Danfoss BOCK FK20 GEA Vehicle Compressors User Guide
- June 13, 2024
- Danfoss
Table of Contents
Danfoss BOCK FK20 GEA Vehicle Compressors
Product Information
The product is a compressor, available in various models:
- FK20/120 N
- FK20/120 K
- FK20/120 TK
- FKX20/120 N
- FKX20/120 K
- FKX20/120 TK
- FK20/145 N
- FK20/145 K
- FK20/145 TK
- FKX20/145 N
- FKX20/145 K
- FKX20/145 TK
- FK20/170 N
- FK20/170 K
- FK20/170 TK
- FKX20/170 N
- FKX20/170 K
- FKX20/170 TK
About these instructions
These instructions should be read before assembling and using the compressor.
They contain important safety information to prevent misunderstandings and
damage. Improper assembly and use can result in serious or fatal injuries. The
safety instructions must be followed. These instructions should be provided to
the end customer along with the installed unit.
Contents
The user manual includes the following sections:
- Safety
- Product Description
- Areas of application
- Compressor assembly
- Commissioning
- Maintenance
- Accessories
- Technical Data
- Dimensions and Connections
- Declaration of incorporation
Safety
Identification of safety instructions
- DANGER! Indicates a dangerous situation which, if not avoided, will cause immediate fatal or serious injury.
- WARNING! Indicates a dangerous situation which, if not avoided, may cause fatal or serious injury.
- CAUTION! Indicates a dangerous situation which, if not avoided, may cause fairly severe or minor injury.
- ATTENTION! Indicates a situation which, if not avoided, may cause property damage.
- INFO! Important information or tips on simplifying work.
Qualifications required of personnel
Inadequately qualified personnel poses the risk of accidents, which can
result in serious or fatal injury. Work on compressors should only be
performed by personnel with the following qualifications:
- Engineer
- Professions with comparable training that enables personnel to assemble, install, maintain, and repair refrigeration and air-conditioning systems
- Personnel capable of assessing the work and recognizing potential dangers
Product Usage Instructions
To use the compressor, follow these steps:
- Read and understand the safety instructions provided in the user manual.
- Assemble the compressor according to the instructions provided in the user manual.
- Ensure that the compressor is set up correctly and placed on a stable surface.
- Check the maximum permissible inclination of the compressor and ensure it is within the specified limits.
- If using a V-belt drive, follow the instructions provided in the user manual for proper installation.
- Take note of the main bearing load and ensure it is within the recommended range.
- If applicable, assemble the electromagnetic clutch assembly according to the instructions provided in the user manual.
- Connect the necessary pipes to the compressor following the pipe connection guidelines provided in the user manual.
- Operate the shut-off valves as instructed in the user manual.
- Understand and follow the operating mode of the lockable service connections.
- If applicable, install and maintain the suction pipe filter according to the instructions provided in the user manual.
- Before starting up the compressor, make sure all necessary preparations have been made, including a pressure strength test, leak test, evacuation, and refrigerant charge.
- If needed, refer to the user manual for instructions on replacing the shaft seal.
- Avoid liquid shocks during operation as indicated in the user manual.
- Maintain the compressor regularly by following the recommended maintenance procedures provided in the user manual.
- Use recommended spare parts and accessories when carrying out maintenance or repairs.
- Refer to the user manual for information on lubricants and oils to be used with the compressor.
- When decommissioning the compressor, follow the decommissioning guidelines provided in the user manual.
- If using the TK version, refer to the user manual for specific instructions regarding the valve plate.
About these instructions
Read these instructions before assembly and before using the compressor. This
will avoid misunderstandings and prevent damage. Improper assembly and use of
the compressor can lead to serious or fatal injury. Observe the safety
instructions contained in these instructions. These instructions must be
passed on to the end customer along with the unit in which the compressor is
installed. The safety advice, which is contained in these instructions for
assembly, and which is relevant for regular operation and maintenance, must be
forwarded by the manufacturer in his own documents to the operator of the
entire system. It must also be ensured, that personnel working in daily
operation with the compressor have access to important information such as
safety and warning advice about the compressor. Such persons must read the
safety advice and have understood it. Bock assumes no liability for any damage
arising from non-compliance.
