Operating instructions - Compressors for Commercial Refrigeration
Contents
1. ca 370 375 i DV i i ie J sy m V A 7 C E x e L 053 190 85 L 255 L ca 430 D Additional SV on FK50 660 775 830 980 in series K Design Shaft end DV 8x M8 130 6x M8 72 A5x9 DIN 6888 i i l IIT I M12x28 i QE o S ma is T re Sy m 50 Ld 54 1 5 ae a 100 u Dimensions in mm Leak oil drain hose 20 Connections A A1 B Bl D E F G H K L M Suction side connection not lockable Suction side connection lockable Discharge side connection not lockable Discharge side connection lockable Oil pressure safety switch connection OIL Oil pressure safety switch connection LP Oil pressure gauge connection Oil drain plug Opt connection for oil sump heater Oil charge plug Sight glass Connection thermal protection thermostat Oil filter SV10pt pos of connection for suction line valve 1 only possible ex factory 1 8 NP TF 7 16 UNF 1 8 NP TF 7 16 UNF2. COMPRESSORS 6 Operating instructions Types FK50 460 K FK50 460 N FK50 460 TK FK50 830 K FK50 830 N FK50 555 K FK50 660 K FK50 775 K FK50 555 N FK50 660 N FK50 775 N FK50 555 TK FK50 660 TK FK50 775 TK FK50 980 K FK50 980 N TR RC 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 sys tem 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 addition for German speaking countries we have set up a toll free hotline under 00 800 800 000 88 from Monday to Saturday between 8 a m and 9 p m Any suggestions you may have regarding the on going devel opment of our compressor equipment and parts programme are welcome at any time Please read the information summarised for you in this manual before starting work It contains important instructions for safety installation initial comissioning and handling In addition you will find information on maintenance spare parts and accessories Some instructions are identified by spec
3. 1 8 NP TF 1 8 NP TF 1 8 NPTF M22 x 1 5 M22 x 1 5 2 x 1 1 8 18 UNEF 1 8 NPTF M22 x 1 5 21 22 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 Cc o en Dr Harald Kaiser Technical Director 23 COMPRESSORS www bock de Bock Kaltemaschinen GmbH Benzstraf e 7 D 72636 Frickenhausen Telefon 49 7022 9454 0 Telefax 49 7022 9454 137 mail bock de Art Nr 09704 09 08 DGbFITrRc Subject to change without notice
4. 9C te condensing temperature C t h suction gas temperature C Ateh suction gas overheating K 10 2 30 da 20 10 0 0 t C TK Version Available models eFK50 460TK eFK50 555 TK eFK50 660 TK e FK50 775 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 of application 60 Reduced suction gas temperature 50 3 i x Sas t evaporation temperature C 40 te condensing temperature C R404A R507 tah suction gas temperature C 30 Atah suction gas overheating K t 20 C 20 50 40 30 20 10 0 10 t C Designs for other areas upon request Limits of application R22 TK version Speed range TK version 500 2600 rpm Max tol operating pressure HP 28 bar t C 70 Unrestricted area 66 of application 60 Reduced suction gas temperature 50 t evaporation temperature C 40 te condensing temperature C t h suction gas temperature C 30 Atoh suction gas overheating K 20 50 740 30 20 10 0 10 t C Designs for other areas upon request 9 Installation instructions Mounting the compressor e Transport and suspension at the transport eyes see fig right side e Bock must be consulted before any other components e g pipe brackets additional appliances etc may be mounted to the compressor e Propererection of the compress
5. 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 eThe 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 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 e Before starting the compressor open the discharge shut off valve and suction shut off valve e Do
6. must be visible in at least one sight glass After the exchange of a compressor the oil level must 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 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 i The following points are particularly important for its proper operation L The entire cooling circuit has to be expertly built and its interior must be clean Violent shocks or vibrations on the shaft as well as intermittent operation for longer periods have to be avoided 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 the axial face seal The axial face seal ensures tightness thanks to the lubricating oil Small oil losses a few drops are thus normal This is particularly true during the run in period 200 300 h The FK50 is fitted with an integrated leak oil trapping device with oil reservoir for trapping and collecting leaked oil see page 6 fig item 4 Replacement of the axial face seal As the replacementofthe shaft seal requires opening ofthe refrigerant circuit itis only recommende
7. Close the shut off valve on the com pressor 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 Compressor is under pressure Avoid injures to skin and eyes Wear goggles 17 18 Capacity regulation Special accessory 12 V Special accessory 24 V Compressor type Art No Art No FK50 N and FK50 TK 08703 08704 FK50 K 08708 08709 1 For detailed description please also refer to technical information Capacity Regulation Art No 09900 When installed in the factory the capacity regulator is integrated in a specially designed cylinder cover When retrofitted it is supplied together with the cylinder cover The regulator closes one cylinder bank in each case output regulation approx 33 96 Two regulators are required for a output regulation ao approx 66 96 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 capa city regulation mode e Electri
