Table of contents

1 Introduction ....................................................................................................................................................... 46

2 Safety.................................................................................................................................................................. 48

3 Start with frequency inverter (FI) ..................................................................................................................... 49

3.1 Application with BITZER compressors........................................................................................................ 49

4 Start with electronic soft starter (ESS)............................................................................................................ 54

4.1 Application with BITZER compressors........................................................................................................ 55

5 Direct-on-line start in star or in delta wiring (Y or Δ)..................................................................................... 61

5.1 Application with BITZER compressors........................................................................................................ 61

6 Star-delta start (Y/Δ).......................................................................................................................................... 65

6.1 Application with BITZER compressors........................................................................................................ 66

7 Part winding start (PW start, Y/YY or Δ/ΔΔ) ................................................................................................... 73

7.1 Application with BITZER compressors........................................................................................................ 75

8 Additional start unloading (SU) ....................................................................................................................... 81

8.1 Application with BITZER reciprocating compressors ................................................................................. 81
8.2 Application with BITZER screw compressors ............................................................................................. 85

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1 Introduction
This document gives an overview of the starting modes for BITZER compressors. The reason for developing differ-
ent starting modes for larger motors is the high starting current when they are operated and switched on directly at
the mains connection (direct-on-line start): At the moment of switching on, starting currents occur that can be sev-
eral times the nominal operating current (typically: 600 ... 800%) and both load the motor and disturb the power
supply system. To avoid this, different methods are used in refrigeration systems to limit the starting current. The
following are presented in this document:
• see chapter Start with frequency inverter (FI), page 49
• see chapter Start with electronic soft starter (ESS), page 54
• see chapter Direct-on-line start in star or in delta wiring (Y or Δ), page 61
• see chapter Star-delta start (Y/Δ), page 65
• see chapter Part winding start (PW start, Y/YY or Δ/ΔΔ), page 73
Some of these starting modes may be combined with start unloading (see chapter Additional start unloading (SU),
page 81). Further starting modes such as resistance start are not mentioned here, because they are not intended
for BITZER compressors.
For further information read and observe the operating instructions for the respective compressor!

Methods to reduce the starting current for BITZER compressors

Type of motor Start with FI Start with ESS Direct-on-line Y/Δ start PW start
start in Y or Δ
wiring
Y or Δ motor not possible not possible
Y/Δ motor not possible
PW motor not possible
LSPM motor not possible not possible
Link to chapter see chapter Ap- see chapter Ap- see chapter Ap- see chapter Ap- see chapter Ap-
plication with plication with plication with plication with plication with
BITZER com- BITZER com- BITZER com- BITZER com- BITZER com-
pressors, page pressors, page pressors, page pressors, page pressors, page
49 55 61 66 75
Tab. 1: Motors in BITZER compressors and possible methods to reduce the starting current
: starting current not reduced
: starting current significantly reduced
: starting current strongly reduced

The LSPM motor consists of an asynchronous motor part for starting and a synchronous motor part for normal op-
eration. Due to the limited space in the rotor, the size of the asynchronous motor is also limited, as is the starting
current and the starting torque. During the start, the synchronous motor part generates a torque opposite to the
starting torque of the asynchronous motor. If the asynchronous part of the torque is reduced further, the motor will
not start. A significantly reduced starting current of the LSPM motor is therefore only possible with a frequency in-
verter, not with a soft starter.
Which motors are available for which compressors can be found in the following documents:
• KT-410: Motorcodes for BITZER reciprocating compressors
• ST-410: Motorcodes for BITZER screw compressors
• EST-410: Motorcodes for BITZER scroll compressors

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In the terminal box cover of the BITZER compressors, an adhesive label shows the intended electrical connection
or starting mode:

Fig. 1: Terminal box of a BITZER reciprocating compressor. The adhesive label in the cover shows i.a. the correct connection of the mains
phases to the motor pins for star-delta start and direct-on-line start in delta and star wiring (from left to right).

Schematic wiring diagrams for BITZER compressors are compiled in the Technical Information AT-300.

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2 Safety

Authorized staff
All work done on the products and the systems in which they are or will be installed may only be performed by
qualified and authorised staff who have been trained and instructed in all work. The qualification and competence
of the qualified staff must correspond to the local regulations and guidelines.

Residual risks
The products, electronic accessories and further system components may present unavoidable residual risks.
Therefore, any person working on it must carefully read this document! The following are mandatory:
• relevant safety regulations and standards
• generally accepted safety rules
• EU directives
• national regulations and safety standards
Example of applicable standards: EN378, EN60204, EN60335, EN ISO14120, ISO5149, IEC60204, IEC60335,
ASHRAE 15, NEC, UL standards.

Personal protective equipment

When working on systems and their components: Wear protective work shoes, protective clothing and safety
goggles. In addition, wear cold-protective gloves when working on the open refrigeration circuit and on components
that may contain refrigerant.

Fig. 2: Wear personal protective equipment!

Safety references
Safety references are instructions intended to prevent hazards. They must be stringently observed!

NOTICE

! Safety reference to avoid situations which may result in damage to a device or its equipment.

CAUTION
Safety reference to avoid a potentially hazardous situation which may result in minor or moderate injury.

WARNING
Safety reference to avoid a potentially hazardous situation which could result in death or serious injury.

DANGER
Safety reference to avoid an imminently hazardous situation which may result in death or serious injury.

In addition to the safety references listed in this document, it is essential to observe the references and residual
risks in the respective operating instructions!

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3 Start with frequency inverter (FI)
A frequency inverter can increase the speed steplessly - and thus not only fine-tune the compressor's cooling capa-
city, but also control a stepless start. In contrast to part winding and star-delta start, the full torque is available here
even with lower current consumption, since the voltage-frequency ratio is constant. Unlike a soft starter, a fre-
quency inverter can also be used with LSPM motors (see chapter Introduction, page 46).
For detailed informationen see the following documents:
• KT-420: Operation of BITZER reciprocating compressors with external frequency inverters
• ST-420: Operation of BITZER screw compressors with external frequency inverters
• EST-420: Operation of BITZER scroll compressors with external frequency inverters

3.1 Application with BITZER compressors

All BITZER compressors are designed for operation in a wide frequency range and can therefore in principle be op-
erated with frequency inverters. With the VARIPACK, BITZER also offers its own frequency inverter. It was spe-
cially developed for capacity control of BITZER compressors and, in addition to speed control, can also cover con-
trol and regulation functions of the refrigeration system. In addition, BITZER offers compressors with integrated fre-
quency inverters:
• Reciprocating compressors ECOLINE VARISPEED (see brochure KP-100)
• Screw compressors series CSV. (see brochure SP-170)

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Information in the BITZER SOFTWARE
In the BITZER SOFTWARE, many compressors can already be designed with frequency inverter ("Capacity con-
trol" - "External FI").

