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Bitzer Installation
� Installation of compressor
�Semi Hermetic
�Open drive
� Installation of condensing unit
� Capacity regulator
� Pipe connections & fittings
Mounting_E – 1
� 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
Mounting_E – 2
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!)
Mounting_E – 3
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
Mounting_E – 4
� 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
Mounting_E – 6
� 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
Mounting_E – 7
� 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
Mounting_E – 8
� 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
Mounting_E – 9
� 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
Mounting_E – 10
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
Mounting_E – 11
� 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
Mounting_E – 12
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)
Mounting_E – 13
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
Mounting_E – 14
� 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
Mounting_E – 15
� 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
Mounting_E – 16
� 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
Mounting_E – 17
� 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
Mounting_E – 18
� 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
Mounting_E – 19
� 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
Mounting_E – 20
� 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
Mounting_E – 21
� 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
Mounting_E – 22
� 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
Mounting_E – 23
�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
Mounting_E – 24
� 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
Mounting_E – 25
� Mount cylinder head, valve plate and gaskets
�asbestos free gaskets not be oiled!
� Tighten screws in two steps in crosswise sequence
Valve Plate Replacement
Mounting_E – 26
Mounting_E – 27
End Installation Session