Operating instructions - Compressors for Commercial Refrigeration
Contents
1. 49 7022 9454 0 Fax 49 7022 9454 137 mail bock de www bock de Please read the information summarised for you in this manual before starting work It contains important instructions for safety installation initial commissioning and handling In addition you will find information on maintenance spare parts and acces sories Some instructions are identified by special symbols with the following meaning WARNING This symbol is used to indicate that inaccurate compliance or total failure to comply with the instructions could cause injury to persons or damage to the com pressor or refrigerating machine This symbol indicates important additional instructions which you should observe during your work The high quality standard of Bock compressors is guar anteed also by on going further development of machine features and accessories This could possibly result in nonconformities between this present manual and your compressor Please understand that it is not possible for any claims to be derived from the details illustrations and descriptions Your team at Bock K ltemaschinen GmbH Subject to modifications 097 16 07 07 DGbFITrRc 09716 07 07 DGbFITrRc Safety instructions Product description Use as intended Short description Nameplate Type code Main and functional components Limits of application N and K version Limits of application R134a Limits of application R407C TK version Limits of application R2. COMPRESSORS Betriebsanleitung FK 40 Operating instructions FK 40 Instructions de service FK 40 Istruzioni per Puso FK 40 Isletme k lavuzu FK 40 H i BA FKgo Operating instructions Types FK 40 390 N FK 40 470 N FK 40 560 N FK 40 655 N FK 40 390 K FK 40 470 K FK 40 560 K FK 40 655 K FK 40 390 TK FK40 470 TK FK40 560TK FK 40 655 TK E Dear Customer Bock compressors are top quality reliable service friendly quality products Please comply with the following operating and maintenance instructions so that you can benefit from all advantages to the full and use your refrigerating system throughout its entire service life If you have any questions about installation operation and accessories please contact our technical service or your refrigerating system wholesale dealer or our representative The Bock service team is available by phone under 49 7022 9454 0 by e mail under mail bock de or on the internet under www bock de In addi tion for German speaking countries we have set up a toll free hotline under 00 800 800 00 88 from Monday to Saturday between 8 a m and 9 p m Any suggestions you may have regarding the on going development of our compressor equipment and parts programme are welcome at any time QUALITY SYSTEM certified by DQS according to DIN EN ISO 9001 2000 Reg No 2177 Bock K ltemaschinen GmbH Postfach 11 61 D 72632 Frickenhausen Benzstr 7 D 72636 Frickenhausen Fon
3. Leak oil drain hose Shaft end 19 20 MANUFACTURER DECLARATION for use of the compressors within the European Union refering to the EU machinery directive 98 37 EEC annex II B We herewith declare that the refrigerating compressors named in the title in the version supplied by us are intended for installation in a machine which complies with the machinery directive 98 37 EEC Applied harmonised standards EN ISO 12100 1 EN 349 EN 60529 EN ISO 12100 2 EN 60204 1 It is however not permitted to start up our products before the machine in which they are integrated has been tested according to the corresponding statutory regulations and declared to be conforming in all points Frickenhausen 17 05 2004 CZ 5 e gt Dr Harald Kaiser Technical Director 09716 07 07 DGbFITrRc 9411149490 20 20 91 60 21 COMPRESSORS wwWw bock de Bock K ltemaschinen GmbH Benzstra e 7 D 72636 Frickenhausen Telefon 49 7022 9454 0 Telefax 49 7022 9454 137 mail bock de Art Nr 09716 07 07 DGbFITrRc Subject to change without notice
