KB-104-7

Semi-hermetic reciprocating compressors BITZER ECOLINE and ECOLINE VARISPEED

Translation of the original Operating Instructions
English....................................................................................................................................................... 2

Halbhermetische Hubkolbenverdichter BITZER ECOLINE und ECOLINE VARISPEED

Originalbetriebsanleitung
Deutsch ..................................................................................................................................................... 27

Compresseurs à piston hermétiques accessibles BITZER ECOLINE et ECOLINE VARISPEED

Traduction des instructions de service d'origine
Français..................................................................................................................................................... 52

2KES-05(Y) .. 2FES-3(Y) 66JE-50(Y) .. 66FE-100(Y)

2EES-2(Y) .. 2CES-4(Y) 8GE-50(Y) .. 8FE-70(Y)
22EES-4(Y) .. 22CES-8(Y) 4FDC-5Y .. 4CDC-9Y
4FES-3(Y) .. 4BES-9(Y) 4VDC-10Y .. 4NDC-20Y
44FES-6(Y) .. 44BES-18(Y) 2DES-3.F1Y
4VE(S)-6Y .. 4NE(S)-20(Y) 4FE-5.F1Y .. 4CE-6.F1Y
44VE(S)-14(Y) .. 44NE(S)-40(Y) 4DE-7.F3Y .. 4CE-9.F3Y
4JE-13Y .. 4FE-35(Y) 4VE-7.F3Y .. 4NE-20.F4Y
44JE-30(Y) .. 44FE-70(Y)
6JE-22Y .. 6FE-50(Y)

Installer
Monteur
Monteur
Table of contents

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

2 Safety .................................................................................................................................................................... 4
2.1 Authorized staff.............................................................................................................................................. 4
2.2 Residual risks ................................................................................................................................................ 4
2.3 Safety references........................................................................................................................................... 4
2.3.1 General safety references.................................................................................................................. 4

3 Application ranges ................................................................................................................................................. 5

3.1 Use of flammable refrigerants of the A2L safety group (e.g. R1234yf).......................................................... 5
3.1.1 Compressor and refrigeration system requirements.......................................................................... 6
3.1.2 General operation requirements ........................................................................................................ 6

4 Mounting................................................................................................................................................................ 6
4.1 Transporting the compressor......................................................................................................................... 6
4.2 Installing the compressor............................................................................................................................... 7
4.2.1 Vibration dampers.............................................................................................................................. 7
4.2.2 Type I vibration dampers ................................................................................................................... 8
4.2.3 Type II vibration dampers .................................................................................................................. 8
4.2.4 Type III vibration dampers ................................................................................................................. 8
4.3 Connecting the pipelines ............................................................................................................................... 9
4.3.1 Pipe connections................................................................................................................................ 9
4.3.2 Shut-off valves ................................................................................................................................... 9
4.3.3 Pipelines ............................................................................................................................................ 9
4.4 Start unloading (SU) and Capacity control (CRII) ....................................................................................... 10
4.4.1 Start unloading (SU) ........................................................................................................................ 11
4.4.2 Capacity control (CRII)..................................................................................................................... 11
4.5 Connections and connection diagrams........................................................................................................ 12
4.5.1 Connection diagrams of single compressors ................................................................................... 12
4.5.2 Connection diagrams of tandem compressors ................................................................................ 16

5 Electrical connection ........................................................................................................................................... 17

5.1 Mains connections ....................................................................................................................................... 18
5.1.1 Motor version ................................................................................................................................... 18
5.2 High potential test (insulation strength test)................................................................................................. 19
5.3 Line start permanent magnet motor (LSPM) ............................................................................................... 19
5.3.1 Overload protection for LSPM motors.............................................................................................. 19
5.4 Protection devices ....................................................................................................................................... 20
5.4.1 SE-B1 or SE-B3 ............................................................................................................................... 20
5.4.2 SE-B2 or SE-B3 ............................................................................................................................... 20
5.4.3 Differential oil pressure switch Delta-PII (option) ............................................................................. 20
5.4.4 Opto-electronic oil level monitoring OLC-K1 (option)....................................................................... 20
5.4.5 Discharge gas temperature sensor.................................................................................................. 20
5.4.6 Safety devices for pressure limiting (HP and LP) ............................................................................ 21
5.4.7 Oil heater ......................................................................................................................................... 21
5.4.8 CIC system ...................................................................................................................................... 21

6 Commissioning .................................................................................................................................................... 21
6.1 Checking the strength pressure................................................................................................................... 22

2 KB-104-7
 6.2 Checking tightness ...................................................................................................................................... 22
6.3 Evacuation ................................................................................................................................................... 22
6.4 Charging refrigerant..................................................................................................................................... 22
6.5 Checks prior to compressor start................................................................................................................. 22
6.6 Compressor start ......................................................................................................................................... 23
6.6.1 Lubrication/oil level monitoring......................................................................................................... 23
6.6.2 Oil monitoring (option)...................................................................................................................... 23
6.6.3 Vibrations and frequencies .............................................................................................................. 23
6.6.4 Cycling rate ...................................................................................................................................... 24
6.6.5 Checking the operating data ............................................................................................................ 24
6.6.6 Particular notes on safe compressor and system operation ............................................................ 24

7 Operation............................................................................................................................................................. 24
7.1 Regular checks ............................................................................................................................................ 24
7.2 Condensation water..................................................................................................................................... 24

8 Maintenance ........................................................................................................................................................ 25
8.1 Oil change.................................................................................................................................................... 25
8.2 Internal pressure relief valve........................................................................................................................ 25

9 Decommissioning ................................................................................................................................................ 26
9.1 Standstill ...................................................................................................................................................... 26
9.2 Dismantling the compressor ........................................................................................................................ 26
9.2.1 Disposing of the compressor ........................................................................................................... 26

KB-104-7 3
1 Introduction 2.3 Safety references
These refrigeration compressors are intended for incor- are instructions intended to prevent hazards. Safety ref-
poration into refrigeration systems in accordance with erences must be stringently observed!
the 2006/42/EC Machinery Directive. They may only be
put into operation if they have been installed in the refri- NOTICE
geration systems according to these Mounting/Operat-
ing Instructions and if the overall system complies with
the applicable legal provisions (applied standards: see
declaration of incorporation).
! Safety reference to avoid situations which may
result in damage to a device or its equipment.

