oil types Recommended alternatives HFC (e.g. R134a, R407, R 404A) Fuchs Reniso Triton SE 55 (see also chap. 6.3) Fuchs SEZ 32/68/80 Esso/Mobil EAL Arctic 46 HCFC (e.g. R22) Fuchs Reniso SP 46 (see also chap. 6.
7| Accessories 7.1 Thermal protection thermostat (Item No. 07595) A special intermediate flange, located below the discharge line valve, is used to attach the sensor element (Part no. 04175). Wire the thermal protection thermostat in series with the control line. Technical Data: Switching voltage max. Switching current max. Switch-off temperature Switch-on temperature : : : : 24 V DC 2.5 A at 24 V DC 145 °C ± 5 K approx. 115 °C D GB F I 20 09740-09.
2 Nr. of Cyl. 170 143 118 cm3 Displacement 14,8 12,4 10,3 m3/h (1450 rpm) Swept volume 14,0 14,0 15,0 kg Weight 16 / 5/8 mm / inch 16 / 5/8 mm / inch Connections Discharge Suction line line DV SV The technical data for the different designs K, N and TK are identical. The compressor type data therefore do not mention these additions. FK20/170 FK20/145 FK20/120 Type 09740-09.2013-DGbFITr 0,0013 0,7 Ltr.
9| Dimensions and connections ca.215 73 78,5 ca.263 155 B1 A2 30° 30 115 60 ca.270 (280) H 4x M10 LK 130 110 h8 X B F,G ca.263 155 B SV DV 4x B1 58 11 155 ca.150 99 B 3xM10 beidseitig both sides 125 = Centre of gravity Dimensions in () = K Design Dimensions in mm Fig. 18 30 GB 115 F ca.135 60 D ca.135 78,5 I Shaft end 6x M5 3xM10 beidseitig Dimensions in mm 22 1:4 A A1 Fig. 19 09740-09.
9| Dimensions and connections SV DV Suction line see technical data, Chapter 8 Discharge line A Connection suction side, not lockable 7/ A1 Connection suction side, lockable 7/ A2 Connection suction side, not lockable B Connection discharge side, not lockable B1 Connection discharge side, lockable B2 Connection discharge side, not lockable F Oil drain plug G Opt.
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 FK20 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 I GEA Bock GmbH Benzstraße 7, 72636 Frickenhausen, Germany Telephone: +49 7022 9454-0, Fax: +49 7022 9454-137 bock@gea.com, www.bock.
