KB-104-6

Semi-hermetic reciprocating compressors BITZER ECOLINE and ECOLINE VARISPEED Translation of the original Operating InstructionsEnglish....................................................................................................................................................... 2

Halbhermetische Hubkolbenverdichter BITZER ECOLINE und ECOLINE VARISPEED OriginalbetriebsanleitungDeutsch ..................................................................................................................................................... 26

Compresseurs piston hermtiques accessibles BITZER ECOLINE et ECOLINE VARISPEED Traduction des instructions de service d'origineFranais..................................................................................................................................................... 50

2KES-05(Y) .. 2FES-3(Y)

2EES-2(Y) .. 2CES-4(Y)

22EES-4(Y) .. 22CES-8(Y)

4FES-3(Y) .. 4CES-9(Y)

44FES-6(Y) .. 44CES-18(Y)

4VE(S)-6Y .. 4NE(S)-20(Y)

44VE(S)-14(Y) .. 44NE(S)-40(Y)

4JE-13Y .. 4FE-35(Y)

44JE-30(Y) .. 44FE-70(Y)

6JE-22Y .. 6FE-50(Y)

66JE-50(Y) .. 66FE-100(Y)

8GE-50(Y) .. 8FE-70(Y)

4FDC-5Y .. 4CDC-9Y

4VDC-10Y .. 4NDC-20Y

2DES-3.F1Y

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4VE-7.F3Y .. 4NE-20.F4Y

InstallerMonteurMonteur

KB-104-62

Table of contents

1 Introduction............................................................................................................................................................ 41.1 Also observe the following technical documents ...........................................................................................4

2 Safety .................................................................................................................................................................... 42.1 Authorized staff..............................................................................................................................................42.2 Residual risks ................................................................................................................................................42.3 Safety references...........................................................................................................................................4

2.3.1 General safety references.................................................................................................................. 4

3 Application ranges ................................................................................................................................................. 53.1 Use of flammable refrigerants of the A2L safety group (e.g. R1234yf)..........................................................5

3.1.1 Compressor and refrigeration system requirements.......................................................................... 63.1.2 General operation requirements ........................................................................................................ 6

4 Mounting................................................................................................................................................................ 64.1 Transporting the compressor.........................................................................................................................64.2 Installing the compressor...............................................................................................................................7

4.2.1 Vibration dampers.............................................................................................................................. 74.2.2 Type I vibration dampers ................................................................................................................... 84.2.3 Type II vibration dampers .................................................................................................................. 84.2.4 Type III vibration dampers ................................................................................................................. 8

4.3 Connecting the pipelines ...............................................................................................................................94.3.1 Pipe connections................................................................................................................................ 94.3.2 Shut-off valves ................................................................................................................................... 94.3.3 Pipelines ............................................................................................................................................ 9

4.4 Start unloading (SU) and Capacity control (CRII) .......................................................................................104.4.1 Start unloading (SU) ........................................................................................................................ 114.4.2 Capacity control (CRII)..................................................................................................................... 11

4.5 Connections and connection diagrams........................................................................................................124.5.1 Connection diagrams of single compressors ................................................................................... 124.5.2 Connection diagrams of tandem compressors ................................................................................ 16

5 Electrical connection ........................................................................................................................................... 175.1 Mains connections .......................................................................................................................................18

5.1.1 Motor version ................................................................................................................................... 185.2 Protection devices .......................................................................................................................................19

5.2.1 SE-B1 or SE-B3 ............................................................................................................................... 195.2.2 SE-B2 or SE-B3 ............................................................................................................................... 195.2.3 Differential oil pressure switch Delta-PII (option) ............................................................................. 195.2.4 Opto-electronic oil level monitoring OLC-K1 (option)....................................................................... 195.2.5 Discharge gas temperature sensor.................................................................................................. 195.2.6 Safety devices for pressure limiting (HP and LP) ............................................................................ 205.2.7 Oil heater ......................................................................................................................................... 205.2.8 CIC system ...................................................................................................................................... 20

6 Commissioning .................................................................................................................................................... 206.1 Checking the strength pressure...................................................................................................................216.2 Checking tightness ......................................................................................................................................216.3 Evacuation ...................................................................................................................................................216.4 Charging refrigerant.....................................................................................................................................21

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6.5 Checks prior to compressor start.................................................................................................................216.6 Compressor start .........................................................................................................................................22

6.6.1 Lubrication/oil level monitoring......................................................................................................... 226.6.2 Oil monitoring (option)...................................................................................................................... 226.6.3 Vibrations and frequencies .............................................................................................................. 226.6.4 Cycling rate ...................................................................................................................................... 236.6.5 Checking the operating data ............................................................................................................ 236.6.6 Particular notes on safe compressor and system operation ............................................................ 23

7 Operation............................................................................................................................................................. 237.1 Regular checks ............................................................................................................................................23

8 Maintenance ........................................................................................................................................................ 248.1 Oil change....................................................................................................................................................248.2 Internal pressure relief valve........................................................................................................................24

9 Decommissioning ................................................................................................................................................ 249.1 Standstill ......................................................................................................................................................249.2 Dismantling the compressor ........................................................................................................................25

9.2.1 Disposing of the compressor ........................................................................................................... 25

KB-104-64

1 Introduction

These refrigeration compressors are intended for incor-poration into refrigeration systems in accordance withthe 2006/42/EC Machinery Directive. They may only beput into operation if they have been installed in the refri-geration systems according to these Mounting/Operat-ing Instructions and if the overall system complies withthe applicable legal provisions (applied standards: seedeclaration of incorporation).

The compressors have been built in accordance withstate-of-the-art methods and current regulations. Partic-ular importance was placed on user safety.

These Operating Instructions must be kept availablenear the refrigeration system during the whole lifetimeof the compressor.

1.1 Also observe the following technical documents

KT-210: ECOLINE VARISPEED with .F1.

KT-220: ECOLINE VARISPEED with .F3 and .F4.

KW-100: Tightening torques for screw fixings.

2 Safety

2.1 Authorized staff

All work done on compressors and refrigeration sys-tems may only be performed by qualified and author-ized staff who have been trained and instructed accord-ingly. The qualification and expert knowledge of thepersonnel must correspond to the local regulations andguidelines.

2.2 Residual risks

The compressor may present unavoidable residualrisks. That is why any person working on this devicemust carefully read these Operating Instructions.

The following rules and regulations are mandatory:

relevant safety regulations and standards (e.g. EN378, EN60204 and EN 60335),

generally accepted safety rules,

EU directives,

national regulations.

2.3 Safety references

are instructions intended to prevent hazards. Safety ref-erences must be stringently observed!

!!NOTICEInstructions on preventing possible damage toequipment.

CAUTIONInstructions on preventing a possible minor haz-ard to persons.

WARNINGInstructions on preventing a possible severehazard to persons.

DANGERInstructions on preventing an immediate risk ofsevere hazard to persons.

2.3.1 General safety references

State of delivery

CAUTIONThe compressor is filled with a holding charge:Excess pressure 0.2 ..0.5 bar.Risk of injury to skin and eyes.Depressurize the compressor!Wear safety goggles!

For work on the compressor once it has beencommissioned

WARNINGThe compressor is under pressure!Serious injuries are possible.Depressurize the compressor!Wear safety goggles!

CAUTIONSurface temperatures of more than 60C or be-low 0C.Risk of burns or frostbite.Close off accessible areas and mark them.Before performing any work on the compressor:switch it off and let it cool down.

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3 Application ranges

Compressor types 2KES-05(Y) .. 8FE-70(Y) and 22EES-4(Y) .. 66FE-100(Y) 4FDC-5Y ..4NDC-20Y

Permitted refriger-ants

(Further refrigerantsupon request)

R134a, R404A, R407A/C/F,R448A, R449A, R450A,R452A, R507A, R513A,R1234yf, R1234ze(E)

further HFO and HFO/HFC blends only afterconsultation withBITZER

R22 R410A

Oil charge BSE32

BSE55 for R134a:tc> 70C

Pleasecontact BITZER

B5.2 BSE55

Application limits see brochure KP-104 and BITZER software see brochure KP-101and BITZER software

Tab.1: Application ranges of ECOLINE compressors

Compressor types 2DES-3.F1Y .. 4NE-20.F4YAllowed refrigerants

(Further refrigerantsupon request)

R134a, R404A, R407A/C/F,R448A, R449A, R450A,R452A, R507A, R513A,R1234yf, R1234ze(E)

Oil charge BSE32

BSE55 for R134a:tc> 70CApplication limits see brochure KP-102 and

BITZER software

Tab.2: Application ranges of ECOLINE VARISPEED compressors

WARNINGRisk of bursting due to counterfeit refrigerants!Serious injuries are possible!Purchase refrigerants only from reputable man-ufacturers and reliable distributors!

Risk of air penetration during operation in the vacuumrange

!!NOTICEPotential chemical reactions as well as in-creased condensing pressure and rise in dis-charge gas temperature.Avoid air penetration!

WARNINGA critical shift of the refrigerant ignition limit ispossible.Avoid air penetration!

3.1 Use of flammable refrigerants of the A2L safetygroup (e.g. R1234yf)

InformationThe information in this chapter about the use ofrefrigerants of the A2L safety group refer toEuropean regulations and directives. In regionsoutside the EU, observe the local regulations.

InformationFor refrigerants of the A3 safety group, e.g.R290 propane or R1270 propylene, specificcompressor designs can be delivered upon re-quest. In this case, also observe the additionalOperating Instructions.

This chapter describes and gives explanations to theadditional residual risks originating from the com-pressor when using refrigerants of the A2L safetygroup. This information helps the manufacturer of thesystem to make the risk assessment for the system.This information may in no way replace the risk assess-ment for the system.

Design, maintenance and operation of refrigeration sys-tems using refrigerants of the A2L safety group aresubject to particular safety regulations.

When installed according to these Operating Instruc-tions and in normal operation conditions without mal-functions, the compressors are free from ignitionsources that could ignite the flammable refrigerantsR1234yf and R1234ze(E). They are considered astechnically tight. No ignition source assessment isavailable for other refrigerants of the A2L safety group.

KB-104-66

InformationWhen using flammable refrigerants, attach theadhesive label with the warning symbol from theterminal box to the oil separator.