CAUTION
The compressors have been built in accordance with Safety reference to avoid a potentially hazard-
state-of-the-art methods and current regulations. Partic- ous situation which may result in minor or mod-
ular importance was placed on user safety. erate injury.
These Operating Instructions must be kept available
near the refrigeration system during the whole lifetime WARNING
of the compressor. Safety reference to avoid a potentially hazard-
ous situation which could result in death or seri-
ous injury.
1.1 Also observe the following technical documents
KT-210: ECOLINE VARISPEED with .F1. DANGER
Safety reference to avoid an imminently hazard-
KT-220: ECOLINE VARISPEED with .F3 and .F4. ous situation which may result in death or seri-
KT-230: Compressor module for reciprocating com- ous injury.
pressors.
KW-100: Tightening torques for screw fixings. 2.3.1 General safety references

State of delivery

2 Safety CAUTION
The compressor is filled with a holding charge:
Excess pressure 0.2 .. 0.5 bar.
2.1 Authorized staff Risk of injury to skin and eyes.
All work done on compressors and refrigeration sys- Depressurize the compressor!
tems may only be performed by qualified and author- Wear safety goggles!
ized staff who have been trained and instructed accord-
ingly. The qualification and expert knowledge of the For work on the compressor once it has been
personnel must correspond to the local regulations and commissioned
guidelines.
WARNING
The compressor is under pressure!
2.2 Residual risks Serious injuries are possible.
The compressor may present unavoidable residual Depressurize the compressor!
risks. That is why any person working on this device Wear safety goggles!
must carefully read these Operating Instructions!
The following regulations shall apply: CAUTION
• relevant safety regulations and standards (e.g. Surface temperatures of more than 60°C or be-
EN 378, EN 60204 and EN 60335), low 0°C.
Risk of burns or frostbite.
• generally accepted safety rules, Close off accessible areas and mark them.
• EU directives, Before performing any work on the compressor:
switch it off and let it cool down.
• national regulations.

4 KB-104-7
3 Application ranges

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

4NDC-20Y
Permitted refriger- R134a, R404A, R407A/C/F, further HFO and HFO/ R22 R410A
ants R448A, R449A, R450A, HFC blends only after
R452A, R507A, R513A, consultation with
(Further refrigerants
R1234yf, R1234ze(E) BITZER
upon request)
Oil charge BSE32 Please contact BITZER B5.2 BSE55
BSE55 for R134a: tc > 70°C
Application limits see brochure KP-104 and BITZER software see brochure KP-101
and BITZER software
Tab. 1: Application ranges of ECOLINE compressors

Compressor types 2DES-3.F1Y .. 4NE-20.F4Y 3.1 Use of flammable refrigerants of the A2L safety
Allowed refrigerants R134a, R404A, R407A/C/F, group (e.g. R1234yf)
R448A, R449A, R450A,
(Further refrigerants Information
R452A, R507A, R513A,
upon request) The information in this chapter about the use of
R1234yf, R1234ze(E)
refrigerants of the A2L safety group refer to
Oil charge BSE32 European regulations and directives. In regions
BSE55 for R134a: tc > 70°C outside the EU, observe the local regulations.
Application limits see brochure KP-102 and
Information
BITZER software
For refrigerants of the A3 safety group, e.g.
Tab. 2: Application ranges of ECOLINE VARISPEED compressors R290 propane or R1270 propylene, specific
compressor designs can be delivered upon re-
WARNING quest. In this case, also observe the additional
Risk of bursting due to counterfeit refrigerants! Operating Instructions.
Serious injuries are possible!
Purchase refrigerants only from reputable man- This chapter describes and gives explanations to the
ufacturers and reliable distributors! additional residual risks originating from the com-
pressor when using refrigerants of the A2L safety
Risk of air penetration during operation in the vacuum group. This information helps the manufacturer of the
range system to make the risk assessment for the system.
This information may in no way replace the risk assess-
NOTICE ment for the system.

! Potential chemical reactions as well as in-

creased condensing pressure and rise in dis-
charge gas temperature.
Avoid air penetration!
Design, maintenance and operation of refrigeration sys-
tems using refrigerants of the A2L safety group are
subject to particular safety regulations.
When installed according to these Operating Instruc-
WARNING tions and in normal operation conditions without mal-
A critical shift of the refrigerant ignition limit is functions, the compressors are free from ignition
possible. sources that could ignite the flammable refrigerants
Avoid air penetration! R1234yf and R1234ze(E). They are considered as
technically tight. No ignition source assessment is
available for other refrigerants of the A2L safety group.

KB-104-7 5
 Information • Observe the max. refrigerant charge according to the
When using a flammable refrigerant: installation place and the installation zone! See
Affix the warning sign “Warning: flammable ma- EN378-1 and local regulations.
terials” (W021 according to ISO7010) well vis-
• No operation in the vacuum range! Install safety
ibly to the compressor. An adhesive label show-
devices for protection against insufficient and ex-
ing this warning sign is enclosed with the Oper-
cessive pressure and make sure that they are de-
ating Instructions.
signed in accordance with the requirements of the
safety regulations (e.g. EN378-2).
Refrigerant burning in the terminal box may only hap-
pen if several very rare errors occur at the same time. • Avoid air penetration in the system – also during and
The probability of this event occurring is extremely low. after maintenance work!
When suspecting burnt refrigerant in the terminal box,
wait at least 30 minutes before opening it. According to
3.1.2 General operation requirements
the present knowledge, this is the time needed for the
toxic combustion products to be degraded. It is neces- Operation of the system and personal protection are
sary to use appropriate, acid-resistant gloves. Do not usually subject to national regulations on product
touch moist residues, but let them dry, because they safety, operating reliability and accident prevention. To
may contain dissolved toxic substances. Never inhale this end, separate agreements between the contractor
evaporation products. Let the concerned parts be and the end user must be made. The provision of the
cleaned by trained staff or, if the parts are corroded, necessary risk assessment for work environment prior
dispose of them properly. to installation and operation of the system is the re-
sponsibility of the end user. To this end, cooperation
with a notified body is recommended.
3.1.1 Compressor and refrigeration system
requirements • To open the pipelines, use only pipe cutters and no
open flame.
DANGER
Fire hazard in the event of refrigerant leakage
and in the presence of an ignition source!
Avoid open fire and ignition sources in the en- 4 Mounting
gine room and in the hazardous zone!
Information
Observe tightening torques for screw fixings ac-
• Pay attention to the ignition point in air of the refri- cording to maintenance instructions KW-100!
gerant used, see also EN378-1.
• Vent engine room according to EN378 or install an 4.1 Transporting the compressor
extraction device.
Either transport the compressor screwed onto the pallet
• To open the pipelines, use only pipe cutters and no or lift it on the eyebolts. Lift the tandem compressor
open flame! only with a lifting beam, see figure 1, page 7.
• Install components from which refrigerant may leak
(e.g. low and high pressure limiter or low and high DANGER
pressure cut-out) only outside the switch cabinet! Suspended load!
Do not step under the machine!
If the following safety regulations and adaptions are ob-
served, the BITZER ECOLINE standard compressors
can be run with refrigerants of the A2L safety group.
Operation of BITZER VARISPEED compressors with
refrigerants of the A2L safety group only upon request.

