assembly instructions - bock displacement at 1450 rpm 3 lp: max. permissible operating pressure (g)...

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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

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1 Safety 4 1.1 Identificationofsafetyinstructions 1.2 Qualificationsrequiredofpersonnel 1.3 Generalsafetyinstructions 1.4 Intendeduse 2 Product description 6 2.1 Briefdescription 2.2 Nameplate 2.3 Typekey 3 Areas of application 8 3.1 Refrigerants 3.2 Oilcharge 3.3 Limitsofapplication 3.4 NandKversions 3.4.1 LimitsofapplicationR134a 3.4.2 LimitsofapplicationR407C 3.5 TKversion 3.5.1 LimitsofapplicationR404A/R507 3.5.2 LimitsofapplicationR22 4 Compressor assembly 11 4.1 Settingup 4.2 Maximumpermissibleinclination 4.3 V-beltdrive 4.4 Mainbearingload 4.5 Electromagneticcouplingassembly 4.6 Pipeconnections 4.7 Pipes 4.8 Operatingtheshut-offvalves 4.9 Operatingmodeofthelockableserviceconnections 5 Commissioning 15 5.1 Preparationsforstart-up 5.2 Pressurestrengthtest 5.3 Leaktest 5.4 Evacuation 5.5 Refrigerantcharge 5.6 Oillevelcheck 5.7 Shaftseal 5.8 Shaftseal,emptyingtheoilreservoir 5.9 Avoidingliquidshocks 6 Maintenance 18 6.1 Preparation 6.2 Worktobecarriedout 6.3 Recommendedspareparts 6.4 Integrateddecompressionvalve 6.5 Extractfromthelubricantstable 6.6 Decommissioning 7 Accessories 20 7.1 Capacityregulator 7.2 Thermalprotectionthermostat 8 Technical data 21 9 Dimensions and connections 22 10 Installationcertificate 24 11 Service 25

About these instructionsReadtheseinstructionsbeforeassemblyandbeforeusingthecompressor.Thiswillavoidmisunder-standings andpreventdamage.Improperassemblyanduseofthecompressorcanleadtoseriousorfatalinjury.Observethesafetyinstructionscontainedintheseinstructions.Theseinstructionsmustbepassedontotheendcustomeralongwiththeunitinwhichthecompres-sorisinstalled.

GEABockGmbH

72636Frickenhausen

GEABockGmbH

Benzstraße7

72636Frickenhausen

Germany

Telephone +49702294540

Fax +4970229454-137

[email protected]

www.bock.de

Manufacturer

Contact

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Contents Page

1 Safety 4 1.1 Identificationofsafetyinstructions 1.2 Qualificationsrequiredofpersonnel 1.3 Generalsafetyinstructions 1.4 Intendeduse 2 Product description 6 2.1 Briefdescription 2.2 Nameplate 2.3 Typekey 3 Areas of application 8 3.1 Refrigerants 3.2 Oilcharge 3.3 Limitsofapplication 3.4 NandKversions 3.4.1 LimitsofapplicationR134a 3.4.2 LimitsofapplicationR407C 3.5 TKversion 3.5.1 LimitsofapplicationR404A/R507 3.5.2 LimitsofapplicationR22 4 Compressor assembly 11 4.1 Settingup 4.2 Maximumpermissibleinclination 4.3 V-beltdrive 4.4 Mainbearingload 4.5 Electromagneticcouplingassembly 4.6 Pipeconnections 4.7 Pipes 4.8 Operatingtheshut-offvalves 4.9 Operatingmodeofthelockableserviceconnections 5 Commissioning 15 5.1 Preparationsforstart-up 5.2 Pressurestrengthtest 5.3 Leaktest 5.4 Evacuation 5.5 Refrigerantcharge 5.6 Oillevelcheck 5.7 Shaftseal 5.8 Shaftseal,emptyingtheoilreservoir 5.9 Avoidingliquidshocks 6 Maintenance 18 6.1 Preparation 6.2 Worktobecarriedout 6.3 Recommendedspareparts 6.4 Integrateddecompressionvalve 6.5 Extractfromthelubricantstable 6.6 Decommissioning 7 Accessories 20 7.1 Capacityregulator 7.2 Thermalprotectionthermostat 8 Technical data 21 9 Dimensions and connections 22 10 Installationcertificate 24 11 Service 25

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1.1 Identificationofsafetyinstructions:

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 Qualificationsrequiredofpersonnel

1.3 General 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.

WARNING! Inadequately qualified personnel poses the risk of accidents, the consequencebeingseriousorfatalinjury.Workoncompressorsis 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-conditioningsystems.Personnelmustbecapableofassessingthe worktobecarriedoutandrecognisinganypotentialdangers.

