Bitzer Installation

� Installation of compressor

�Semi Hermetic

�Open drive

� Installation of condensing unit

� Capacity regulator

� Pipe connections & fittings

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� Lubricant

� Start cycles

� Operating conditions

� Evacuation

� Charging

� Starting

� Starting Errors

� Service & Maintenance

Mounting - General Recommendations

Installation of Compressor

Semi-Hermetic

� Horizontal, either on vibration dampers or rigid

� Direct installation on W-condensers only with vibration dampers

� Vibration dampers are marked

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Vibration dampers are marked

Open Belt Drive

� Horizontal and rigid on base frame

� Install base frame on vibration dampers to foundation

� Pulleys must be in exact alignment

� Belts: with calibrated lengths & check pre stress exactly

Mounting - General Recommendations

Installation of Compressor (cont´)

Open Coupling Drive

� Use couplings with elastic elements only

� Use couplings without axial force only (danger for bearings!)

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Open Drive & Integrated Coupling Housing

� Easy to assemble

� Very reliable

� Very safe with stiff housing

Mounting - General Recommendations

Installation of air cooled condensing units

� Distance from walls at least same available area as condenser

face area

� Installation on solid foundation only

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� Installation on solid foundation only

� Frequency inverter drive to compressor is not recommended

� Release transport brackets to compressor

� Units with oil separator: add neccessary oil charge

Crank case side Motor side

Octagon Series C1, C2, C3Octagon Series C1, C2, C3Octagon Series C1, C2, C3Octagon Series C1, C2, C3 2EL2EL2EL2EL----2.2 .. 6F2.2 .. 6F2.2 .. 6F2.2 .. 6F----50.250.250.250.2

Mounting - General Recommendations

Mounting_E – 5

Octagon Series C1, C2, C3Octagon Series C1, C2, C3Octagon Series C1, C2, C3Octagon Series C1, C2, C3 2EL2EL2EL2EL----2.2 .. 6F2.2 .. 6F2.2 .. 6F2.2 .. 6F----50.250.250.250.2

Transport Operation

Capacity Regulator (CR)

� Upper parts of the valve simple to install on site

� Simple construction, shut off gas vapor flow to cylinder

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� Exchange with oval flange on cylinder head

� Install gasket with correct position (� index pin)

� Capacity regulator cannot be applied in combination with CIC-operation

Pipe Line To Compressor

Pipe connections

� Soldering adapters are equipped with stepped diameters for ease of

application

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� Remove valves from compressor before soldering

� Protect valve for thermal overload with wet cloth

� Remove Rotalock adapters and sealing plate from valve before

soldering

Pipe Line To Compressor

Vibration absorber in discharge line

� Fix pipe directly after vibration absorber

� Vibration absorber must be parallel to crankshaft

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� Vibration absorber must be parallel to crankshaft

� Use long radius pipe bends on HP-side

� Ensure ice build up in vibration absorber cannot collect in

volutes if used on suction line.

Pipe Work / Filter / Oil Separator

Pipe Dimensions

� Pipe dimension must be based on capacity demand, not based on

compressor valve size

� Limit suction P.D. To max. 1.1K equivalent

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� Low temperature applications P.D. critical to efficient operation

� Consider capacity regulation when dimensioning pipes to ensure oil return in

low load mode

� Ensure pipes are configured so liquid cannot drain to compressor on

off cycle

Pipe Work / Filter / Separator

Discharge Line

� Incline away from compressor to avoid flow back of condensate

oil into cylinder head in off cycle

� Muffler suggested with long straight pipes / 2stage compressors

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Suction Clean-up Filter

� Large systems

� Soldering without protecting atmosphere

� Steel pipes

� Acid formation (e.g. after motor burn out)

Pipe Work / Filter / Separator

Suction Accumulator

� Use if oil/liquid refrigerant flood back possible

� Hot/cold gas defrosting

� Switching from cooling to heating mode

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� Reversing valves are not very tight due to design

�Measures against refrigerant migration

�Possible liquid slugging when starting compressor

� Low temperatures of suction line during shut-off period

� Flooded evaporators need special liquid separation and oil return

systems

Pipe work / Filter / Separator

Filter dryer

� Largely dimensioned

� Must be matched with refrigerant and oil type in use

� Recomended for all systems

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Oil Separator

� Low temperature systems

� Flooded evaporator

� Large pipe work / system

� Oil separators must be charged with oil before installation

Standard Lubricants Reciprocating Compressors

(H)CFC B 5.2

R22 (R12, R502)