6 KB-104-7
Fig. 1: Lifting the ECOLINE compressor

4.2 Installing the compressor NOTICE

Install/mount the compressor horizontally. Take suit-
able measures if the compressor is operated under ex-
treme conditions (e.g. aggressive atmosphere, low out-
! Do not mount the compressor solidly on the
heat exchanger!
Risk of damage to the heat exchanger (fatigue
fractures).
side temperatures, etc.). Consultation with BITZER is
recommended.
Mounting the suction gas and discharge gas lines:
Place compressor on the vibration elements or mount it
4.2.1 Vibration dampers rigidly. In this position (operational position), connect
the suction gas and discharge gas lines free of stress.
The compressor may be mounted rigidly if there is no
danger of fatigue fractures in the pipeline system con-
Transport locks for condensing units
nected to it. To do so, for compressors
To avoid transport damage to condensing units in their
• 2KES-05(Y) .. 2FES-3(Y)
state of delivery, the vibration dampers of the com-
• 2EES-2(Y) .. 2CES-4(Y) pressors are blocked by transport locks. It is absolutely
necessary to remove or loosen these locks after mount-
• 4FES-3(Y) .. 4BES-9(Y)
ing.
• 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 compressor
must be mounted on vibration dampers, see figure 2,
page 8. This is in particular required when mounting
it on shell and tube heat exchangers:

KB-104-7 7
4.2.2 Type I vibration dampers • Loosen nut (1) to such an extent that the slotted
washer (4) can be removed.
After mounting:
• Remove washer (4).
• Remove red transport lock (1).
• Retighten fixing screws and fixing nuts (2) and (3).
4.2.4 Type III vibration dampers
After mounting:
4.2.3 Type II vibration dampers
• Loosen nut (1) to such an extent that the slotted
After mounting:
washer (4) can be removed.
• Remove washer (4).

Transport Operation
3
1

Type I 2

M8

1
4

Type II 2
3
M10

1
4
2
Type III
A B 3
M10

Fig. 2: Vibration dampers

Vibration Compressor Crankcase side (A) Motor side (B)

dampers

Kit number Hardness/ Kit number Hardness/

Colour 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) 370 000 20 55 shore 370 000 20 55 shore
2DES-3.F1Y
22EES-4(Y) .. 22CES-8(Y)
• 4FDC-5Y .. 4CDC-9Y 370 000 20 55 shore 370 000 20 55 shore
4FES-3(Y) .. 4BES-9(Y)
4FE-5.F1Y .. 4CE-9.F3Y
44FES-6(Y) .. 44BES-18(Y)
Type II • 4VDC-10Y .. 4NDC-20Y 370 003 05 yellow 370 003 07 brown
4VE(S)-6Y .. 4NE(S)-20(Y)
• 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

8 KB-104-7
 Vibration Compressor Crankcase side (A) Motor side (B)
dampers

4GE-20Y, 4GE-23(Y)
4FE-25(Y)
• 4GE-30(Y) 370 004 01 brown 370 004 03 blue
4FE-28(Y) .. 4FE-35(Y)
6JE-22Y .. 6FE-50(Y)
• 8GE-50(Y) .. 8FE-70(Y) 370 004 02 red 370 004 04 black
Type 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) 2x 370 002 01 brown 2x 370 002 03 blue
44FE-56(Y), 44FE-70(Y)
• 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 • After that, retighten the packing gland and screw the
protective cap on again.
WARNING
Any installation position and flow direction can be
The compressor is under pressure!
chosen.
Serious injuries are possible.
Depressurize the compressor!
CAUTION
Wear safety goggles!
Depending on the operation mode, the shut-off
valves may become very cold or very hot.
Risk of burning or frostbite!
NOTICE

!
Wear suitable protective equipment!
Potential chemical reactions due to air penetra-
tion!
Proceed swiftly and keep shut-off valves closed NOTICE

4.3.1
until evacuation.

Pipe connections
! Do not overheat the shut-off valves!
Cool the valve body during and after the brazing
operation.
Maximum brazing temperature 700°C!
The pipe connections are suitable for pipes in all com-
mon dimensions in millimetres and inches. Brazed con- When turning or mounting shut-off valves:
nections have stepped diameters. The pipe will im-
merge more or less depending on its dimensions. If ne- NOTICE
cessary, the bushing may even be cut at the end with
the largest diameter.
! Risk of damage to the compressor.
Tighten screws crosswise in at least 2 steps to
the prescribed tightening torque.
Test tightness before commissioning!
4.3.2 Shut-off valves
During operation: Only operate the shut-off valves
either fully opened or fully closed. 4.3.3 Pipelines

• Remove the protective cap. Use only pipelines and system components which are

• First loosen the packing gland with ¼ turn to the left. • clean and dry inside (free from slag, swarf, rust and
phosphate coatings) and
• Then open or close the valve spindle.
• which are delivered with an air-tight seal.

KB-104-7 9
Depending on the compressor versions, they are sup- 4.4 Start unloading (SU) and Capacity control (CRII)
plied with blanking plates on the pipe connections or
For protection against transport damage, the valve top
shut-off valves. These plates must be removed before
parts will be delivered as accessories kit. Prior to evac-
commissioning.
uation, they must be mounted. To do so, replace the
blind flange with the top part.
NOTICE

! For systems with rather long pipelines or for

brazing operations without protective gas:
Install the suction-side cleaning filter (mesh size
< 25 μm).
WARNING
The compressor is under pressure!
Serious injuries are possible.
Depressurize the compressor!
Wear safety goggles!
NOTICE

! Risk of compressor damage!

Generously sized filter dryers should be used to
ensure a high degree of dehydration and to
maintain the chemical stability of the circuit.
To avoid mix-ups, the cylinder head and valve flange
are labelled with SU and CR, respectively. An align-
ment pin in the flange surface only allows correct posi-
Make sure to choose a suitable quality (molecu-
tioning (see figure 3, page 10).
lar sieves with specially adapted pore sizes).

Start unloading (SU)

SU

LP

HP
HP

SU HP

4VE(S)-6Y .. 4NE(S)-20(Y) 4JE-13Y .. 6FE-50(Y)

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

Capacity control (CRII)

LP
CR

CR LP CR
CR
LP HP
HP

HP
HP

HP
HP

2EES-2(Y) .. 2CES-4(Y) 4VE(S)-6Y .. 4NE(S)-20(Y) 4JE-13Y .. 6FE-50(Y) 8GE-50(Y) .. 8FE-70(Y)

4FES-3(Y) .. 4BES-9(Y) 4VDC-10Y .. 4NDC-20Y
4FDC-5Y .. 4CDC-9Y

Fig. 3: Cylinder heads for start unloading (SU) and capacity control (CRII)

Activation of the start unloading and capacity control

functions can be performed advantageously by the
compressor module CM-RC-01, see Technical Informa-
tion KT-230 and brochure KP-104.