Safety
Identification of safety instructions:
DANGER!
Indicates a dangerous situation which, if not avoided, will cause immediate
fatal or serious injury.
WARNING!
Indicates a dangerous situation which, if not avoided, may cause fatal or
serious injury.
CAUTION!
Indicates a dangerous situation which, if not avoided, may cause fairly
severe or minor injury.
ATTENTION!
Indicates a situation which, if not avoided, may cause property damage.
INFO! Important information or tips on simplifying work.
Qualifications required of personnel
WARNING! Inadequately qualified personnel poses the risk of accidents, the consequence being serious or fatal injury. Work on compressors is therefore reserved for personnel with the qualifications listed below:
- For example, a refrigeration technician, or refrigeration mechatronic engineer.
- As well as professions with comparable training, which enables personnel to assemble, install, maintain, and repair refrigeration and air-conditioning systems. Personnel must be capable of assessing the work to be carried out and recognizing any potential dangers.
- Danger to life and limb in the event of faults during operation
WARNING! If a compressor continues to be operated during extreme running noise and/or a sharp reduction in refrigerating capacity, there is the danger of further events occurring, such as the fracture of the housing wall. If people are standing in the immediate surroundings, there is the risk of severe injury or even death from flying parts.
- In the event of extreme running noise, switch the compressor off immediately.
- If there is a sharp reduction in refrigerating capacity, switch the compressor off immediately.
- Secure the compressor against being switched on again.
- In such cases do not continue to operate the compressor under any circumstances.
DANGER! Refrigerating compressors are pressurized 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.
Intended use
These assembly instructions describe the standard version of the FK20 manufactured by Bock. The compressor is intended for use in refrigeration systems in compliance with the limits of application. Only the refrigerant specified in these instructions may be used. Any other use of the compressor is prohibited! The Bock refrigerating compressor named in the title is intended for installation in a machine (within the EU according to the EU Directives 2006/42/EC Machinery Directive, 2014/68/EU Pressure Equipment Directive). Commissioning is permissible only if the compressor has been installed in accordance with these assembly instructions and the entire system into which it is integrated has been inspected and approved in accordance with legal regulations.
Product Description
Brief description
Three different designs are available for various ranges of applications:
- for air-conditioning the K Design
- for air-conditioning or normal cooling the N Design
- for deep freezing the TK Design
- The differences lie mainly in the valve plate tooling which is adapted to each application
- the range where operational safety and efficiency are concerned.
- The compact two-cylinder compressor in a single row.
- Three capacity ranges.
- Lightweight aluminum design.
- Lubricating oil pump with oil pressure relief valve independent of rotational direction.
- Variable connection and fixing options.
Nameplate (example)
Type key (example)
Areas of application
Refrigerants
- HFKW / HFC: R134a, R404A/R507, R407C
- HFCKW / HCFC: R22
Oil charge
The compressors are factory-filled with the following oil type:
- for R134a, R404A/R507, R407C BOCK lub E55
- for R22 BOCK lub A46
- Compressors with ester oil charge (BOCK lub E55) are marked with an X in the type designation (e.g.
- FKX20/170 N).
Limits of application
ATTENTION! Compressor operation is possible within the operating limits.
These can be found in the Bock compressor selection tool (VAP) under
vap.bock.de. Observe the information given there.
- Max. permissible discharge end temperature: 140°C
- Permissible ambient temperature: (-20°C) – (+100°C)
- Max. permissible switching frequency: 12 x /h
- A minimum running time of 2 min. at equilibrium (continuous operation) must be achieved
Avoid continuous operation near the threshold. Should the compressor happen to be used near the thresholds, we recommend the use of a thermal protection thermostat (Accessories, Chap. 7). When operating in the vacuum range, there is a danger of air entering 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 Max. permissible operating pressure (g) high-pressure side (HP): 28 bar
Compressor assembly
INFO! New compressors are factory-filled with inert gas. 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.
