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5.4.2 CM-SW-01
Standard for all CSW105 compressors
The compressor module integrates the entire electronic
periphery of the compressor: It allows monitoring the
essential operating parameters of the compressor: mo-
tor and discharge gas temperature, phase and rotation
direction monitoring, oil supply and application limits
and thus protects the compressor from operation under
critical conditions. For further information, see Tech-
nical Information ST-150.
!
!
NOTICE
The compressor module may be damaged or
fail!
Never apply any voltage to the terminals of CN7
to CN12 – not even for test purposes!
The voltage applied to the terminals of CN13
must not exceed 10 V!
The voltage applied to terminal 3 of CN14 must
not exceed 24 V! Do no apply voltage to the
other terminals!
The following components are completely installed and
wired in the state of delivery:
• Slider position indicator.
• Oil monitoring (OLC-D1).
• Solenoid valves for capacity control and V
i
.
• Discharge gas temperature sensor.
• Low pressure and high pressure transmitter.
Modification to these components or their wiring is not
required and should not be done without consulting
BITZER.
The following components are not installed and wired in
the state of delivery and need to be connected:
• Motor temperature monitoring (PTC sensor in motor
winding).
• Phase monitoring (in case of a phase failure or inad-
missibly high phase asymmetry).
The compressor module internally supplies voltage to
the peripheral devices (solenoid valves, oil monitoring
device and slider position indicator) and to the terminal
strips CN7 to CN12.
Please refer to the Technical Information ST-150 for in-
formation on all connections.
5.4.3 SE-i1
This protection device with extended monitoring func-
tions can be used as an option for all HS.53 .. HS.85
compressors and CSH and CSW compressors.
Monitoring functions:
• Temperature monitoring.
• Monitoring of the PTC control circuit to detect any
short-circuit or line break/sensor failure.
• Rotation direction monitoring.
• Monitoring of phase failure and asymmetry.
• Monitoring of the maximum cycling rate.
For further information, see Technical Information
CT-110.
5.4.4 SE-E2
Optional protection device for operation with frequency
inverter and soft starter (for a ramp time shorter than
1 s).
• Dimensions and integration in the control identical to
SE-E1.
• Suitable for all CS. compressors.
• Monitoring functions are basically identical to those
of SE-E1. However, the SE-E2 monitors phase fail-
ure during the entire running time of the compressor.
For further information, see Technical Information
ST-122.
5.4.5 Monitoring of the oil circuit
• For short circuits without liquid injection (LI) for addi-
tional cooling and for small system volume and small
refrigerant charge: Indirect monitoring with oil tem-
perature sensor (standard)
!
!
NOTICE
Lack of oil leads to a too high increase in tem-
perature.
Risk of damage to the compressor!
• For circuits with liquid injection (LI) for additional
cooling and / or for great system volume as well as
parallel compounding: Monitor oil level directly with
opto-electronic oil level monitoring (option), see
chapter Opto-electronic oil level monitoring OLC-D1-
S, page 26. The connection is on the compressor
housing, see chapter Connections and dimensional
drawings, page 14, position 8.
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6.6.8 Remarques particulières pour le fonctionnement
sûr du compresseur et de l'installation
Les analyses prouvent que les défaillances du com-
presseur sont souvent dues à des modes de fonction-
nement non autorisés. Ceci vaut particulièrement pour
les dommages dus à un défaut de lubrification :
• Fonctionnement du détendeur – prendre en compte
les remarques du fabricant !
– Positionner la sonde de température correctement
au niveau de la conduite de gaz d'aspiration et la
fixer.
– Si un échangeur de chaleur interne est utilisé :
positionner normalement la sonde après l'évapo-
rateur – en aucun cas après l'échangeur de cha-
leur.
– Garantir une surchauffe suffisante du gaz d'aspi-
ration et des températures de gaz de refoulement
minimales.