Fig. 3: Designing a reciprocating compressor with external frequency inverter (FI)

Overload capacity
The frequency inverter needs a certain overload capacity to provide the required starting current and to start the
compressor. When designing a VARIPACK in the BITZER SOFTWARE, this is automatically taken into account.
When designing other frequency inverters, the notes in the documents mentioned below should be taken into ac-
count.
The starting current of the compressor (FI output side) is compensated on the mains side (FI input side) by the DC
link of the frequency inverter. The inverter must provide the starting current with a correspondingly low frequency
(and thus voltage). Since the full supply voltage is present at the input of the frequency inverter, the resulting cur-
rent on the mains side is correspondingly lower. It can be assumed that the line-side current of the frequency in-
verter does not exceed the maximum operating current of the inverter during compressor start, so that there is no
starting current peak.
Detailed information e.g. on permitted frequency ranges and application limits, overload capacity and recommen-
ded motor versions can be found in the BITZER SOFTWARE as well as in the following documents:
• KT-420: Operation of BITZER reciprocating compressors with external frequency inverters

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• ST-420: Operation of BITZER screw compressors with external frequency inverters
• EST-420: Operation of BITZER scroll compressors with external frequency inverters
• CB-110: Operating instructions VARIPACK – external BITZER frequency inverters

NOTICE

! Compressor and motor damage!

Do not combine a frequency inverter with mechanical capacity control of the compressor! Especially at low
speed, adequate motor cooling is not guaranteed because refrigerant mass flow is heavily reduced. Certain
exceptions for screw compressors are possible in consultation with BITZER.

Setting in the BEST SOFTWARE

When using the compressor modules CM-RC or CM-SW, they must be integrated according to the schematic wir-
ing diagrams in the Technical Information KT-230 (for CM-RC) or ST-150 (for CM-SW). The starting mode can be
set in the BEST SOFTWARE:

Fig. 4: Choosing the starting mode in the BEST SOFTWARE, here with CM-SW-01.

In order to optimally adapt the phase monitoring to the starting mode (frequency inverter or soft starter) and to
avoid false cut-outs, the motor starting mode must or can also be configured with the SE-i1 in the future.

Arrangement of the wiring in the terminal box of the compressor

WARNING
Risk of electric shock!
Before performing any work in the terminal box: Switch off the main switch and secure it against being
switched on again!
Close the terminal box before switching on again!

In the terminal box cover of the BITZER compressors, an adhesive label shows the possible starting modes and
the respective connection of the mains phases to the motor pins. For start with a frequency inverter (direct-on-line
start), the cable bridges supplied may have to be mounted.

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Arrangement of the wiring for reciprocating compressors:

9 3 L3 L3 W Y

FI FI
8 2 L2 L2 V X
FU FU
CF L1 CF
7 1 L1 U Z

40P motor 40S motor in star wiring

Fig. 5: Motor terminals at the terminal plate for operation with external frequency inverter (FI), examples for reciprocating compressors

Arrangement of the wiring for screw compressors:

L1 7
3 9 L3
FI 1
FI
L2 FU 8
2 8 FU L2
CF 2
L3 9 CF
1 7 L1
3

HS.85 / CS.85 HS.53 / CS.65

PW motor PW motor

Fig. 6: Motor terminals at the terminal plate for operation with external frequency inverter (FI), examples for screw compressors

Schematic wiring diagrams

In the schematic wiring diagram the operation with a frequency inverter is e.g. depicted like this:

1 2 3 4 5

L1
L2
L3
PE F01 1
0
Q01 F02

3!

K01
K01

T02
K19
STO
K18

3!

F08
1A FF

M01

M
3!

Fig. 7: Start with frequency inverter for an OS.95 screw compressor

T02: frequency inverter
M01: motor

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Schematic wiring diagrams for BITZER compressors are compiled in the Technical Information AT-300.

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4 Start with electronic soft starter (ESS)
The soft starter reduces the starting current for the motor by increasing the motor voltage up to the nominal value
according to predefined functions. Compared to direct-on-line start, starting current peaks and torque surges are
reduced. This is usually implemented with phase-angle control of the sine half-waves: Each half-wave of the AC
voltage is not switched through to the motor with the zero crossing, but later. The resulting reduced root mean
square (RMS) of the voltage is increased in a ramp up to the full supply voltage.

TOR
U

Fig. 8: Soft starter: phase angle control and bypass contact (TOR: top of ramp, full sine half-waves).

2- or 3-phase controlled
A distinction is made between 2-phase and 3-phase controlled soft starters depending on the structure of the
power sections.

2-phase controlled soft starter 3-phase controlled soft starter

• mostly for lower motor power • mostly for higher motor power
• only in line connection possible • more extensive parameterisation
• higher unbalance of the starting currents • lower starting current than with 2-phase controlled soft starter
• cheaper to buy • depending on type, in line and inside delta connection possible
Tab. 2: Comparison of 2- and 3-phase controlled soft starters

L1 L2 L3
U (L1 .. L3)

M3~

Fig. 9: Schematic structure of a 2-phase controlled soft starter with integrated bypass contacts

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With 3-phase controlled soft starters, 2 different wirings are possible:

In line connection (standard con- Inside delta connection (root 3 connection, √3 connection)
nection)
• Corresponds to direct-on-line start, • Only possible with star-delta motors in delta wiring. The motor wind-
3 cables are led to the motor. ings are connected in series with the thyristors (term from "thyratron"
and "transistor") in delta, 6 cables are led to the motor.
• Load contactors can be dispensed
with for devices with safe torque off • The soft starter is only loaded with 58% (1/√3) of the current and can
(STO). be designed accordingly for a lower current.
• Requires a 3-phase controlled soft starter and is only supported by
some manufacturers and types.
Tab. 3: Soft starter: In line connection and inside delta connection

3-phase controlled soft starter

Inside delta connection (root 3 connection)

In line connection (standard connection) L1 L2 L3

L1 L2 L3

Fig. 10: Comparison of in line vs. inside delta connection of a 3-phase controlled soft starter

Soft starter vs. frequency inverter

Purchase and maintenance costs are lower for soft starters than for frequency inverters, but a soft starter is less
flexible: It can only be used for starting and not for part load operation, for example. In addition, the soft starter (un-
like the frequency inverter) also reduces the torque of the motor, and the lower starting torque may not be sufficient
to start the motor against high condensing pressure if the configuration is unfavourable.