4. compliance with the given safety instructions The following torques must be used when re assembling the compressor Cylinder cover M10 60 Nm Axial face cover M8 37 Nm Connecting rod M6 15 Nm Oil drain screw M22 x1 5 70 Nm Oil filler plug 1 4 NPTF 25 Nm Flange connection Soldered connection shut off valve le Dal Electromagnetic clutch M12 85 Nm Safety valve M24 x 1 5 70 Nm 1 Screw with aluminium seal Notes Cylinder head valve plate tighten screws from the middle outwards crosswise in at least two stages torque 50 100 Decommissioning For major repairs or when decommissioning Comply with the safety instructions on page 15 Close the shut off valve on the compressor vacuum out the refrigerant do not blow out and dispose of correctly Open the screwed unions or flanges at the compressor valves and remove the compressor using hoisting gear if necessary When scrapping the compressor drain the oil and dispose of correctly Comply with the national regulations A WARNING Compressor is under pressure Avoid injures to skin and eyes Wear goggles 09716 07 07 DGbFITrRc 09716 07 07 DGbFITrRc Capacity regulation Special accessory 12 V Special accessory 24 V Compressor type Art No Art No FK 40 N und FK 40 TK 08703 08704 FK 40 K 08708 08709 For detailed description please also refer to technical information Capacity Regulation Art No 09900 When installed in the factory the capacity regulator i
5. dried nitrogen N e n the following evacuation procedure evacuate the system first then include the compressor in the evacuation procedure Release pressure in the compressor Open the suction and discharge shut off valves Evacuate the suction and high pressure side with the vacuum pump Vacuum lt 1 5 mbar with pump switched off Repeat procedure several times Refrigerant filling e Before filling with refrigerant check the oil level in the compressor e With the compressor switched off fill in liquid refrigerant into the system breaking the vacuum straight into the receiver e Start operation of the compressor If the refrigerant needs topping up after starting the com pressor it can be topped up in vapor form on the suction side NM e Do not fill liquid refrigerant into the suction shut off valve on the compressor e Do not mix additives with the oil or refrigerant Oil level check Immediately after starting check the oil level of the compressor e Drive motor in operating mode high idle high idle speed e The compressor should run for min 10 minutes e The machine should have reached the operating points e Check the oil level In view of the fact that the installation position of the compressor can differ in practice inclined position we recommend checking the oil level in both sight glasses The oil level must be visible in at least one sight glass e After the exchange of a compressor the oil level m
6. pipes of all normal metric and inch dimensions can be used The solder connections of the shut off should be removed during soldering The pipes and unit components should always be clean and dry on the inside and free of cinders metal chips rust and phosphate coats Furthermore the parts including the hoses must be delivered sealed air tight Shut off valves Opening the shut off valve a Open spindle 1 to the left anti clockwise as far as it will go Shut off valve fully opened service connection 2 closed setting A fig Opening the service connection 2 b Turn spindle 1 1 2 1 turn to the right clockwise Service connection 2 opened shut off valve open setting B fig Connection 3 is for safety purposes and not lockable Note Before opening or closing the shut off valve loosen the valve spindle seal fig left 1 4 of a turn Tighten the valve spindle seal again carefully after activating the shut off valve fig right 09716 07 07 DGbFITrRc 09716 07 07 DGbFITrRc The compressor has undergone trials in the factory and all functions have been tested There are therefore no special running in instructions Caution To protect the compressor from intolerable operating pressures high and low pressure pressure gauges are necessary Please comply with the accident prevention regulations Leak test evacuation e Check the cooling system for leaks without including the compressor preferably with
7. 404A R507 Limits of application R22 Installation instructions Mounting the compressor Inclined position Belt drive Main bearing load Installation of electromagnetic clutch Pipe connections pipes Shut off valves Putting into operation Leak test evacuation Refrigerant filling Oil level check Tightness of the shaft seal Replacement of the axial face seal Liquid operation Maintenance Safety instructions Service intervals Recommended spare parts Integrated overcurrent safety valve Excerpt from the lubricant table Screwed unions Decommissioning Accessories Capacity regulation Heat protection thermostat Specifications Connections Dimensions Manufacturer declaration D Q 00 00 O Y J Y O 91 01 01 01 01 A Safety The Bock refrigerating compressors named in the title are intended for installation in machines within the EU according to EU directive 98 37 EC Machinery Directive 97 23 EC Pressure Equipment Directive and 73 23 EC Low Voltage Directive Initial commissioning is only allowed when the compressor has been installed according to these instructions and the whole machine in which it is integrated has been tested and accepted according to the statutory regulations Bock refrigerating compressors have been designed to state of the art engineering Safety forthe user is given particular priority during the design stage However it is always possible for the refrigerating machine and operation thereof to pose un