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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 compliancewith the operating limits. Only the refrigerant specified in these instructions may be used. Any other use of the compressor is prohibited!

TheBockrefrigeratingcompressornamedinthetitleisintendedforinstallationinamachine(withintheEUaccordingtotheEUDirectives2006/42/ECMachineryDirective,97/23/ECPressureEquipmentDirective).Commissioningispermissibleonlyifthecompressorhasbeeninstalledinaccordancewiththeseas-semblyinstructionsandtheentiresystemintowhichitisintegratedhasbeeninspectedandapprovedinaccordancewithlegalregulations.

1.4 Intended use

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2| Product description

Threedifferentdesignsareavailableforvariousrangesofapplication:> for air-conditioning the K Design> for air-conditioning or normal cooling the N Design> for deep freezing the TK DesignThedifferencesliemainlyinthevalveplatetoolingwhichisadaptedtoeachapplicationrangewhereoperationalsafetyandefficiencyareconcerned.

CompactfourcylindercompressorinVdesign. Fourcapacityranges. Lightweightaluminumdesign. Lubricatingoilpumpwithoilpressurereliefvalveindependentofrotationaldirection. Variablearrangementoftheshut-offvalves.

Nameplate

Fig.1

2.1 Brief description

Fig.2

Oilsightglass

Valveplate

Cylindercover

Dischargeshut-offvalve

Shaftend

Shaftseal

Suctionshut-offvalve

Oilpump

DimensionandconnectionvaluescanbefoundinChapter9

Eyebolt

Oilsightglass

Leakoiltrappingdevicewithoilreservoir

Leakoil drainhose

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2| Product description

/FK 04 655 NX

1 Typedesignation2 Displacementat1450rpm3 LP:Max.permissibleoperatingpressure

(g)Lowpressureside HP:Max.permissibleoperatingpressure

(g)Highpressureside

4 Machinenumber5 Factory-filledoiltype

Fig.3

2.2 Name plate (example)

2.3 Type key (example)

¹)K- speciallyforair-conditioning

N- speciallyforair-conditioningornormalcooling

TK-speciallyfordeepfreezing

²)X- Esteroilcharging(HFCrefrigerant,e.g.R134a,R407C)

Designs¹)

Sweptvolume

Size

Esteroilcharging²)

Series

1

2

3

4

5

AS12345A020

19/28bar

Observe the limits of application diagrams!}

GEA Bock GmbH72636 Frickenhausen, Germany

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3| Areas of application

ATTENTION! Compressor operation is possible within the limits of application showninthediagrams.Pleasenotethesignificanceoftheshadedareas. The limits of application must be observed. Thresholds should not be selected as design or continuous operating points.

-Max.permissibledischargeendtemperature:140°C -Max.permissibleambienttemperature:100°C -Max.permissibleswitchingfrequency:12x/h -Aminimum running time of 2min. at equilibrium (continuous operation) must be achieved.

Avoid continuous operation near the threshold. Should the com-pressor happen to be used near the thresholds, we recommend the useofathermalprotectionthermostat(Accessories,Chap.7).

When capacity regulators are used, the limits of application can move.

When operating in the vacuum range, there is a danger of air en-tering on the suction side. This can cause chemical reactions, a pressure rise in the condenser and an elevated compressed-gas temperature. Prevent the ingress of air at all costs!

Thecompressorsarefactory-filledwiththefollowingoiltype:-forR134a,R404A/R507,R407C FUCHSRenisoTritonSE55 -forR22 FUCHSRenisoSP46Compressorswithesteroilcharge(FUCHSRenisoTritonSE55)aremarkedwithanXinthetypedesignation (e.g.FKX40/655N).

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

3.2 Oil charge

3.3 Limits of application

INFO! Forrecharging,werecommendtheaboveoiltypes.Alternativesare: see lubricants table, Chapter 6.5.

