Danfoss Bock Fk40 Gea Vehicle Compressor User Guide (+ PDF)

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BOCK FK40 GEA Vehicle Compressor

provide the necessary knowledge and skills to work on compressors.
1.3 Danger to life and limb in the event of faults during
operation: DANGER Failure to follow safety instructions and proper
maintenance procedures can result in serious or fatal injury.
Faults during operation can lead to dangerous situations, such as
high-pressure leaks or electrical malfunctions. It is important to
always observe safety precautions and promptly address any faults
or abnormalities. 1.4 Safety instructions: – Read and understand
all safety instructions before assembling or using the compressor.
– Only qualified personnel should work on compressors. – Follow
proper maintenance procedures to ensure safe operation. – Use
appropriate personal protective equipment (PPE) when working on or
near the compressor. – Keep the compressor and surrounding area
clean and free from debris. – Do not modify or alter the compressor
without proper authorization. – Do not operate the compressor if it
is damaged or shows signs of malfunction. – Keep children and
unqualified individuals away from the compressor. – Follow all
local regulations and codes when installing or operating the
compressor. 1.5 Intended use: The compressor is designed for use in
various applications, including refrigeration systems. It is
intended to compress refrigerant gases and facilitate the cooling
process. The compressor should only be used for its intended
purpose and in accordance with the manufacturer’s instructions.
Product Description: The product is a compressor used in
refrigeration systems. It is available in different models,
including FK40/390 N, FK40/470 N, FK40/560 N, FK40/655 N, FKX40/390
N, FKX40/470 N, FKX40/560 N, FKX40/655 N, FK40/390 K, FK40/470 K,
FK40/560 K, FK40/655 K, FK40/755 K, FKX40/390 K, FKX40/470 K,
FKX40/560 K, FKX40/655 K, FKX40/755 K, FK40/390 K1, FK40/470 K1,
FK40/560 K1, FK40/655 K1, FK40/755 K1, FKX40/390 K1, FKX40/470 K1,
FKX40/560 K1, FKX40/655 K1, FKX40/755 K1, FK40/390 TK, FK40/470 TK,
FK40/560 TK, FK40/655 TK, FKX40/390 TK, FKX40/470 TK, FKX40/560 TK,
and FKX40/655 TK. Product Usage Instructions: 1. Safety: – Before
assembling or using the compressor, read and understand all safety
instructions provided in the user manual. – Only qualified
personnel should work on the compressor. – Follow proper
maintenance procedures to ensure safe operation. – Use appropriate
personal protective equipment (PPE) when working on or near the
compressor. 2. Product Assembly: – Follow the instructions provided
in the user manual for setting up the compressor. – Ensure that the
compressor is placed on a stable surface. – Do not exceed the
maximum permissible inclination specified in the user manual. – If
applicable, connect the V-belt drive according to the instructions
provided. – Pay attention to the main bearing load and ensure it is
within the recommended limits. – If applicable, assemble the
electromagnetic coupling according to the instructions provided. –
Connect the pipe connections as per the user manual. – Install the
necessary pipes and ensure they are properly secured. – Operate the
shut-off valves according to the instructions provided. – If
applicable, follow the operating mode of the lockable service
connections as specified in the user manual. – Install the suction
pipe filter if required. – If using a K1 special housing, refer to
the characteristics mentioned in the user manual for proper
assembly. 3. Commissioning: – Before starting up the compressor,
make necessary preparations as instructed in the user manual. –
Perform a pressure strength test to ensure the compressor is
functioning correctly. – Conduct a leak test to identify any
potential leaks. – Evacuate the system as per the instructions
provided. – Charge the recommended amount of refrigerant into the
compressor. – Check the oil level and adjust if necessary. –
Inspect the shaft seal and ensure it is in good condition. – Take
precautions to avoid liquid shocks during commissioning. 4.
Maintenance: – Follow the preparation steps outlined in the user
manual before performing any maintenance tasks. – Carry out the
necessary work as specified in the user manual. – If required,
empty the oil reservoir and replace the shaft seal according to the
instructions provided. – Refer to the recommended spare
parts/accessories list for any replacements or additions. – If
applicable, utilize the integrated decompression valve as
instructed. – Use the recommended lubricants/oils for maintenance
purposes. 5. Decommissioning: – Follow the recommended steps in the
user manual for decommissioning the compressor when necessary.
Note: This is a general overview of product information and usage
instructions. For specific details and instructions, refer to the
complete user manual provided with the product.