10 KB-104-7
4.4.1 Start unloading (SU) The motor of the 8-cylinder compressor equipped with
a special winding wiring guarantees a high torque even
Option for:
in case of a part winding start. This is why no start un-
• 4VE(S)-6Y .. 4NE(S)-20(Y) loading is required for these compressors.
• 4JE-13Y .. 4FE-35(Y) Mounting position of the valve top parts for start un-
loading, see figure 4, page 11.
• 6JE-22Y .. 6FE-50(Y)
Mounting the discharge gas temperature sensor, see
• 4VDC-10Y .. 4NDC-20Y
chapter Discharge gas temperature sensor, page 20.
Retrofitting requires the cylinder head in question to be
The start unloading requires a check valve in the dis-
replaced.
charge gas line. For detailed information on the start
• 8GE-50(Y) .. 8FE-70(Y) unloading, see Technical Information KT-110.

Start unloading (SU)

SU

SU CRII SU CRII

CRII (2) CRII (1)

2 (HP) 2 (HP) 2 (HP)

4VE(S)-6(Y) .. 4NE(S)-20(Y) 4JE-13Y .. 4FE-35(Y) 6JE-22Y .. 6FE-50(Y)

4VCD-10Y .. 4NDC-20Y

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 • 4FDC-5Y .. 4CDC-9Y

• 4VDC-10Y .. 4NDC-20Y
4.4.2 Capacity control (CRII) Retrofitting requires the cylinder head in question to be
optionally for: replaced.

• 2EES-2(Y) .. 2CES-4(Y) Mounting position of the valve top parts for capacity
control, see figure 5, page 12.
• 4FES-3(Y) .. 4BES-9(Y)
• Tandem compressors: With a possible load se-
• 4VE(S)-6Y .. 4NE(S)-20(Y) quence switching in mind, both compressor parts
• 4JE-13Y .. 4FE-35(Y) should be equipped with the same number of CRII
cylinder heads, see figure 5, page 12.
• 6JE-22Y .. 6FE-50(Y)
For detailed information on the CRII system, the capa-
• 8GE-50(Y) .. 8FE-70(Y) city control for ECOLINE compressors, see Technical
• 22EES-4(Y) .. 66FE-100(Y) Information KT-101.

KB-104-7 11
 Capacity control (CRII)
CRII (3)
CRII (2) CRII (1)
CRII (2) CRII (1)

CRII (2) CRII (1)

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

4.5 Connections and connection diagrams Legend, see table 4, page 17.

4.5.1 Connection diagrams of single compressors

3 (LP) SL 1 (HP) DL
1/8-27 NPTF 1/8-27 NPTF

5/8 6 10
7/16-20 UNF M10x1,5 Ø12

Fig. 6: 2DES-3.F1Y

DL SL 3 (LP) 2 (HP) 16 1 (HP)

1/8-27 NPTF 1/8-27 NPTF M20x1,5 1/8-27 NPTF

5/8 11 6 10 12
7/16-20 UNF 7/16-20 UNF M10x1,5 Ø12 7/16-20 UNF

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

12 KB-104-7
 3 (LP) 4 DL SL 1 (HP) 2 (HP) 11 16
1/8-27 NPTF 1/8-27 NPTF 1/8-27 NPTF 1/8-27 NPTF 7/16-20 UNF M20x1,5

5/8 21 7 6 10 12
1/4-18 NPTF 1/2-14 NPTF M22x1,5 M10x1,5 Ø12 7/16-20 UNF

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

SL DL

3 (LP) 1 (HP) 6 5/8 10

1/8-27 NPTF 1/8-27 NPTF M8x1,5 7/16-20 UNF Ø11

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

3 (LP) SL 1 (HP) DL
1/8-27 NPTF 1/8-27 NPTF

5/8 6 10
7/16-20 UNF M10x1,5 Ø12

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

KB-104-7 13
 DL SL 3 (LP) 2 (HP) 1 (HP)
1/8-27 NPTF 1/8-27 NPTF 1/8-27 NPTF

5/8 16 6 10
7/16-20 UNF M20x1,5 M10x1,5 Ø12

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

DL SL 1 (HP) 2 (HP)
1/8-27 NPTF 1/8-27 NPTF

3 (LP) 4 5/8 21 6 10 16
1/8-27 NPTF 7/16-20 UNF 1/4-18 NPTF 1/2-14 NPTF M10x1,5 Ø12 M20x1,5

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

DL SL 1 (HP) 2 (HP) 16
1/8-27 NPTF 1/8-27 NPTF M20x1,5

11
7/16-20 UNF

3 (LP) 4 5/8 21 7 6 10 12
1/8-27 NPTF 1/8-27 NPTF 1/4-18 NPTF 1/2-14 NPTF M22x1,5 M10x1,5 Ø12 7/16-20 UNF

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

14 KB-104-7
 3 (LP) 4 DL SL 11 1 (HP)
1/8-27 NPTF 1/8-27 NPTF 7/16-20 UNF 1/8-27 NPTF

12
7/16-20 UNF

9a
3/4-14 NPTF

9b
1/2-14 NPTF

Ø21
2 (HP) 16 5 8 10 6/7
1/8-27 NPTF M20x1,5 1/4-18 NPTF 1/4-18 NPTF 3/8-18 NPTF M26x1,5

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

2 (HP) 3 (LP) DL SL
1/8-27 NPTF 1/8-27 NPTF
11
7/16-20 UNF

12
7/16-20 UNF

4
1/8-27 NPTF

9a
3/4-14 NPTF

9b
1/2-14 NPTF

1 (HP) 4 16 5 8 10 6/7
1/8-27 NPTF 1/8-27 NPTF M20x1,5 1/4-18 NPTF 1/4-18 NPTF 3/8-18 NPTF M26x1,5

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

DL 1 (HP) SL 2 (HP)
1/8-27 NPTF 1/8-27 NPTF

11
7/16-20 UNF

12
7/16-20 UNF

5
1/4-18 NPTF

8
1/4-18 NPTF

16 9b 9a 3 (LP) 10 6/7
M20x1,5 1/2-14 NPTF 3/4-14 NPTF 1/8-27 NPTF 3/8-18 NPTF M26x1,5

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

KB-104-7 15
4.5.2 Connection diagrams of tandem compressors Legend, see table 4, page 17.
Other connections same as in the corresponding single
compressor