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Designforotherrangesonrequest

Max. permissible operating pressure(g)onthehigh-pressureside(HP):28bar


Unrestrictedapplicationrange


reducedsuctiongastemperature


Evaporatingtemperature(°C)


Condensingtemperature(°C)


Suctiongassuperheat(K)


Suctiongastemperature(°C)


Fig.4

Fig.5

20

30

50

70

80

-20 -10 100 20 30 t (°C)o

t (°C)c

82

-30

40

60

90

t + 25 °Coh

< ? toh 20 K

R134a

20

30

50

-20 -10 100 20 t (°C)o

t (°C)c

61

-30

40

60

-25

< ? toh 20 K

t + 25 °Coh

R407C

3.4.1LimitsofapplicationR134a(NandKversions)

3.4 N and K versionsModelsavailable:

•FKX40/390N •FKX40/470N •FKX40/560N•FKX40/655N •FKX40/390K •FKX40/470K •FKX40/560K•FKX40/655K

Permissiblerotationspeeds:

NDesign:500-3000¹/rpm(maxrotationspeed3500rpm)KDesign:500-3500¹/rpm

3.4.2LimitsofapplicationR407C(NandKversions)


NDesign:500-2600¹/rpmKDesign:500-3500¹/rpm

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3.5 TK version

Modelsavailable:

•FK40/390TK •FK40/470TK •FK40/560TK •FK40/655TK•FKX40/390TK •FKX40/470TK •FKX40/560TK •FKX40/655TK

3.5.1LimitsofapplicationR404A/R507(TKversion)

3.5.2LimitsofapplicationR22(TKversion)


TKdesign:500-2600¹/rpm


TKdesign:500-2600¹/rpm

FK

100-10-20-30-40-5020

30

40

50

60

70

t (°C)o

t (°C)c

Dtoh<20K

t +20°Coh

58

-45

R404A/R507

R404A/R507 TK

t c

t 0

toh

Dt oh

Verdampfungstemperatur (°C)

Verflüssigungstemperatur (°C)

Sauggasüberhitzung (K)

Sauggastemperatur (°C)

UneingeschränkterAnwendungsbereich

reduzierte Sauggastemperatur

FK

R22

t c

t 0

toh

Dt oh

Verdampfungstemperatur (°C)

Verflüssigungstemperatur (°C)

Sauggasüberhitzung (K)

Sauggastemperatur (°C)

UneingeschränkterAnwendungsbereich

reduzierte Sauggastemperatur

R22 TK

100-10-20-30-40-5020

30

40

50

60

70

t (°C)o

t (°C)c

Dtoh<20K

t +25°Coh

66

-45








Fig.6

R404A/R507

R22








Designforotherrangesonrequest

Fig.7

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4| Compressor assembly

4.1 Setting up

4.2 Maximum permissible inclination

A max.30°, max.2minutes

a max.15°,continuousoperation

ATTENTION! Poor lubrication can damage the compressor. Respect the stated values.

INFO! Newcompressorsarefactory-filledwithinertgas(3barnitrogen).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.

Fig.8 Fig.9

Transportandsuspensionunitontheeyebolt(Fig.8)ordirectonthedischargelinevalve (Fig.9).

Fittings (e.g. pipe holders, additional units etc.) on the compressor are permissible onlyfollowingconsultationwithBock.

Setuponanevensurfaceorframewithsufficientload-bearingcapacity.Useall4fasteningpoints.

Correctsetupofthecompressorandmountingofthebeltdrivearedecisiveforrunningcomfort,operatingsafetyandtheservicelifeofthecompressor.

Aa

Aa

WARNING! Movecompressorsonlywithhoiststhathaveadequateload-bearingcapacity.

Aa

Aa

Fig.10

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Duringoperationwith capacity controllers (Accessories,Chap.7), the changing load can causeincreasedrunningnoisesandbeltdrivevibrations.

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 that the drive belt is designed correctly, e.g. by using tensionersandselectingthebeltprofileandthebeltlength.

Thefollowingdescriptionappliesforanelectromagneticclutchsecuredtoashaft. Toabsorbthemagneticfieldof theelectromagneticclutch, thefrontbearingflangehasasnugfitØ148h8(seeFig.12).