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BOCK® FK40
Operating guide

FK40/390 N FK40/470 N FK40/560 N FK40/655 N
FKX40/390 N FKX40/470 N FKX40/560 N FKX40/655 N

FK40/390 K FK40/470 K FK40/560 K FK40/655 K FK40/755 K
FKX40/390 K FKX40/470 K FKX40/560 K FKX40/655 K FKX40/755 K

FK40/390 K1 FK40/470 K1 FK40/560 K1 FK40/655 K1 FK40/755 K1
FKX40/390 K1 FKX40/470 K1 FKX40/560 K1 FKX40/655 K1 FKX40/755 K1

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

Translation of the original instructions

AQ453249013813en-000201

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 onto 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.
D GB F E PT
I TR Ru

2 | AQ453249013813en-000201

Contents
1 Safety 1.1 Identification of safety instructions 1.2 Qualifications required of personnel 1.3 Danger to life and limb in the event of faults during operation 1.4 Safety instructions 1.5 Intended use
2 Product description 2.1 Brief description 2.2 Name plate 2.3 Type key
3 Areas of application 3.1 Refrigerants 3.2 Oil charge 3.3 Limits of application
4 Compressor assembly 4.1 Setting up 4.2 Maximum permissible inclination 4.3 V-belt drive 4.4 Main bearing load 4.5 Electromagnetic coupling assembly 4.6 Pipe connections 4.7 Pipes 4.8 Operating the shut-off valves 4.9 Operating mode of the lockable service connections 4.10 Suction pipe filter 4.11 Characteristics for K1 special housing
5 Commissioning 5.1 Preparations for start-up 5.2 Pressure strength test 5.3 Leak test 5.4 Evacuation 5.5 Refrigerant charge 5.6 Oil level check 5.7 Shaft seal 5.8 Avoiding liquid shocks
6 Maintenance 6.1 Preparation 6.2 Work to be carried out 6.3 Shaft seal, emptying the oil reservoir 6.4 Recommended spare parts/accessories 6.5 Integrated decompression valve 6.6 Lubricants / Oils
6.7 Decommissioning 7 Accessories
7.1 Capacity regulator 7.2 Thermal protection thermostat 8 Technical data
9 Dimensions and connections
10 Declaration of incorporation

Page 4
6
8
9
D GB F E 14 PT
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19 21 22 24

AQ453249013813en-000201| 3

1| Safety

1.1 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.

1.2 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 which is qualified to work on

pressurized refrigerant systems:

· For example, a refrigeration technician, refrigeration mechatronic

engineer. As well as professions with comparable training, which

enables personnel to assemble, install, maintain and repair refrigeration

and air-conditioning systems. Personnel must be capable of assessing

the work to be carried out and recognising any potential dangers.

1.3 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.

4 | AQ453249013813en-000201

1| Safety

1.4 Safety instructions

WARNING

Risk of accidents. Refrigerating compressors are pressurised machines and as such call for heightened caution and care in handling.
The maximum permissible overpressure must not be exceeded, even for testing purposes.
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. – Avoid contact with refrigerant necessarily. Contact with refrigerant can cause severe burns and skin damage.

1.5 Intended use

These assembly instructions describe the standard version of the FK40 manufactured by Bock. The GB

compressor is intended for use in refrigeration systems in compliance with the operating limits.

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 (with-

in 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 as-

sembly instructions and the entire system into which it is integrated has been inspected and approved Ru

in accordance with legal regulations.

AQ453249013813en-000201| 5

2| Product description

2.1 Brief description

Three different designs are available for various ranges of application:

> 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 range where operational safety and efficiency are concerned.

Compact four cylinder compressor in V design. Four capacity ranges (5 at K Design). Lightweight aluminum design.
Lubricating oil pump with oil pressure relief valve independent of rotational direction.
Variable arrangement of the shut-off valves.