8. 7C Version N and K Speed range N version 500 2600 rpm peak rotational speed 3500 rpm K version 500 3500 rpm Max tol operating pressure HP 28 bar E C Unrestricted area 6160 of application Reduced suction 50 gas temperature 40 to evaporation temperature C R407C te condensing temperature C 30 tah suction gas temperature C t 25 C ish A At suction gas overheating K de 30 20 0 l 20 E 25 a 10 0 1 E C TK Version Available models e FK 40 390 TK eFK240 470 TK eFK 40 560 TK e FK 40 655 TK Limits of application R404A R507 TK version Speed range TK version 500 2600 rpm Max tol operating pressure HP 28 bar t PC 70 Unrestricted area GB of application 60 8 Reduced suction gas temperature 50 1 EE aa to evaporation temperature C 40 te condensing temperature C R404A R507 toh Suction gas temperature C 30 At suction gas overheating K tn 20 C 20 L PPP 50 40 30 20 10 0 10 t C 4 5 8 Designs for other areas upon request 097 16 07 07 DGbFITrRc 09716 07 07 DGbFITrRc Limits of application R22 TK version Speed range TK version 500 2600 rpm Max tol operating pressure HP 28 bar t PC FO 66 60 50 40 At lt 20K R2 2 30 20 50 40 30 20 10 45 Designs for other areas upon request 9 Unrestricted area of application Reduced suction gas temperature to evapora
9. avoidable residual risks This is why these instructions must be observed carefully by every person working at the compressor Work on the compressor may only be carried out by persons whose technical training skills and experience together with their knowledge of pertinent regulations and documentation means that they are capable of assessing the work to be carried out and detecting any possible dangers trained staff as per DIN 31000 A SAFETY INSTRUCTIONS Caution Refrigerating compressors are pressurised machines and therefore require particularly careful and meticulous handling e Only qualified staff are allowed to handle refrigerating compressors e National safety regulations accident prevention regulations technical rules and other specifications incl EN 378 etc must be observed e The compressor may only be operated in refrigerating systems and only with coolants approved for this compressor by Bock eThe maximum tolerable operating overpressure may not be exceeded not even for test purposes e Pressure switches are required to safeguard the machine from excess pressures e New compressors are provided with an inert gas filling in the factory approx 3 bar nitrogen The pressure in the compressor must be relieved before connecting up the refrigerating system e Before starting the compressor check for any signs of transport damage e Before starting up check that all components mounted by the user have been properly
10. dingly use of tensioning pulleys selection of belt profile and belt length etc Main bearing load The following should be observed to avoid overloading of the compressor s main bearing e g by the belt drive e The force applied to the point of acting forces see fig may not exceed F 2750 N e f this point of acting force is moved forward see fig small dots then the force Fis diminished according to the following for mula F 245 kNmm 90mm L4 mm Incorrectly executed belt drives particularly belt beats due to jumping belts or excessive tensioning forces can result in compressor damage hy Fmax 2750N 7 Mymax 245 kNmm Installation of electromagnetic clutch The subsequent description applies to an electromagnetic clutch type LA 16 made by Linnig e For centering and mounting the magnetic coil of clutch the front bearing flange has a snug fit of 8148 h8 see left fig e To install the magnetic coil unscrew the 4 socket head screws M8 on the bearing flange see circles and arrows fig e Mount the magnetic coil on the seat snug fit and secure with the four socket head screws M8 right fig Screw tightening torque 34 Nm e Continue with the installation of the electromagnetic coupling according to the instructions of the clutch manufacturer Magnetic _ coil Ad Installat on instructions Pipe connections pipes The pipe connections are designed in such a way that