Toconnectthemagneticfield,loosenthe4cheeseheadscrewsM8onthebearingflange(seeFig.12).

Slidethemagneticfieldtoasnugfitandre-attachusingthefourcheeseheadscrewsM8(Fig.13).Screwtorque=34Nm.

Furtherassemblyoftheelectromagneticclutchaccordingtotheclutchmanufacturer.

Fig.12

Bearingflange,front

Magneticfield

Fig.13148h8

Toprevent thebeltdriveoverloadingthecompressormainbearing,ensurethat:

The forceappliedat the forceengagement forceby thebelttension(seeFig.11)mustnotexceedFmax=2750N.

Iftheforceengagementpointshiftsforwards(seeFig.11,smallpoint),theforceFmaxreducesasperthefollowingformula:

Fmax=245kNmm

(90mm+L1[mm])

Fmax= 2750 NMbmax= 245kNmm

L1 (mm)

Fig.11

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4.7 Pipes

Pipesandsystemcomponentsmustbecleananddryinsideandfreeofscale,swarfandlayersofrustandphosphate.Onlyuseair-tightparts.

Laypipescorrectly.Suitablevibrationcompensatorsmustbeprovidedtopreventpipesbeingcrackedandbrokenbyseverevibrations.

Ensureaproperoilreturn. Keeppressurelossestoanabsoluteminimum.

ATTENTION! Overheating can damage the valve. Therefore, remove the pipe supports from the valve before soldering.

Solderonlyusinginertgastoinhibitoxidationproducts(scale).

Thepipe connectionshavesteppedinternaldiameterssothatpipeswithstandardmillimetreandinchdimensionscanbeused. The connection diameters of the shut-off valves are designed for maximum compressor output.The required pipe cross-sectionmust be matched to the capacity. The same applies for non-return valves.

Fig.14:Steppedinternaldiameters

4.6 Pipe connections

Valve spindle seal

4.8 Operating the shut-off valves

Beforeopeningorclosingtheshut-offvalve,releasethevalvespindlesealbyapprox.¼ofaturncounter-clockwise.

Afteractivatingtheshut-offvalve,re-tightentheadjustablevalvespindlesealclockwise.

Fig.15 Fig.16

Release

Tighten

Therequiredtighteningtorquefortheflangeconnectionis60Nm.

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4.9 Operating mode of the lockable service connections

1

1

3

3

Pipeconnection

Pipeconnection

2

2

Fig.17

Openingtheshut-offvalve:a) Spindle1:turntotheleft(counter-clockwise)asfarasitwillgo. —>Shut-offvalvefullyopened/serviceconnection2closed.

Fig.18

Openingtheserviceconnection(2):b) Spindle1:Turn½-1rotationtotheright. —>Serviceconnection2opened/shut-offvalveopened. Connection3isprovidedforsafetydevicesandisnotlockable.

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5| Commissioning

5.2 Pressure strength test

DANGER! Risk of bursting! The compressor must never be pressurised using oxygen or other technical gases!

The maximum permissible overpressure of the compressor must not beexceededatanytimeduringthetestingprocess(seenameplatedata)!Donotmixanyrefrigerantwiththetestingmedium(N2), as this could cause the ignition limit to shift into the critical range.

5.1 Preparations for start-up

Thecompressorhasbeenfactory-testedforpressureresistance.Thefollowingmustbeobservediftheentireplantissubjectedtoanadditionalpressurestrengthtest:

TesttherefrigerationcircuitaccordingtoEN378-2oracorrespondingsafetystandard. Thepressurestrengthtestisbestcarriedoutusingdrynitrogen(N2).

5.3 Leak test

5.4 Evacuation

Firstevacuatethesystem andthenincludethe compressor in the evacuation process. Relievethecompressorpressure. Openthesuctionanddischargelinevalves. Evacuatethesuctionanddischargepressuresidesusingthevacuumpump. Attheendoftheevacuationprocess,thevacuumshouldbe<1.5mbarwhenthepumpisswitchedoff. Repeattheprocessasoftenasisrequired.

INFO! To protect the compressor against inadmissible operating conditions, high-pressure and low-pressure pressostats are mandatory on the installation side.