4.1 Application with BITZER compressors

BITZER does not offer its own soft starters and can therefore only give general recommendations. All BITZER com-
pressors with motors designed for asynchronous start directly powered from the supply network can be operated
with soft starters. With LSPM motors, however, experience has shown that the advantage of combining it with a
soft starter is very limited compared to a standard asynchronous motor. In addition, the soft starter must be care-
fully adjusted, as too low a starting voltage could prevent the LSPM motor from starting.

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 Type of soft starter
Usually a 3-phase controlled soft starter is advantageous. Furthermore, to avoid potential problems with the rota-
tion direction monitoring of the compressor protection device, an inside delta connection is recommended: It allows
the rotation direction monitoring to be connected to the side of the phases not directly controlled by the soft starter.
For this, however, the soft starter must not switch on the contactor of the directly controlled phase until directly or
shortly before the compressor starts and switch off immediately when the compressor stops or a fault occurs. Oth-
erwise, the module will interpret the operating conditions of the compressor incorrectly. Especially with open drive
and semi-hermetic screw compressors, this can lead to incorrect control of the oil solenoid valve (with the risk that
the compressor is flooded with oil) or to erroneous fault shutdowns.

L1 L2 L3

L3

Fig. 11: Recommended connection of the rotation direction monitoring to the 3-phase controlled soft starter with inside delta connection: either
at the points of the red circles or the blue ellipse.

Based on customer experience, BITZER is continuously developing the rotation direction monitoring to make it
generally reliable and robust for the various soft starters and configuration options. However, should false shut-
downs and difficulties occur, an individual reaction and adapted configuration is possible at least for the com-
pressor modules CM-SW, CM-RC and the SE-i1 protection device. In such a case, please consult BITZER.

Configuration of the soft starter

First of all, the name plate data of the compressor are decisive.
• For hermetic and semi-hermetic compressors, sizing to the compressor's max. operating current (see name
plate) should be sufficient.
• With open drive compressors, experience has shown that in order to ensure a safe start, the soft starter must
be significantly oversized due to the necessary construction size resp. the high mass moment of inertia of the
external motor.
Many soft starters offer different starting modes and configuration options: from the classic "voltage ramp" and
"constant current control" to "current ramp", "torque control", "adaptive control" and special pre-configurations for
compressors, pumps or ventilators. Since the different starting modes in turn require the configuration of various
further parameters, a general recommendation is hardly possible. If a pre-configuration for compressors is avail-
able, this often offers a good result. Alternatively, there is good experience with the "voltage ramp".
The most important parameters for configuration are:
• Voltage/current ramp: The initial voltage of the soft starter is set in % of the nominal voltage or the initial cur-
rent of the soft starter in % of the nominal operating current. Good experience is available for approx. 40%.
• Ramp/run-up time: If ramp times are too short, the output voltage rises faster than the compressor needs to run
up. Unnecessarily long ramp times can lead to malfunctions in the compressor protection device (rotation direc-
tion monitoring) and problems with oil management and lubrication. It should be noted that the motor does not
necessarily start at the end of the ramp time, but as soon as it receives sufficient current.

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 – For hermetic and semi-hermetic compressors, approx. 3 s have proven to be useful,
– with (large) open drive compressors, up to 7 s are required for a reliable start.
• Current limitation in % of the max. operating current: To ensure that the motor starts safely, it should be set to
min. 300%, with open drive compressors to min. 600%.
• There is no need to set a run-down time, as the compressor comes to a standstill quickly by itself when it is
switched off due to the back pressure.
If detailed measurements on the system are possible, the soft starter should be set to minimise the amplitude of the
current and the time until the motor starts. The compressor must still start safely even with unfavourable pressure
ratios.
If there is no experience with the design of soft starters of the desired type, BITZER recommends asking the re-
spective manufacturer for support.

Combination with compressor protection devices

BITZER recommends the compressor protection devices SE-G1, its successor SE-G4, SE-i1 and the compressor
module CM-SW for operation with soft starters.
• Reciprocating compressors are equipped with compressor protection devices without rotation direction monit-
oring.
• Screw compressors: BITZER recommends the SE-i1 protection device, especially for larger screw com-
pressors, which may require longer ramp times than smaller ones due to their higher inertia. In case of diffi-
culties with the rotation direction monitoring, the corresponding alarms on the SE-i1 can be delayed (after con-
sultation) to ensure reliable operation of the compressor. This is also possible when using the compressor mod-
ule CM-SW-01. For soft starters with inside-delta connection, there should be no problems if the rotation direc-
tion monitoring is connected to the directly connected side of the motor winding - in this case, a normal protec-
tion device such as SE-E1 and its successor SE-E4 can also be used. (The SE-E2 is only suitable for start with
frequency inverter.)
• Scroll compressors: If a protection device with rotation direction and phase failure monitoring is desired, the
SE-G1 and its successor SE-G4 can be used with soft starters.

NOTICE

! Compressor protection device may fail after too high voltage has been applied. Possible subsequent fault:
compressor failure.
The cables and terminals of the temperature control circuit must not come into contact with the control
voltage or operating voltage!

Mind label in terminal box cover. Observe the notes.

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Comparison of starting currents
As an example, the following 2 figures show the starting currents for a typical CS. compressor with soft starter vs.
star-delta start. The starting current resulting from the use of the soft starter can vary greatly depending on the type
and configuration.
The starting current indicated in the BITZER SOFTWARE is the RMS value (root mean square value) of the cur-
rent. To derive this from the oscillogram, the current must be divided by √2.