Eyebolt

Discharge shut-off valve D

Leak oil trapping device

with oil reservoir

E Shaft seal
PT
Shaft end I

Fig. 1

Name plate Leak oil drain hose
Oil sight glass

Suction shut-off valve

Cylinder cover Valve plate

Oil pump

Oil sight glass

Fig. 2

Dimension and connection values can be found in Chapter 9

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2| Product description

2.2 Name plate (example)

BOCK Bock GmbH, Benzstr. 7 72636 Frickenhausen, Germany

AS12345A020

1 2 3
Fig. 3

19/28bar Öl: BOCK lub E55 5

1 Type designation 2 Displacement at 1450 rpm

4 Machine number 5 Factory-filled oil type

} 3 LP: Max. permissible operating pressure (g) Low pressure side HP: Max. permissible operating pressure

Observe the limits of application diagrams!

(g) High pressure side

2.3 Type key (example)

FK X 4 0 / 655 N

E Designs ¹)

PT Swept volume

Size

Ester oil charge ²)

Series

¹) K – specially for air-conditioning N – specially for air-conditioning or normal cooling TK – specially for deep freezing
²) X – Ester oil charge (HFC refrigerant, e.g. R134a, R407C)

AQ453249013813en-000201| 7

3| Areas of application

3.1 Refrigerants
· HFKW / HFC: · HFCKW / HCFC:

R134a, R404A/R507, R407C, R513A R22

3.2 Oil charge

The compressors are factory-filled with the following oil type:

– for R134a, R404A/R507, R407C, R513A

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. FKX40/655 N).

INFO

For recharging, we recommend the above oil types.

See chapter 6.6.

3.3 Limits of application

ATTENTION Compressor operation is possible within the operating limits.

These can be found in 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. I

Avoid continuous operation near the threshold. Should the com-

pressor happen to be used near the thresholds, we recommend the

use of a thermal protection thermostat (Accessories, Chap. 7).

For operation with capacity regulator: – Continuous operation, when the capacity regulator is activated,
is not permissible and can cause damage to the compressor.
See chapter 7.1. – The suction gas superheat temperature may need to be reduced
or set individually when operating near to the threshold. – When the capacity regulator is activated, the gas velocity in the
system can not under certain circumstances ensure that sufficient oil is transported back to the compressor.

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

Maximum admissible
operating pressure (g) (LP/HP)1): 19/28 bar

1) LP = Low pressure HP = High pressure

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4| Compressor assembly

INFO

New compressors are factory-filled with inert gas. Leave this ser-

vice 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.

4.1 Setting up WARNING

Move compressors only with hoists that have adequate load-bearing capacity.

Transport and suspension unit on the eyebolt (Fig . 4) or direct on the discharge line valve (Fig. 5).

Fig. 4

Fig. 5

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. Use all 4 fastening

points.

Correct setup of the compressor and mounting of the belt drive are decisive for running comfort, Ru

operating safety and the service life of the compressor.

4.2 Maximum permissible inclination

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

Fig. 6
© Danfoss | Climate Solutions | 2023.07

A max. 30°, max. 2 minutes
a max. 15°, continuous operation
AQ453249013813en-000201| 9

4| Compressor assembly

4.3 V-belt drive

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.

During operation with capacity regulator (Accessories, Chap. 7), the changing load can cause increased running noises and belt drive vibrations.

4.4 Main bearing load

To prevent the belt drive overloading the compressor main bearing,

ensure that:

The force applied at the force engagement force by the belt

tension (see Fig. 7) must not exceed F = 2750 N. max
If the force engagement point shifts forwards (see Fig.11, small

point),

the

force

F max

reduces

per

the

following

formula:

Fmax= 2750 N Mbmax= 245 kNmm

GB F

Fmax =

245 kNmm (90 mm + L1 [mm])

Fig. 7

L1 (mm)

4.5 Electromagnetic clutch assembly

The following description applies for an electromagnetic clutch secured to a shaft.

To absorb the magnetic field of the electromagnetic clutch, the front bearing flange has a

snug fit Ø 148 h8 (see Fig. 8).

To connect the magnetic field, loosen the 4 cheese head screws M8 on the bearing flange

(see Fig. 8).