Refrigerant burning in the terminal box may only hap-pen if several very rare errors occur at the same time.The probability of this event occurring is extremely low.When suspecting burnt refrigerant in the terminal box,wait at least 30minutes before opening it. According tothe present knowledge, this is the time needed for thetoxic combustion products to be degraded. It is neces-sary to use appropriate, acid-resistant gloves. Do nottouch moist residues, but let them dry, because theymay contain dissolved toxic substances. Never inhaleevaporation products. Let the concerned parts becleaned by trained staff or, if the parts are corroded,dispose of them properly.

3.1.1 Compressor and refrigeration systemrequirements

The specifications are established in standards (e.g.EN 378). In view of the high requirements and productliability, it is generally recommended to carry out therisk assessment in cooperation with a notified body.Depending on the design and the refrigerant charge, anassessment according to EU Framework Directives2014/34/EU and 1999/92/EC (ATEX 137) may be ne-cessary.

DANGERFire hazard in the event of refrigerant leakageand in the presence of an ignition source!Avoid open fire and ignition sources in the en-gine room and in the hazardous zone!

Pay attention to the ignition point in the air of the re-frigerant used, see also EN 378-1.

Vent engine room according to EN 378 or install anextraction device.

If the following safety regulations and adaptations areobserved, the standard compressors can be run withrefrigerants of the A2L safety group.

Observe the max. refrigerant charge according to theinstallation place and the installation zone! SeeEN378-1 and local regulations.

No operation in the vacuum range! Install safetydevices for protection against insufficient and ex-cessive pressure and make sure that they are de-signed in accordance with the requirements of thesafety regulations (e.g. EN378-2).

Avoid air penetration in the system also during andafter maintenance work!

3.1.2 General operation requirements

Operation of the system and personal protection areusually subject to national regulations on productsafety, operating reliability and accident prevention. Tothis end, separate agreements between the contractorand the end user must be made. The provision of thenecessary risk assessment for work environment priorto installation and operation of the system is the re-sponsibility of the end user. To this end, cooperationwith a notified body is recommended.

To open the pipelines, use only pipe cutters and noopen flame.

4 Mounting

InformationObserve tightening torques for screw fixings ac-cording to maintenance instructions KW-100!

4.1 Transporting the compressor

Either transport the compressor screwed onto the palletor lift it on the eyebolts. Lift the tandem compressoronly with a lifting beam, see figure 1, page 7.

DANGERSuspended load!Do not step under the machine!

KB-104-6 7

Fig.1: Lifting the ECOLINE compressor

4.2 Installing the compressor

Install/mount the compressor horizontally. Take suit-able measures if the compressor is operated under ex-treme conditions (e.g. aggressive atmosphere, low out-side temperatures, etc.). Consultation with BITZER isrecommended.

4.2.1 Vibration dampers

The compressor may be mounted rigidly if there is nodanger of fatigue fractures in the pipeline system con-nected to it. To do so, for compressors

2KES-05(Y) .. 2FES-3(Y)

2EES-2(Y) .. 2CES-4(Y)

4FES-3(Y) .. 4CES-9(Y)

2DES-3.F1Y

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4FDC-5Y .. 4CDC-9Y

place a disk between each compressor base and frame(part number 313 095 01). Otherwise, the compressormust be mounted on vibration dampers, see figure 2,page 8. This is in particular required when mountingit on shell and tube heat exchangers:

!!NOTICEDo not mount the compressor solidly on theheat exchanger!Risk of damage to the heat exchanger (fatiguefractures).

Mounting the suction gas and discharge gas lines:Place compressor on the vibration elements or mount itrigidly. In this position (operational position), connectthe suction gas and discharge gas lines free of stress.

Transport locks for condensing units

To avoid transport damage to condensing units in theirstate of delivery, the vibration dampers of the com-pressors are blocked by transport locks. It is absolutelynecessary to remove or loosen these locks after mount-ing.

KB-104-68

4.2.2 Type I vibration dampers

After mounting:

Remove red transport lock (1).

Retighten fixing screws and fixing nuts (2) and (3).

4.2.3 Type II vibration dampers

After mounting:

Loosen nut (1) to such an extent that the slottedwasher (4) can be removed.

Remove washer (4).

4.2.4 Type III vibration dampers

After mounting:

Loosen nut (1) to such an extent that the slottedwasher (4) can be removed.

Remove washer (4).

Transport

A B

Operation

Type I

Type II

Type III

3

M8

1

2

1

M10

4

2

3

1

M10

4

2

3

Fig.2: Vibration damper

Vibrationdampers

Compressor Crankcase side (A) Motor side (B)

Kit number Hardness/Colour

Kit number Hardness/Colour

Type I 2KES-05(Y) .. 2FES-3(Y) 370 000 19 43 shore 370 000 19 43 shore 2EES-2(Y) .. 2CES-4(Y)

2DES-3.F1Y

22EES-4(Y) .. 22CES-8(Y)

370 000 20 55 shore 370 000 20 55 shore

4FDC-5Y .. 4CDC-9Y

4FES-3(Y) .. 4CES-9(Y)

4FE-5.F1Y .. 4CE-9.F3Y

44FES-6(Y) .. 44CES-18(Y)

370 000 20 55 shore 370 000 20 55 shore

Type II 4VDC-10Y .. 4NDC-20Y

4VE(S)-6Y .. 4NE(S)-20(Y)

370 003 05 yellow 370 000 20 brown

4VE-7.F3Y .. 4NE-20.F4Y 370 004 07 red 370 004 08 black 4JE-13Y .. 4HE-25(Y) 370 004 01 brown 370 004 02 red

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Vibrationdampers

Compressor Crankcase side (A) Motor side (B)

4GE-20Y, 4GE-23(Y)

4FE-25(Y) 4GE-30(Y)

4FE-28(Y) .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

370 004 01 brown 370 004 03 blue

8GE-50(Y) .. 8FE-70(Y) 370 004 02 red 370 004 04 blackType III 44VE(S)-14(Y) .. 44NE(S)-40(Y) 2x 370 002 08 brown 2x 370 002 08 brown

44JE-30(Y) .. 44GE-46(Y) 2x 370 002 01 brown 2x 370 002 02 red 44GE-60(Y)

44FE-56(Y), 44FE-70(Y)

2x 370 002 01 brown 2x 370 002 03 blue

66JE-50(Y) .. 66FE-100(Y) 2x 370 002 02 red 2x 370 002 03 blue 8GE-50(Y) .. 8FE-70(Y) 370 002 02 red 370 002 06 black

Tab.3: Vibration dampers

4.3 Connecting the pipelines

WARNINGThe compressor is under pressure!Serious injuries are possible.Depressurize the compressor!Wear safety goggles!

!!NOTICEPotential chemical reactions due to air penetra-tion!Proceed swiftly and keep shut-off valves closeduntil evacuation.

4.3.1 Pipe connections

The pipe connections are suitable for pipes in all com-mon dimensions in millimetres and inches. Brazed con-nections have stepped diameters. The pipe will im-merge more or less depending on its dimensions. If ne-cessary, the bushing may even be cut at the end withthe largest diameter.

4.3.2 Shut-off valves

During operation: Only operate the shut-off valveseither fully opened or fully closed.

Remove the protective cap.

First loosen the packing gland with turn to the left.

Then open or close the valve spindle.

After that, retighten the packing gland and screw theprotective cap on again.

Any installation position and flow direction can bechosen.

CAUTIONDepending on the operation mode, the shut-offvalves may become very cold or very hot.Risk of burning or frostbite!Wear suitable protective equipment!

!!NOTICEDo not overheat the shut-off valves!Cool the valve body during and after the brazingoperation.Maximum brazing temperature 700C!

When turning or mounting shut-off valves:

!!NOTICERisk of damage to the compressor.Tighten screws crosswise in at least 2 steps tothe prescribed tightening torque.Perform a tightness test before commissioning!

4.3.3 Pipelines

Use only pipelines and system components which are

clean and dry inside (free from slag, swarf, rust andphosphate coatings) and

which are delivered with an air-tight seal.

Depending on the compressor versions, they are sup-plied with blanking plates on the pipe connections or

KB-104-610

shut-off valves. These plates must be removed beforecommissioning.

!!NOTICEFor systems with rather long pipelines or forbrazing operations without protective gas:Install the suction-side cleaning filter (mesh size

KB-104-6 11

4.4.1 Start unloading (SU)

Option for:

4VE(S)-6Y .. 4NE(S)-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

4VDC-10Y .. 4NDC-20Y

Retrofitting requires the cylinder head in question to bereplaced.

8GE-50(Y) .. 8FE-70(Y)

The motor of the 8-cylinder compressor equipped witha special winding wiring guarantees a high torque evenin case of a part winding start. This is why no start un-loading is required for these compressors.

Mounting position of the valve top parts for start un-loading, see figure 4, page 11.

Mounting the discharge gas temperature sensor, seechapter Discharge gas temperature sensor, page 19.

The start unloading requires a check valve in the dis-charge gas line. For detailed information on the startunloading, see Technical Information KT-110.

Start unloading (SU)

CRIISU

2 (HP)

4VE(S)-6(Y) .. 4NE(S)-20(Y)4VCD-10Y .. 4NDC-20Y

CRIISU

2 (HP)

4JE-13Y .. 4FE-35(Y)

CRII (2) CRII (1)

SU

2 (HP)

6JE-22Y .. 6FE-50(Y)

Fig.4: Position of the cylinder heads and valve top parts for start unloading in case of factory mounting

2 (HP) Discharge gas temperature sensor

4.4.2 Capacity control (CRII)

optionally for:

2EES-2(Y) .. 2CES-4(Y)

4FES-3(Y) .. 4CES-9(Y)

4VE(S)-6Y .. 4NE(S)-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

8GE-50(Y) .. 8FE-70(Y)

22EES-4(Y) .. 66FE-100(Y)

4FDC-5Y .. 4CDC-9Y

4VDC-10Y .. 4NDC-20Y

Retrofitting requires the cylinder head in question to bereplaced.

Mounting position of the valve top parts for capacitycontrol, see figure 5, page 12.

Tandem compressors: With a possible load se-quence switching in mind, both compressor partsshould be equipped with the same number of CRIIcylinder heads, see figure 5, page 12.

For detailed information on the CRII system, the capa-city control for ECOLINE compressors, see TechnicalInformation KT-101.

KB-104-612

CRII (2) CRII (1)

Capacity control (CRII)

CRII (2) CRII (1)

CRII (3)

CRII (2) CRII (1)

Fig.5: ECOLINE 4-, 6- and 8-cylinder compressors are each completely equipped with the CRII system.

4.5 Connections and connection diagrams

4.5.1 Connection diagrams of single compressors

Legend, see table 4, page 17.