Fig. 12: Starting current (peak value) for a screw compressor model CSW10593-360Y with soft starter. Its max. operating current is 565 A.

Fig. 13: Starting current (peak value) for a screw compressor model CSW10593-360Y with star-delta start. The starting current (Rotor locked) is
955 A (star) / 2913 A (delta).

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Setting in the BEST SOFTWARE
When using the compressor modules CM-RC or CM-SW, they must be integrated according to the schematic wir-
ing diagrams in the Technical Information KT-230 (for CM-RC) or ST-150 (for CM-SW). The starting mode can be
set in the BEST SOFTWARE:

Fig. 14: Choosing the starting mode in the BEST SOFTWARE, here with CM-SW-01.

In order to optimally adapt the phase monitoring to the starting mode (frequency inverter or soft starter) and to
avoid false shutdowns, the starting mode must resp. can be configured in the future also with the SE-i1.

Arrangement of the wiring in the terminal box of the compressor

WARNING
Risk of electric shock!
Before performing any work in the terminal box: Switch off the main switch and secure it against being
switched on again!
Close the terminal box before switching on again!

In the terminal box cover of BITZER compressors, an adhesive label shows the possible starting modes and the re-
spective connection of the mains phases to the motor pins. For a start with soft starter (as for a direct-on-line start),
the cable bridges supplied may have to be mounted.

ORBIT8 (GSD8)
+ SE-B* ORBIT6 (GSD6)

M1 1
L3 L1
L2
M1 M2
L1
L3 L2

M2 2
1 2

Fig. 15: Motor connection for start with a soft starter for BITZER scroll compressors (examples). For these, no other connections are possible.

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Schematic wiring diagrams
In the schematic wiring diagram a start with soft starter is depicted like this, for example:

1 2 3 4

L1
L2
L3
N F1 1
PE 0
F2
Q1

K1
10
F13
10

N3 B1

1
2 M3~
3

R1..6

Fig. 16: Start with soft starter for an ORBIT scroll compressor
N3: soft starter
K1: compressor contactor
M: motor

Schematic wiring diagrams for BITZER compressors are compiled in the Technical Information AT-300.

Mass moments of inertia for screw compressors

The mass moments of inertia are relevant for the configuration of the soft starter and mey be requested by the soft
starter manufacturers.

Compressor Mass moment of inertia [kg*m²]

male rotor (driven) female rotor (not driven)
OS. compressors
OS8571 (with coupling) 0.122 0.023
OS8581 (with coupling) 0.138 0.023
OS8591 (with coupling) 0.222 0.035
OS9573 0.186 0.065
OS9583 0.204 0.076
OS9593 0.240 0.099
OS95103 0.263 0.112
CS. compressors (incl. rotor)
CS.6563 0.043 0.003
CS.7573 0.087 0.012
CSH7593 0.112 0.015
CSH8573 0.165 0.023
CSH8593 0.183 0.025
CSH9573 0.491 0.057
CSH9593 0.583 0.064

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 Compressor Mass moment of inertia [kg*m²]
male rotor (driven) female rotor (not driven)
CS.95113 0.700 0.060
CSW10593 1.51 0.34
HS. compressors (incl. rotor)
HS.9573 0.520 0.066
HS.9583 0.586 0.076
HS.9593 0.631 0.103
HS.95103 0.690 0.115
Tab. 4: Mass moments of inertia for BITZER screw compressors in relation to the rotation axis of the respective rotor.

5 Direct-on-line start in star or in delta wiring (Y or Δ)

In star wiring, the 3 winding phases of the motor are combined to form the so-called star point. With a supply
voltage of 400 V, the phase voltage (voltage between the line conductors) is about 230 V each.
In delta wiring, the ends of the 3 winding phases are combined and connected to the individual phases. With a
supply voltage of 400 V, the phase voltage is 400 V each.
A motor that is approved for direct-on-line start in star and in delta wiring allows connection to two different voltage
sources. The voltage in star wiring is √3 higher than in delta wiring, i.e.
• a motor specified as 40S has a nominal voltage of 400 V in star wiring or 400 V/√3 = 230 V in delta wiring,
• a motor specified as 70S has a nominal voltage of approx. 690 V in star wiring or 690 V/√3 = 400 V delta wiring.
Switching between star and delta wiring is possible, provided the motor is suitable. However, the arrangement of
the wiring must be changed - i.e. the motor cannot switch during the start, in contrast to a star-delta start (see
chapter Star-delta start (Y/Δ), page 65). Special voltage motors are available for deviating nominal voltages.

5.1 Application with BITZER compressors

Motors for direct-on-line start in star or delta wiring (star or delta motors, Y or Δ motors) are used in some smaller
compressors, they are e.g. standard in:
• reciprocating compressors 2KES .. 4BES, 2NSL .. 4CSL, 2MME .. 4DME, 2MTE .. 4KTE
• scroll compressors (these are internally star wired, there is only one nominal voltage each - special voltage mo-
tors are available for other grids)

Suitable BITZER motors for direct-on-line start in star or delta wiring

For direct-on-line start in star wiring those motors are suitable in principle which are marked in the Technical In-
formation KT-410 or ST-410 with motor code "..S" and motor connection "Y":

Voltage range Nominal voltage Motor code Motor connec- Nominal voltage Voltage range
(V) (V) tion (V) (V)
50 Hz 60 Hz
500-550 500 50S Y 575 575-660
Tab. 5: Example from KT-410 for compressors 2KES .. 4BES: The 50S motor is suitable for direct-on-line start in star wiring.

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For direct-on-line start in delta wiring those motors are suitable in principle which are marked in the Technical In-
formation KT-410 or ST-410 with motor code "..D" and motor connection "∆":

Voltage range Nominal voltage Motor code Motor connec- Nominal voltage Voltage range
(V) (V) tion (V) (V)
50 Hz 60 Hz
180-200 200 20D ∆ 200 200-230
Tab. 6: Example from KT-410 for compressors 2KES .. 4BES: The 20D motor is suitable for direct-on-line start in delta wiring.

For a given compressor, an adhesive label in the terminal box cover shows the possible starting modes.