Setting up
- Storage at (-40°C) – (+100°C), maximum permissible relative Humidity 10% – 95%, no condensation
- Fittings (e.g. pipe holders, additional units, etc.) on the compressor are permissible only following consultation with Bock.
- Setup on an even surface or frame with sufficient load-bearing capacity. The compressor can be fastened as follows:
- using the 4 drill holes on the baseplate
- using the 3-side M10 tapped blind holes on the left or right of the compressor housing
- using the 4 M10 tapped blind holes on the front of the compressor housing.
- Correct setup of the compressor and mounting of the belt drive is decisive for running comfort, operating safety, and the service life of the compressor
Respect the stated values. Maximum permissible inclination
ATTENTION! Poor lubrication can damage the compressor. Respect the stated
values.
ATTENTION! Inappropriately designed belt drives, especially belt knocking (offsets, inclinations) or excessive tensioning forces can cause compressor damage! Make sure that the drive belt is designed correctly, e.g. by using tensioners and selecting the belt profile and the belt length.
Main bearing load
To prevent the belt drive from overloading the compressor main bearing,
ensure that:
- The engagement force applied by the belt tension (see Fig. 5) must not exceed Fmax per. = 600 N.
- If the force engagement point shifts to the right (see Fig. 5, small point), the force Fmax per. reduces as per the following formula:
- Fmax per. = 30 km
- (50 mm + L1 [mm])
Electromagnetic clutch assembly
ATTENTION! Inappropriately designed belt drives, especially belt knocking
(offsets, inclinations) or excessive tensioning forces can cause compressor
damage! Make sure that the drive belt is designed correctly, e.g. by using
tensioners and selecting the belt profile and the belt length. The following
description applies to an electromagnetic clutch secured to a shaft. To absorb
the magnetic field of the electromagnetic clutch, the sliding ring lid has a
snug fit Ø 38 h8 (see Fig. 6). To connect the magnetic field, remove the
marked Allen head screws of the sliding ring lid (see Fig. 7). Slide the
magnetic field to a snug fit and fasten using the three M5 x 20 cheese head
screws provided (Fig. 7). Screw torque = 9 Nm. Further assembly of the
electromagnetic clutch according to the clutch manufacturer
Pipe connections
- The pipe connections, if installed, have graduated inside diameters so that pipes in the common millimeter and inch dimensions can be used. The connection diameters of the shut-off valves are designed for maximum compressor output. The required pipe cross-section must be matched to the capacity. The same applies for non-return valves.
ATTENTION! Overheating can damage the valve. Solder only uses inert gas to inhibit oxidation products
Pipes
Pipes and system components must be clean and dry inside and free of scale,
swarf and layers of rust and phosphate. Only use air-tight parts. Lay pipes
correctly. Suitable vibration compensators must be provided to prevent pipes
from being cracked and broken by severe vibrations. Ensure a proper oil
return. Keep pressure losses to an absolute minimum.
Pipe connections
Valve spindle seal
Operating the shut-off valves
Before opening or closing the shut-off valve, release the valve spindle seal
by approx. ¼ of a turn counter-clockwise. After activating the shut-off valve,
re-tighten the adjustable valve spindle seal clockwise The operating mode of
the lockable service connections
Opening the shut-off valve:
Spindle 1: turn to the left (counter-clockwise) as far as it will go.
- Shut-off valve fully opened service connection 2 closed
Opening the service connection (2)
Spindle 1: Turn ½ – 1 rotation to the right.
- Service connection 2 opened / shut-off valve opened.