– Mode de fonctionnement stable dans n'importe
quelles conditions de fonctionnement et n'importe
quel état de charge (y compris charge partielle,
fonctionnement estival/hivernal).
– Phase liquide et sans bulles à l'entrée du déten-
deur, voir avant même l'entrée du sous-refroidis-
seur de liquide en cas de fonctionnement en
mode ECO.
• Éviter tout déplacement de fluide frigorigène du côté
haute pression vers le côté basse pression ou le
compresseur en cas de temps d'arrêt prolongés !
– Toujours laisser le chauffage d'huile en marche
pendant les temps d'arrêt. Cela vaut pour toutes
les applications.
En cas d'installation dans des zones de basses
températures, il peut être nécessaire d'isoler le
séparateur d'huile. Au démarrage du compres-
seur, la température de l'huile mesurée sous le
voyant d'huile doit être de 15 .. 20 K au-dessus de
la température ambiante.
– Commutation de séquences automatique sur les
installations avec circuits frigorifiques multiples
(env. toutes les 2 heures).
– Monter un clapet de retenue additionnel dans la
conduite de gaz de refoulement si en cas d'arrêts
prolongés, aucune égalisation de température ou
de pression n'est atteinte.
– Le cas échéant, monter une commande par pump
down commandée en fonction du temps ou de la
pression ou un séparateur de liquide à l'aspiration
– en particulier en cas de grande contenance en
fluide frigorigène et/ou quand l'évaporateur est
susceptible de chauffer plus que la conduite de
gaz d'aspiration ou le compresseur.
• Pour d'autres remarques relatives à la pose de la
tuyauterie, se reporter au manuel SH-170.
Information
Pour les fluides frigorigènes à faible exposant
isentropique (p. ex. R134a), un échangeur de
chaleur entre les conduites de gaz de refoule-
ment et de fluide peut avoir un effet positif sur le
fonctionnement et le coefficient de performance
de l'installation.
Ajuster la sonde de température du détendeur
comme décrit ci-dessus.
7 Fonctionnement
7.1 Contrôles réguliers
Contrôler régulièrement l’installation conformément aux
réglementations nationales. Contrôler en particulier les
points suivants :
• Caractéristiques de fonctionnement, voir chapitre
Démarrage du compresseur, page 95.
• Alimentation d’huile, voir chapitre Démarrage du
compresseur, page 95.
• Dispositifs de protection et toutes les pièces servant
à contrôler le compresseur (clapets de retenue, limi-
teur de température du gaz de refoulement, presso-
stat différentiel d’huile, limiteur de pression, etc.).
• S’assurer que les connexions des câbles et les as-
semblages à vis sont suffisamment serrés.
• Pour le couple de serrage des assemblages à vis, se
reporter à SW-100.
• Contrôler la charge de fluide frigorigène.
• Essai d’étanchéité.
• Soigner le procès-verbal.
– При необходимости примените регулируемую
по времени и давлению систему откачки или
установите отделитель жидкости на линии
всасывания – особенно для систем с большой
заправкой хладагентом и/или, если испаритель
может стать теплее, чем линия всасывания или
компрессор.
• Дополнительную информацию – в том числе в
отношении прокладки труб смотрите в руководстве
SH-170.
Информация
При использовании хладагентов, имеющих
низкие показатели изоэнтропы (например,
R134a), применение теплообменника между
линией всасывания и жидкостной линией
может положительно сказаться на режиме
эксплуатации и энергоэффективности системы.
Термобаллон ТРВ размещайте так, как указано
выше.
7 Эксплуатация
7.1 Регулярные проверки
Регулярно проводите проверки системы в соответствии
с национальными предписаниями. Проверяются
следующие позиции:
• Рабочие параметры, смотрите главу Запуск
компрессора, стр. 95.
• Смазка/контроль масла, смотрите главу Запуск
компрессора, стр. 95.