Slide the magnetic field to a snug fit and re-attach using the four cheese head screws M8

(Fig. 9). Screw torque = 37 Nm.

Further assembly of the electromagnetic clutch according to the clutch manufacturer.

Bearing flange, front Magnetic field

Fig. 8

148 h8

10 | AQ453249013813en-000201

Fig. 9
© Danfoss | Climate Solutions | 2023.07

4| Compressor assembly

4.6 Pipe connections
Fig. 10: Stepped internal diameters

The pipe connections, if installed, have stepped internal diameters so that pipes with standard millimetre 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. Therefore, remove the pipe supports from the valve before soldering. Solder only using inert gas to inhibit oxidation products (scale).

4.7 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 being cracked GB

and broken by severe vibrations.

Ensure a proper oil return.

Keep pressure losses to an absolute minimum.

PT 4.8 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.

Release

Valve spindle seal Fig. 11

Tighten Fig. 12

AQ453249013813en-000201| 11

4| Compressor assembly

4.9 Operating mode of the lockable service connections

Pipe connection Fig. 13

Opening the shut-off valve: a) Spindle 1: turn to the left (counter-clockwise) as far as it will go.
–> Shut-off valve fully opened / service connection 2 closed.

Pipe connection Fig. 14

Opening the service connection (2):

b) 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.
4.10 Suction pipe filter For systems with long pipes and higher degree of contamination, a filter on the suction-side is recommended. The filter has to be be renewed depending on the degree of contamination (reduced pressure loss).

12 | AQ453249013813en-000201

Anschluss Saugseite, absperrbar A1
Connection suction side, lockable Anschluss Druckseite, nicht absperr B Connection discharge side, not lock

Anschluss Saugseite, nicht absperrb Connection suction side, not lockabl

Anschluss Druckseite, absperrbar B1
Connection discharge side, lockable

Anschluss Öldrucksicherheitsschalte C
Connection oil pressure safety switc

Anschluss Öldrucksicherheitsschalte D Connection oil pressure safety switc

Schauglas K
Sight glass

Stopfen Ölfüllung H
Oil charge plug

Anschluss Öldruckmanometer E
Connection oil pressure gauge

108,5

50 D

146| 8C,o5mpresso1r3a0ssembly

Ölablass F
Oil drain

604.11 CharacteristicnsufrorbKe1i Ksp1eAciuasl fhüohursuinngg only for K1 version Z

78 3xM10

Opt. Anschlussmöglichkeit Ölsumpfh G
Opt. connection oil sump heater 1)

Anschluss Wärmeschutzthermostat L Connection thermal protection therm

Ölsieb M
Oil filter Opt. Anschlussmöglichkeit Saugabs SV1 Opt. connection suction line valve (L)* = Lötanschluss / brazing connec 1) = Nur ab Werk möglich / ony poss

ung N+TK-Version on N+TK-version

13 G M
210 232

145
Opt. Anschlussmöglichkeit Saugabsperrventil SV1
Opt. connection suction line valve (L)* = Lötanschluss / brazing connection 1) = Nur ab Werk möglich / ony possible ex factory
167,8

148 h8 130 110 9 8

7 2

9 8

110

78 130167,8

123,5 A

170 253

Z
148 h8

3xM10

only for K1 version

nur bei K1 Ausführung

150 4xM10
5 4 2 6
50 D
130

Ventilausführung K+K1-Version valve version K+K1-version

Fahrzeugverdichter / Vehicle Compressor

Typ /

type

FKX40/390 N

FKX40/470 N

FKX40/560 N

Teile-Nr. / Typ /

part-no. type

13985 FKX40/390 K

13987 FKX40/470 K

13989 FKX40/560 K

Mounting thread only on this side of the compressor available.