8. P 219 28 bar Ol SE55 5 Type of compressor 4 Serial number 2 Displace volume at 1450 rpm 5 Oil grade filled 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 X50 775N Application Capacity size Size Ester oil filling fluorocarbons e g R134a R407C Series Product description Main function parts 9 1 2 17 3 4 16 l 18 5 10 6 1 12 1 Cylinder cover 12 Baseplate 2 Valve plate 13 Suction shut off valve 3 Compressor housing FK50 660 775 830 and 980 4 Integrated leakage oil collector with 2 suction shut off valves 5 Adapter for magnetic clutch 14 Oilpump 6 Shaft end 15 Oil drain plug oil filter 7 Axial face seal 16 Connection of suction shut off valve 8 Connection for heat protection thermostat Optional 9 Discharge shut off valve 17 Nameplate 10 Oil filler plug 18 Leak oil drain hose 11 Oil sight glasses 2x B2 Limits of application Explanations It is possible to operate the compressor within the shown diagrams Please note the significance of the areas shaded in grey The application limits must be observed The max discharge temperature 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 A
9. cal control of the solenoid disenergized open corresponds to 100 compressor capacity e Cylinder covers for capacity regulation are marked with CR Capacity Regula tor Heat protection thermostat Special accessory can also be retrofitted Art No 07595 On the hot gas side ofthe compressor housing there is a connection for the sensor element fig page 6 item 8 The heat protection thermostat is to be connected in series with the control line Technical specifications Switching voltage max 24 V DC Switching current max 2 5 A at 24 V DC Cut off temperature 145 C 5K Cut on temperature approx 115 C oil pump independent of sense of rotation Forced lubrication yI BUI NO junoooe aul u gt JOU ae suonippe Ju UOSSGUCLUOD jo SAA eun uuau eyep eun ul LL pue N A QUEEN UBISSp SNOLIEN au JO aures au ae eyep OUP eur d Wo Jo E B LUD EU tuci OSPI au yau NJA EAA eu sa amS 19
10. d if the compressor is really loosing refrigerant Emptying the oil reservoir The oil reservoir can be emptied very simply without having to dismantle the coupling and or belt drive Itis recommended thatthis is done atthe same time as the air conditioning maintenance and motor service P roceed by removing the oil hose from the bracket remove the sealing plug and drain the oil into a collecting 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 14 Liguid operation Liquid operation can damage the compressor and cause leakage of refrigerant In order to avoid liquid operation the following points should be carefully observed The complete refrigerating plant must be properly rated and executed All components ofthe installation mustbe matched to each other in their perform ance characteristics particularly evaporator and expansion valve The suction gas superheatatthe outlet of the evaporator should be atleast 7 to 10K check the setting of the expansion valve Machine must reach steady state condition 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 15 16 Safety instructions Before starting any work on the compressor e Switch the
11. e 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 Technical data Dimensions and connections Manufacturer declaration Page 10 13 16 18 19 22 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 for the user IS given particular priority during the design stage However it is always possible for the refrigerating machine and operation thereof to pose unavoidable 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
12. ght 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 activat ing the shut off valve fig right Putting into operation 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 acci dent prevention regulations Pressure strength test The compressor was tested in the factory for pressure strength If the entire plant should be subjected in addition to a pressure strength test then observe the following e Testthe cold circuit according to EN 3 82 or a corresponding safety standard e Perform the pressure strength test preferably with dry nitrogen N e Do not mix any refrigerant with the testing medium N gt since otherwise shifting the ignition limit into the critical range is possible By no means the compressor may be pressure tested with oxygen or other industrial gases The maximum permissible operating pressure of the compressor may not be exceeded during the entire testing process see name plate information Leak test evacua
13. ial 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 compressor or refrigerating machine DANGER This symbol refers to instructions for avoiding direct severe dangers to 1 persons This symbol indicates important additional instructions which you should observe during your work The high quality standart of Bock compressors is guaranteed 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 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 R404A R507 Limits of application R 22 Installation instructions Mounting the compressor Inclined position Belt drive Main bearing load Installation of electromagnetic clutch Pipe connections pipes 5 hut off valves Initial commissioning Pressure strength test Leak test evacuation Refrigerant filling Oil level check Tightness of th
14. machine off and secure it against being switched back on e Relieve machine from the system pressure After maintenance has been performed e Comnect safety switch e Evacuate compressor e Cancel switch on blockage 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 e Oil change Basically it is not vital for the oil to be changed in machines which have been manu factured and are operated correctly But on the basis of our decades of experience we recom mend 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 FK50 460 N TK FK50 660 N TK All FK50 K FK50 555 N TK FK50 775 N TK FK50 830 N FK50 980 N Only use original Bock spare parts Integrated overcurrent safety valves The valves require no main