• Защитные устройства и все компоненты,
предназначенные для контроля работы компрессора
(обратные клапаны, датчик температуры газа на
нагнетании, реле перепада давления масла, реле
давления и т.д.).
• Проверка надежности подключения электрических
кабельных соединений и винтовых соединений.
• Моменты затяжки см. в SW-100.
• Проверка на плотность.
• Ведите протокол данны
6.6.8 Особые указания для надежной
эксплуатации компрессора и агрегата
Анализ показывает, что подавляющее большинство
отказов компрессоров происходит из-за недопустимых
условий эксплуатации. Это в особенности относится к
повреждениям, возникающим вследствие недостатка
смазки:
• Функционирование расширительного клапана -
соблюдайте указания производителя!
– Правильно располагайте и закрепляйте
термобаллон на линии всасывания.
– При использовании внутреннего
теплообменника располагайте датчик как
обычно за испарителем, но ни в коем случае не
за теплообменником.
– Достаточно высокий перегрев, при этом также
учитывайте минимальную температуру газа на
нагнетании.
– Стабильный рабочий режим при всех рабочих
состояниях и нагрузках (также при частичной
нагрузке, в летнем и зимнем режимах).
– Сплошная (без пузырьков) жидкость на
входе расширенного клапана; при работе с
экономайзером, уже на входе в переохладитель
жидкости.
• При длительных периодах простоя избегайте
миграции хладагента со стороны высокого
давления на сторону низкого давления или в
компрессор!
– Подогреватель масла должен быть постоянно
включен во время стоянки компрессора (это
относится ко всем применениям).
При установке в районах с низкой температурой
окружающей среды может потребоваться
теплоизоляция маслоотделителя. При запуске
компрессора температура масла, измеренная
под смотровым стеклом, должна на 15 .. 20 К
превышать температуру окружающей среды.
– Автоматическое переключение
последовательности в системах с несколькими
контурами хладагента (примерно каждые 2
часа).
– Установите дополнительный обратный клапан
на линию нагнетания, если в течение долгих
периодов простоя не достигается выравнивание
температуры и давления.
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6.6.7 Control logic requirements
!
!
NOTICE
Risk of motor failure!
The specified requirements must be ensured by
the control logic!
• Desirable minimum running time: 5 minutes!
• Switching the compressor off:
When using a star-delta motor, shut it off from the
25%-CR stage!
• Minimum standstill time:
– 5 minutes (CSW105: 10 minutes).
This is the time the control slider needs to reach
the optimal start position.
– 1 minute.
Only if the compressor has been shut off from the
25%-CR stage!
– Also observe minimum standstill times during
maintenance work!
• Maximum cycling rate:
– CS.65 and CS.75: max. 6 starts per hour.
– CS.85, CS.95 and CSW105: max. 4 starts per
hour.
• Switching time of the motor contactors:
– Part winding: 0.5 s.
– Star-delta: 1 to 2 s for CS.65, CS.75 and CS.85.
– Star-delta: 1.5 to 2 s for CS.95 and CSW105.
6.6.8 Particular notes on safe compressor and
system operation
Analysis show that compressor failures are most often
due to an inadmissible operating mode. This applies
especially to damage resulting from lack of lubrication:
• Function of the expansion valve – observe the manu-
facturer's notes!
– Position the temperature sensor correctly at the
suction gas line and fasten it.
– When using a liquid suction line heat exchanger:
Position the sensor as usual after the evaporator
and not after the heat exchanger.
– Ensure sufficiently high suction gas superheat,
while also taking into account the minimum dis-
charge gas temperatures.
– Stable operating mode under all operating and
load conditions (also part-load, summer/winter op-
eration).
– Solid liquid at the expansion valve inlet, during
ECO operation already before entering the liquid
subcooler.
• Avoid refrigerant migration from the high-pressure
side to the low-pressure side or into the compressor
during long shut-off periods!
– Always maintain oil heater operation when the
system is at standstill. This is valid for all applica-
tions.