3 (LP) SL DL
1/8-27 NPTF

5 8
7/16-20 UNF 1/4-18 NPTF

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

DL 2 (HP) 3 (LP) SL 2 (HP) DL 1 (HP)

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

5 8 16
7/16-20 UNF 1/8-27 NPTF M20x1,5

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

DL SL 4 DL
7/16-20 UNF

5 8 16
1/4-18 NPTF 1/8-27 NPTF M20x1,5

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

16 KB-104-7
 DL 16 5 SL 8 DL 11
M20x1,5 1/4-18 NPTF 3/8-18 NPTF 7/16-20 UNF

12
7/16-20 UNF

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

Connection positions Connection positions

1 High-pressure connection (HP) 18 Refrigerant outlet on the subcooler
2 Connection for discharge gas temperature 19 Clamping area
sensor (HP) (in 4VE(S)-6Y .. 4NE(S)-20(Y) 20 Terminal plate
alternative connection for CIC sensor)
21 Maintenance connection for oil valve
3 Low pressure connection (LP)
22 Pressure relief valve to the atmosphere
4 CIC system: Injection nozzle (LP) (pressure side)
4b Connection for CIC sensor 23 Pressure relief valve to the atmosphere
4c Connection for CIC sensor (MP / operation (suction side)
with refrigerant subcooler) 24 Compressor module
5 Oil fill plug SL Suction gas line
6 Oil drain DL Discharge gas line
7 Oil filter (magnetic screw)
Tab. 4: Connection positions
8 Oil return (oil separator)
Dimensions (if specified) may have tolerances accord-
8* Oil return for NH3 with insoluble oil
ing to EN ISO 13920-B.
9 Connection for oil and gas equalisation
(parallel operation) The legend applies to all open and semi-hermetic
BITZER reciprocating compressors and contains con-
9a Connection for gas equalisation (parallel
nection positions that do not occur in every compressor
operation)
series.
9b Connection for oil equalisation (parallel op-
eration)
10 Connection for oil heating
11 Oil pressure connection + 5 Electrical connection
12 Oil pressure connection – Electrical connection of the ECOLINE VARISPEED
13 Cooling water connection compressors:
14 Intermediate pressure connection (MP) • 2DES-3.F1Y
15 Refrigerant injection (operation without li- • 4FE-5.F1Y .. 4CE-6.F1Y
quid subcooler and with thermostatic ex-
• 4DE-7.F3Y .. 4CE-9.F3Y
pansion valve)
16 Connection for oil monitoring (opto-elec- • 4VE-7.F3Y .. 4NE-20.F4Y
tronic oil monitoring device "OLC-K1" or See enclosed Technical Information KT-210 or KT-220.
differential oil pressure switch "Delta-PII")
17 Refrigerant inlet on the subcooler

KB-104-7 17
Compressors and electrical equipment comply with the Part winding (PW) motor
EU Low Voltage Directive 2014/35/EU.
Time delay until switch-on of the 2nd part winding: max.
Connect mains cables, protective earth conductors and 0.5 s!
bridges (if needed) as specified on the labels in the ter-
Make the connections correctly! Wrong electrical con-
minal box. Observe EN60204-1, the safety standard
nections will lead to opposite fields of rotation or to
series IEC60364 and national safety regulations.
fields of rotation out of phase and therefore to a motor
lock!
NOTICE

! Risk of short-circuit due to condensation water

in the terminal box!
Use only standardised cable bushings.
When mounting, pay attention to proper sealing.
Standard motor for:
• 4VE(S)-6Y .. 4NE(S)-20(Y)
• 4JE-13Y .. 4FE-35(Y)
• 6JE-22Y .. 6FE-50(Y)
NOTICE

! Risk of motor damage!

Improper electrical connection or compressor
operation at incorrect voltage or frequency may
lead to motor overload.
• 44VE(S)-14(Y) .. 44NE(S)-40(Y)
• 44JE-30(Y) .. 44FE-70(Y)
• 66JE-50(Y) .. 66FE-100(Y)
Observe the specifications on the name plate.
• 4VDC-10Y .. 4NDC-20Y
Connect properly and check the connections for
tight fitting. Winding partition 50%/50%.
Motor contactor selection:
5.1 Mains connections
1st contactor (PW 1): 60% of the max. operating cur-
When dimensioning motor contactors, feed lines and rent.
fuses:
2nd contactor (PW 2): 60% of the max. operating cur-
• Use the maximum operating current or maximum rent.
power consumption of the motor as a basis.
Motor version 3 when operated with external frequency
• Select the contacts according to the operational cat- inverter: Select contactors for max. operating current at
egory AC3. 70 Hz!
• Set the thermal overload relays to the maximum op-
erating current of the compressor.
• 8GE-50(Y) .. 8FE-70(Y)
Motor version Δ/ΔΔ with 60%/40% winding partition.
5.1.1 Motor version
Motor contactor selection:
Star or delta motor
1st contactor (PW 1): approx. 70% of the max. operat-
Standard motor for: ing current.
• 2KES-05(Y) .. 2FES-3(Y) 2nd contactor (PW 2): approx. 50% of the max. operat-
ing current (see adhesive label in terminal box). Strictly
• 2EES-2(Y) .. 2CES-4(Y)
observe the order of the part windings!
• 4FES-3(Y) .. 4BES-9(Y)
Star-delta motor
• 22EES-4(Y) .. 22CES-8(Y)
The time delay between the switch-on of the com-
• 44FES-6(Y) .. 44BES-18(Y)
pressor and the switch-over from star to delta operation
• 4FDC-5Y .. 4CDC-9Y shall not exceed 2 s.
Make the connections correctly!
This motor has been designed for direct-on-line start at
Wrong electrical connections will lead to short-circuit!
two different voltages. The higher voltage is used for
star 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 or
have their functions performed externally (e.g. by
means of contactors).

