Operating instructions - Compressors for Commercial Refrigeration
Contents
1. COMPRESSORS Betriebsanleitung FK30 Operating instruction FK30 Instructions de service FK30 Istruzioni per l uso FK30 Isletme kilavuzu FK30 Operating instructions Types FK30 235 K FK30 275 K FK30 325 K FK30 235N FK30 275 N FK30 325 N FK30 235 TK FK30 275TK FK30 325 TK 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 n 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 QUALITY SYSTEM certified by DOS according to DIN EN ISO 9001 Reg No 2177 oe k aa R oe ZZ Bock K ltemaschinen GmbH Postfach 11 61 D 72632 Frickenhausen Benzstr 7 D 72636 Frickenhausen Fon 49 7022 9454 0 Fax 49 7022 9454 137 mai2. Nameplate Example MAMMALS Frickenhausen BOCK Nr AP12345A017 4 Typ FKX30 325N Ja 28 3M h bei n 1450min Pmax ND LP HD HP 19 28 bar Ol SE55 5 1 Type of compressor 4 Serial number 2 Displacement at 1450 rom 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 X30 325 N Application Swept volume Size Ester oil filling Series K specially for AC systems N for AC systems or normal refrigeration TK for deep freezing 2X Ester oil filling HFC refrigerants e g R134a R407C gt Main function parts S BE ED N DO nO A Cylinder cover Valve plate Compressor housing Integrated leakage oil collector Adapter for magnetic clutch Shaft end Axial face seal Connection for heat protection thermostat Nameplate Discharge shut off valve Oil filler plug Oil sight glass Installation feet Connection of suction shut off valve Optional Suction shut off valve Oilpump Oil drain plug oil filter 09705 10 07 DGbFITr 09705 10 07 DGbFITr 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 disc
3. 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 WARNING Compressor is under pressure Avoid injures to skin and eyes Wear goggles 09705 10 07 DGbFITr 09705 10 07 DGbFITr 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 fig page 6 item 8 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 A at 24 V DC Cut off temperature 145 C 5K Cut on temperature approx 115 C 17 Technical data Nr dis Weight Connections of place Dischar Suction An Type cyl ment ge side side 1 yP 1450 rpm HP LP m h k mm Inch mm Inch g Ltr Inertia moment of the driving unit kgm2 0 0028 Lubrication Forced lubrication Oil pump independent of sense of rotation Connections A Connection suction side not lockable 7 16 UNF A1 Connection suction side lockable 7 16 UNF A2 Connection suction side not lockable 1 8 NPTF B Connection discharge side not lockable 7116 UNF B1 Connection discharge side lockable 7 16 UNF C Connection oil pressure switch OIL 1
4. 8 NPTF D Connection oil pressure switch LP 1 4 NPTF E Oil pressure gauge connection 1 8 NPTF F Oil drain M22 x 1 5 G Opt connection for oil sump heater H Oil charge plug 1 4 NPTF K Sight glass 1 1 8 18 UNEF L Connection thermal protection thermostat 1 8 NPTF M Oil filter M22 x 1 5 SV1 Optional position of connection for suction line valve L Soldering connection Only possible ex factory 09705 10 07 DGbFITr ca 330 294 D H L B1 B 99 90 K svi ca 325 330 G Lx 11 _ 4x M10 175 Both sides ca 270 260 Only on K Version FK30 235 cm only FK 30 235 LO 34 A5x6 5 DIN 6888 B1 B DV 28 of LA E 2 J CIT T H3 E S T 15 63 09705 10 07 DGbFITr 19 20 MANUFACTURER DECLARATION for use of the compressors within the European Union refering to the EU machinery directive 98 37 EEC annex Il B We herewith declare that the refrigerating compressors named in the title in the version supplied by us are intended for installati
5. 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 perform ance characteristics particularly evaporator and expansion valve e The suction gas superheat at the outlet of the evaporator should be at least 7 to 10K 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 09705 10 07 DGbFITr 09705 10 07 DGbFITr Safety instructions Before starting any work on the compressor e Switch off the compressor 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 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
6. 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 replace the oil felt of the shaft 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 Pleasa use original Bock spare parts exclusively FK 30 235 FK 30 275 FK 30 325 FK 30 235 K N TK N TK N TK FK 30 275 K FK 30 325 K Designation Art No Art No Art No Art No Valve plate kit 80240 80242 80241 80010 Set of gaskets 80232 80126 Set of shaft seals 80123 Oil collector ring 80127 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 Screwed unions Various installation maintenance and servicing work entails intervention in the compressor All work must therefore be performed with strict compliance with the given safety instructions The following torques must be used when re assembling the compressor 16 A A Cylinder cover M10