11. e direction of rotation with oil relief valve Variable arrangement of the shut off valves Ideal valve plate configuration for every working range Integrated pulsation damper for extremely quiet running Nameplate Exemple Frickenhausen Z _ _ BOCH Nr AP12345A017 4 1 Typ FKX40 655 N 2 Vin 56 6 m h bei n 1450min 3 Dmax ND LPYHD HP 19 28bar l SE55 5 1 Type of compressor 4 Serial number 2 Displacement at 1450 rom 5 Oil type filled in compressor by the manufacturer 3 LP max tol standstill pressure intake side note limits of HP max tol operating pressure high pressure side application diagrams Type key Example Explanation of the type designation FK X40 655 N Application Capacity size Size Ester oil filing fluorocarbons e g R134a R407C Series Product description Main and functional components ES SI PA 1 o O A O N 10 Discharge shut off valve Valve plate Cylinder cover Compressor housing Adapter for magnetic clutch Integrated leakage oil collector Leak oil drain hose Axial face seal Shaft end Base plate Connection for heat protection thermostat Oil filler plug Oil sight glasses 2x Oil drain plug Suction shut off valve Oil pump Oil drain plug oil filter Nameplate 097 16 07 07 DGbFITrRc 09716 07 07 DGbFITrRc Areas of application Explanations It is possible to operate the compressor within the shown diagram
12. fitted and are connected pressure tight with the compressor e g pipelines bungs union nuts replaced parts etc e Before starting up evacuate the refrigerating machine carefully with the compressor and then fill with coolant eBefore starting the compressor open the discharge shut off valve and suction shut off valve eDo not start the compressor in a vacuum Only operate the compressor when the whole system has been filled e Surface temperatures of more than 100 C are possible on the pressure side respectively below 0 C on the suction side depending on operating conditions 09716 07 07 DGbFITrRc 09716 07 07 DGbFITrRc Use as intended This operating manual describes FK40 in the standard version produced by BOCK The vehicle compressors in series FK40 are designed for mobile use other applications on request Short description Three design variations are available for different areas of application gt for air conditioning the K Design gt for air conditioning or normal cooling the N Design gt for deep freezing the TK Design The differences are mostly associated with the valve plate version which is adapted to each application range where operational safety and efficiency are concerned Additional features e Compact four cylinder compressor in V design Low wearing long lifed mechanism Four sizes Light weight aluminium design Crankshaft mounted on either side with roller bearings Lubrication oil pump independent of th
13. iving unit kgm 0 0043 Lubrication Forced lubrication Oil pump oil pump independent of sense of rotation Connections A Suction side connection not lockable 1 8 NPTF A1 Suction side connection lockable 7 16 UNF B Discharge side connection not lockable 1 8 NPTF B1 Discharge side connection lockable 7 16 UNF C Oil pressure safety switch connection OIL 1 8 NPTF D Oil pressure safety switch connection LP 118 NPTF E Oil pressure gauge connection 1 8 NPTF F Oil drain plug 1 4 NPTF G Opt connection for oil sump heater M22 x 1 5 H Oil charge plug 1 4 NPTF K Sight glass 2 x 1 1 g 18 UNEF L Connection thermal protection thermostat 1 8 NPTF M Oil filter M22 x 1 5 SV1 Opt pos of connection for suction line valve Only possible ex factory 097 16 07 07 DGbFITrRc ca 320 325 SV1 ca 370 09716 07 07 DGbFITrRc E Y gt BIO a J L OJ O A 5 x A u M o l CIE 2 B H N e QO SLIDE MES M A F 4x 813 109 210 _ 169 130 232 _ 344 _ ca 385 _ 8x M8 130 6x M8 972 A5x9 DIN 6888 M12x28 D148 hs
14. on Art No Art No Art No Art No Art No Valve plate kit 80240 80241 80010 80240 80241 Set of gaskets 80230 80001 80230 Set of shaft seals 80023 Integrated overcurrent safety valve The valve requires no maintenance However abnormal operating conditions can result in constant leaks after blowing off This can lead to reduced output and increased compressed gas temperature Check the valve and replace if necessary Excerpt from the lubricant table The oil type filled in the compressor as a standard in the factory is indicated on the nameplate This oil type should be given preference other oil types are listed in the following excerpt from our lubricant table 15 16 Lubricants Recommended alternatives Bock standard oil grade for H CFCs e g R22 FUCHS Reniso SP 46 MOBIL SHC 425 SUNOIL Suniso 4 GS SHELL Clavus SD 22 12 TEXACO Capella WF 46 SUNOIL Suniso 3 GS for fluorocarbons e g R 134a R404A R407C FUCHS Reniso Triton SE 55 FUCHS SEZ 32 68 80 MOBIL Arctic EAL 46 ICI Emkarate RL 46 S SHELL Clavus R 46 Information about other suitable supplementary or substitute oils is available in the Bock lubricant tables Caution The oils are to be checked for suitability according to the operating conditi A ons and refigerants Screwed unions Various installation maintenance and servicing work entails intervention in the compressor All work must therefore be performed with strict