When installing the system in zones where the
temperatures are low, it may be necessary to in-
sulate the oil separator. At compressor start, the
oil temperature, that is measured under the oil
sight glass, should be 15 .. 20 K above the ambi-
ent temperature.
– Automatic sequence change for systems with sev-
eral refrigerating circuits (approximately every 2
hours).
– Mount an additional check valve in the discharge
gas line if no temperature and pressure compens-
ation is reached even after long standstill times.
– If needed, mount a time and pressure-dependant
controlled pump down system or liquid separators
on the suction side – particularly for high refriger-
ant charges and/or when the evaporator may be-
come hotter than the suction gas line or the com-
pressor.
• For further information about pipe layout, see
manual SH-170.
Information
In the case of refrigerants with low isentropic ex-
ponent (e.g. R134a), a heat exchanger between
the suction gas line and the liquid line may have
a positive effect on the system's operating mode
and coefficient of performance.
Arrange the temperature sensor of the expan-
sion valve as described above.
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6.6.7 Control logic requirements
!
!
NOTICE
Risk of motor failure!
The specified requirements must be ensured by
the control logic!
• Desirable minimum running time: 5 minutes!
• Switching the compressor off:
When using a star-delta motor, shut it off from the
25%-CR stage!
• Minimum standstill time:
– 5 minutes (CSW105: 10 minutes).
This is the time the control slider needs to reach
the optimal start position.
– 1 minute.
Only if the compressor has been shut off from the
25%-CR stage!
– Also observe minimum standstill times during
maintenance work!
• Maximum cycling rate:
– CS.65 and CS.75: max. 6 starts per hour.
– CS.85, CS.95 and CSW105: max. 4 starts per
hour.
• Switching time of the motor contactors:
– Part winding: 0.5 s.
– Star-delta: 1 to 2 s for CS.65, CS.75 and CS.85.
– Star-delta: 1.5 to 2 s for CS.95 and CSW105.
6.6.8 Particular notes on safe compressor and
system operation
Analysis show that compressor failures are most often
due to an inadmissible operating mode. This applies
especially to damage resulting from lack of lubrication:
• Function of the expansion valve – observe the manu-
facturer's notes!
– Position the temperature sensor correctly at the
suction gas line and fasten it.
– When using a liquid suction line heat exchanger:
Position the sensor as usual after the evaporator
and not after the heat exchanger.
– Ensure sufficiently high suction gas superheat,
while also taking into account the minimum dis-
charge gas temperatures.
– Stable operating mode under all operating and
load conditions (also part-load, summer/winter op-
eration).
– Solid liquid at the expansion valve inlet, during
ECO operation already before entering the liquid
subcooler.
• Avoid refrigerant migration from the high-pressure
side to the low-pressure side or into the compressor
during long shut-off periods!
– Always maintain oil heater operation when the
system is at standstill. This is valid for all applica-
tions.
When installing the system in zones where the
temperatures are low, it may be necessary to in-
sulate the oil separator. At compressor start, the
oil temperature, that is measured under the oil
sight glass, should be 15 .. 20 K above the ambi-
ent temperature.
– Automatic sequence change for systems with sev-
eral refrigerating circuits (approximately every 2
hours).
– Mount an additional check valve in the discharge
gas line if no temperature and pressure compens-
ation is reached even after long standstill times.
– If needed, mount a time and pressure-dependant
controlled pump down system or liquid separators
on the suction side – particularly for high refriger-
ant charges and/or when the evaporator may be-
come hotter than the suction gas line or the com-
pressor.
• For further information about pipe layout, see
manual SH-170.
Information
In the case of refrigerants with low isentropic ex-
ponent (e.g. R134a), a heat exchanger between
the suction gas line and the liquid line may have
a positive effect on the system's operating mode
and coefficient of performance.
Arrange the temperature sensor of the expan-
sion valve as described above.