7. 04A 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 Initial commissioning Preparations for start up 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 Torques for screwed connections Decommissioning Accessoires Heat protection thermostat Technical data Specifications and connections Dimensions Manufacturer declaration 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 unavoidabl
8. 60 Nm Axial face cover M6 15 Nm Connecting rod M6 15 Nm Oil drain screw M22 x1 5 100 Nm Oil filler plug 1 4 NPTF 25 Nm Soldered connection 11 4 12 UNF 110 Nm Shut off valve M8 M10 37 Nm 60 Nm Electromagnetic clutch M12 85 Nm Safety valve M24 x 1 5 100 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 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 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 conditions and refigerants Decommissioning For major repairs or when decommissioning Comply with the safety instructions on page 15 Close the shut off valve on the com pressor vacuum out the refrigerant do not blow out
9. FK30 235 TK FK30 275 TK eFK30 325 TK Limits of application R404A R507 TK version Speed range TK version 500 2600 rom Max tol operating pressure HP 28 bar Unrestricted area of application Reduced suction gas temperature to evaporation temperature C te condensing temperature C toh suction gas temperature C At suction gas overheating K t C 707 Unrestricted area of application 5 69 Reduced suction gas temperature 50 11 nt lt 201 ty evaporation temperature C 40 te condensing temperature C R404A R507 toh Suction gas temperature C 30 Atah suction gas overheating K tn 20 C 20 L 44 MX 1 50 40 30 20 10 0 10 t C AS 5 Designs for other areas upon request 09705 10 07 DGbFITr 09705 10 07 DGbFITr Limits of application R22 TK version Speed range TK version 500 2600 rom Max tol operating pressure HP 28 bar t C 70 66 60 50 40 t lt 20K R22 30 t 25 C 20 50 40 30 20 10 45 0 Unrestricted area of application Reduced suction gas temperature ty evaporation temperature C te condensing temperature C toh suction gas temperature C tn Suction gas overheating K 10 t C Designs for other areas upon request 9 10 Installation Mounting the compressor e Bock must be consulted before any other components e g e Proper erection of the compress
10. ding to the following formula F 245 kNmm 90mm L4 mm Incorrectly executed belt drives particularly belt beats due to jumping belts or excessive tension ing forces can result in compressor damage Fmax 2750 N Mymax 245 kNmm Installation of electromagnetic clutch The subsequent description applies to an electromagnetic clutch type LA 30 1 made by Linnig e For centering and mounting the magnetic coil of clutch the front bearing flange has a snug fit of 95 f7 see fig left e For the installation push the magnetic field on snugly and fasten with 2 cheese head screws M6 x 16 fig right Screw tightening torque 15 Nm Bearing flange front Magnetic coil Continue with the installation of the electromagnetic coupling according to the instructions of the clutch manufacturer 11 12 G 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 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 valves a Open spindle 1 to the left anti clockwise as far as it will go Shut off valve fully opened service connection 2 closed sett
11. e 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 train ing 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 Safety instructions e Any handling of the compressor is permissible only by skilled personnel Observe national safety regulations accident prevention regulations generally recognized technical rules as well as specific regulations EN 378 EN 60204 EN 60355 etc Convey compressors only with hoists with sufficient lifting power Operate compressors only in refrigeration plants with approved refrigerants Do not exceed permissible operating pressure even for testing purposes Caution Compressors are filled with protective gas ex works approx 3 bar nitrogen Avoid possible injuries to skin and eyes Wear goggles Pressure relieve compressors before connection to the refrigeration system Before start up check compressor for transport damage Before start up check that all components installed by the user are attached correctly and connected pressure tight with the compressor pipes plugs union nuts replaced components etc Before start up evacuate the refrigeration plant with compressor carefully and then fill with refrigerant Op
12. en pressure and suction shutoff valves before starting the compressor Do not start the compressor in vacuum Operate only with filled plant Corresponding to the conditions of use surface temperatures of more than 100 C on the pressure side and below 0 C on the suction side can be reached 09705 10 07 DGbFITr 09705 10 07 DGbFITr Use as intended This operating manual describes FK30 in the standard version produced by BOCK The vehicle compressors in series FK30 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 High performance compact two cylinder compressor in in line construction e Three output sizes e Light weight aluminium design e Crankshaft mounted on either side with roller bearings e Reduced number of sealing places due to dispensing with a base plate 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