Thecompressorhasundergonetrialsinthefactoryandallfunctionshavebeentested.Therearethereforenospecialrunning-ininstructions.

Check the compressor for transport damage!

DANGER! Risk of bursting! Do not mix any refrigerant with the testing medium (N2), as this could cause the ignition limit to shift into the critical range.

CarryouttheleaktestoftherefrigeratingsysteminaccordancewithEN378-2oracorresponding safetystandardwithout including the compressor.

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5| Commissioning

CAUTION! Wear personal protective clothing such as goggles and protective gloves!

Makesurethatthesuctionanddischargelinevalvesareopen.

Withthecompressorswitchedoff,addtheliquidrefrigerantdirectlytothecondenserorreceiver,breakingthevacuum.

Iftherefrigerantneedstoppingupafterstartingthecompressor,itcanbetoppedupinvapourformonthesuctionside,or,takingsuitableprecautions,alsoinliquidformattheinlettotheevaporator.

Afterstarting,checkthecompressor'soillevel. Drivemotorinoperatingcondition"Highidle". Compressorruntimemin.10minutes. Thesystemshouldhavereachedoperatingpoints. Checkoillevel.Astheinstallationlocationofthecompressorcandifferinpractice(inclinations),it

isrecommendedthattheoillevelischeckedinbothsightglasses.Theoillevelmustbevisibleinatleastonesightglass.

ATTENTION! Avoidoverfillingthesystemwithrefrigerant! Toavoidshiftsinconcentration,zeotropicrefrigerantblends(e.g.

R407C)mustalwaysbeaddedtotherefrigeratingplantinliquid form.

Donotpourliquidrefrigerantthroughthesuctionlinevalveonthe compressor.

It is not permissible to mix additives with the oil and refrigerant.

5.5 Refrigerant charge

5.6 Oil level check

5.7 Shaft seal

ATTENTION! Failure to observe the following instructions can cause loss of refrigerant and damage to the shaft seal!

INFO! The shaft seal seals and lubricates with oil. An oil leakage of 0.05 ml per operating hour is therefore normal. This applies particularlyduringtherun-inphase(200-300h).

Totrapandcollectleakedoil,theFK40isfittedwithanintegratedleakoiltrappingdevicewithoilreservoir(P.6,Fig.1).

ATTENTION! After a compressor is replaced, the oil level must be checked again. If the level is too high, oil must be drained off (riskofoil impact, reduced performance of the air-conditioning system).

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5| Commissioning

Aschangingtheshaftseal involvesopeningtherefrigerantcircuit,thisisrecommendedonlyifthesealislosingrefriger-ant.Replacingtheshaftseal isdescribed in thesparepartkitconcerned.Emptyingtheoilreservoir:Theoilreservoircanbeemptiedverysimplewithouthavingtodismantlethecouplingand/orbeltdrive. It isrecommendedthatthis isdoneatthesametimeastheair-conditioningmaintenanceandmotorservice.Toproceed,detachtheoilhosefromthebracket,removethesealingpluganddrain theoil intoacollectingvessel.Afteremptying,resealtheoilhoseandclampit intothebracket. Dispose of the used oil in accordance with national regulations.

Thecompressorshaft issealedtooutsideusingashaftseal.Thesealingelementrotateswiththeshaft.Thefollowingisespeciallyimportanttoensuringfault-freeoperation: Thecompleterefrigerantcircuitmustbecorrectlyexecutedandcleaninside. Heavyshocksandvibrationstotheshaftaswellascontinuouscyclicoperationaretobeavoided. Thesealingsurfacescansticktogetherduringprolongeddowntimes(e.g.winter).Therefore,run

thesystemevery4weeksfor10minutes.

5.8 Shaft seal, emptying the oil reservoir

5.9 Avoidingliquidshocks

ATTENTION! Slugging can damage the compressor and cause refrigerant to leak.

Toavoidliquidshocks,thefollowingpointsshouldbeobserved: Thecompleterefrigerationplantmustbecorrectlydesignedandexecuted. The capacities of all componentsmust be compatible (particularly evaporator and expansion

valve). Suctiongassuperheatingattheevaporatoroutputshouldbeatleast7–10K(checksettingof

theexpansionvalve). Thesystemmustreachastateofequilibrium. Particularly in critical systems (e.g. several evaporator points), suitablemeasures, e.g. use of

liquidtraps,solenoidvalveintheliquidline,etc.arerecommended.