15. ressor and secure to prevent unintentional switching on e Relieve pressure in the compressor After completed maintenance e Connect the safety switch e Evacuate the compressor e De activate the switch on safeguard Service intervals To guarantee optimum safety and service life for the compressor we recommend that the following servicing activities and checks be carried out at regular intervals particularly recommended when the machine is used in the limit range at high temperature and pressure conditions eQil change Basically it is not vital for the oil to be changed in machines which have been manufactured and are operated correctly But on the basis of our decades of experience we recommend the following oil change services first oil change when servicing the vehicle for the first time then every 5 000 operating hours or at the latest after 3 years whichever happens first cleaning the oil filter and the filter intake side at the same time If necessary empty the oil reservoir at the rotary seal e Function tests Once per year oil level compressor leak test operating noise pressure temperatures correct functioning of additional components e g capacity regulation Recommended spare parts Please use original Bock spare parts exclusively FK 40 390 N FK 40 560 N FK 40 390 K FK 40 390 TK FK 40 560 TK FK 40 470 N FK 40 655 N FK 40 470 K FK 40 470 TK FK 40 655 TK FK 40 560 K FK 40 655 K Designati
16. s Please note the significance of the areas shaded in grey The application limits must be observed The max discharge tempera ture of 140 C and the max ambient temperature of 100 C may not be exceeded Thresholds should not be selected as design or continuous operating points e Avoid continuous operation in the limit range If nevertheless the compressor is used for operation in the limit range we recommend use of a thermal protective thermostat accessory e Switching frequency The compressor should not be started more frequently then 12 times per hour and should not run for less than 2 minutes at a time e The limits of application can be altered when using capacity regulators N and K version Available models e FK 40 390 N eFK40 470N eFK 40 560 N e FK 40 655 N e FK40 3900K _ eFK40 470K e FK 40 560 K e FK 40 655 K Limits of application R134a Version N and K Speed range N version 500 3000 rpm peak rotational speed 3500 rpm K version 500 3500 rpm Max tol operating pressure high pressure side HD 28 bar t C 82 i Unrestricted area 80 of application 70 Y Reduced suction gas temperature 60 to evaporation temperature C 50 te condensing temperature C ig R134a th suction gas temperature C At suction gas overheating K 30 t 25C 4 gt 20 lt 30 20 10 0 10 20 30 t C 25 Designs for other areas upon request v Limits of application R40
17. s integrated in a specially designed cylinde cover When retrofitted it is supplied together with the cylinder cover The regulator controls a bank of cylinders capacity reduction approx 50 A e Capacity regulated operation changes the gas velocities and pressure ratios in the refrigerating system adjust the routing and rating of the suction line accordingly adjust the regulation intervals so that these are not too short do not switch more frequently than 12 times per hour refrigerating system must reach equilibrium We do not recommend continuous operation in the capacity regulation mode e Electrical control of the solenoid disenergized open corresponds to 100 compressor capacity e Cylinder covers for capacity regulation are marked with CR Capacity Regulator Heat protection thermostat Special accessory can also be retrofitted Art No 07595 On the hot gas side of the compressor housing there is a connection for the sensor element page 6 fig item 10 The heat protection thermostat is to be connected in series with the control line Technical specifications Switching voltage max 24V DC Switching current max 2 5 Aat 24 V DC Cut off temperature 145 C 5K Cut on temperature approx 115 C Tf 18 Technical specifications Theor Connections displace Weight Discharge Suction Oil filling ment side HP side LP 1450 rpm Le m h mm Inch mm Inch kg i Inertia moment of the dr