Starting current for the design of direct-on-line start in star or delta wiring
The starting current shown in the BITZER SOFTWARE refers to the measured starting current when the rotor of
the three phase motor is blocked (mean value of the currents in L1, L2 and L3, measured simultaneously after 4 s).
This starting current (locked rotor) refers to the RMS value (root mean square value): To calculate it, the peak value
of the corresponding alternating variable (here current) is divided by √2.
If the motor starts directly in star or delta wiring, these are the maximum starting currents to be expected.
However, the first measured amplitude may be larger due to the high unbalances.

Information in the BITZER SOFTWARE

If a specific compressor is selected in the BITZER SOFTWARE, the available motors are displayed under "Power
supply" - "Power voltage" according to the specified supply frequency (additional motors for North America (UL) un-
der "60Hz UL"). The standard motor is preselected.
The selection corresponds to the specifications in the Technical Information on motor codes (KT-410 for reciprocat-
ing compressors, ST-410 for screw compressors, EST-410 for scroll compressors).

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All further information concerning the motor can be found in the tab "Technical Data" under "Motor data":

Fig. 17: Available motors and motor data for reciprocating compressor 4DES-5Y. "Starting current (Rotor locked)" indicates the measured cur-
rent (root mean square, RMS) when the rotor is locked.

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Arrangement of the wiring in the terminal box of the compressor

WARNING
Risk of electric shock!
Before performing any work in the terminal box: Switch off the main switch and secure it against being
switched on again!
Close the terminal box before switching on again!

In the terminal box cover of BITZER compressors, an adhesive label shows the possible starting modes and the re-
spective connection of the mains phases to the motor pins. For a direct-on-line start, the cable bridges supplied
may have to be mounted.

L1 L2 L3 L1 L2 L3
U1 V1 W1 U1 V1 W1
U V W U V W

Z X Y Z X Y
W2 U2 V2 W2 U2 V2
High voltage Low voltage

Fig. 18: Motor connection for direct-on-line start in star (Y) or delta (Δ) wiring for reciprocating compressors 2KES .. 2CES (example)

L1 L2 L3 L1 L2 L3
U1 V1 W1 U1 V1 W1
1 2 3 M1 1 2 3 M1

6 4 5 M2 6 4 5 M2
W2 U2 V2 W2 U2 V2

High voltage Low voltage

Fig. 19: Motor connection for direct-on-line start in star (Y) or delta (Δ) wiring for reciprocating compressors 4FES .. 4BES (example)

Schematic wiring diagrams

In the schematic wiring diagram a direct-on-line start in star wiring is depicted like this, for example:

1 2 3 4

L1
L2
L3
PE F1 1
0
Q1 F2

K1
10
F13
8
M1

M 3!

R1..6

Fig. 20: Direct-on-line start in star wiring for a reciprocating compressor

K1: main contactor

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M1: motor
R1 .. 6: temperature sensors in motor winding

A direct-on-line start in delta wiring is depicted like this, for example:

1 2 3 4

L1
L2
L3
PE F1 1
0
Q1 F2

K1
10
F13
8

M1

M 3!

R1..6

Fig. 21: Direct-on-line start in delta wiring for a reciprocating compressor

K1: main contactor
M1: motor
R1 .. 6: temperature sensors in motor winding

Schematic wiring diagrams for BITZER compressors are compiled in the Technical Information AT-300.

6 Star-delta start (Y/Δ)

Star-delta start is possible with motors that can be operated in delta connection at the nominal supply voltage. In
addition, the motor windings must be open, i.e. the ends of the windings must be accessible at the terminal plate. 3
contactors are required in the main circuit of the motor.
The motor windings are operated in star connection during compressor start and in delta connection after a certain
time delay. The start is divided into 3 phases:
1. Star phase: Time in which the compressor motor starts in star wiring. This time from switching on the com-
pressor to switching to delta operation should be sufficient to reach 75 .. 80% of the nominal speed.
2. Transition break: Time during which the motor switches from star to delta operation. During this time, the com-
pressor is briefly voltage-free and its speed decreases. The transition break influences the position of the
voltage vectors in the motor and thus directly the height of the switching current peak. The duration of the trans-
ition break is either determined by the reaction time of the contactors or set by programming. The transition
break must not be too long, otherwise the compressor speed will reduce too much. If, on the other hand, it is
too short, the switch-off arc of the star contactor will not be extinguished and a short circuit may occur.
In order to reduce this second current peak,
– the IEC motor connection should be used,
– the start unloading (see chapter Additional start unloading (SU), page 81) should only be switched off after
switching to delta operation.
3. Delta operation: The compressor motor continues to run in delta wiring.
At standard conditions and with locked rotor, star-delta starting reduces the starting current to approx. ⅓ compared
to direct-on-line start in delta wiring, as the voltage at the windings is smaller by a factor of √3.

AT-330-2 // PDF Download 65

Fig. 22: Starting current (peak value) for a compressor model CSH8593-140Y with star-delta start (IEC connection) and start unloading (i.e.
slider position at 25%).

Since the torque is proportional to the square of the voltage, the starting torque for star-delta start also drops to ⅓.
If the motor is to start in this wiring, the load torque must not exceed ⅓ of the torque for direct-on-line start. There-
fore, additional start unloading is often necessary (see chapter Additional start unloading (SU), page 81).

6.1 Application with BITZER compressors

Motors for star-delta start (star-delta motors, Y/Δ motors) are used in some larger compressors, they are e.g.
• standard for screw compressors HS.95 and CS.95 .. 105 as well as reciprocating compressors 8FTE .. 8CTC
(for transcritical R744 applications),
• available as option for reciprocating compressors 4VES .. 8FE and screw compressors HS.85, CS.65 .. 85.

Suitable BITZER motors for star-delta start

For reciprocating compressors those motors may be suitable for star-delta start which are marked in the Tech-
nical Information KT-410 with motor code "..D" or "..S" and motor connection "∆" and "Y" (possibly in different
lines). In addition, it should be noted whether the specified voltage ranges are available in the voltage network on
site. If necessary, please consult BITZER.