13. harge 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 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 N und K version Available models e FK30 235 N e FK30 235 K e FK30 275 N e FK30 275 K Limits of application R134a Version N and K Speed range e FK30 325 N e FK30 325 K N version 500 3000 rpm peak rotational speed 3500 rpm K version 500 3500 rpm Max tol operating pressure HP 28 bar R134a t 25 C Unrestricted area of application Reduced suction gas temperature to evaporation temperature C te condensing temperature C toh suction gas temperature C At suction gas overheating K 30 20 10 0 10 20 25 30 t C Designs for other areas upon request 7 Limits of application R407C Version N and K Speed range N version 500 2600 rom K version 500 3500 rpm Max tol operating pressure HP 28 bar t C 61 60 50 ai R407C 30 tan t25 C 20 i j 30 20 10 20 3 10 0 t C TK Version Available models e
14. ing A fig Position A 2 3 __ Compressor 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 lock able Position B 2 3 Compressor 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 09705 10 07 DGbFITr 09705 10 07 DGbFITr 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 accident prevention regulations Leak test evacuation e Check the cooling system for leaks without including the compressor preferably with dried nitrogen N e Inthe 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 fi
15. l 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 informa tion on maintenance spare parts and accessories 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 compressor or refrigerating machine This symbol indicates important additional instructions which you should observe during your work The high quality standard 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 Kaltemaschinen GmbH Subject to modifications 09705 10 07 DGbFITr 09705 10 07 DGbFITr Page 10 13 15 17 18 19 20 Safety instructions Product description Use as intended Short description Nameplate Type code Main and functional components Areas of application N and K version Limits of application R134a Limits of application R407C TK version Limits of application R4
16. lling 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 Start operation 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 Do not mix additives with the oil or refrigerant 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 oil level the oil level must be visible in the 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 G amp B 13 14 OF 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 intermitten
17. on 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 C r gt 2 Dr Harald Kaiser Technical Director 09705 10 07 DGbFITr 41114990 20 01 S0260 21 COMPRESSORS WWWw bock de Bock K ltemaschinen GmbH Benzstra e 7 D 72636 Frickenhausen Phone 49 7022 9454 0 Fax 49 7022 9454 137 mail bock de Art Nr 09705 10 07 DGbFITr Subject to change without notice
18. or and installation of the e n the condition on delivery the compressor is provided with pipe brackets additional appliances etc may be mounted to the compressor belt drive play a major role in the running comfort operating safety and service life of the compressor installation feet see Fig right Alternatively the compres sor can also be bolted directly without installation feet on the substructure Warning Compressor is under pressure e Avoid injuries to skin and eyes Wear goggles 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 max 30 max 30 max 2 min max 2 min max 15 max 15 ermanent inclined pos Permanent inclined pos Belt drive 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 09705 10 07 DGbFITr 09705 10 07 DGbFITr 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 lf this point of acting force is moved forward see fig small dots then the force F is diminished accor
19. t 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 the axial face seal e 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 e In order to retain the leakage oil as long as possible the FK 30 is fitted with an integrated leakage oil collector see page 6 fig item 4 It collects the leakage oil and the oil generally evaporates without leaving any visible trace Replacement of the axial face seal As the replacement of the shaft seal requires open ee a ing of the refrigerant circuit it is only recommended if the compressor is really loosing refrigerant If an oil leakage occurs above the leakage oil collector we recommend replacement only of the collector ring which is provided with felt on its inside fig The collector is available as a spare part see table page 15 The replacement of the sliding ring seal is described in the note accompanying each spare part kit Liquid operation Liquid operation can damage the compressor and cause leakage of refrigerant In order to avoid liquid operation the following points should be
Download Pdf Manuals
Related Search