- Connection 3 is provided for safety devices and is not lockable
After activating the spindle, generally fit the spindle protection cap again and tighten with 14-16 Nm. This serves as a second sealing feature during operation. For systems with long pipes and a higher degree of contamination, a filter on the suction side is recommended. The filter has to be renewed depending on the degree of contamination (reduced pressure loss).
Commissioning
Preparations for start-up
INFO! To protect the compressor against inadmissible operating
conditions, high-pressure and low-pressure press stats are mandatory on the
installation side. The compressor has undergone trials in the factory and all
functions have been tested. There are therefore no special running-in
instructions. Check the compressor for transport damage!
Pressure strength test
The compressor has been tested in the factory for pressure integrity. If
however, the entire system is to be subjected to a pressure integrity test,
this should be carried out in accordance with EN 378-2 or a corresponding
safety standard without the inclusion of the compressor
DANGER! Risk of bursting!
The compressor must only be pressurized using dried nitrogen (N2). Never
pressurize with oxygen or other gases! The maximum permissible overpressure of
the compressor must not be exceeded at any time during the testing process
(see nameplate data)! Do not mix any refrigerant with the nitrogen as this
could cause the ignition limit to shift into the critical range.
Leak test
Carry out the leak test on the refrigerating plant in accordance with EN 378-2
or a corresponding safety standard, while always observing the maximum
permissible overpressure for the compressor.
Evacuation
First, evacuate the system and then include the compressor in the evacuation
process. Relieve the compressor pressure. Open the suction and discharge line
valves. Evacuate the suction and discharge pressure sides using the vacuum
pump. At the end of the evacuation process, the vacuum should be < 1.5 bar
when the pump is switched off. Repeat the process as often as is required.
Refrigerant charge
CAUTION! Wear personal protective clothing such as goggles and protective gloves! Make sure that the suction and discharge line valves are open. With the compressor switched off, add the liquid refrigerant directly to the condenser or receiver, breaking the vacuum. If the refrigerant needs topping up after starting the compressor, it can be topped up in vapor form on the suction side, or, taking suitable precautions, also in liquid form at the inlet to the evaporator.
ATTENTION! Avoid overfilling the system with refrigerant! To avoid shifts in concentration, zeotropic refrigerant blends (e.g. R407C) must always be added to the refrigerating plant in liquid form.Do not pour liquid refrigerant through the suction line valve on the compressor. It is not permissible to mix additives with the oil and refrigerant
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 particularly
during the run-in phase (200 – 300 h). The compressor shaft is sealed to the
outside using a shaft seal. The sealing element rotates with the shaft. The
following is especially important to ensuring fault-free operation: The
complete refrigerant circuit must be correctly executed and clean inside.
Heavy shocks and vibrations to the shaft, as well as continuous cyclic
operation, are to be avoided. The sealing surfaces can stick together during
prolonged downtimes (e.g. winter). Therefore, run the system every 4 weeks for
10 minutes.
Notes on replacing the shaft seal
Since changing the shaft seal involves encroaching into the refrigerant
circuit, this is only recommended, if the seal is losing refrigerant, or if
oil is escaping in excess of the permissible amount (see information on page
14, chapter 5.6, “Shaft seal”). Changing the shaft seal is described in the
relevant spare part kit. The shaft seal is a wearing part, and its service
life depends on the prevailing conditions. Damaging effects on the shaft seal:
- Too little suction gas superheat, particularly during wet operation
- Too high or too low belt tension
- Thermal overload (operation outside the limits of application)
- Frequent cycling
- Long periods of stoppage
- Material deposits/dirt from the system
- Due to these effects, the shaft seal can develop leaks, and it must then be replaced.
Avoiding liquid shocks
To prevent liquid shocks: The complete refrigeration plant must be correctly
designed and executed. The capacities of all components must be compatible
(particularly the evaporator and expansion valve).
Suction gas superheating at the evaporator output should be at least 7 – 10 K
(check the setting of the expansion valve). The system must reach a state of
equilibrium. Particularly in critical systems (e.g. several evaporator
points), suitable measures, e.g. use of liquid traps, solenoid valves in the
liquid line, etc. are recommended.