18 KB-104-7
Option for: Safety signs attached to the compressor
• 4VE(S)-6Y .. 4NE(S)-20(Y)
WARNING
• 4JE-13Y .. 4FE-35(Y) Strong magnetic field!
Keep magnetic and magnetizable objects away
• 6JE-22Y .. 6FE-50(Y)
from compressor!
• 44VE(S)-14(Y) .. 44NE(S)-40(Y) Persons with cardiac pacemakers, implanted
heart defibrillators or metallic implants: maintain
• 44JE-30(Y) .. 44FE-70(Y)
a clearance of at least 30 cm!
• 66JE-50(Y) .. 66FE-100(Y)
Work on a compressor with LSPM motor
Upon request:
Any work on the compressor may only be performed by
• 8GE-50(Y) .. 8FE-70(Y)
persons that are not part of the specified group. Main-
tenance work beyond the work described in the present
5.2 High potential test (insulation strength test) document and in the Operating Instructions KB-104
may only be performed after consultation with BITZER.
The compressor was already submitted to a high po-
tential test in the factory according to EN12693 or ac-
WARNING
cording to UL984 or UL60335-2-34 for the UL model.
Induction, electric voltage!
Never operate the motor with the terminal box
NOTICE

!
open!
Risk of defect on the insulation and motor fail-
ure!
When the rotor rotates, electric voltage is induced in
Never repeat the high potential test in the same
the terminal pins – even with the motor switched off.
way!
Permitted work on a compressor with LSPM motor
However, a repeated test at reduced voltage of max.
1000 V AC is possible. Work on the electric supply and screw fixings in the ter-
minal box, oil change as well as inspection and re-
placement of pressure relief valves, cylinder banks and
5.3 Line start permanent magnet motor (LSPM)
sight glass. No special tools are needed for this work.
Compressors equipped with a line start permanent Before opening the compressor, thoroughly clean its
magnet motor (LSPM) can be identified by the letter "L" environment. Pay special attention to loose metal
added to the type designation (e. g. 6CTEU-50LK or particles! Do not open the motor cover!
4JTC-10LK). The built-in permanent magnets generate
a non-negligible magnetic field which, however, is shiel-
5.3.1 Overload protection for LSPM motors
ded by the compressor housing.
The PTC temperature sensor integrated in the stator as
a standard protects the LSPM motor from overload
when the temperature rises (e. g. in case of prolonged
locked rotor conditions). It is recommended installing
an additional overload protective device that reacts
more quickly, since repeated locking conditions would
damage the magnets. Be sure that it is properly sized
to ensure quick protection against serious electrical
faults below the trigger level of the compressor fuse.
For example, an overload relay with adjustable time or
Fig. 21: Warning and prohibition signs on a compressor with perman-
thermal overload switch may be selected.
ent magnet motor
• Allowed current values and durations:
– Starting: max. 0.5 s (1.25 x LRA)
– Operation: max. 2 s (1.25 x max operating cur-
rent)

KB-104-7 19
 Information 5.4.3 Differential oil pressure switch Delta-PII (option)
Manual reset of compressor protection devices
for the following compressors equipped with oil pump,
must not be changed to automatic reset by us-
incl. the respective tandem compressors:
ing external measures!
• 4VE-6Y .. 4NE-20(Y)
5.4 Protection devices • 4JE-13Y .. 4FE-35(Y)
All protective functions listed can also be assumed by • 6JE-22Y .. 6FE-50(Y)
the compressor module CM-RC-01 (motor temperature,
• 8GE-50(Y) .. 8FE-70(Y)
CIC) or connected to it (Delta PII, OLC-K1, HP, LP, oil
heater). For further information, see Technical Informa- • 4FE-5.F1Y .. 4CE-6.F1Y
tion KT-230 and brochure KP-104.
• 4DE-7.F3Y .. 4CE-9.F3Y
NOTICE • 4VE-7.F3Y .. 4NE-20.F4Y

! Potential failure of the compressor protection

device and the motor due to improper connec-
tion and/or faulty operation!
The terminals M1-M2 or T1-T2 on the com-
For the electrical connection and information on func-
tion testing, see Technical Information KT-170.

pressor and B1-B2 on the protection device as 5.4.4 Opto-electronic oil level monitoring OLC-K1
well as its two orange cables must not come (option)
into contact with the control voltage or operating
for the following compressors equipped with centrifugal
voltage!
lubrication, incl. the respective tandem compressors:
• 4FES-3(Y) .. 4BES-9(Y)
5.4.1 SE-B1 or SE-B3
• 4VES-6Y .. 4NES-20(Y)
Standard for:
• 4FDC-5Y .. 4CDC-9Y
• 2KES-05(Y) .. 2FES-3(Y)
• 4VDC-10Y .. 4NDC-20Y
• 2EES-2(Y) .. 2CES-4(Y)
For the electrical connection and information on func-
• 4FES-3(Y) .. 4BES-9(Y)
tion testing, see Technical Information KT-180.
• 4VE(S)-6Y .. 4NE(S)-20(Y)
• 2DES-3.F1Y 5.4.5 Discharge gas temperature sensor
• 4FE-5.F1Y .. 4CE-6.F1Y Option for:
• 4DE-7.F3Y .. 4CE-9.F3Y • 4FES-3(Y) .. 4BES-9(Y)
• 4VE-7.F3Y .. 4NE-20.F4Y • 4VE(S)-6Y .. 4NE(S)-20(Y)
• 4FDC-5Y .. 4CDC-9Y • 4JE-13Y .. 4FE-35(Y)
• 4VDC-10Y .. 4NDC-20Y • 6JE-22Y .. 6FE-50(Y)
• 8GE-50(Y) .. 8FE-70(Y)
5.4.2 SE-B2 or SE-B3
• 4FE-5.F1Y .. 4CE-6.F1Y
Standard for:
• 4DE-7.F3Y .. 4CE-9.F3Y
• 4JE-13Y .. 4FE-35(Y)
• 4VE-7.F3Y .. 4NE-20.F4Y
• 6JE-22Y .. 6FE-50(Y)
• 4FDC-5Y .. 4CDC-9Y
• 8GE-50(Y) .. 8FE-70(Y)
• 4VDC-10Y .. 4NDC-20Y
Both protection devices are permanently incorporated
can be retrofitted.
in the terminal box. The instrument leads for the motor
temperature sensor are wired. For further connections, • Screw the sensor element into the HP connection,
see Technical Information KT-122 or KT-210 and see chapter Connection diagrams of single com-
KT-220. pressors, page 12.

20 KB-104-7
 – Compressors with integrated start unloading: 5.4.6 Safety devices for pressure limiting (HP and LP)
The sensor must be incorporated in the start un-
• These safety devices are required for securing the
loading cylinder head (see figure 22, page 21).
compressor's application range in order to avoid un-
• Connect the instrument leads in series to the motor acceptable operating conditions.
temperature sensors (see adhesive label in terminal
• Do not connect any safety devices to the service
box) and see figure 22, page 21).
connection of the shut-off valve!

1
5.4.7 Oil heater
M2 The oil heater ensures the lubricity of the oil even after
L M1 long standstill periods. It prevents increased refrigerant
Reset
SE-B* N concentration in the oil and therefore reduction of vis-
B1
cosity.
Relais max
2,5A 250 V B2 The oil heater must be operated while the compressor
300 VA
12 is at standstill in case of
14
2 • outdoor installation of the compressor,
11
• long shut-off periods,
• high refrigerant charge,
• possible refrigerant condensation in the compressor.
4
Connection according to Technical Information KT-150.