1/8-27 NPTF

1 (HP)3 (LP)

1/8-27 NPTF

M10x1,5

6 10

12

5 / 8

7/16-20 UNF

SL DL

Fig.6: 2DES-3.F1Y

7/16-20 UNF

5 / 8

SLDL

12

16

M10x1,5

10

1 (HP)3 (LP)

1/8-27 NPTF1/8-27 NPTF

2 (HP)

1/8-27 NPTF

126

M20x1,5

11

7/16-20 UNF7/16-20 UNF

Fig.7: 4FE-5.F1Y .. 4CE-9.F3Y (figure shows compressor with .F1 frequency inverter)

KB-104-6 13

DL SL

5 / 8

1/4-18 NPTF

21

1/2-14 NPTF

1 (HP)

1/8-27 NPTF

2 (HP)

1/8-27 NPTF

M10x1,5 12

106

16

M20x1,5

12

7/16-20 UNF

11

7/16-20 UNF

7

M22x1,5

Fig.8: 4VE-7.F3Y .. 4NE-20.F4Y

SL DL

5 / 81 (HP)

1 8 7 NPTF/ -2

3 (LP)

1 8 7 NPTF/ -2

6

7/16-20 UNF

10

M8x ,51 11

Fig.9: 2KES-05(Y) .. 2FES-3(Y)

5 / 8

7/16-20 UNF

1/8-27 NPTF

1 (HP)3 (LP)

1/8-27 NPTF

DL

M10x1,5

6 10

12

SL

Fig.10: 2EES-2(Y) .. 2CES-4(Y)

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7/16-20 UNF

5 / 8

1 (HP)3 (LP)

1/8-27 NPTF 1/8-27 NPTF

DL SL

6

M10x1,5

10

12M20x1,5

16

2 (HP)

1/8-27 NPTF

Fig.11: 4FES-3(Y) .. 4CES-9(Y), 4FDC-5Y .. 4CDC-9Y

DL

7/16-20 UNF

43 (LP)

SL

5 / 8

1/4-18 NPTF

21

1/2-14 NPTF

6

M10x1,5

10

12

16

M20x1,5

1 (HP)

1/8-27 NPTF

2 (HP)

1/8-27 NPTF

1/8-27 NPTF

Fig.12: 4VES-6Y .. 4NES-20(Y), 4VDC-10Y .. 4NDC-20Y

DL

7/16-20 UNF

43 (LP)

SL

5 / 8

1/4-18 NPTF

21

1/2-14 NPTF

6

M10x1,510

12

16

M20x1,5

1 (HP) 2 (HP)

1/8-27 NPTF

1/8-27 NPTF

7

M22x1,512

7/16-20 UNF

11

1/8-27 NPTF

7/16-20 UNF

Fig.13: 4VE-6Y .. 4NE-20(Y)

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3 (LP)

1/4-18 NPTF

816 52 (HP)1/8-27 NPTF

117/16-20 UNF

1 (HP)1/8-27 NPTF

6 / 7M26x1,5

103/8-18 NPTF

127/16-20 UNF

9a

9b

3/4-14 NPTF

1/2-14 NPTF

1/8-27 NPTF

21

41/8-27 NPTF

M20x1,5 1/4-18 NPTF

DL SL

Fig.14: 4JE-13Y .. 4FE-35(Y)

16M20x1,5

DL

51/4-18 NPTF

81/4-18 NPTF

9b

1/2-14 NPTF

SL

M26x1,5

6 / 7103/8-27 NPTF

9a

3/4-14 NPTF

4

1/8-27 NPTF

12

11

7/16-20 UNF

7/16-20 UNF

1 (HP)1/8-27 NPTF

41/8-27 NPTF

2 (HP)1/8-27 NPTF

3 (LP)1/8-27 NPTF

Fig.15: 6JE-22Y .. 6FE-50(Y)

3/4-14 NPTF1/2-14 NPTFM20x1,5

7/16-20 UNF

M26x1,5

7/16-20 UNF

1/4-18 NPTF

16 9b 9a

1/4-18 NPTF

1/8-27 NPTF

1 (HP)

103/8-18 NPTF

6 / 7

8

5

12

11

SLDL1/8-27 NPTF

2 (HP)

1/8-27 NPTF

3 (LP)

Fig.16: 8GE-50(Y) .. 8FE-70(Y)

KB-104-616

4.5.2 Connection diagrams of tandem compressors

Other connections same as in the corresponding singlecompressor

Legend, see table 4, page 17.

SL DL3 (LP)

1/8-27 NPTF

5

7/16-20 UNF 1/4-18 NPTF

8

Fig.17: 22EES-2(Y) .. 22CES-4(Y)

5

7/16-20 UNF 1/8-27 NPTF

8

DL SL DL3 (LP)

1/8-27 NPTF 1/8-27 NPTF

1 (HP)2 (HP)

1/8-27 NPTF

2 (HP)

1/8-27 NPTF

M20x1,5

16

Fig.18: 44FES-6(Y) .. 44CES-18(Y)

DL DLSL

1/4-18 NPTF

5

1/8-27 NPTF

8 16

M20x1,5

7/16 0 U-2 NF

4

Fig.19: 44VE(S)-14(Y) .. 44NE(S)-40(Y)

KB-104-6 17

16DL DLSL 8

3/8-18 NPTF

5

1/4-18 NPTFM20x1,5

11

7/16-20 UNF

12

7/16-20 UNF

Fig.20: 44JE-30(Y) .. 66FE-100(Y)

Connection positions1 High-pressure connection (HP)2 Connection for discharge gas temperature

sensor (HP) (in 4VE(S)-6Y .. 4NE(S)-20(Y)alternative connection for CIC sensor)

3 Low pressure connection (LP)4 CIC system: Injection nozzle (LP)

4b Connection for CIC sensor4c Connection for CIC sensor (MP / operation

with refrigerant subcooler)5 Oil fill plug6 Oil drain7 Oil filter (magnetic screw)8 Oil return (oil separator)

8* Oil return for NH3 with insoluble oil9 Connection for oil and gas equalisation

(parallel operation)9a Connection for gas equalisation (parallel

operation)9b Connection for oil equalisation (parallel op-

eration)10 Connection for oil heating11 Oil pressure connection +12 Oil pressure connection 13 Cooling water connection14 Intermediate pressure connection (MP)15 Refrigerant injection (operation without li-

quid subcooler and with thermostatic ex-pansion valve)

16 Connection for oil monitoring (opto-elec-tronic oil monitoring device "OLC-K1" ordifferential oil pressure switch "Delta-PII")

17 Refrigerant inlet on the subcooler

Connection positions18 Refrigerant outlet on the subcooler19 Clamping area20 Terminal plate21 Maintenance connection for oil valve22 Pressure relief valve to the atmosphere

(pressure side)23 Pressure relief valve to the atmosphere

(suction side)SL Suction gas lineDL Discharge gas line

Tab.4: Connection positions

Dimensions (if specified) may have tolerances accord-ing to ENISO13920-B.

The legend applies to all open and semi-hermeticBITZER reciprocating compressors and contains con-nection positions that do not occur in every compressorseries.

5 Electrical connection

Electrical connection of the ECOLINE VARISPEEDcompressors:

2DES-3.F1Y

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4VE-7.F3Y .. 4NE-20.F4Y

See enclosed Technical Information KT-210 or KT-220.

KB-104-618

General information

Compressors and electrical equipment comply with theEU Low Voltage Directives 2006/95/EC and 2014/35/EU.

Connect mains cables, protective earth conductors andbridges (if needed) as specified on the labels in the ter-minal box. Observe the safety standards EN60204,IEC60364 and national safety regulations.

!!NOTICERisk of short-circuit due to condensation waterin the terminal box!Use only standardised cable bushings.When mounting, pay attention to proper sealing.

!!NOTICERisk of motor damage!Improper electrical connection or compressoroperation at incorrect voltage or frequency maylead to motor overload.Observe the specifications on the name plate.Connect properly and check the connections fortight fitting.

5.1 Mains connections

When dimensioning motor contactors, feed lines andfuses:

Use the maximum operating current or maximumpower consumption of the motor as a basis.

Select the contacts according to the operational cat-egory AC3.

Set the thermal overload relays to the maximum op-erating current of the compressor.

5.1.1 Motor version

Star or delta motor

Standard motor for:

2KES-05(Y) .. 2FES-3(Y)

2EES-2(Y) .. 2CES-4(Y)

4FES-3(Y) .. 4CES-9(Y)

22EES-4(Y) .. 22CES-8(Y)

44FES-6(Y) .. 44CES-18(Y)

4FDC-5Y .. 4CDC-9Y

This motor has been designed for direct-on-line start attwo different voltages. The higher voltage is used forstar mode operation and the lower voltage for perman-ent operation in delta mode. Depending on the selected

mode, adjust the positions of the connection bridges orhave their functions performed externally (e.g. bymeans of contactors).

Part winding (PW) motor

Time delay until switch-on of the 2nd part winding: max.0.5s!

Make the connections correctly! Wrong electrical con-nections will lead to opposite fields of rotation or tofields of rotation out of phase and therefore to a motorlock!

Standard motor for:

4VE(S)-6Y .. 4NE(S)-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

44VE(S)-14(Y) .. 44NE(S)-40(Y)

44JE-30(Y) .. 44FE-70(Y)

66JE-50(Y) .. 66FE-100(Y)

4VDC-10Y .. 4NDC-20Y

Winding partition 50%/50%.

Motor contactor selection:

1st contactor (PW1): 60% of the max. operating cur-rent.

2nd contactor (PW2): 60% of the max. operating cur-rent.

Motor version 3 when operated with external frequencyinverter: Select contactors for max. operating current at70 Hz!

8GE-50(Y) .. 8FE-70(Y)

Motor version / with 60%/40% winding partition.

Motor contactor selection:

1st contactor (PW 1): approx. 70% of the max. operat-ing current.

2nd contactor (PW 2): approx. 50% of the max. operat-ing current (see adhesive label in terminal box). Strictlyobserve the order of the part windings!

Star-delta motor

The time delay between the switch-on of the com-pressor and the switch-over from star to delta operationshall not exceed 2s.Make the connections correctly!Wrong electrical connections will lead to short-circuit!