Maintenance
WARNING! Before starting any work on the compressor: Switch off the
compressor and secure it to prevent a restart. Relieve compressor of system
pressure. Prevent air from infiltrating the system!
After maintenance has been performed: Connect the safety switch. Evacuate
compressor. Release switch lock.
Work to be carried out
Maintenance
Oil change: In principle, an oil change is not a mandatory requirement, if the
equipment is correctly manufactured and properly operated. Based on decades of
experience, we recommend however that the following oil change/service work is
carried out: Initial oil change during the first maintenance of the vehicle
(at the latest after one year) Then after every 5,000 operating hours, at the
latest however after 3 years. Also, clean the oil filter. An oil change is
also necessary, if the oil is very cloudy and dark, or after repairs have been
carried out on the compressor.
Emptying the shaft seal oil reservoir: As required depending on use, but at the latest after 1 year or approx. 1,400 operating hours Where requirements are higher during use (frequent operation at the limits of application, or in hot lands with over +40 °C ambient temperature, or in the case of deep freezing), the following requirements must be observed: Initial oil change during the first maintenance of the vehicle (at the latest after one year) Then an oil change after every 2,000 operating hours, at the latest however after two years. Also, clean the oil filter.
Preventive maintenance
The above requirements for higher-use applications also apply in the case of
preventive maintenance. The shaft seal must also be changed after 3 years.
Regular inspections (at least annually): Checks to be carried out on the oil
level in the oil sight glass, oil fill level of the shaft seal in the oil
drain hose, absence of leaks in the compressor, running noise, vibrations,
pressures, temperatures, and functioning of auxiliary devices such as capacity
control.
Recommended spare parts/accessories
Maintenance set for an oil change
- BOCK lub E55 1 l
- Oil drain screw with seal
Maintenance set for shaft seal
- shaft seal kit
- BOCK lub E55 1 l
- Oil drain screw with seal
Available spare parts and accessories can be found on our compressor selection tool under vap.bock.de as well as in our online spare parts catalog at bockshop.bock.de. Only use original Bock spare parts!
Lubricants / Oils
The oil type filled as standard in the factory is marked on the nameplate, and
this should always be used, even in the case of maintenance units. Alternative
oil types can vary significantly in quality due to additives or inferior raw
materials by the manufacturer. Validation within the compressor’s entire
operating limits can not be guaranteed if such alternative oil types are used.
It is for this reason, that we only recommend the use of oil from Bock! Bock
assumes no liability for any damage arising from alternative oil types.
Decommissioning
Close the shut-off valve on the compressor. Drain the refrigerant (it must not
be discharged directly into the environment) and dispose of it according to
the regulations. When the compressor is depressurized, undo the fastening
screws of the shut-off valves. Remove the compressor using an appropriate
hoist. Dispose of the oil inside in accordance with the valid national
regulations.
Valve plate, TK version
Based on the tried-and-tested N valve plate system, a valve plate with reduced
dead space has been adapted to the FK20 TK specifically for applications in
the deep freeze area. The system is equipped with a non-interchange safeguard
to avoid confusing it with an N valve plate
Accessories
*Thermal protection thermostat (Item No. 097B07595)*
A special intermediate flange, located below the discharge line valve, is used
to attach the sensor element (Part no. 097B04175). Wire the thermal
protection thermostat in series with the control line.
Technical Data:
- Switching voltage max. : 24 V DC
- Switching current max. : 2.5 A at 24 V DC
- Switch-off temperature: 145 °C ± 5 K
- Switch-on temperature: approx. 115 °C
*Thermal protection thermostat (Item No. 097B07595)
Valve plate, TK version**
Based on the tried-and-tested N valve plate system, a valve plate with reduced
dead space has been adapted to the FK20 TK specifically for applications in
the deep freeze area. The system is equipped with a non-interchange safeguard
to avoid confusing it with the N valve plate. Fig. 13 Non-interchange
safeguard for the FK20 valve plate, TK version:
Accessories
Please note that the legacy BOCK code numbers are without 097B
Technical data
The technical data for the different designs K, N, and TK are identical. The compressor type data, therefore, do not mention these additions.