5.4.8 CIC system

Electronically regulated liquid injection (LI) serves for
3a ensuring the application limits in low temperature ap-
3b plications using certain refrigerants such as R407F,
HP
R407A and R22. For the technical description as well
as for mounting and electrical connection information,
HP

SU

see Technical Information KT-130. An improved ver-

sion of the refrigerant injection (RI) is used together
LP

with the compressor module CM-RC-01, see Technical

HP
Information KT-230.
SU

4FES-6(Y) .. 4NE(S)-20(Y) 4JE-13Y .. 6FE-50(Y) 6 Commissioning

4VDC-10Y .. 4NDC-20Y
The compressor has been carefully dried, checked for
Fig. 22: Discharge temperature sensor for start unloading tightness and filled with a holding charge (N2) before
leaving the factory.
1 Terminal plate
2 Discharge gas temperature sensor DANGER
3 Connection position at the cylinder head Risk of explosion!
4 Safety chain Never pressurize the compressor with oxygen
(O2) or other industrial gases!

KB-104-7 21
 WARNING With the vacuum pump shut off, a "standing vacuum"
Risk of bursting! lower than 1.5 mbar must be achieved.
A critical shift of the refrigerant ignition limit is
• Repeat the operation several times if necessary.
possible in case of excess pressure.
Do not add a refrigerant (e.g. as a leak indic-
NOTICE

!
ator) to the test gas (N2 or air).
Risk of damage to the motor and compressor!
Environmental pollution in case of leakage and
Do not start the compressor while it is in a va-
when deflating!
cuum!
Do not apply any voltage, not even for testing!
NOTICE

! Risk of oil oxidation!

Check the entire system for strength pressure
and tightness, preferably using dried nitrogen
(N2).
6.4 Charging refrigerant
Use only allowed refrigerants, see table 1, page 5 and
see table 2, page 5.
When using dried air: Remove the compressor
from the circuit – make sure to keep the shut-off
DANGER
valves closed.
Risk of bursting of components and pipelines
due to hydraulic excess pressure while feeding
6.1 Checking the strength pressure liquid.
Serious injuries are possible.
Check the refrigerant circuit (assembly) according to
Avoid overcharging the system with refrigerant
EN378-2 (or other applicable equivalent safety stand-
under all circumstances!
ards). The compressor had been already tested in the
factory for strength pressure. A tightness test is there-
WARNING
fore sufficient, see chapter Checking tightness, page
Risk of bursting due to counterfeit refrigerants!
22. If you still wish to perform a strength pressure test
Serious injuries are possible!
for the entire assembly:
Purchase refrigerants only from reputable man-
ufacturers and reliable distributors!
DANGER
Risk of bursting due to excessive pressure!
NOTICE

!
The pressure applied during the test must never
Risk of wet operation during liquid feeding!
exceed the maximum permitted values!
Measure out extremely precise quantities!
Test pressure: 1.1-fold of the maximum allow-
Keep the oil temperature above 40°C.
able pressure (see name plate). Make a distinc-
tion between the high-pressure and low-pres-
◦ Before charging with refrigerant:
sure sides!
◦ Do not switch on the compressor!
6.2 Checking tightness ◦ Switch on the oil heater.
Check the refrigerant circuit (assembly) for tightness, ◦ Check the oil level in the compressor.
as a whole or in parts, according to EN378-2 (or other
• Charge condenser or receiver, on systems with
applicable equivalent safety standards). For this, create
flooded evaporator, maybe also the evaporator dir-
an excess pressure, preferably using dried nitrogen.
ectly with liquid refrigerant.
Observe test pressures and safety reference, see
• Blends must be taken out of the charging cylinder as
chapter Checking the strength pressure, page 22.
a solid liquid.
• After commissioning, it may be necessary to add re-
6.3 Evacuation
frigerant: While the compressor is running, charge
• Switch on the oil heater. with refrigerant on the suction side, preferably at the
evaporator inlet.
• Open all shut-off valves and solenoid valves.
• Use a vacuum pump to evacuate the entire system,
6.5 Checks prior to compressor start
including the compressor, on the suction side and
the high pressure side. • Oil level (within the marked sight glass area).

22 KB-104-7
• Oil temperature (approx. 15 .. 20 K above ambient 6.6.2 Oil monitoring (option)
temperature or suction-side saturation temperature).
Oil pressure monitoring
• Setting and functions of safety and protection
devices. • Protection device: Delta-PII.
• Setpoints of the time relays. • Electronic differential oil pressure switch – Option for
compressors with integrated oil pump, see chapter
• Cut-out pressure values of the high-pressure and
Differential oil pressure switch Delta-PII (option),
low-pressure switches.
page 20.
• Check if the shut-off valves are opened.
• Differential cut-out pressure: 0.65 bar.
In case of compressor replacement • Cut-out time delay when differential oil pressure is
too low: 90 s ± 5 s.
Oil is already in the circuit. It may therefore be neces-
sary to drain off some oil. For further information, see Technical Information
KT-170.
NOTICE

! In case of larger oil quantities in the refrigerant

circuit: Risk of liquid slugging when the com-
pressor starts!
Maintain the oil level within the marked sight
Oil level monitoring
• Protection device: OLC-K1.
• Opto-electronic oil level monitoring – Option for com-
glass area! pressors equipped with centrifugal lubrication, see
chapter Opto-electronic oil level monitoring OLC-K1
(option), page 20.
6.6 Compressor start
This system is recommended in particular for systems
with widely extended pipe work or in applications in
6.6.1 Lubrication/oil level monitoring
which larger quantities of oil may migrate to the suction
• Check the lubrication of the compressor directly after gas line or to the evaporator. For further details, see
the compressor start. Technical Information KT-180.
The oil level must be visible in the middle of the sight
NOTICE

!
glass (¼ to ¾ of the sight glass height).
Risk of wet operation!
• Check the oil level repeatedly within the first hours of Maintain the discharge gas temperature well
operation! above the condensing temperature: at least
20 K.
Compressor equipped with oil pump At least 30 K for R407A, R407F and R22.
• 4VE-6Y .. 4NE-20(Y)
NOTICE
• 4JE-13Y .. 4FE-35(Y)
• 6JE-22Y .. 6FE-50(Y)
• 8GE-50(Y) .. 8FE-70(Y)
! Risk of compressor failure due to liquid slug-
ging!
Before adding larger quantities of oil: check the
oil return!
• 4FE-5.F1Y .. 4CE-6.F1Y
6.6.3 Vibrations and frequencies
• 4DE-7.F3Y .. 4CE-9.F3Y
Check the system carefully to detect any abnormal vi-
• 4VE-7.F3Y .. 4NE-20.F4Y
bration. In the case of strong vibrations, take mechan-
• If necessary, check oil pressure (on the Schrader ical measures (e.g. use pipe clamps or install vibration
connections of the oil pump, using a pressure dampers).
gauge)
Speed-controlled compressors
Differential oil pressure (setpoint): 1.4 – 3.5 bar.
• 2DES-3.F1Y
Minimum allowed suction pressure (at oil pump on suc-
tion side): 0.4 bar. • 4FE-5.F1Y .. 4CE-6.F1Y
• 4DE-7.F3Y .. 4CE-9.F3Y