KB-104-6 19

Option for:

4VE(S)-6Y .. 4NE(S)-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

44VE(S)-14(Y) .. 44NE(S)-40(Y)

44JE-30(Y) .. 44FE-70(Y)

66JE-50(Y) .. 66FE-100(Y)

Upon request:

8GE-50(Y) .. 8FE-70(Y)

5.2 Protection devices

!!NOTICEPotential failure of the compressor protectiondevice and the motor due to improper connec-tion and/or faulty operation!The terminals M1-M2 or T1-T2 on the com-pressor and B1-B2 on the protection device aswell as its two orange cables must not comeinto contact with the control voltage or operatingvoltage!

5.2.1 SE-B1 or SE-B3

Standard for:

2KES-05(Y) .. 2FES-3(Y)

2EES-2(Y) .. 2CES-4(Y)

4FES-3(Y) .. 4CES-9(Y)

4VE(S)-6Y .. 4NE(S)-20(Y)

2DES-3.F1Y

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4VE-7.F3Y .. 4NE-20.F4Y

4FDC-5Y .. 4CDC-9Y

4VDC-10Y .. 4NDC-20Y

5.2.2 SE-B2 or SE-B3

Standard for:

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

8GE-50(Y) .. 8FE-70(Y)

Both protection devices are permanently incorporatedin the terminal box. The instrument leads for the motortemperature sensor are wired. For further connections,

see Technical Information KT-122 or KT-210 andKT-220.

5.2.3 Differential oil pressure switch Delta-PII (option)

for the following compressors equipped with oil pump,incl. the respective tandem compressors:

4VE-6Y .. 4NE-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

8GE-50(Y) .. 8FE-70(Y)

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4VE-7.F3Y .. 4NE-20.F4Y

For the electrical connection and information on func-tion testing, see Technical Information KT-170.

5.2.4 Opto-electronic oil level monitoring OLC-K1(option)

for the following compressors equipped with centrifugallubrication, incl. the respective tandem compressors:

4FES-3(Y) .. 4CES-9(Y)

4VES-6Y .. 4NES-20(Y)

4FDC-5Y .. 4CDC-9Y

4VDC-10Y .. 4NDC-20Y

For the electrical connection and information on func-tion testing, see Technical Information KT-180.

5.2.5 Discharge gas temperature sensor

Option for:

4FES-3(Y) .. 4CES-9(Y)

4VE(S)-6Y .. 4NE(S)-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

8GE-50(Y) .. 8FE-70(Y)

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4VE-7.F3Y .. 4NE-20.F4Y

4FDC-5Y .. 4CDC-9Y

4VDC-10Y .. 4NDC-20Y

can be retrofitted.

KB-104-620

Screw the sensor element into the HP connection,see chapter Connection diagrams of single com-pressors, page 12.

Compressors with integrated start unloading:The sensor must be incorporated in the start un-loading cylinder head (see figure 21, page 20).

Connect the instrument leads in series to the motortemperature sensors (see adhesive label in terminalbox) and see figure 21, page 20).

1

L

N

12

14

11

Relais max

2,5A 250 V

300 VA

Reset

B1

B2

SE-B*M1

M2

2

4

3a

SU

HP

LP

SU

HP

HP

3b

4FES-6(Y) .. 4NE(S)-20(Y)

4VDC-10Y .. 4NDC-20Y

4JE-13Y .. 6FE-50(Y)

Fig.21: Discharge temperature sensor for start unloading

1 Terminal plate2 Discharge gas temperature sensor3 Connection position at the cylinder head4 Safety chain

5.2.6 Safety devices for pressure limiting (HP and LP)

These safety devices are required for securing thecompressor's application range in order to avoid un-acceptable operating conditions.

Do not connect any safety devices to the serviceconnection of the shut-off valve!

5.2.7 Oil heater

The oil heater ensures the lubricity of the oil even afterlong standstill periods. It prevents increased refrigerantconcentration in the oil and therefore reduction of vis-cosity.

The oil heater must be operated while the compressoris at standstill in case of

outdoor installation of the compressor,

long shut-off periods,

high refrigerant charge,

possible refrigerant condensation in the compressor.

Connection according to Technical Information KT-150.

5.2.8 CIC system

serves for ensuring the application limits in low temper-ature applications using certain refrigerants such asR407F, R407A and R22. For the technical descriptionand mounting and electrical connection information,see Technical Information KT-130.

6 Commissioning

The compressor has been carefully dried, checked fortightness and filled with a holding charge (N2) beforeleaving the factory.

DANGERRisk of explosion!Never pressurize the compressor with oxygen(O2) or other industrial gases!

WARNINGRisk of bursting!A critical shift of the refrigerant ignition limit ispossible in case of excess pressure.Do not add a refrigerant (e.g. as a leak indic-ator) to the test gas (N2 or air).Environmental pollution in case of leakage andwhen deflating!

KB-104-6 21

!!NOTICERisk of oil oxidation!Check the entire system for strength pressureand tightness, preferably using dried nitrogen(N2).When using dried air: Remove the compressorfrom the circuit make sure to keep the shut-offvalves closed.

6.1 Checking the strength pressure

Check the refrigerant circuit (assembly) according toEN378-2 (or other applicable equivalent safety stand-ards). The compressor had been already tested in thefactory for strength pressure. A tightness test is there-fore sufficient, see chapter Checking tightness, page21. If you still wish to perform a strength pressure testfor the entire assembly:

DANGERRisk of bursting due to excessive pressure!The pressure applied during the test must neverexceed the maximum permitted values!Test pressure: 1.1-fold of the maximum allow-able pressure (see name plate). Make a distinc-tion between the high-pressure and low-pres-sure sides!

6.2 Checking tightness

Check the refrigerant circuit (assembly) for tightness,as a whole or in parts, according to EN378-2 (or otherapplicable equivalent safety standards). For this, createan excess pressure, preferably using dried nitrogen.

Observe test pressures and safety reference, seechapter Checking the strength pressure, page 21.

6.3 Evacuation

Switch on the oil heater.

Open all shut-off valves and solenoid valves.

Use a vacuum pump to evacuate the entire system,including the compressor, on the suction side andthe high pressure side.

With the vacuum pump shut off, a "standing vacuum"lower than 1.5mbar must be achieved.

Repeat the operation several times if necessary.

!!NOTICERisk of damage to the motor and compressor!Do not start the compressor while it is in a va-cuum!Do not apply any voltage, not even for testing!

6.4 Charging refrigerant

Use only allowed refrigerants, see table 1, page 5 andsee table 2, page 5.

DANGERRisk of bursting of components and pipelinesdue to hydraulic excess pressure while feedingliquid.Serious injuries are possible.Avoid overcharging the system with refrigerantunder all circumstances!

WARNINGRisk of bursting due to counterfeit refrigerants!Serious injuries are possible!Purchase refrigerants only from reputable man-ufacturers and reliable distributors!

!!NOTICERisk of wet operation during liquid feeding!Measure out extremely precise quantities!Keep the oil temperature above 40C.

Before charging with refrigerant:

Do not switch on the compressor!

Switch on the oil heater.

Check the oil level in the compressor.

Charge condenser or receiver, on systems withflooded evaporator, maybe also the evaporator dir-ectly with liquid refrigerant.

Blends must be taken out of the charging cylinder asa solid liquid.

After commissioning, it may be necessary to add re-frigerant: While the compressor is running, chargewith refrigerant on the suction side, preferably at theevaporator inlet.

6.5 Checks prior to compressor start

Oil level (within the marked sight glass area).

Oil temperature (approx. 15 .. 20K above ambienttemperature or suction-side saturation temperature).

Setting and functions of safety and protectiondevices.

Setpoints of the time relays.

Cut-out pressure values of the high-pressure andlow-pressure switches.

Check if the shut-off valves are opened.

KB-104-622

In case of compressor replacement

Oil is already in the circuit. It may therefore be neces-sary to drain off some oil.

!!NOTICEIn case of larger oil quantities in the refrigerantcircuit: Risk of liquid slugging when the com-pressor starts!Maintain the oil level within the marked sightglass area!

6.6 Compressor start

6.6.1 Lubrication/oil level monitoring

Check the lubrication of the compressor directly afterthe compressor start.

The oil level must be visible in the middle of the sightglass ( to of the sight glass height).

Check the oil level repeatedly within the first hours ofoperation!

Compressor equipped with oil pump

4VE-6Y .. 4NE-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

8GE-50(Y) .. 8FE-70(Y)

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4VE-7.F3Y .. 4NE-20.F4Y

If necessary, check oil pressure (on the Schraderconnections of the oil pump, using a pressuregauge)

Differential oil pressure (setpoint): 1.4 3.5 bar.

Minimum allowed suction pressure (at oil pump on suc-tion side): 0.4bar.

6.6.2 Oil monitoring (option)

Oil pressure monitoring

Protection device: Delta-PII.

Electronic differential oil pressure switch Option forcompressors with integrated oil pump, see chapterDifferential oil pressure switch Delta-PII (option),page 19.

Differential cut-out pressure: 0.65bar.

Cut-out time delay when differential oil pressure istoo low: 90s 5 s.

For further information, see Technical InformationKT-170.

Oil level monitoring

Protection device: OLC-K1.

Opto-electronic oil level monitoring Option for com-pressors equipped with centrifugal lubrication, seechapter Opto-electronic oil level monitoring OLC-K1(option), page 19.

This system is recommended in particular for systemswith widely extended pipe work or in applications inwhich larger quantities of oil may migrate to the suctiongas line or to the evaporator. For further details, seeTechnical Information KT-180.

!!NOTICERisk of wet operation!Maintain the discharge gas temperature wellabove the condensing temperature: at least20K.At least 30K for R407A, R407F and R22.

!!NOTICERisk of liquid slugging!Before adding larger quantities of oil: check theoil return!

6.6.3 Vibrations and frequencies

Check the system carefully to detect any abnormal vi-bration. In the case of strong vibrations, take mechan-ical measures (e.g. use pipe clamps or install vibrationdampers).

Speed-controlled compressors

2DES-3.F1Y

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4VE-7.F3Y .. 4NE-20.F4Y

Skip frequencies that may nevertheless give rise to res-onances in the programming of the frequency inverter.

!!NOTICERisk of burst pipes and leakages on the com-pressor and system components!Avoid strong vibrations!

KB-104-6 23

6.6.4 Cycling rate

The compressor should not start more than 8 times perhour. Be sure to adhere to the minimum running time:

Motor power Minimum running time< 5.5 kW 2 min5.5 .. 15 kW 3 min> 15 kW 5 min

6.6.5 Checking the operating data

Evaporating temperature

Suction gas temperature

Condensing temperature

Discharge gas temperature

Oil temperature

Cycling rate

Current

Voltage

Prepare data protocol.