Dimensions and connections
Only possible ex-factory
- SV DV Suction line
- For discharge line see technical data, Chapter 8
- 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 7/16″ UNF
- B1 Connection discharge side, lockable 7/16″ UNF
- F Oil drain plug G 1/8″
- G Opt. connection for oil sump heating G 3/8″ 1)
- H Oil charge plug 1/4″ NPTF
- K Sight glass 1 1/8″ – 18 UNEF
Declaration of incorporation
Declaration of incorporation for incomplete machinery in accordance with EC
Machinery Directive 2006/42/EC, Annex II 1. B
Manufacturer: Bock GmbH
Benzstraße 7
72636 Frickenhausen, Germany
We, as manufacturer, declare in sole responsibility that the incomplete
machinery
Name: Semi-hermetic compressor
- Types: HG(X)12P/60-4 S (HC) ……………………HG(X)88e/3235-4(S) (HC)
- UL-HGX12P/60 S 0,7……………………… UL-HGX66e/2070 S 60
- HGX12P/60 S 0,7 LG …………………….. HGX88e/3235 (ML/S) 95 LG
- HG(X)22(P)(e)/125-4 A …………………… HG(X)34(P)(e)/380-4 (S) A
- HGX34(P)(e)/255-2 (A) ………………….. HGX34(P)(e)/380-2 (A)(K)
- HA(X)12P/60-4 ……………………………… HA(X)6/1410-4
- HAX22e/125 LT 2 LG ……………………. HAX44e/665 LT 14 LG
- HGX12e/20-4 (ML/S) CO2 (LT) ……….. HGX44e/565-4 S CO2
- UL-HGX12e/20 (S/ML) 0,7 CO2 (LT)… UL-HGX44e/565 S 31 CO2
- HGX12/20-4 (ML/S/SH) CO2T………….. HGX46/440-4 (ML/S/SH) CO2 T
- UL-HGX12/20 ML(P) 2 CO2T…………. UL-HGX46/440 ML(P) 53 CO2T
- HGZ(X)7/1620-4 ……………………………. HGZ(X)7/2110-4
- HGZ(X)66e/1340 LT 22…………………… HGZ(X)66e/2070 LT 35
- HRX40-2 CO2 T H………………………….. HRX60-2 CO2 T H
- Name: Open type compressor
- Types: F(X)2 …………………………………… F(X)88/3235 (NH3)
- FK(X)1………………………………….. FK(X)3
- FK(X)20/120 (K/N/TK)…………….. FK(X)50/980 (K/N/TK)
- Serial number: BC00000A001 – BN99999Z999
complies with the following provisions of the above-mentioned Directive:
- According to Annex I, points 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.3, 1.3.7, 1.5.1, 1.5.2, 1.5.13 and 1.7.1 to 1.7.4 (excepted 1.7.4 f) are fulfilled.
- Applied harmonized standards, in particular: EN ISO 12100:2010 Safety of machinery — General principles for design — Risk assessment and risk reduction
- EN 12693:2008 Refrigerating systems and heat pumps — Safety and Environmental requirements — Positive displacement refrigerant compressors
- Remarks: We also declare that the special technical documentation for this incomplete machine has been created in accordance with Annex VII, Part B and we obligate to provide these upon reasoned
- request from the individual national authorities by data transfer.
- Commissioning is prohibited until it has been confirmed that the machinery into which the incomplete machine above is to be incorporated complies with the EC Machinery Directive and an EC
- Declaration of Conformity, Annex II. 1. A exists
References
- bockshop.bock.de
- vap.bock.de
- Danfoss BOCK® Compressors: Eco-Friendly Solutions for Refrigeration Systems | Danfoss
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