Voltage range Nominal voltage Motor code Motor connec- Nominal voltage Voltage range
(V) (V) tion (V) (V)
50 Hz 60 Hz
220-240 230 40S ∆ - -
380-420 400 40S Y 460 440-480
380-420 400 70S ∆ 460 440-480
660-720 690 70S Y - -
Tab. 7: Example from KT-410 for compressors 2KES .. 4BES:
The 70S motor is suitable for star-delta start in voltage networks with 50 Hz and 400 V (3 phase).
The 40S motor is also suitable for star-delta start, but would need 230 V (3 phase) at 50 Hz, which is unusual e.g. in the EU.

For screw compressors those motors are suitable for star-delta start which are marked in the Technical Informa-
tion ST-410 with motor code "D" and motor connection "Y/∆".

AT-330-2 // PDF Download 66

 Voltage range Nominal voltage Motor code Motor connec- Nominal voltage Voltage range
(V) (V) tion (V) (V)
50 Hz 60 Hz
380-415 400 40D Y/∆ 460 440-480
Tab. 8: Example from ST-410 for HS.95 compressors: The 40D motor is suitable for star-delta start.

For a given compressor, an adhesive label in the terminal box cover shows the possible starting modes. For star-
delta start, the bridges for direct-on-line start may have to be removed.

Starting current for the design of star-delta start

The starting current shown in the BITZER SOFTWARE refers to the measured starting current when the rotor of
the three phase motor is blocked (mean value of the currents in L1, L2 and L3, measured simultaneously after 4 s).
This starting current (locked rotor) refers to the RMS value (root mean square value): To calculate it, the peak value
of the corresponding alternating variable (here current) is divided by √2. The starting current in star (locked rotor)
refers to the rated operating voltage in delta wiring. If the motor starts directly in star or delta wiring, these are the
maximum starting currents to be expected. However, the first measured amplitude may be larger due to the high
unbalances.
With star-delta start, the max. starting current can be reduced to up to approx. 66% of the delta starting
current (rotor locked) in the BITZER SOFTWARE. However, this depends on the compressor in question. Fur-
thermore, star phase and transition break must be optimally matched, the IEC connection must be used and start
unloading must be correctly applied.

AT-330-2 // PDF Download 67

Information in the BITZER SOFTWARE
If a specific compressor is selected in the BITZER SOFTWARE, the available motors are displayed under "Power
supply" - "Power voltage" according to the specified supply frequency (additional motors for North America (UL) un-
der "60Hz UL"). The standard motor is preselected.
The selection corresponds to the specifications in the Technical Information on motor codes (KT-410 for reciprocat-
ing compressors, ST-410 for screw compressors, EST-410 for scroll compressors).
All further information concerning the motor can be found in the tab "Technical Data" under "Motor data":

Fig. 23: Available motors and motor data for compact screw compressor CSH9573-240Y. "Starting current (Rotor locked)" indicates the meas-
ured current (root mean square, RMS) when the rotor is locked. This is the current for direct-on-line start in star wiring (650 A) or in delta wiring
(2029 A) with a phase voltage of 400 V in this case. (The phase voltage for star-delta start always refers to the phase voltage in delta operation.)

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Configuration star-delta start
For star-delta start, 3 contactors are required in the main circuit:
• main contactor: is connected to the 3 phases
• star contactor: sets the star bridge
• delta contactor: establishes the delta wiring
If the duration of the star phase and transition break is not controlled by the compressor module, it must be set cor-
rectly. Details can be found in the respective operating instructions (e.g. SB-110, SB-170). In general, the following
applies:

CS.65 .. CS.85 CS.95 .. 96 CS.105 HS.

Duration of the star phase 1 .. 2 s 1.5 .. 2 s 1.5 .. 2 s 1.5 .. 2 s
Duration of the transition break 60 .. 80 ms 60 .. 80 ms 250 ms 60 .. 80 ms
when switching from star to delta
operation (incl. reaction time of the
contactors)
Tab. 9: Duration of star phase and transition break for BITZER screw compressors

With star-delta start, additional start unloading is usually required (see chapter Additional start unloading (SU),
page 81).

Measuring the real starting current for star-delta start and direct-on-line start in star wiring
The starting current of the compressor must not be measured at the cables between the switch cabinet and the
compressor (outlined in red in the picture), because then the current via the star contactor is by mistake measured,
too. To avoid this, the starting current should be measured directly at or before the compressor fuse (outlined in
green in the picture):

L1
L2
L3
PE F01 1
0
Q01 F02

B60

Q02 Q03 Q04

X
M01
W1 U2
V1 M W2
U1 3! V2

Fig. 24: The real starting current is best measured directly before the compressor fuse (here: F02), so that the current via the star contactor
(during the start in star wiring) is not measured as well.

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Setting in the BEST SOFTWARE
When using the compressor modules CM-RC or CM-SW, the module controls the contactors for the desired start-
ing mode and, if necessary, the start unloading. For details, see Technical Information KT-230 (for CM-RC) and
ST-150 (for CM-SW). The starting mode can be set in the BEST SOFTWARE:

Fig. 25: Choosing the starting mode in the BEST SOFTWARE, here with CM-SW-01.

Arrangement of the wiring in the terminal box of the compressor

WARNING
Risk of electric shock!
Before performing any work in the terminal box: Switch off the main switch and secure it against being
switched on again!
Close the terminal box before switching on again!

NOTICE

! Make the connections correctly!

Reversed arrangement of the electrical connections leads to a short-circuit!

In the terminal box cover of BITZER compressors, an adhesive label shows the possible starting modes and the re-
spective connection of the mains phases to the motor pins. For a direct-on-line start, the cable bridges supplied
may have to be mounted.