Fig.19

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6.1 Preparation

6.2 Work to be carried out

6| Maintenance

Oilchange:Inprinciple,anoilchangeisnotmandatoryifthesystemiscorrectlymanufactured andoperated.However, basedondecadesof experiencewe recommend that the followingoilchange/serviceworkiscarriedout:

- Firstoilchangeduringthefirstmaintenanceofthevehicle. - Thenafterevery5,000operatinghours,thoughnomorethan3years,cleantheoilstrainer

atthesametime.Ifnecessary,alsoemptytheoilreservoirattheshaftseal.

Annualchecks:Oil level, tightnessof thecompressor, runningnoise,pressures, temperatures,functionofauxiliarydevicessuchascheckingthecapacitycontrol.

Thevalveismaintenancefree.

However,constant leakagecanoccurafterblowingoffduetoabnormaloperatingconditions.Thisleadstoreducedperformanceandincreasesthecompressedgastemperature.Inthiscasecheckthevalveandreplaceasnecessary.

6.4 Integrated decompression valve

Only use genuine Bock spare parts!

6.3 Recommended spare parts

WARNING! Beforestartinganyworkonthecompressor: Switch off the compressor and secure it to prevent a restart. Relieve compressor of system pressure. Preventairfrominfiltratingthesystem! Aftermaintenancehasbeenperformed: Connect safety switch. Evacuate compressor. Release switch lock.

FK40 / ... 390 N470 N

560 N655 N

390K470K560K655K

390TK470TK

560TK655TK

Designation Art.-Nr. Art.-Nr. Art.-Nr. Art.-Nr. Art.-Nr.

Setofgaskets 80230 80001 80230

Valveplatekit 80240 80241 80010 80240 80241

Setofshaftseals 80023

OilSP46,1Ltr. 02279

OilSE55,1Ltr. 02282

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6.6 Decommissioning

Closetheshut-offvalveonthecompressor.Draintherefrigerant(itmustnotbedischargeddirectlyintotheenvironment)anddisposeofitaccordingtotheregulations.Whenthecompressorisdepres-surised,undothefasteningscrewsoftheshut-offvalves.Removethecompressorusinganappropri-atehoist.Disposeoftheoilinsideinaccordancewiththevalidnationalregulations.

6| Maintenance

6.5 Extract from the lubricants table

Theoiltypechargedasstandardinthefactoryismarkedonthename plate. This oil type should be used as a preference.Alternativesarestatedintheextractfromourlubricantstablebelow.

Refrigerant Bock standard oil grade Recommendedalternatives

HFC(e.g.R134a,R407,R404A)

Fuchs Reniso Triton SE 55(seealsochap.6.3)

FuchsSEZ32/68/80ICIEmkarateRL46SMobilArcticEAL46ShellClavusR46

HCFC(e.g.R22) Fuchs Reniso SP 46(seealsochap.6.3)

MobilSHC425ShellClavusSD22-12SunoilSuniso4GSTexacoCapellaWF46

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7| Accessories

7.1 Capacity regulation

Foradescription,seetechnicalinformation"Capacityregulation"(ItemNo.09900)

Ifthecapacityregulatorisfactory-fitted,itisintegratedintoanextra,dedicatedcylindercover.Forretrofits,itissuppliedwiththecylindercover.Theregulatorclosesonecylinderbank(capacityregula-tionapprox.50%).

A screw-in option is provided for the sensor element on the hot gas side of the compressor housing(seeChap.9).Connectthethermalprotectionthermostatinserieswiththecontrolline.

TechnicalData:

Switchingvoltagemax. : 24VDCSwitchingcurrentmax. : 2.5Aat24VDCSwitch-offtemperature: 145°C±5KSwitch-ontemperature : approx.115°C

7.2 Thermalprotectionthermostat(ItemNo.07595)

FK40 / ... ... N + TK ... K

Designation Art.-Nr. Art.-Nr.