18. tion temperature C te condensing temperature C toh suction gas temperature C At Suction gas overheating K 0 10 t C Installation instructions Mounting the compressor e Transport and suspension possibilities at the transport eyelet or directly at the pressure shut off valve e Bock must be consulted before any other components e g pipe brackets additional appliances etc may be mounted to the compressor e Proper erection of the compressor and installation of the belt drive play a major role in the running comfort operating safety and service life of the compressor Warning Compressor is under pressure e Avoid injuries to skin and eyes Wear goggles AN e Leave protective gas filling in the compressor up to evacuation e Absolutely avoid entry of air e Do not open shutoff valves up to evacuation Inclined position Please note the max tolerable inclined position max 30 max 2 min max 30 max 2 min i max 15 perm aren ien ned position max 15 e permanent inclined position 09716 07 07 DGbFITrRc 09716 07 07 DGbFITrRc Belt drive e Incorrectly executed belt drives particularly belt hammers or excessive belt tension can cause damage to the compressor e When using capacity regulators accessories the changing load can result in increased run ning noise and vibration of the belt drive Please ensure that the belt drive is designed accor
19. ust be controlled again When the oil level is too high oil must be discharged danger of oil impacts less performance of the air conditioning system As Tightness of the shaft seal The tightness of the compressor shaft is obtained by an axial face seal see page 6 fig item 7 This seal rotates with the compressor shaft The following points are particularly important for its proper operation e The entire cooling circuit has to be expertly built and its interior must be clean e Violent shocks or vibrations on the shaft as well as intermittent operation for longer periods have to be avoided e During longer standstill periods e g in the winter it is possible for the sealing surfaces to stick together For this reason the machine should be started up for 10 minutes about every four weeks Disregard of these directives may cause loss of refrigerant or damage NM the axial face seal e The axial face seal ensures tightness thanks to the lubricating oil Small oil G losses a few drops are thus normal This is particularly true during the run in period 200 300 h e The FK 40 is fitted with an integrated leak oil trapping device with oil reservoir for trapping and collecting leaked oil see page 6 fig item 6 Replacement of the axial face seal As the replacement of the shaft seal requires opening of the refrigerant circuit it is only recommended if the compressor is really loosing refrigerant Emptying the oil reser
20. voir The oil reservoir can be emptied very simply without having to disman tle the coupling and or belt drive It is recommended that this is done at the same time as the air conditioning maintenance and motor service Proceed by removing the oil hose from the bracket remove the sealing plug and drain the oil into a collect ing vessel After emptying the oil hose must be resealed and clamped into the bracket Dispose of used oil in accordance with the regulations applicable in the country of use ge Liquid operation NM Liquid operation can damage the compressor and cause leakage of refrigerant In order to avoid liquid operation the following points should be carefully observed e The complete refrigerating plant must be properly rated and executed e All components of the installation must be matched to each other in their performance characteristics particularly evaporator and expansion valve e The suction gas superheat at the outlet of the evaporator should be at least 7 to 10 K check the setting of the expansion valve e Machine must reach steady state condition e Especially on critical installations having for example several evaporation points it is recommended that appropriate measures be taken such as the use of liquid traps solenoid valves in the liquid lines etc 4 09716 07 07 DGbFITrRc 09716 07 07 DGbFITrRc Safety instructions Before starting any work on the compressor NM e Switch off the comp
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