6.6.6 Particular notes on safe compressor andsystem operation

Analyses show that the vast majority of compressorfailures occur due to inadmissible operating conditions.This is especially true for failures deriving from lack oflubrication:

Expansion valve operation pay attention to themanufacturer's guidelines!

Position the temperature sensor correctly at thesuction gas line and fasten it.

When using a liquid suction line heat exchanger:Position the sensor as usual after the evaporatorand not after the heat exchanger.

Ensure sufficiently high suction gas superheat,while also taking into account the minimum dis-charge gas temperatures.

Stable operation at all operating and load condi-tions (also part load, summer/winter operation).

Solid liquid at the expansion valve inlet.

Avoid refrigerant migration (from high pressure tolow pressure side or into compressor) during longershut-off periods!

Always maintain oil heater operation when thesystem is at standstill. This is valid for all applica-tions.

Pump down system (especially if evaporator canget warmer than suction line or compressor).

Automatic sequence change for systems withmultiple refrigerant circuits.

InformationIn the case of refrigerants with low isentropic ex-ponent (e.g. R134a), a heat exchanger betweenthe suction gas line and the liquid line may havea positive effect on the system's operating modeand coefficient of performance.Arrange the temperature sensor of the expan-sion valve as described above.

7 Operation

7.1 Regular checks

Check the system at regular intervals according to na-tional regulations. Check the following points:

Operating data, see chapter Compressor start, page22.

Oil supply, see chapter Compressor start, page 22.

Safety and protection devices and all componentsfor compressor monitoring (check valves, dischargegas temperature sensors, differential oil pressurelimiters, pressure limiters, etc.).

Tight seat of electrical cable connections andscrewed joints.

Screw tightening torques (see KW-100).

Refrigerant charge.

Tightness.

Prepare data protocol.

KB-104-624

Fig.22: Drain plug for condensation water on the terminal box

8 Maintenance

8.1 Oil change

Oil change is not compulsory for factory-made systems.In the case of "field installations" or operation near ap-plication limits, it is recommended to change the oil forthe first time after approx. 100 operating hours. Duringoil change, also clean oil filters and magnetic plugs (forcompressors with integrated oil pump).

After that, change the oil and clean oil filters and mag-netic plugs approximately every 3 years or 10,000 ..12,000 operating hours. Oil types: see table 1, page 5and see table 2, page 5.

!!NOTICEDamage to the compressor caused by degradedester oil.Moisture is chemically bound to the ester oil andcannot be removed by evacuation.Proceed with extreme care:Any penetration of air into the system and oildrum must be avoided under all circumstances.Use only oil drums in their original unopenedstate!

When using A2L refrigerants

WARNINGRisk of refrigerant evaporation from the used oil.Increased risk with A2L refrigerants due to flam-mability!Used oil may still contain relatively high percent-ages of dissolved refrigerant even at atmo-spheric pressure.Transport and storage Fill used oil into a pres-sure-resistant vessel. Store under a nitrogen at-mosphere (holding charge).

Dispose of waste oil properly!

8.2 Internal pressure relief valve

One pressure relief valve each built into:

4NE-14.F3Y and 4NE-20.F4Y

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

2 pressure relief valves each built into:

8GE-50(Y) .. 8FE-70(Y)

The valves are maintenance-free.

However, after repeated venting, it may leak perman-ently because of abnormal operating conditions. Theconsequences are reduced performance and a higherdischarge gas temperature.

9 Decommissioning

9.1 Standstill

Leave the oil heater switched on until disassembly.This prevents increased refrigerant concentration in theoil.

WARNINGRisk of refrigerant evaporation from the oil.Increased risk of flammability, depending on therefrigerant!Shut-down compressors or used oil may stillcontain rather high amounts of dissolved refri-gerant.Close the shut-off valves on the compressorand extract the refrigerant!

KB-104-6 25

9.2 Dismantling the compressor

WARNINGThe compressor is under pressure!Serious injuries are possible.Depressurize the compressor!Wear safety goggles!

Close the shut-off valves on the compressor. Extractthe refrigerant. Do not deflate the refrigerant, but dis-pose of it properly!

Loosen screwed joints or flanges on the compressorvalves. Remove the compressor from the system; usehoisting equipment if necessary.

9.2.1 Disposing of the compressor

Drain the oil from the compressor. Dispose of waste oilproperly! Have the compressor repaired or dispose of itproperly!

When returning compressors that have been operatedwith flammable refrigerant, mark the compressor withthe symbol "Caution flammable gas", as the oil may stillcontain refrigerant.

KB-104-626

Inhaltsverzeichnis

1 Einleitung............................................................................................................................................................. 281.1 Zustzlich folgende technische Dokumente beachten ................................................................................28

2 Sicherheit............................................................................................................................................................. 282.1 Autorisiertes Fachpersonal ..........................................................................................................................282.2 Restgefahren ...............................................................................................................................................282.3 Sicherheitshinweise .....................................................................................................................................28

2.3.1 Allgemeine Sicherheitshinweise ...................................................................................................... 28

3 Anwendungsbereiche .......................................................................................................................................... 293.1 Einsatz von brennbaren Kltemitteln der Sicherheitsgruppe A2L (z.B. R1234yf) ......................................29

3.1.1 Anforderungen an den Verdichter und die Klteanlage ................................................................... 303.1.2 Allgemeine Anforderungen an den Betrieb ...................................................................................... 30

4 Montage............................................................................................................................................................... 304.1 Verdichter transportieren .............................................................................................................................304.2 Verdichter aufstellen ....................................................................................................................................31

4.2.1 Schwingungsdmpfer ...................................................................................................................... 314.2.2 Schwingungsdmpfer Typ I ............................................................................................................. 314.2.3 Schwingungsdmpfer Typ II ............................................................................................................ 324.2.4 Schwingungsdmpfer Typ III ........................................................................................................... 32

4.3 Rohrleitungen anschliessen.........................................................................................................................334.3.1 Rohranschlsse ............................................................................................................................... 334.3.2 Absperrventile .................................................................................................................................. 334.3.3 Rohrleitungen................................................................................................................................... 33

4.4 Anlaufentlastung (SU) und Leistungsregelung (CRII)..................................................................................344.4.1 Anlaufentlastung (SU)...................................................................................................................... 354.4.2 Leistungsregelung (CRII) ................................................................................................................. 35

4.5 Anschlsse und Anschlusszeichnungen......................................................................................................364.5.1 Anschlusszeichnungen Einzelverdichter.......................................................................................... 364.5.2 Anschlusszeichnungen Tandemverdichter ...................................................................................... 40

5 Elektrischer Anschluss ........................................................................................................................................ 415.1 Netzanschlsse ...........................................................................................................................................42

5.1.1 Motorausfhrung.............................................................................................................................. 425.2 Schutzgerte................................................................................................................................................43

5.2.1 SE-B1 oder SE-B3 ........................................................................................................................... 435.2.2 SE-B2 oder SE-B3 ........................................................................................................................... 435.2.3 ldifferenzdruckschalter Delta-PII (Option) ..................................................................................... 435.2.4 Opto-elektronische lniveauberwachungOLC-K1 (Option) .......................................................... 435.2.5 Druckgastemperaturfhler ............................................................................................................... 435.2.6 Sicherheitseinrichtungen zur Druckbegrenzung (HP und LP) ......................................................... 445.2.7 lheizung......................................................................................................................................... 445.2.8 CIC-System...................................................................................................................................... 44

6 In Betrieb nehmen ............................................................................................................................................... 446.1 Druckfestigkeit prfen ..................................................................................................................................456.2 Dichtheit prfen............................................................................................................................................456.3 Evakuieren...................................................................................................................................................456.4 Kltemittel einfllen......................................................................................................................................45

KB-104-6 27

6.5 Vor dem Verdichteranlauf prfen.................................................................................................................456.6 Verdichteranlauf...........................................................................................................................................46

6.6.1 Schmierung / lkontrolle.................................................................................................................. 466.6.2 lberwachung (Option).................................................................................................................. 466.6.3 Schwingungen und Frequenzen ...................................................................................................... 466.6.4 Schalthufigkeit................................................................................................................................ 476.6.5 Betriebsdaten berprfen ................................................................................................................ 476.6.6 Besondere Hinweise fr sicheren Verdichter- und Anlagenbetrieb ................................................. 47

7 Betrieb ................................................................................................................................................................. 477.1 Regelmige Prfungen..............................................................................................................................47

8 Wartung ............................................................................................................................................................... 488.1 lwechsel ....................................................................................................................................................488.2 Integriertes Druckentlastungsventil..............................................................................................................48

9 Auer Betrieb nehmen ........................................................................................................................................ 489.1 Stillstand ......................................................................................................................................................489.2 Demontage des Verdichters ........................................................................................................................49

9.2.1 Verdichter entsorgen........................................................................................................................ 49

KB-104-628

1 Einleitung

Diese Kltemittelverdichter sind zum Einbau in Kltean-lagen entsprechend der EU-Maschinenrichtlinie2006/42/EG vorgesehen. Sie drfen nur in Betrieb ge-nommen werden, wenn sie gem vorliegender Monta-ge-/Betriebsanleitung in diese Klteanlagen eingebautworden sind und als Ganzes mit den entsprechendengesetzlichen Vorschriften bereinstimmen (angewandteNormen: siehe Einbauerklrung).

Die Verdichter sind nach dem aktuellen Stand derTechnik und entsprechend den geltenden Vorschriftengebaut. Auf die Sicherheit der Anwender wurde beson-derer Wert gelegt.

Diese Betriebsanleitung whrend der gesamten Ver-dichterlebensdauer an der Klteanlage verfgbar hal-ten.

1.1 Zustzlich folgende technische Dokumentebeachten

KT-210: ECOLINE VARISPEED mit .F1.

KT-220: ECOLINE VARISPEED mit .F3 und .F4.

KW-100: Anzugsmomente fr Schraubverbindungen.

2 Sicherheit

2.1 Autorisiertes Fachpersonal

Smtliche Arbeiten an Verdichtern und Klteanlagendrfen nur von Fachpersonal ausgefhrt werden, das inallen Arbeiten ausgebildet und unterwiesen wurde. Frdie Qualifikation und Sachkunde des Fachpersonalsgelten die jeweils landesblichen Vorschriften undRichtlinien.

2.2 Restgefahren

Vom Verdichter knnen unvermeidbare Restgefahrenausgehen. Jede Person, die an diesem Gert arbeitet,muss deshalb diese Betriebsanleitung sorgfltig lesen!