KB-104-7 23
• 4VE-7.F3Y .. 4NE-20.F4Y – Stable operation at all operating and load condi-
tions (also part load, summer/winter operation).
Skip frequencies that may nevertheless give rise to res-
onances in the programming of the frequency inverter. – Solid liquid at the expansion valve inlet.
• Avoid refrigerant migration (from high pressure to
NOTICE

!
low pressure side or into compressor) during longer
Risk of burst pipes and leakages on the com-
shut-off periods!
pressor and system components!
Avoid strong vibrations! – Always maintain oil heater operation when the
system is at standstill. This is valid for all applica-
tions.
6.6.4 Cycling rate
– Pump down system (especially if evaporator can
The compressor should not start more than 8 times per
get warmer than suction line or compressor).
hour. Be sure to adhere to the minimum running time:
– Automatic sequence change for systems with
Motor power Minimum running time multiple refrigerant circuits.
< 5.5 kW 2 min
Information
5.5 .. 15 kW 3 min In the case of refrigerants with low isentropic ex-
> 15 kW 5 min 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
6.6.5 Checking the operating data
and coefficient of performance.
• Evaporating temperature Arrange the temperature sensor of the expan-
sion valve as described above.
• Suction gas temperature
• Condensing temperature
• Discharge gas temperature 7 Operation
• Oil temperature
• Cycling rate 7.1 Regular checks
• Current Check the system at regular intervals according to na-
tional regulations. Check the following points:
• Voltage
• Operating data, see chapter Compressor start, page
Prepare data protocol. 23.
• Oil supply, see chapter Compressor start, page 23.
6.6.6 Particular notes on safe compressor and
system operation • Safety and protection devices and all components
for compressor monitoring (check valves, discharge
Analyses show that the vast majority of compressor gas temperature sensors, differential oil pressure
failures occur due to inadmissible operating conditions. limiters, pressure limiters, etc.).
This is especially true for failures deriving from lack of
lubrication: • Tight seat of electrical cable connections and
screwed joints.
• Expansion valve operation – pay attention to the
manufacturer's guidelines! • Screw tightening torques (see KW-100).
– Position the temperature sensor correctly at the • Refrigerant charge.
suction gas line and fasten it. • Tightness.
– When using a liquid suction line heat exchanger: • Prepare data protocol.
Position the sensor as usual after the evaporator
and not after the heat exchanger.
7.2 Condensation water
– Ensure sufficiently high suction gas superheat,
while also taking into account the minimum dis- For applications with ambient air, low suction gas su-
charge gas temperatures. perheat and/or insufficient sealing of the terminal box,
condensation water may form in the terminal box. In

24 KB-104-7
this case it’s recommended to coat the terminal plate • 4FES-3(Y) .. 4BES-9(Y)
and terminals with contact grease (e.g. Shell Vaseline
• 4FDC-5Y .. 4CDC-9Y
8401, contact grease 6432, or equivalent).
the condensing water may be drained by permanently
Furthermore for the compressors
removing the drain plug (see figure 23, page 25).
• 2KES-05(Y) .. 2FES-3(Y)
If the drain plug is removed, the enclosure class of the
• 2EES-2(Y) .. 2CES-4(Y) terminal box drops from IP65 to IP54!

Fig. 23: Drain plug for condensation water on the terminal box

8 Maintenance When using A2L refrigerants

WARNING
8.1 Oil change
Risk of refrigerant evaporation from the used oil.
Oil change is not compulsory for factory-made systems. Increased risk with A2L refrigerants due to flam-
In the case of "field installations" or operation near ap- mability!
plication limits, it is recommended to change the oil for Used oil may still contain relatively high percent-
the first time after approx. 100 operating hours. During ages of dissolved refrigerant even at atmo-
oil change, also clean oil filters and magnetic plugs (for spheric pressure.
compressors with integrated oil pump). Transport and storage Fill used oil into a pres-
sure-resistant vessel. Store under a nitrogen at-
After that, change the oil and clean oil filters and mag-
mosphere (holding charge).
netic plugs approximately every 3 years or 10,000 ..
12,000 operating hours. Oil types: see table 1, page 5
Dispose of waste oil properly!
and see table 2, page 5.

NOTICE 8.2 Internal pressure relief valve

! Damage to the compressor caused by degraded

ester oil.
Moisture is chemically bound to the ester oil and
cannot be removed by evacuation.
One pressure relief valve each built into:
• 4NE-14.F3Y and 4NE-20.F4Y
• 4JE-13Y .. 4FE-35(Y)
Proceed with extreme care:
Any penetration of air into the system and oil • 6JE-22Y .. 6FE-50(Y)
drum must be avoided under all circumstances.
Use only oil drums in their original unopened
state! 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. The

KB-104-7 25
consequences are reduced performance and a higher 9.2 Dismantling the compressor
discharge gas temperature.
WARNING
The compressor is under pressure!
Serious injuries are possible.
9 Decommissioning Depressurize the compressor!
Wear safety goggles!
9.1 Standstill
Leave the oil heater switched on until disassembly. Close the shut-off valves on the compressor. Extract
This prevents increased refrigerant concentration in the the refrigerant. Do not deflate the refrigerant, but dis-
oil. pose of it properly!
Loosen screwed joints or flanges on the compressor
WARNING
valves. Remove the compressor from the system; use
Risk of refrigerant evaporation from the oil.
hoisting equipment if necessary.
Increased risk of flammability, depending on the
refrigerant!
Shut-down compressors or used oil may still 9.2.1 Disposing of the compressor
contain rather high amounts of dissolved refri-
Drain the oil from the compressor. Dispose of waste oil
gerant.
properly! Have the compressor repaired or dispose of it
Close the shut-off valves on the compressor
properly!
and extract the refrigerant!
When returning compressors that have been operated
with flammable refrigerant, mark the compressor with
the symbol "Caution flammable gas", as the oil may still
contain refrigerant.

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Notes
80411206 // 07.2017

Subject to change
Änderungen vorbehalten
Toutes modifications réservées

BITZER Kühlmaschinenbau GmbH

Eschenbrünnlestraße 15 // 71065 Sindelfingen // Germany
Tel +49 (0)70 31 932-0 // Fax +49 (0)70 31 932-147
bitzer@bitzer.de // www.bitzer.de

Subject to change // Änderungen vorbehalten // Toutes modifications réservées // 80411206 // 07.2017