( ) K + K1 Ausführung [ ] TK Ausführung

( ) K + K1 version

[ ] TK version

168,5

e Compressor
Teile-Nr. / Typ / part-no. type

150 4xM10
Teile-Nr. / Typ / part-no. type

123,5

108,5

Teile-Nr. / Typ /

part-no. type

13986 FKX40/390 K1

14055 FKX40/390 TK

13988 FKX40/470 K1

14056 FKX40/470 TK

13990 FKX40/560 K1

14057 FKX40/560 TK

13992 FKX40/655 K1

14058 FKX40/655 TK

13999 FKX40/755 K1

14059

6 0

K F
108,5 168,5
60

Massenschwerpunkt Centre of gravity
Teile-Nr. / part-no. 14343 14344 14345 14346
Fig. 15

D
GB ÄSunbdjeerFcutntgoe
E
PT
I
TR Ru

Lecköl-Ablass Schlauch Leak oil drain hose
L C/E Z
H K F

4xM10x21

170 150 123,5

13986 FKX40/390 K1

13988 FKX40/470 K1

13990 FKX40/560 K1

( ) K + K1 Ausführung [ ] TK Ausführung

( ) K + K1 version

part-no. type

50 D
130
nur bei K1 Ausführung only for K1 version
Z
78 3xM10

[ ] TK version

Teile-Nr. / Typ /

54 The M10 threads in the housing can be used for screwing on attachments and bracing the

compressor.

Gußtoleranzen / General casting tolerances:

Zeichnu

26 · Maximum load on the screw connection = 6 g-forc-e

Maximum tightening torque of the and friction coefficient = µ 0,15.

screws

NmBNwaeuiintmh/ umNsoitneirmgeumprüsfct r/eTwy-pine

deexpatmh i=na2t0ionm:m

· Maximum screw-in depth 25 mm.

Gewicht / Weight: (kg) –

Drawing
1. 0

· Usable screws up to strength class 10.9. In case of screw-in depths less than 15 mm or torques and maximum load must be reduced.

lower

Allgemeintoleranzen / General tolerances
füDribcINetiroISn/ aOcbo2oe7vff6eic8i-emnKt0s-.Et5han µ =60.153, t0he ti1g2ht0enin4g00 bis / up to 6 30 120 400 1000

Benen

INFO If the M10 threads are used as addit±io0n.a1l b±r0ac.2ing±, 0in.3sta±lla0t.i5on ±is0.8

overdetermined. distorted during

iInt smtaulslattbioeUne.nnTbsheumereasdpßettehciaRftiactdahiteeinocn/osUmonpfdrtiemhseesnomsroiohtnooeurds/irncahgdaiiiss: s-nisot

manufacturer are mandatory.

Oberflä
17 Indicatio
DIN EN

Ventilausführung K+K1-Version valve version K+K1-version
B B1 DV

14055 FKX40/390 TK

14056 FKX40/470 TK

14057 FKX40/560 TK

AQ453249013813en-000201| 13

S
167,8

5| Commissioning

5.1 Preparations for start-up

INFO

To protect the compressor against inadmissible operating condi-

tions, high-pressure and low-pressure pressostats 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!

5.2 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.

D GB 5.3 Leak test

DANGER Risk of bursting!

The compressor must only be pressurised using dried nitrogen (N2). Never pressurise with oxygen or other gases!

The maximum permissible overpressure of the compressor must

not be exceeded at any time during the testing process (see name

plate data)! Do not mix any refrigerant with the nitrogen as this

could cause the ignition limit to shift into the critical range.

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.

5.4 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 mbar when the pump is switched off. Repeat the process as often as is required.

14 | AQ453249013813en-000201

5| Commissioning

5.5 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 vapour 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 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.

5.6 Oil level check

After starting, check the compressor’s oil level.

Drive motor in operating condition “High idle”.

Compressor run time min. 10 minutes.

The system should have reached Operating point and steady state

Check oil level. As the installation location of the compressor can differ in practice (inclinations), it

is recommended that the oil level is checked in both sight glasses. The oil level must be visible in

at least one sight glass.

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

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

INFO

The shaft seal seals and lubricates with oil. An oil leakage of

0.05 ml per operating hour is therefore normal. This applies

particularly during the run-in phase (200 – 300 h).

To trap and collect leaked oil, the FK40 is fitted with an inte-

grated leak oil trapping device with oil reservoir (P.6, Fig. 1).

AQ453249013813en-000201| 15

5| Commissioning

The compressor shaft is sealed to 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.
5.8 Avoiding liquid shocks

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

To avoid liquid shocks, the following points should be observed:

The complete refrigeration plant must be correctly designed and executed.