Es gelten zwingend

die einschlgigen Sicherheitsvorschriften und Nor-men (z.B. EN 378, EN60204 und EN 60335),

die allgemein anerkannten Sicherheitsregeln,

die EU-Richtlinien,

nationale Vorschriften.

2.3 Sicherheitshinweise

sind Anweisungen um Gefhrdungen zu vermeiden. Si-cherheitshinweise genauestens einhalten!

!!HINWEISAnweisungen um eine mgliche Gefhrdungvon Gerten zu vermeiden.

VORSICHTAnweisung um eine mgliche minderschwereGefhrdung von Personen zu vermeiden.

WARNUNGAnweisung um eine mgliche schwere Gefhr-dung von Personen zu vermeiden.

GEFAHRAnweisung um eine unmittelbare schwere Ge-fhrdung von Personen zu vermeiden.

2.3.1 Allgemeine Sicherheitshinweise

Auslieferungszustand

VORSICHTDer Verdichter ist mit Schutzgas gefllt: ber-druck 0,2..0,5bar.Verletzungen von Haut und Augen mglich.Verdichter auf drucklosen Zustand bringen!Schutzbrille tragen!

Bei Arbeiten am Verdichter, nachdem er in Betriebgenommen wurde

WARNUNGVerdichter steht unter Druck!Schwere Verletzungen mglich.Verdichter auf drucklosen Zustand bringen!Schutzbrille tragen!

VORSICHTOberflchentemperaturen von ber 60C bzw.unter 0C.Verbrennungen und Erfrierungen mglich.Zugngliche Stellen absperren und kennzeich-nen.Vor Arbeiten am Verdichter: Ausschalten undabkhlen lassen.

KB-104-6 29

3 Anwendungsbereiche

Verdichtertypen 2KES-05(Y) .. 8FE-70(Y) und 22EES-4(Y) .. 66FE-100(Y) 4FDC-5Y ..4NDC-20Y

Zulssige Kltemittel

(weitere Kltemittelauf Anfrage)

R134a, R404A, R407A/C/F,R448A, R449A, R450A,R452A, R507A, R513A,R1234yf, R1234ze(E)

weitere HFO und HFO/HFKW-Gemische nurnach Rcksprache mitBITZER

R22 R410A

lfllung BSE32

BSE55 fr R134a:tc> 70C

Rcksprache mitBITZER

B5.2 BSE55

Einsatzgrenzen siehe Prospekt KP-104 und BITZER Software siehe ProspektKP-101 und BITZERSoftware

Tab.1: Anwendungsbereiche ECOLINE Verdichter

Verdichtertypen 2DES-3.F1Y .. 4NE-20.F4YZulssige Kltemittel

(weitere Kltemittel aufAnfrage)

R134a, R404A, R407A/C/F,R448A, R449A, R450A,R452A, R507A, R513A,R1234yf, R1234ze(E)

lfllung BSE32

BSE55 fr R134a: tc > 70CEinsatzgrenzen siehe Prospekt KP-102 und

BITZER Software

Tab.2: Anwendungsbereiche ECOLINE VARISPEED Verdichter

WARNUNGBerstgefahr des Verdichters durch geflschteKltemittel!Schwere Verletzungen mglich!Kltemittel nur von renommierten Herstellernund serisen Vertriebspartnern beziehen!

Bei Betrieb im Unterdruckbereich Gefahr von Lufteintritt

!!HINWEISChemische Reaktionen mglich sowie berhh-ter Verflssigungsdruck und Anstieg der Druck-gastemperatur.Lufteintritt vermeiden!

WARNUNGKritische Verschiebung der Kltemittelzndgren-ze mglich.Lufteintritt vermeiden!

3.1 Einsatz von brennbaren Kltemitteln derSicherheitsgruppe A2L (z.B. R1234yf)

InformationDie Angaben in diesem Kapitel zum Einsatz vonKltemitteln der Sicherheitsgruppe A2L bezie-hen sich auf europische Vorschriften undRichtlinien. In Regionen auerhalb der EU diedort geltenden lnderspezifischen Vorschriftenbeachten.

InformationFr Kltemittel der Sicherheitsgruppe A3, wieR290 Propan oder R1270 Propylen, sind eigeneVerdichterausfhrungen auf Anfrage lieferbar.Dafr ist eine zustzliche Betriebsanleitung zubercksichtigen.

Dieses Kapitel beschreibt die vom Verdichter beim Ein-satz von Kltemitteln der Sicherheitsklasse A2L ausge-henden zustzlichen Restrisiken und gibt Erluterun-gen dazu. Diese Informationen dienen dem Anlagen-hersteller fr die von ihm auszufhrende Risikobewer-tung der Anlage. Diese Informationen knnen in keinerWeise die Risikobewertung fr die Anlage ersetzen.

Bei der Ausfhrung, der Wartung und dem Betrieb vonKlteanlagen mit brennbaren Kltemitteln der Sicher-heitsgruppe A2L gelten besondere Sicherheitsbestim-mungen.

Die Verdichter sind bei Installation entsprechend dieserBetriebsanleitung im Normalbetrieb ohne Fehlfunktionfrei von Zndquellen, die die brennbaren KltemittelR1234yf und R1234ze(E) entznden knnen. Sie gel-ten als technisch dicht. Fr andere Kltemittel der Si-cherheitsgruppe A2L liegen keine Zndquellenbewer-tungen vor.

KB-104-630

InformationAufkleber mit Warnsymbol aus Anschlusskastenbei brennbarem Kltemittel am labscheideranbringen.

Die Verbrennung von Kltemittel im Anschlusskastenkann nur bei gleichzeitigem Auftreten mehrerer sehrseltener Fehler geschehen. Die Wahrscheinlichkeit da-fr ist als uerst gering einzuschtzen. Bei Verdachtauf verbranntes Kltemittel im Anschlusskasten vordem ffnen mindestens 30 Minuten warten. In dieserZeit sind nach dem aktuellen Stand der Erkenntnissedie giftigen Verbrennungsprodukte abgebaut. Die Ver-wendung von geeigneten, surefesten Handschuhenist erforderlich. Feuchte Rckstnde nicht berhrensondern trocknen lassen, da sie gelste giftige Stoffeenthalten knnen. Verdampfungsprodukte keinesfallseinatmen. Betroffene Teile durch ausgebildetes Fach-personal reinigen lassen bzw. im Falle von Korrosionsind die betroffenen Teile fachgerecht zu entsorgen.

3.1.1 Anforderungen an den Verdichter und dieKlteanlage

Die Ausfhrungsbestimmungen sind in Normen festge-legt (z.B. EN378). Mit Blick auf die hohen Anforderun-gen und die Produkthaftung ist generell die Durchfh-rung der Risikobewertung in Zusammenarbeit mit einernotifizierten Stelle zu empfehlen. Je nach Ausfhrungund Kltemittelfllung, kann dabei eine Bewertung ent-sprechend EU Rahmenrichtlinien2014/34/EU und1999/92/EG (ATEX 137) erforderlich werden.

GEFAHRBrandgefahr bei Kltemittelaustritt und vorhan-dener Zndquelle!Offenes Feuer und Zndquellen im Maschinen-raum bzw. Gefhrdungsraum vermeiden!

Zndgrenzen des jeweiligen Kltemittels in Luft be-achten, siehe auch EN 378-1.

Maschinenraum entsprechend EN378 belften bzw.Absaugvorrichtung installieren.

Wenn folgende Sicherheitsvorschriften und Anpassun-gen eingehalten werden, knnen die Standardverdich-ter mit Kltemitteln der Sicherheitsgruppe A2L betrie-ben werden.

Max. Kltemittelfllung nach Aufstellungsort und Auf-stellungsbereich beachten! Siehe EN378-1 und lo-kale Vorschriften.

Kein Betrieb im Unterdruckbereich! Sicherheitsein-richtungen zum Schutz gegen zu niedrigen und auchzu hohen Druck installieren und entsprechend denAnforderungen der Sicherheitsbestimmungen (z. B.EN378-2) ausfhren.

Lufteintritt in die Anlage vermeiden auch bei undnach Wartungsarbeiten!

3.1.2 Allgemeine Anforderungen an den Betrieb

Fr den Betrieb der Anlage und den Schutz von Perso-nen gelten blicherweise nationale Verordnungen zurProduktsicherheit, Betriebssicherheit und zur Unfallver-htung. Hierzu sind gesonderte Vereinbarungen zwi-schen dem Hersteller der Anlage und dem Betreiber zutreffen. Die Durchfhrung der erforderlichen Gefhr-dungsbeurteilung fr Aufstellung und Betrieb der An-lage liegt dabei in der Verantwortung des Betreibersbzw. Arbeitgebers. Die Zusammenarbeit mit einer noti-fizierten Stelle ist dabei zu empfehlen.

Zum ffnen der Rohrleitungen, nur Rohrabschnei-der, keine offene Flamme, verwenden.

4 Montage

InformationAnzugsmomente fr Schraubverbindungen ent-sprechend Wartungsanleitung KW-100 beach-ten!

4.1 Verdichter transportieren

Verdichter entweder verschraubt auf der Palette trans-portieren oder an Transportsen anheben. Tandemver-dichter nur mit Traverse anheben, siehe Abbildung 1,Seite 31.

GEFAHRSchwebende Last!Nicht unter die Maschine treten!

KB-104-6 31

Abb.1: ECOLINE Verdichter anheben

4.2 Verdichter aufstellen

Den Verdichter waagrecht aufstellen/einbauen. Bei Ein-satz unter extremen Bedingungen (z.B. aggressive At-mosphre, niedrige Auentemperaturen u. a.) geeigne-te Manahmen treffen. Ggf. empfiehlt sich Rckspra-che mit BITZER.

4.2.1 Schwingungsdmpfer

Der Verdichter kann starr montiert werden, wenn keineGefahr von Schwingungsbrchen im angeschlossenenRohrleitungssystem besteht. Dazu bei den Verdichtern

2KES-05(Y) .. 2FES-3(Y)

2EES-2(Y) .. 2CES-4(Y)

4FES-3(Y) .. 4CES-9(Y)

2DES-3.F1Y

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4FDC-5Y .. 4CDC-9Y

zwischen jeden Verdichterfu und Rahmen eine Schei-be legen (Teilenummer 313 095 01). Andernfalls mussder Verdichter auf Schwingungsdmpfern montiert wer-den, siehe Abbildung 2, Seite 32. Dies ist insbesonde-

re bei der Montage auf Bndelrohrwrmebertragernerforderlich:

!!HINWEISVerdichter nicht starr auf Wrmebertragermontieren!Beschdigungen des Wrmebertragers mg-lich (Schwingungsbrche).