Specialaccessory12V 08703 08708

Specialaccessory24V 08704 08709

ATTENTION! Capacity-regulated operation alters the gas speeds and pressure ratiosoftherefrigeratingplant:Adjustthesuctionlineroutingand dimensioning accordingly, do not set the control intervals too close and donotletthesystemswitchmorethan12timesperhour(refriger-atingplantmusthavereachedastateofequilibrium).Continuousoperation in the control stage is not recommended as the gas velocity in the plant system under certain circumstances does not guaranteesufficientoil return to thecompressorwithactivated capacity regulator for a compressor speed below 1200 - 1500 rpm.

Werecommendswitchingtounregulatedoperation(100%capacity) for at least 5 minutes per capacity-regulated operating hour. An assuredoilreturncanalsoberealisedbya100%capacityrequire- ment after each compressor restart as otherwise the compressor can also be shut down in the regulated operating time by the thermostat. Electricalactuationofthesolenoidvalve:Normallyopen,(corre-

spondsto100%compressorcapacity). Cylinder covers for capacity regulation are marked with the

designation"CR"(CapacityRegulator).

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8| Technical dataTy

peNr

. of

Cyl.

Disp

lace

-m

ent

cm3

Swep

t vo

lum

e(145

0 rpm)

m3 /h

Wei

ght

kg

Disc

harg

e

line

DV

mm/inch

Suct

ion

line

SV

mm/inch

Oil

char

ge

Ltr.

Iner

tia

mom

ent

of th

e dr

ivin

g un

it[kgm

2 ]

Lubr

i-ca

tion

Oil p

ump

FK40

/390

4

385

33.5

34.0

22 /7/ 8

28 /1

1/ 8

2.0

0.00

43Forced

lubrication

Rotatio

n-inde

pend

ent

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

35 /1

3/ 8

35 /1

3/ 8

Conn

ectio

ns

Thetech

nicald

ataforthe

differen

tdesignsK,N

and

TKareiden

tical.

Thecompressortypeda

tath

ereforedo

notm

entio

nthesead

ditio

ns.

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9| Dimensions and connections

Dimensionsin()=K-Design

Shaft end

Centreofgravity

Dimensionsinmm

Dimensionsinmm

Fig.20

Fig.21

169ca.110

ca.1

70

M

SV

A

SV1

A1C/E

G

13

232210

145

329

ca.3

70

4x

ca.320 (325)

F

DV B B1

L

H

K

D

Y

109130

170

4xM

10 L

K

253

344ca.385

Leakoildrainhose

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9| Dimensions and connections

1)=Noconnectionavailableasstandard.Availableonrequest(ConnectionM22x1,5)

SVDV

SuctionlineDischargelineseetechnicaldata,Chapter8

A Connectionsuctionside,notlockable 1/8"NPTF

A1 Connectionsuctionside,lockable 7/16"UNF

B Connectiondischargeside,notlockable 1/8"NPTF

B1 Connectiondischargeside,lockable 7/16"UNF

C ConnectionoilpressuresafetyswitchOIL 1/8"NPTF

D ConnectionoilpressuresafetyswitchLP 1/8"NPTF

E Connectionoilpressuregauge 1/8"NPTF

F Oildrain 1/4"NPTF

G Opt.connectionforoilsumpheating 1)

H Oilchargeplug 1/4"NPTF

K Sightglass 2x11/8"-18UNEF

L Connectionthermalprotectionthermostat 1/8"NPTF

M Oilstrainer M22x1.5

SV1 Opt.connectionforsuctionlinevalve - -

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10| Installation certificate

INSTALLATION CERTIFICATE

forusingthecompressorswithintheEuropeanUnion(inaccordancewithMachineryDirective2006/42/EC)

Themanufacturer: GEABockGmbH,Benzstraße7 D-72636Frickenhausen,Tel.:07022/9454-0

herebydeclaresthattherefrigeratingcompressor FK40conformstotheessentialrequirementsofAnnexII1BoftheMachineryDirective2006/42/EC. Thefollowingharmonisedstandardshavebeenapplied:

EN ISO 12100-1EN ISO 12100-2 EN 12693 EN 349

Apartlycompletedmachinemayonlybeputintooperationwhenithasbeenestablishedthatthemachine,intowhichthepartlycompletedmachineistobeinstalled,conformstotheregulationsoftheMachineryDirective(2006/42/EC).

Themanufacturerundertakestotransmitelectronicallythespecialdocumentationrequired byindividualstatesforpartlycompletedmachineryuponrequest.