15. 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 Use as intended This operating manual describes FK50 in the standard version produced by BOCK The vehicle compressors in series FK50 are designed for mobile use other applications on request Short description Three design variations are available for different areas of application for air conditioning the K Design for air conditioning or normal cooling the N Design gt for deep freezing the TK Design not FK50 830 and 980 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 High performance compact six cylinder compressor in W design e Low wearing long lifed mechanism e Six sizes e Light weight aluminium design e Crankshaft mounted on either side with roller bearings e Lubrication oil pump independent of the direction of rotation with oil relief valve e Variable arrangement of the shut off valves e Ideal valve plate configuration for every working range e Integrated pulsation damper for extremely quiet running Nameplate Example Frickenhausen Germany Nr AP12345A017 4 676m h bei n 1450min Pmax ND LPVHD H
16. or and installation of the belt drive play a major role in the running comfort operating safety and service life of the compressor Compressors are filled with protective gas ex works approx 3 bar nitrogen AN e Leave protective gas filling in the compressor up to evacuation e Do not open shutoff valves up to evacuation e Absolutely avoid entry of air Pipe connections Inclined position max 30 max 2 min max 30 max 2 min 115 Ne Ee max permanent indined position permanent inclined position Belt drive ENRIN e Incorrectly executed belt drives particularly belt hammers or excessive belt tension can cause damage to the compressor Please ensure that the belt drive is designed accordingly use of tensioning pulleys selection of belt profile and belt length etc 10 Installation instructions Main bearing load The following should be observed to avoid overloading of the compressor s main bearing e g by the belt drive e Theforce applied to the point of acting forces see fig may not exceed F x 2 2750 N e lf this point of acting force is moved forward see fig small dots then the force F is diminished according to the following formula F 2245 kNmm 90mm L1 mm Incorrectly executed belt drives particularly belt beats due to jumping belts or excessive tension ing forces can result in compressor damage h Fmax 2750N Installation of electromagne
17. tenance 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 valves and replace them if necessary AN e A Excerpt from the lubricant table The oil type filled in the compressor as a standard in the factory is indicated on the name plate This oil type should be given preference other oil types are listed in the following excerpt from our lubricant table Lubricants Bock standard oil grade Recommended alternatives for H CFCs e g R22 FUCHS Reniso SP 46 MOBIL SHC 425 SHELL Clavus SD 22 12 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 The oils are to be checked for suitability according to the operating conditions an refigerants Screwed unions SUNOIL Suniso 4 GS TEXACO Capella WF 46 Various installation maintenance and servicing work entails intervention in the compres sor All work must therefore be performed with complianse with the given safety instructions The screw starting torques are to be considered Current table under www bock de Decommissioning For major repairs or when decommissioning Comply with the safety instructions on page 16
18. tic clutch accessories The subsequent description applies to an electromagnetic clutch type LA 16 FK50 460 115 and LA 26 FK50 830 980 made by Linnig e Forcentering and mounting the magnetic coil of clutch the front bearing flange has a snug fit of 9 148 h8 see fig left e To install the magnetic coil unscrew the 4 socket head screws M8 on the bearing flange see circles and arrows fig left e Mount the magnetic coil on the seat snug fit and secure with the four socket head screws M6 fig right Screw tightening torque 34 Nm e Continue with the installation of the electromagnetic coupling according to the instructions of the clutch manufacturer Bearing flange front Magnetic coll 11 12 Installation instructions Pipe connections pipes The pipe connections are designed in such a way that 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 unitcomponents 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 valves a Open spindle 1 to the left anti clock wise as far as it will go Shut off valve fully opened service connec tion 2 closed fig Opening the service connection 2 b Tum spindle 1 1 5 1 turn to the ri
19. tion e Check the cooling system for leaks without including the compressor preferably with dried nitrogen N e nthe 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 1 5 mbar with pump switched off Repeat procedure several times Refrigerant filling e Check whether the compressor suction and discharge shut off valves are open e With the compressor switched off fill in liquid refrigerant into the system breaking the vacuum straight into the receiver e Startoperation of the compressor If the refrigerant needs topping up after starting the compressor it can be topped up in vapor form on the suction side e Do not fill liquid refrigerant into the suction shut off valve on the compressor e Donotmix additives with the oil or refrigerant 13 Oil level check Immediately after starting check the oil level of the compressor Drive motor in operating mode high idle high idle speed The compressor should run for min 10 minutes The machine should have reached the operating points 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
20. void 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 ata time e The limits of application can be altered when using capacity regulators accessories N and K version Available models e FK50 460 N eFK50 555N eFK50 660N e FK50 775 N e FK50 460 K eFK50 555K eFK50 660K e FK50 775 K e FK50 830 N e FK50 980 N e FK50 830 K e FK50 980 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 90 Unrestricted area z5 of application Reduced suction 70 gas temperature 60 t o evaporation temperature C 50 te condensing temperature C 40 ton suction gas temperature C m Ateh suction gas overheating K 20 30 20 10 0 10 20 30 t C Designs for other areas upon request 7 Limits of application R407C 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 t C Unrestricted area of application Reduced suction gas temperature to evaporation temperature
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