Montage von Sauggas- und Druckgasleitung: Verdich-ter auf die Dmpfungselemente stellen oder starr mon-tieren. In dieser Position (Betriebsstellung) Sauggas-und Druckgasleitung spannungsfrei anschlieen.

Transportsicherungen bei Verflssigungsstzen

Um Transportschden zu vermeiden sind bei Verflssi-gungsstzen im Lieferzustand die Schwingungsdmp-fer der Verdichter durch Transportsicherungen blo-ckiert. Diese Sicherungen mssen nach der Montageunbedingt entfernt bzw. gelst werden.

4.2.2 Schwingungsdmpfer Typ I

Nach Montage:

Rote Transportsicherung (1) enfernen.

Befestigungsschrauben bzw. Befestigungsmuttern(2) und (3) wieder fest anziehen.

KB-104-632

4.2.3 Schwingungsdmpfer Typ II

Nach Montage:

Mutter (1) so weit lsen, bis sich die geschlitzte Un-terlegscheibe (4) entfernen lsst.

Unterlegscheibe (4) entfernen.

4.2.4 Schwingungsdmpfer Typ III

Nach Montage:

Mutter (1) so weit lsen, bis sich die geschlitzte Un-terlegscheibe (4) entfernen lsst.

Unterlegscheibe (4) entfernen.

Transport

A B

Betrieb

Typ I

Typ II

Typ III

3

M8

1

2

1

M10

4

2

3

1

M10

4

2

3

Abb.2: Schwingungsdmpfer

Schwin-gungs-dmpfer

Verdichter Kurbelgehuseseite (A) Motorseite (B)

Bausatznum-mer

Hrte/Farbe Bausatznum-mer

Hrte/Farbe

Typ I 2KES-05(Y) .. 2FES-3(Y) 370 000 19 43 shore 370 000 19 43 shore 2EES-2(Y) .. 2CES-4(Y)

2DES-3.F1Y

22EES-4(Y) .. 22CES-8(Y)

370 000 20 55 shore 370 000 20 55 shore

4FDC-5Y .. 4CDC-9Y

4FES-3(Y) .. 4CES-9(Y)

4FE-5.F1Y .. 4CE-9.F3Y

44FES-6(Y) .. 44CES-18(Y)

370 000 20 55 shore 370 000 20 55 shore

Typ II 4VDC-10Y .. 4NDC-20Y

4VE(S)-6Y .. 4NE(S)-20(Y)

370 003 05 gelb 370 000 20 braun

4VE-7.F3Y .. 4NE-20.F4Y 370 004 07 rot 370 004 08 schwarz 4JE-13Y .. 4HE-25(Y)

4GE-20Y, 4GE-23(Y)

4FE-25(Y)

370 004 01 braun 370 004 02 rot

4GE-30(Y) 370 004 01 braun 370 004 03 blau

KB-104-6 33

Schwin-gungs-dmpfer

Verdichter Kurbelgehuseseite (A) Motorseite (B)

4FE-28(Y) .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y) 8GE-50(Y) .. 8FE-70(Y) 370 004 02 rot 370 004 04 schwarz

Typ III 44VE(S)-14(Y) .. 44NE(S)-40(Y) 2x 370 002 08 braun 2x 370 002 08 braun 44JE-30(Y) .. 44GE-46(Y) 2x 370 002 01 braun 2x 370 002 02 rot 44GE-60(Y)

44FE-56(Y), 44FE-70(Y)

2x 370 002 01 braun 2x 370 002 03 blau

66JE-50(Y) .. 66FE-100(Y) 2x 370 002 02 rot 2x 370 002 03 blau 8GE-50(Y) .. 8FE-70(Y) 370 002 02 rot 370 002 06 schwarz

Tab.3: Schwingungsdmpfer

4.3 Rohrleitungen anschliessen

WARNUNGVerdichter steht unter Druck!Schwere Verletzungen mglich.Verdichter auf drucklosen Zustand bringen!Schutzbrille tragen!

!!HINWEISChemische Reaktionen bei Lufteintritt mglich!Zgig arbeiten und Absperrventile bis zum Eva-kuieren geschlossen halten.

4.3.1 Rohranschlsse

Die Rohranschlsse sind so ausgefhrt, dass Rohre inden gngigen Millimeter- und Zollabmessungen ver-wendet werden knnen. Ltanschlsse haben gestufteDurchmesser. Je nach Abmessung wird das Rohr mehroder weniger tief eintauchen. Falls ntig kann dasBuchsenende mit dem greren Durchmesser auchabgesgt werden.

4.3.2 Absperrventile

Im Betrieb: Absperrventile nur voll geffnet oder vollgeschlossen betreiben.

Schutzkappe entfernen.

Anschlieend Stopfbuchse zunchst mit Umdre-hung nach links lsen.

Danach Ventilspindel ffnen bzw. schlieen.

Anschlieend Stopfbuchse wieder anziehen undSchutzkappe wieder anschrauben.

Einbaulage und Durchflussrichtung ist beliebig.

VORSICHTDie Absperrventile knnen je nach Betrieb sehrkalt oder sehr hei werden.Verbrennungs- oder Erfrierungsgefahr!Geeignete Schutzausrstung tragen!

!!HINWEISAbsperrventile nicht berhitzen!Whrend und nach dem Lten Ventilkrper kh-len.Maximale Lttemperatur 700C!

Falls Absperrventile gedreht oder neu montiert werden:

!!HINWEISBeschdigungen des Verdichters mglich.Schrauben mit vorgeschriebenem Anzugsmo-ment ber Kreuz in mindestens 2 Schritten an-ziehen.Vor Inbetriebnahme Dichtheitsprfung durchfh-ren!

4.3.3 Rohrleitungen

Grundstzlich nur Rohrleitungen und Anlagenkompo-nenten verwenden, die

innen sauber und trocken sind (frei von Zunder, Me-tallspnen, Rost- und Phosphatschichten) und

luftdicht verschlossen angeliefert werden.

Die Verdichter werden je nach Ausfhrung mit Ver-schlussscheiben an den Rohranschlssen bzw. Ab-sperrventilen ausgeliefert. Diese mssen vor Inbetrieb-nahme entfernt werden.

KB-104-634

!!HINWEISBei Anlagen mit lngeren Rohrleitungen oderwenn ohne Schutzgas geltet wird:Saugseitigen Reinigungsfilter einbauen (Filter-feinheit

KB-104-6 35

4.4.1 Anlaufentlastung (SU)

Sonderzubehr fr:

4VE(S)-6Y .. 4NE(S)-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

4VDC-10Y .. 4NDC-20Y

Nachrsten erfordert Austausch des jeweiligen Zylin-derkopfs.

8GE-50(Y) .. 8FE-70(Y)

Der mit einer speziellen Wicklungsschaltung ausgefhr-te Motor des 8-Zylinder-Verdichters gewhrleistet auchbei PW-Anlauf ein hohes Drehmoment. Deshalb wirdfr diese Verdichter keine Anlaufentlastung bentigt.

Montageposition der Ventiloberteile fr Anlaufentlas-tung, siehe Abbildung 4, Seite 35.

Montage des Druckgasberhitzungsschutzes, sieheKapitel Druckgastemperaturfhler, Seite 43.

Bei Anlaufentlastung wird ein Rckschlagventil in derDruckgasleitung erforderlich. Detaillierte Informationenzur Anlaufentlastung, siehe Technische InformationKT-110.

Anlaufentlatsung (SU)

CRIISU

2 (HP)

4VE(S)-6(Y) .. 4NE(S)-20(Y)4VCD-10Y .. 4NDC-20Y

CRIISU

2 (HP)

4JE-13Y .. 4FE-35(Y)

CRII (2) CRII (1)

SU

2 (HP)

6JE-22Y .. 6FE-50(Y)

Abb.4: Position der Zylinderkpfe und Ventiloberteile fr Anlaufentlastung bei werkseitiger Montage

2 (HP) Druckgastemperaturfhler

4.4.2 Leistungsregelung (CRII)

optional fr:

2EES-2(Y) .. 2CES-4(Y)

4FES-3(Y) .. 4CES-9(Y)

4VE(S)-6Y .. 4NE(S)-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

8GE-50(Y) .. 8FE-70(Y)

22EES-4(Y) .. 66FE-100(Y)

4FDC-5Y .. 4CDC-9Y

4VDC-10Y .. 4NDC-20Y

Nachrsten erfordert Austausch des jeweiligen Zylin-derkopfs.

Montageposition der Ventiloberteile fr Leistungsrege-lung, siehe Abbildung 5, Seite 36.

Tandemverdichter: Mit Blick auf eine mglicheGrundlastumschaltung sollten beide Verdichterhlf-ten mit der gleichen Anzahl CRII-Zylinderkpfe be-stckt werden, siehe Abbildung 5, Seite 36.

Detaillierte Informationen zum CRII-System, Leistungs-regelung fr ECOLINE Verdichter, siehe Technische In-formationen KT-101.

KB-104-636

CRII (2) CRII (1)

Leistungsregelung (CRII)

CRII (2) CRII (1)

CRII (3)

CRII (2) CRII (1)

Abb.5: ECOLINE 4-, 6- und 8-Zylinder-Verdichter mit CRII-System jeweils vollstndig ausgerstet

4.5 Anschlsse und Anschlusszeichnungen

4.5.1 Anschlusszeichnungen Einzelverdichter

Legende siehe Tabelle 4, Seite 41.