Thespecialtechnicaldocumentationrequiredforpartlycompletedmachineryhasbeencreated inaccordancewithAnnexVIIPartB.

Personresponsiblefordocumentationis: WolfgangSandkötter,Benzstraße7,72636Frickenhausen.

Frickenhausen,01.11.2011 ppa.WolfgangSandkötter,ChiefDevelopmentOfficer

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Dearcustomer,

Bockcompressorsaretop-quality,reliableandservice-friendlyproducts.Ifyouhaveanyquestionsaboutinstallation,operationandaccessories,pleasecontactourtechnicalserviceorspecialistwhole-salerand/orourrepresentative.TheBockserviceteamcanbecontacted

bytelephone: +49 7022 9454-0 viae-mail: [email protected] orontheInternetat:www.bock.de

In addition, for German-speaking countries we have set up a toll-free Bock hotline 00800/80000088fromMondaytoSaturdaybetween8amand9pm.

Anysuggestionsyoumayhaveregardingtheon-goingdevelopmentofourcompressor,equipmentandsparepartsrangearewelcomeatanytime.

Yours

11| Service

GEABockGmbH

Benzstraße 7

72636 Frickenhausen

Germany

WealsoprovideinformationontheInternetatwww.bock.de. Forexample,underthe"Documentation"linkyouwillfind:

-Technicalinformation-Productinformation-Productbrochures-andmuchmore

10| Installation certificate

- 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: [email protected] oder im Internet: www.bock.de. Für den deutschspra-chigen Raum steht darüber hinaus die kostenlose Bock-Hotline 00 800 / 800 000 88 von montags bis samstags zwischen 8 und 21 Uhr zur Verfügung. Für Anregungen zur Weiterentwicklung unseres Verdichter-, Ausrüstungs- und Ersatzteilprogramms sind wir Ihnen jederzeit sehr dankbar.

Bock Kältemaschinen GmbHPostfach 11 61D-72632 FrickenhausenBenzstr. 7D-72636 FrickenhausenFon: +49 7022 9454-0Fax: +49 7022 [email protected]

Lesen Sie vor Arbeitsbeginn die in dieser Betriebsanlei-tung für Sie zusammengefassten Informationen.Es werden wichtige Hinweise zur Sicherheit, Montage, Inbe-triebnahme und Bedienung gegeben. Darüber hinaus fi nden Sie Informationen zu Wartung, Ersatzteilen und Zubehör.Einige Hinweise sind besonders gekennzeichnet:

WARNUNG! Dieses Symbol weist darauf hin, dass ungenaues Befolgen oder Nichtbefolgen von Anweisungen zu Schäden an Personen, am Verdichter oder an der Kälteanlage führen kann.GEFAHR! Dieses Symbol weist auf Anweisun-gen hin, um unmittelbare schwere Gefährdun-gen von Personen zu vermeiden.GEFAHR! Dieses Symbol weist auf Anweisun-gen hin, um unmittelbare schwere Gefähr-dungen von Personen oder Anlagen durch elektrischen Strom zu vermeiden.Dieses Symbol verweist auf wichtige Zusatz-hinweise, die bei der Arbeit unbedingt zu berücksichtigen sind.

Das hohe Qualitätsniveau der Bock-Verdichter wird durch die ständige Weiterentwicklung der Konstruktion, der Ausstat-tung und des Zubehörs gewährleistet. Daraus können sich Abweichungen zwischen der vorliegenden Betriebsanleitung und Ihrem Verdichter ergeben. Haben Sie bitte Verständnis, dass deshalb aus den Angaben, Abbildungen und Beschrei-bungen keine Ansprüche abgeleitet werden können.

Ihr Team derBock Kältemaschinen GmbH

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Excellence Passion Integrity Responsibility GEA-versity

GEA Group is a global mechanical 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 TechnologiesGEA Bock GmbH

Benzstraße 7, 72636 Frickenhausen, GermanyTelephone: +49 7022 9454-0, Fax: +49 7022 [email protected], www.bock.de 09

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Gro

up A

G. A

ll rig

hts

rese

rved

.

assembly instructions - bock displacement at 1450 rpm 3 lp: max. permissible operating pressure (g)...

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