HFC BSE 32 (tc < 55°C)

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R134a, R404A/R507A, R407C BSE 55 (tc > 55°C)

R717 (NH3) Shell Clavus 68 (or comparable)

Number of starts depends on nominal motor power

� up to 5.5 kW max. 20 minimum run time 2 min

Compressor Start Cycle

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� up to 15 kW max. 12 minimum run time 3 min

� Over 15 kW max. 6 minimum run time 5 min

Operating Temperatures

� Max. disch. line temp. 120°C

� Min. disch. line temp. 20 K above condensing temperature

Operating Conditions

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� Min. disch. line temp. 20 K above condensing temperature

� Max. oil-temp. (body) 75°C

� Min. oil-temp. (body) 35..40°C (min. 30 K above ambient)

� Min. suction gas superheat 5 K

Leak Test and Evacuation

� Leak-test with dry nitrogen

� Evacuate with a vacuum-pump

� Minimum standing vacuum“ < 1,5 mbar

� open shut-off valves

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� open shut-off valves

� switch on crankcase-heater

ATTENTION:

�Do not start compressor under vacuum

�Never pressure test with oxygen

Refrigerant Charging

� Always liquid charge into receiver - condenser (Compressors off)

� Only refrigerant charge with gauges connected

� Crankcase-heater switched on prior to ensure oil temperature

� Vapor charge into suction only

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� Refrigerant mixtures (R407C) should be liquid charged with care

� Charging should be as far as possible away from the compressor

ATTENTION:

Danger of “wet“ operation will damage compressor

Oil-temperature should be mainained above 40°C

Checks Before Starting

� Loosen all transport-locks

� Check oil-level

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� Check valves open

� Oil-temperature should be 15 .. 20 K above ambient

� Check setting and function of safety devices

Start Up

� Oil-level should be within ¼ and ¾ of sight glass

� Oil pressure difference should be within 1.4 and 3.5 bar (20-52psi)

� Min. permitted inlet pressure of the oil pump: 0.4 bar absolute

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� Oil pressure safety switch:

� Switch-off differential pressure 0.7 bar (9psi)

� Switch-on differential pressure 0.2 bar (4psi)

� Switch off time-delay is 90 seconds

Check of Operating Data

Check operating data and note into commissioning data-log

� Evaporating temperature

� Suction gas temperature

� Condensing temperature

Discharge gas temperature

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� Discharge gas temperature

� Oil temperature

Check of abnormal vibrations

� Pipe-lines

� Rack, compressor, components

� Phase failure

� Uneven or asymmetric current

� Start unloader

� Start switch change over (PW)

� Application limits exceeded

Common cause of starting errors - Electrical

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� Application limits exceeded

� Shut-off valves closed or throttled

� Valve plate leaking or defective

� Motor failure

� Liquid locked

� Thermal or power overload

� Lack of oil supply

� High refrigerant dilution during shut off periods

� Liquid sluggings

� Working valves leaking or damaged

Common cause of starting errors - Lubrication

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� Working valves leaking or damaged

� Piston rings worn out

� Suction or oil strainer blocked

� Abnormal working conditions

� Leakage from high to suction side

� Bad oil lubricity

� Blocked oil strainer

Service and Maintenance

Possible service, maintenance & repair on site

�Pressure relief valve

�Oil pump

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�Motor protection device

�Capacity regulator

�Shaft seal

�Valve plate

Service and Maintenance

� Oil & oil filter change:

�Usually not necessary with factory assembled systems

�With on site installations or when operating conditions

close to application limits:

� After first 100 working hours

� Thereafter 3 years or 10 .. 12,000 working hours

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� Thereafter 3 years or 10 .. 12,000 working hours

� Valve plate

�Pre-emptive check after 10 .. 12,000 working hours

�Complete replacement necessary in case:

- heavy wear

- narrowed cross sections due to carbonized oil

- damaged valve seats

Valve Plate Replacement

� Release pressure in head assembly

� Dismantle cylinder head and valve plate

� Change valve plate completely if damaged

�analyse causes of damage

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� Mount cylinder head, valve plate and gaskets

�asbestos free gaskets not be oiled!

� Tighten screws in two steps in crosswise sequence

Valve Plate Replacement

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End Installation Session