The capacities of all components must be compatible (particularly evaporator and expansion valve).

Suction gas superheating at the evaporator output should be at least 7 10 K (check 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 valve in the liquid line, etc. are recommended.

E
PT 6| Maintenance

I 6.1 Preparation

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 safety switch.

Evacuate compressor.

Release switch lock.

6.2 Work to be carried out
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

16 | AQ453249013813en-000201

6| Maintenance

Where requirements are higher during use (frequent operation at the limits of application, or in hotlands 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 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 the capacity
control.

6.3 Shaft seal, emptying the oil reservoir
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 15, chapter 5.7, “Shaft seal”). Changing the shaft seal is described in the relevant spare part kit.
Emptying the oil reservoir: The oil reservoir can be emptied very simple without having to dismantle 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. To proceed, detach the oil hose from the bracket, remove the sealing plug and drain the oil into a collecting vessel. After emptying, reseal the oil hose and clamp it into the bracket. Dispose of the used oil in accordance with national regulations.

D GB F E PT
I TR Ru
Fig. 16

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.

AQ453249013813en-000201| 17

6| Maintenance

6.4 Recommended spare parts/accessories
Maintenance set for oil change · BOCK lub E55 2 x 1 l · Oil drain screw with seal Maintenance set for shaft seal · shaft seal kit · BOCK lub E55 2 x 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 catalogue at bockshop.bock.de.

Only use original Bock spare parts!

6.5 Integrated decompression valve

The valve is maintenance free.

However, constant leakage can occur after blowing off due to abnormal operating conditions. This

leads to reduced performance and increases the compressed gas temperature. In this case check the

valve and replace as necessary.

6.6 Lubricants / Oils E
The oil type filled as standard in the factory is marked on the name plate, 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 compressors 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

Ru alternative oil types.

Refrigerant
HFC (e.g. R134a, R407, R 404A) HCFC (e.g. R22)

Bock standard oil grade BOCK lub E55
BOCK lub A46

6.7 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 depressurised, 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.

18 | AQ453249013813en-000201

7| Accessories

7.1 Capacity regulation

ATTENTION

Capacity-regulated operation alters the gas speeds and pressure
ratios of the refrigerating plant: Adjust the suction line routing and
dimensioning accordingly,do not set the control intervals too close and
do not let the system switch more than 12 times per hour (refrigerating plant must have reached a state of equilibrium). Continuous

operation in the control stage is not recommended as the gas
velocity in the plant system under certain circumstances does not guarantee sufficient oil return to the compressor with activated

capacity regulator for a compressor speed below 1200 – 1500 rpm.

We recommend switching to unregulated operation (100% capacity)
for at least 5 minutes per capacity-regulated operating hour. An assured oil return can also be realised by a 100% capacity require-

ment after each compressor restart as otherwise the compressor can also be shut down in the regulated operating time by the thermostat.

Electrical actuation of the solenoid valve: Normally open, (cor-

responds to 100 % compressor capacity).

Cylinder covers for capacity regulation are marked with the

designation “CR” (Capacity Regulator).

FK40 / …

… N + TK

… K

Designation

Ref. No.*

Special accessory 12 V

097B08703

097B08708

Special accessory 24 V

097B08704

097B08709

For a description, see technical information “Capacity regulation” (Item No. 09900)
If the capacity regulator is factory-fitted, it is integrated into an extra, dedicated cylinder cover. For retrofits, it is supplied with the cylinder cover. The regulator closes one cylinder bank (capacity regulation approx. 50%).

* Please note that the legacy BOCK ref. numbers are without 097B

AQ453249013813en-000201| 19

7| Accessories

7.2 Thermal protection thermostat (Item No. *097B07595)

A screw-in option is provided for the sensor element on the hot gas side of the compressor housing (see Chap. 9). Connect the thermal protection thermostat in series with the control line.

