D GB F I TR CN Bock Compressor FK50 09704-09.
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 09704-09.2013-DGbFITrCn 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 WARNING! 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.
1| Safety 1.4 Intended use These assembly instructions describe the standard version of the FK50 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 six cylinder compressor in W design. Six capacity ranges. Lightweight aluminum design.
2| Product description 2.2 Name plate (example) GEA Bock GmbH 72636 Frickenhausen, Germany AT12345A029 4 FKX50/775N 67,4 1 2 19/28bar 3 5 Fig. 3 1 2 3 4 Type designation 5 Displacement at 1450 rpm LP: Max. permissible operating pressure (g) Low pressure side HP: Max. permissible operating pressure (g) High pressure side 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. FKX50/775 N). INFO! For recharging, we recommend the above oil types. Alternatives are: see lubricants table, Chapter 6.
3| Areas of application 3.4 N and K versions Models available: • FKX50/460 N • FKX50/460 K • FKX50/555 N • FKX50/555 K • FKX50/830 N • FKX50/830 K • FKX50/980 N • FKX50/980 K • FKX50/660 N • FKX50/660 K • FKX50/775 N • FKX50/775 K 3.4.
3| Areas of application 3.5 TK version Models available: • FK50/460 TK • FKX50/460 TK • FK50/555 TK • FKX50/555 TK R404A/R507 • FK50/660 TK • FKX50/660 TK • FK50/775 TK • FKX50/775 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 WARNING! Move compressors only with hoists that have adequate load-bearing capacity. Transport and suspension unit on both eyebolts (Fig. 8). D GB Fig. 8 F Fittings (e.g. pipe holders, additional units etc.
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. During operation with capacity controllers (Accessories, Chap. 7), the changing load can cause increased running noises and belt drive vibrations. 4.
4| Compressor assembly 4.6 Pipe connections Fig. 13: Stepped internal diameters The discharge and suction line valves have stepped internal diameters, enabling the use of pipes with standard millimetre and inch dimensions. The depth of pipe insertion will depend on the dimension. 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.
4| Compressor assembly 4.9 Operating mode of the lockable service connections Opening the shut-off valve 3 Spindle 1: turn to the left (counterclockwise) as far as it will go. —> Shut-off valve fully opened / service connection 2 closed. 1 2 Fig. 16 3 Opening the service connection (2): Spindle 1: 1/2 - 1 rotation to the right —> Service connection 2 opened / shut-off valve opened. Connection 3 is provided for safety devices and is not lockable. D GB Fig. 17 F 1 2 I TR 14 09704-09.
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 The compressor shaft is sealed to outside using a shaft seal. The sealing element rotates with the shaft. The following is especially important to ensuring fault-free operation: The complete refrigerant circuit must be correctly executed and clean inside. Heavy shocks and vibrations to the shaft as well as continuous cyclic operation are to be avoided. The sealing surfaces can stick together during prolonged downtimes (e.g. winter). Therefore, run the system every 4 weeks for 10 minutes. 5.
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 6.5 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 Capacity regulation ATTENTION! Capacity-regulated operation alters the gas speeds and pressure 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).
976 FK50/980 84,9 72,3 67,6 57,6 48,3 40,1 m3/h (1450 rpm) Swept volume 41,0 43,0 41,0 42,0 43,0 44,0 kg Weight 35 / 1 3/8 35 / 1 3/8 35 / 1 3/8 35 / 1 3/8 28 / 1 1/8 28 / 1 1/8 mm / inch 2 x 35 / 1 3/8 2 x 35 / 1 3/8 2 x 35 / 1 3/8 2 x 35 / 1 3/8 35 / 1 3/8 35 / 1 3/8 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.
3 1 2 9| Dimensions and connections X B 6 B1 7 5 Centre of gravity 4 ca.370 (375) 3 X 356 B B1 X DV SV1 ca.
9| Dimensions and connections SV DV Suction line see technical data, Chapter 8 Discharge line A Connection suction side, not lockable A1 Connection suction side, lockable B Connection discharge side, not lockable B1 Connection discharge side, lockable C Connection oil pressure safety switch OIL D Connection oil pressure safety switch LP E Connection oil pressure gauge F Oil drain 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 FK50 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.
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