1/8-27 NPTF

1 (HP)3 (LP)

1/8-27 NPTF

M10x1,5

6 10

12

5 / 8

7/16-20 UNF

SL DL

Abb.6: 2DES-3.F1Y

7/16-20 UNF

5 / 8

SLDL

12

16

M10x1,5

10

1 (HP)3 (LP)

1/8-27 NPTF1/8-27 NPTF

2 (HP)

1/8-27 NPTF

126

M20x1,5

11

7/16-20 UNF7/16-20 UNF

Abb.7: 4FE-5.F1Y .. 4CE-9.F3Y (Abbildung zeigt Verdichter mit Frequenzumrichter .F1)

KB-104-6 37

DL SL

5 / 8

1/4-18 NPTF

21

1/2-14 NPTF

1 (HP)

1/8-27 NPTF

2 (HP)

1/8-27 NPTF

M10x1,5 12

106

16

M20x1,5

12

7/16-20 UNF

11

7/16-20 UNF

7

M22x1,5

Abb.8: 4VE-7.F3Y .. 4NE-20.F4Y

SL DL

5 / 81 (HP)

1 8 7 NPTF/ -2

3 (LP)

1 8 7 NPTF/ -2

6

7/16-20 UNF

10

M8x ,51 11

Abb.9: 2KES-05(Y) .. 2FES-3(Y)

5 / 8

7/16-20 UNF

1/8-27 NPTF

1 (HP)3 (LP)

1/8-27 NPTF

DL

M10x1,5

6 10

12

SL

Abb.10: 2EES-2(Y) .. 2CES-4(Y)

KB-104-638

7/16-20 UNF

5 / 8

1 (HP)3 (LP)

1/8-27 NPTF 1/8-27 NPTF

DL SL

6

M10x1,5

10

12M20x1,5

16

2 (HP)

1/8-27 NPTF

Abb.11: 4FES-3(Y) .. 4CES-9(Y), 4FDC-5Y .. 4CDC-9Y

DL

7/16-20 UNF

43 (LP)

SL

5 / 8

1/4-18 NPTF

21

1/2-14 NPTF

6

M10x1,5

10

12

16

M20x1,5

1 (HP)

1/8-27 NPTF

2 (HP)

1/8-27 NPTF

1/8-27 NPTF

Abb.12: 4VES-6Y .. 4NES-20(Y), 4VDC-10Y .. 4NDC-20Y

DL

7/16-20 UNF

43 (LP)

SL

5 / 8

1/4-18 NPTF

21

1/2-14 NPTF

6

M10x1,510

12

16

M20x1,5

1 (HP) 2 (HP)

1/8-27 NPTF

1/8-27 NPTF

7

M22x1,512

7/16-20 UNF

11

1/8-27 NPTF

7/16-20 UNF

Abb.13: 4VE-6Y .. 4NE-20(Y)

KB-104-6 39

3 (LP)

1/4-18 NPTF

816 52 (HP)1/8-27 NPTF

117/16-20 UNF

1 (HP)1/8-27 NPTF

6 / 7M26x1,5

103/8-18 NPTF

127/16-20 UNF

9a

9b

3/4-14 NPTF

1/2-14 NPTF

1/8-27 NPTF

21

41/8-27 NPTF

M20x1,5 1/4-18 NPTF

DL SL

Abb.14: 4JE-13Y .. 4FE-35(Y)

16M20x1,5

DL

51/4-18 NPTF

81/4-18 NPTF

9b

1/2-14 NPTF

SL

M26x1,5

6 / 7103/8-27 NPTF

9a

3/4-14 NPTF

4

1/8-27 NPTF

12

11

7/16-20 UNF

7/16-20 UNF

1 (HP)1/8-27 NPTF

41/8-27 NPTF

2 (HP)1/8-27 NPTF

3 (LP)1/8-27 NPTF

Abb.15: 6JE-22Y .. 6FE-50(Y)

3/4-14 NPTF1/2-14 NPTFM20x1,5

7/16-20 UNF

M26x1,5

7/16-20 UNF

1/4-18 NPTF

16 9b 9a

1/4-18 NPTF

1/8-27 NPTF

1 (HP)

103/8-18 NPTF

6 / 7

8

5

12

11

SLDL1/8-27 NPTF

2 (HP)

1/8-27 NPTF

3 (LP)

Abb.16: 8GE-50(Y) .. 8FE-70(Y)

KB-104-640

4.5.2 Anschlusszeichnungen Tandemverdichter

Sonstige Anschlsse wie beim entsprechenden Einzel-verdichter

Legende siehe Tabelle 4, Seite 41.

SL DL3 (LP)

1/8-27 NPTF

5

7/16-20 UNF 1/4-18 NPTF

8

Abb.17: 22EES-2(Y) .. 22CES-4(Y)

5

7/16-20 UNF 1/8-27 NPTF

8

DL SL DL3 (LP)

1/8-27 NPTF 1/8-27 NPTF

1 (HP)2 (HP)

1/8-27 NPTF

2 (HP)

1/8-27 NPTF

M20x1,5

16

Abb.18: 44FES-6(Y) .. 44CES-18(Y)

DL DLSL

1/4-18 NPTF

5

1/8-27 NPTF

8 16

M20x1,5

7/16 0 U-2 NF

4

Abb.19: 44VE(S)-14(Y) .. 44NE(S)-40(Y)

KB-104-6 41

16DL DLSL 8

3/8-18 NPTF

5

1/4-18 NPTFM20x1,5

11

7/16-20 UNF

12

7/16-20 UNF

Abb.20: 44JE-30(Y) .. 66FE-100(Y)

Anschlusspositionen1 Hochdruckanschluss (HP)2 Anschluss fr Druckgastemperaturfhler

(HP) (bei 4VE(S)-6Y .. 4NE(S)-20(Y) alter-nativ Anschluss fr CIC-Fhler)

3 Niederdruckanschluss (LP)4 CIC-System: Einspritzdse (LP)

4b Anschluss fr CIC-Fhler4c Anschluss fr CIC-Fhler (MP / Betrieb mit

Kltemittelunterkhler)5 leinfllstopfen6 lablass7 lfilter (Magnetschraube)8 lrckfhrung (labscheider)

8* lrckfhrung bei NH3 mit unlslichem l9 Anschluss fr l- und Gasausgleich (Par-

allelbetrieb)9a Anschluss fr Gasausgleich (Parallelbe-

trieb)9b Anschluss fr lausgleich (Parallelbetrieb)10 Anschluss fr lheizung11 ldruckanschluss +12 ldruckanschluss 13 Khlwasseranschluss14 Mitteldruckanschluss (MP)15 Kltemitteleinspritzung (Betrieb ohne Kl-

temittelunterkhler und mit thermostati-schem Expansionsventil)

16 Anschluss fr lberwachung (opto-elek-tronische lberwachung "OLC-K1" oderldifferenzdruckschalter "Delta-PII")

17 Kltemitteleintritt am Unterkhler

Anschlusspositionen18 Kltemittelaustritt am Unterkhler19 Klemmflche20 Stromdurchfhrungsplatte21 Wartungsanschluss fr lventil22 Druckentlastungsventil zur Atmosphre

(Druckseite)23 Druckentlastungsventil zur Atmosphre

(Saugseite)SL SauggasleitungDL Druckgasleitung

Tab.4: Anschlusspositionen

Maangaben (falls angegeben) knnen Toleranzenentsprechend ENISO13920-B aufweisen.

Legende gilt fr alle offenen und halbhermetischenBITZER Hubkolbenverdichter und enthlt Anschlusspo-sitionen, die nicht in jeder Verdichterserie vorkommen.

5 Elektrischer Anschluss

Elektrischer Anschluss der ECOLINE VARISPEED Ver-dichter:

2DES-3.F1Y

4FE-5.F1Y .. 4CE-6.F1Y

4DE-7.F3Y .. 4CE-9.F3Y

4VE-7.F3Y .. 4NE-20.F4Y

siehe beiliegende Technische Information KT-210 bzw.KT-220.

KB-104-642

Allgemeine Hinweise

Verdichter und elektrisches Zubehr entsprechen derEU-Niederspannungsrichtlinie 2006/95/EG und EU-Nie-derspannungsrichtlinie 2014/35/EU.

Netzanschluss, Schutzleiter und ggf. Brcken gemAufkleber im Anschlusskasten anschlieen. Sicher-heitsnormen EN60204, IEC60364 und nationaleSchutzbestimmungen bercksichtigen.

!!HINWEISGefahr von Kurzschluss durch Kondenswasserim Anschlusskasten!Nur genormte Kabeldurchfhrungen verwenden.Auf gute Abdichtung bei der Montage achten.

!!HINWEISGefahr von Motorschden!Falscher elektrischer Anschluss oder Betriebdes Verdichters mit falscher Spannung oderFrequenz knnen zu berlastung des Motorsfhren.Angaben auf dem Typschild beachten.Anschlsse korrekt ausfhren und auf festenSitz prfen.

5.1 Netzanschlsse

Bei der Dimensionierung von Motorschtzen, Zuleitun-gen und Sicherungen:

Maximalen Betriebsstrom bzw. maximale Leistungs-aufnahme des Motors zugrunde legen.

Schtze nach Gebrauchskategorie AC3 whlen.

berstromrelais auf maximalen Betriebsstrom desVerdichters auslegen.

5.1.1 Motorausfhrung

Stern- oder Dreieck-Motor

Standardmotor fr:

2KES-05(Y) .. 2FES-3(Y)

2EES-2(Y) .. 2CES-4(Y)

4FES-3(Y) .. 4CES-9(Y)

22EES-4(Y) .. 22CES-8(Y)

44FES-6(Y) .. 44CES-18(Y)

4FDC-5Y .. 4CDC-9Y

Dieser Motor fr Direktanlauf ist fr zwei verschiedeneSpannungen ausgelegt. Er wird mit der hheren Span-nung in Stern und mit der niederen Spannung in Drei-eck dauerhaft betrieben. Je nach gewhlter Schaltung,

Position der Schaltbrcken anpassen bzw. deren Funk-tion extern realisieren (z. B. mit Schtzen).

Teilwicklungsmotor (Part Winding)

Zeitverzgerung bis zum Zuschalten der 2. Teilwick-lung: max.0,5s!

Anschlsse korrekt ausfhren! Vertauschte Anordnungder elektrischen Anschlsse fhrt zu gegenlufigenoder im Phasenwinkel verschobenen Drehfeldern unddadurch zu Blockierung des Motors!

Standardmotor fr:

4VE(S)-6Y .. 4NE(S)-20(Y)

4JE-13Y .. 4FE-35(Y)

6JE-22Y .. 6FE-50(Y)

44VE(S)-14(Y) .. 44NE(S)-40(Y)

44JE-30(Y) .. 44FE-70(Y)

66JE-50(Y) .. 66FE-100(Y)

4VDC-10Y .. 4NDC-20Y

Wicklungsteilung 50%/50%.

Motorschtzauslegung:

1. Schtz (PW 1): 60% des max. Betriebsstroms.

2. Schtz (PW 2): 60% des max. Betriebsstroms.

Motorversion3 bei Betrieb mit externem Frequenzum-richter: Schtze auf max. Betriebsstrom bei 70 Hz aus-legen!

8GE-50(Y) .. 8FE-70(Y)

Motorausfhrung / mit Wicklungsteilung 60%/40%.

Motorschtzauslegung:

1. Schtz