Technical Data:

Switching voltage max. : Switching current max. : Switch-off temperature : Switch-on temperature :

24 V DC 2.5 A at 24 V DC 145 °C ± 5 K approx. 115 °C

* Please note that the legacy BOCK ref. numbers are without 097B

D GB F E PT
I TR Ru

20 | AQ453249013813en-000201

AQ453249013813en-000201| 21

No. of cylinders
© Danfoss | Climate Solutions | 2023.07

Type

Displace-

Swept

Weight Connections N + TK *

ment

volume (1450 rpm)

Discharge Suction

line

cm3

m3/h

kg mm / inch mm / inch

FK40/390

385

33.5

34.0

22 / 7/8 28 / 1 1/8

FK40/470

466

40.5

33.0 28 / 1 1/8 35 / 1 3/8

FK40/560 4

554

48.3

33.0 28 / 1 1/8 35 / 1 3/8

FK40/655

650

56.6

31.0 35 / 1 3/8 35 / 1 3/8

FK40/755

755

65,6

31.0 35 / 1 3/8

The technical data for the different designs K, N and TK are identical. The compressor type data therefore do not mention these additions. * K design: closed with cardboard disc.

35 / 1 3/8

Oil charge
Ltr.
2.0

D GB F E PT
I TR Ru

Inertia moment of the driving
unit [kgm2]

Lubrication

0.0043

Forced lubrication

Oil pump
Rotationindependent

8| Technical data

+2
369 329 145 +2
170 253
170 170
253

DV B
D
5 GB

9|
B1

Dimensions and connections

Anschlüsse / Connections

FK(X)40/390

FK(X)40/470 FK(X)40/560

FK(X)40/655

FK(X)40/755

X
+2
319 (326)

Saugabsperrventil, Rohr (L)* SV
Suction line valve, tube (L)* Druckabsperrventil, Rohr (L)* DV Discharge line valve, tube (L)* Anschluß Saugseite, nicht absperrbar A Connection suction side, not lockable

mm / Zoll mm / inch

28 1 1/8 ”

35 1 3/8 ”

mm / Zoll mm / inch

22 7/8 ” 28 1 1/8 ”
+2

35 1 3/8 ”

384 Zoll / inch

1/8″ NPTF

SV1

Anschluß Saugseite, absperrbar A1
Connection suction side, lockable

345 Zoll / inch

7/16″ UNF

Anschluß Druckseite, nicht absperrbar B
Connection discharge side, not lockable

Zoll / inch

1/8″ NPTF

Anschluß Druckseite, absperrbar B1
4xM10x21 Connection discharge side, lockable
Anschluß Öldrucksicherheitsschalter OIL C Connection oil pressure safety switch OIL

Zoll / inch Zoll / inch

7/16″ UNF 1/8″ NPTF

Anschluß Öldrucksicherheitsschalter LP D Connection oil pressure safety switch LP

Zoll / inch

1/8″ NPTF

E
C/E F
G

Anschluß Öldruckmanometer
L Connection oil pressure gauge
Ölablaß Oil drain
Y Opt. Anschlußmöglichkeit Ölsumpfheizung 1)
Opt. connection oil sump heater 1)

Zoll / inch mm –

1/8″ NPTF 1/4″ NPTF
–

Stopfen Ölfüllung H
Oil charge plug

1/4″ NPTF

4x 13 +2
50X

GM
210 232
D

Schauglas K
Sight glass

Zoll / inch

Anschluß Wärmeschutzthermostat
F L Connection thermal protection thermostat

Zoll / inch

Ölsieb Oil filter

108,5 Opt. Anschlußmöglichkeit Saugabsperrventil
SV1

–

Opt. connection suction line valve

(L)* = Lötanschluß

168,5

(L)* = Brazing connection

1) = Nur ab Werk möglich

1) = Only possible ex factory

2) = mit Pappscheibe verschlossen

2) = closed with cardboard disc

2 x 1 1/8 ” 18 UNEF 1/8″ NPTF M22x1,5
50 D –
130
Y

68,F5

1N3+0TK version

K + K1 version

E 344

+2
PT 384

B B1

SV Massenschwerpunkt SV

Centre of gravity

Maße in mm Dimensions in mm

mpressor

Shaft end

ype

Teile-Nr. / part-no. Typ / type

0/390 K

13978 (13986) FK(X)40/390 TK

0/470 K

13980 (13988) FK(X)40/470 TK

0/560 K

13982 (13990) FK(X)40/560 TK

0/655 K

13984 (13992) FK(X)40/655 TK

0/755 K

13998 (13999)