AT-330-2 // PDF Download 70

Arrangement of the wiring for reciprocating compressors:

L1 L2 L3
W2 U2 V2 W2 U2 V2
M1 7 8 9 M1 7 8 9

M2 1 2 3 M2 1 2 3
U1 V1 W1 U1 V1 W1
L1 L2 L3 L1 L2 L3
Star-delta start Direct-on-line start

Fig. 26: Motor connection for star-delta start reciprocating compressor 4VES .. 6FE (example)

Arrangement of the wiring for screw compressors:

Supply rotating field

7 T1 7 T1
L2 1 1
L1 L1
8 8
L3 2 2
L2 L2
9 9
L1 3 3
L3 L3
T2 T2

Star-delta start
Direct-on-line start
(preferable connection, IEC)

Fig. 27: Motor connection for star-delta start CS. compressor (example)

Supply rotating field

T2 T1 T2 T1
7 7
L2 1 1
L1 L1
8 8
L3 2 2
L2 L2
9 9
L1 3 3
L3 L3
Star-delta start
Direct-on-line start
(preferable connection, IEC)

Fig. 28: Motor connection for star-delta start HS.85 compressor (example)

The following figure shows the internal wiring in the motor:

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 Star-delta start
Direct-on-line start
(preferable connection, IEC)
1 7 1 1 7

8 3 8 3
1 1
2 9 2 9

Q02

L1
L2
Q02 Q03 Q04 L3

L1
L2
L3

Fig. 29: Schematic illustration of the internal wiring in the motor for star-delta start
Q02: main contactor (star-delta start) resp. compressor contactor (direct-on-line start)
Q03: delta contactor
Q04: star contactor
(1): bridges for direct-on-line start (optional accessories)

Schematic wiring diagrams

In the schematic wiring diagram a star-delta start is depicted like this, for example:

1 2 3 4 5

L1
L2
L3
PE F01 1
0
Q01 F02

B60
8

Q02 Q03 Q04

10 11 12

M01
W1 U2
V1 M W2
U1 3! V2

Fig. 30: Star-delta start for an OS.85 screw compressor

Q02: main contactor
Q03: delta contactor
Q04: star contactor
M01: motor

Schematic wiring diagrams for BITZER compressors are compiled in the Technical Information AT-300.

AT-330-2 // PDF Download 72

7 Part winding start (PW start, Y/YY or Δ/ΔΔ)
Part winding start is possible with motors whose stator winding is divided by design into 2 halves with 3 windings
each. Both winding partitions lie parallel in the stator slots. During start, they are switched on one after the other,
with a time delay of e.g. 0.5 .. 1 s.
2 contactors are required in the main circuit of the motor, which are switched on one after the other:
• contactor for 1. part winding (PW1)
• contactor for 2. part winding (PW2)
In contrast to a star-delta start, there is no transition break in which the motor is voltage-free.

Part winding start (PW) Star-delta start (Y/Δ)

PW1 PW1 + PW2 Y

I I

t t
switching on Y/Δ transition break
2. winding (PW2)
normal starting conditions
heavy starting conditions (insufficient pressure equalisation)

Fig. 31: Course of the starting current for part winding and star-delta start

If start unloading is used, it can be switched off after the 2. part winding has been switched on.
Typical winding partitions (given by design) are
• 60% / 40% (starting current is only 75% of that for direct-on-line start) or
• 50% / 50% (starting current is only 65% of that for direct-on-line start).
The winding partitions can further be connected internally in different ways (winding type). This can no longer be
changed in a given motor and has no practical effects on connections, arrangement of the wiring, etc.
• YY: Each winding partition is connected in itself in star wiring (Y), the part winding start is represented as Y/YY.
• ∆∆: Each winding partition is connected in itself in delta wiring (∆), the part winding start is represented as ∆/∆∆.

AT-330-2 // PDF Download 73

Comparison of starting currents
In contrast to a star-delta start, the voltage is not interrupted during transition, neither is the torque, and a further
current peak is largely prevented. The starting current indicated in the BITZER SOFTWARE is the root mean
square (RMS) value of the current. To derive this from the oscillogram, the current must be divided by √2.
For BITZER CS. compressors, the starting currents can e.g. be as follows.
Part winding start:

Fig. 32: Starting current (peak value) for a compressor model CSH8593-180Y with part winding start (winding partition 50% / 50%, winding type
Δ/ΔΔ) and start unloading (i.e. slider position at 25%).

Star-delta start:

Fig. 33: Starting current (peak value) for a compressor model CSH8593-140Y with star-delta start (IEC connection) and start unloading (i.e.
slider position at 25%).

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Another advantage of a PW start compared to a star-delta start: Only two smaller contactors are required, which
significantly reduces expense and space required for the electrical system. As with star-delta start, additional start
unloading is usually required (see chapter Additional start unloading (SU), page 81).

7.1 Application with BITZER compressors

Motors for part winding start (part winding motors, PW motors) are standard e.g. in:
• Reciprocating compressors 4VES .. 6FE, 4VSL .. 4NSL, 4TME .. 6PME, 4JTE .. 6CTE
Standard: winding partition 50% / 50%, winding type Y/YY, contactors are designed for approx. 60% of the max.
operating current.
• Reciprocating compressors 8GE .. 8FE
Standard: winding partition 60% / 40%, winding type Δ/ΔΔ, the 1. contactor (PW1) is designed for approx. 70%
and the 2. contactor (PW2) for approx. 50% of the max. operating current.
• Screw compressors CS.65 .. 85 and HS.53 .. 85
Winding partition 50% / 50%, winding type Δ/ΔΔ, contactors are designed for approx. 60% of the max. operating
current.
The time delay until the 2. winding is switched on must be set correctly. For details see the respective operating in-
structions, e.g. KB-104, SB-110, SB-170).

Suitable BITZER motors for part winding start

For part winding start those motors are suitable in principle which are marked in the Technical Information KT-410
or ST-410 with motor code "..P" and motor connection "Δ/ΔΔ" or "Y/YY":

Voltage range Nominal voltage Motor code Motor connec- Nominal voltage Voltage range
(V) (V) tion (V) (V)
50 Hz 60 Hz
180-200 200 20P Y/YY 200 200-230 (220)
380-415 400 40P ∆/∆∆ 460 440-480
Tab. 10: Examples from KT-410 resp. ST-410:
The 20P motor is suitable for part winding start, winding type Y/YY.
The 40P motor is suitable for part winding start, winding type ∆/∆∆.

For a given compressor, an adhesive label in the terminal box cover additionally shows the possible starting
modes. For part winding start, the bridges for direct-on-line start may have to be removed.

Starting current for the design of part winding start

The starting current shown in the BITZER SOFTWARE refers to the measured starting current when the rotor of
the three phase motor is blocked (mean value of the currents in L1, L2 and L3, measured simultaneously after 4 s).
This starting current (locked rotor) refers to the RMS value (root mean square value): To calculate it, the peak value
of the corresponding alternating variable (here current) is divided by √2. Operation with 1 winding (Y/Δ) has to be
distinguished from operation with 2 windings (YY/ΔΔ). If the compressor starts with the 1. part winding (Y/Δ),
switching on the 2. part winding (YY/ΔΔ) does not lead to a significant current peak.
With correct part winding start (start unloading, pressure equalisation), the maximum starting current to be
expected is therefore determined by the starting current of the 1. part winding (Y/Δ).