Änderungen vorbehalten Subject to change without notice
8x M8

LLecLekeaöaklk-AoobiillladdsrrasaiinSnchhholosaesuech

6x M8

Teile-NrA. 5/ pxa9rtD-nIoN. 6888Zeichn.-Nr. / Drawing no. :

14339 14340

((11443344431)) :5

14341 (14345) 14342 (14346)

1.0851-13983.0 0h

2 40

148 h8 130 110 9 8 90 72

M12x28

50 Gußtoleranzen / General casting tolerances:

Zeichnungs-Nr. /

Teile-Nr. /

Blatt /

Maßstab / Wer

–

66 Baumustergeprüft / Type examination:
Nein / No

74 Gewicht / Weight: (kg) –
Allgemeintoleranzen / General tolerances
100 DIN ISO 2768-mK

Drawing-No.

Part-No.

Page:

Scale:

Mate

– 1. 08Di5m=e1nCseionn1tsre3inof9mgmr8av3ity .0 1/3 %

–

BenennuDnigm/ eDnessicornipstioinn:() = K + K1 – Design

über / above 0.5 6 30 120 400 bis / up to 6 30 120 400 1000

K F-ig.F17K40/65

±0.1 ±0.2 ±0.3 ±0.5 ±0.8

C – FK40/655 N

22 | AQ453249013813en-0U0n0be2m0a1ßte Radien / Undimensioned radii: –

Indication of surface texture –

DIN EN ISO 1302

–

9| Dimensions and connections

SV Suction line DV Discharge line

see technical data, Chapter 8

Connection suction side, not lockable

A1 Connection suction side, lockable

Connection discharge side, not lockable

B1 Connection discharge side, lockable

Connection oil pressure safety switch OIL

Connection oil pressure safety switch LP

Connection oil pressure gauge

Oil drain

Opt. connection for oil sump heater

1/8″ NPTF 7/16″ UNF 1/8″ NPTF 7/16″ UNF 1/8″ NPTF 1/8″ NPTF 1/8″ NPTF 1/4″ NPTF
1)

Oil charge plug

Sight glass

Connection thermal protection thermostat

Oil filter

1/4″ NPTF

2 x 1 1/8″- 18 UNEF

D GB

1/8″ NPTF

M22 x 1.5

SV1 Opt. connection for suction line valve
1) = No connection available as standard. Available on request (Connection M22 x 1,5)

– –

AQ453249013813en-000201| 23

10| 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: Types:

Name:

Types:

Serial number:

Semi-hermetic compressor 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
Open type compressor 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)
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 harmonised 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.

Authorized person for compiling and handing over technical documentation:

Bock GmbH Alexander Layh Benzstraße 7 72636 Frickenhausen, Germany

Frickenhausen, 04th of January 2021

i. A. Alexander Layh, Global Head of R&D

24 | AQ453249013813en-000201

10| Declaration of incorporation

Declaration of incorporation of partly completed machinery in accordance with UK Statutory Instrument Supply of Machinery (Safety) Regulations 2008, Annex II 1. B

Manufacturer:

Bock GmbH Benzstraße 7 72636 Frickenhausen, Germany

We, as manufacturer, declare in sole responsibility that the partly completed 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)22e/125-4 ……………………………..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………………………….. HR(Z)X60-2 CO2 T (H)(V)

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 Statutory instrument:
PT
According to Schedule 2, part1, 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.

Designated standards: 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 partly completed machine has been created in accordance with Annex II, 1. 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 partly completed machine above is to be incorporated complies with the UK Statutory Instrument Supply machinery (Safety) regulations 2008 and an EC Declaration of Conformity, Annex II, 1. A exists.

Authorized person for compiling and handing over technical documentation:

Bock GmbH Alexander Layh Benzstraße 7 72636 Frickenhausen, Germany

Frickenhausen, 14th of October 2022

i. A. Alexander Layh, Global Head of R&D

AQ453249013813en-000201| 25

26 | AQ453249013813en-000201