Information in the BITZER SOFTWARE

If a specific compressor is selected in the BITZER SOFTWARE, the available motors are displayed under "Power
supply" - "Power voltage" according to the specified supply frequency (additional motors for North America (UL) un-
der "60Hz UL"). The standard motor is preselected.
The selection corresponds to the specifications in the Technical Information on motor codes (KT-410 for reciprocat-
ing compressors, ST-410 for screw compressors, EST-410 for scroll compressors).

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All further information concerning the motor can be found in the tab "Technical Data" under "Motor data":

Fig. 34: Available motors and motor data for reciprocating compressor 4TES-12Y. "Starting current (Rotor locked)" indicates the measured cur-
rent (root mean square, RMS) when the rotor is locked.

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Setting in the BEST SOFTWARE
When using the compressor modules CM-RC or CM-SW, the module controls the contactors for the desired start-
ing mode and, if necessary, the start unloading. For details, see Technical Information KT-230 (for CM-RC) and
ST-150 (for CM-SW). The starting mode can be set in the BEST SOFTWARE:

Fig. 35: Choosing the starting mode in the BEST SOFTWARE, here with CM-SW-01.

Arrangement of the wiring in the terminal box of the compressor

WARNING
Risk of electric shock!
Before performing any work in the terminal box: Switch off the main switch and secure it against being
switched on again!
Close the terminal box before switching on again!

NOTICE

! Observe correct connections!

Wrong arrangement of the electrical connections leads to opposite fields of rotation or rotating fields shifted
in phase angle and thus to blocking of the motor!

In the terminal box cover of the BITZER compressors, an adhesive label shows the possible starting modes and
the respective connection of the mains phases to the motor pins. For a direct-on-line start, the cable bridges sup-
plied may have to be mounted.

AT-330-2 // PDF Download 77

Arrangement of the wiring for reciprocating compressors:

L1 L2 L3 L1 L2 L3
1U1 1V1 1W1 1U1 1V1 1W1
T1 1 2 3 PW 1 T1 1 2 3

7 8 9 T2 PW 2 7 8 9 T2
2U1 2V1 2W1 2U1 2V1 2W1
L1 L2 L3

Part winding start Δ/ΔΔ Direct-on-line start Δ

Fig. 36: Motor connection for part winding start for reciprocating compressor 8GE .. 8FE (example)

L1 L2 L3
2U1 2V1 2W1 2U1 2V1 2W1
M1 7 8 9 PW 2 M1 7 8 9

M2 1 2 3 PW 1 M2 1 2 3
1U1 1V1 1W1 1U1 1V1 1W1
L1 L2 L3 L1 L2 L3

Part winding start Y/YY Direct-on-line start Y

Fig. 37: Motor connection for part winding start for reciprocating compressor 4VES .. 6FE (example)

Arrangement of the wiring for screw compressors:

Supply rotating field

PW2 PW1
7 T1 7 T1
L1 1 1
L1 L1
8 8
L2 2 2
L2 L2
9 9
L3 3 3
L3 L3
T2 T2

Part winding start Direct-on-line start

Fig. 38: Motor connection for part winding start CS.85 compressor (example)

AT-330-2 // PDF Download 78

 Supply rotating field
PW2 PW1
T2 T1 T2 T1
7 7
L1 1 1
L1 L1
8 8
L2 2 2
L2 L2
9 9
L3 3 3
L3 L3

Part winding start Direct-on-line start

Fig. 39: Motor connection for part winding start for HS.85 compressor (example)

The following figure shows the internal wiring in the motor:

Part winding start Y/YY Part winding start ∆/∆∆ Direct-on-line start ∆

U1 U1
W2 W2 U1 W2
U1 U2 1

U2 W1 U2 W1
V1 W2 U2 W1 1
1
V2 W1

V1 V1
V2 V2 V1 V2

Q02 Q03 Q02 Q02 Q03 Q03 Q02

L1 L1
L2 L2
L3 L3
L1 L2 L3 L1 L2 L3

Fig. 40: Schematic illustration of the internal wiring in the motor for part winding start
Q02: contactor for 1. part winding (PW1) resp. compressor contactor (direct-on-line start)
Q03: contactor for 2. part winding (PW2)
(1): bridges for direct-on-line start (optional accessories)

AT-330-2 // PDF Download 79

Schematic wiring diagram
In the schematic wiring diagram a part winding start is depicted like this, for example:

1 2 3 4 5

L1
L2
L3
PE F01 1
0
Q01 F02

Q02 Q03
11 10
B60 B61
8 8
M01
W1 U2
V1 M W2
U1 3! V2

Fig. 41: Part winding start for an OS.85 screw compressor

Q02: contactor for 1. part winding
Q03: contactor for 2. part winding
M01: motor

Schematic wiring diagrams for BITZER compressors are compiled in the Technical Information AT-300.

AT-330-2 // PDF Download 80

8 Additional start unloading (SU)
The starting modes described above often reduce the torque of the motor to a value that allows starting only with
small pressure differences. Therefore, start unloading (SU) may be necessary (in addition to reducing the starting
current).
Even when operating with a frequency inverter, start unloading may be necessary, e.g. in case of heavy starting
conditions or if the frequency inverter lacks the necessary overload capacity (see the recommended factors in the
documents KT-420, ST-420 and EST-420, chapters "Selection with the BITZER SOFTWARE"). VARIPACK fre-
quency inverters provide sufficient overload capacity, and the compressor start has been optimised also for heavy
conditions. For these, no additional start unloading is necessary, and the safe start is accounted for when choosing
the frequency inverter in the BITZER SOFTWARE.
Start unloading is implemented differently for reciprocating and screw compressors, and it can be integrated in the
compressor or implemented externally. Under certain conditions, an integrated capacity control can also be used
as start unloading.

8.1 Application with BITZER reciprocating compressors

Start unloading equalizes the pressure between the high and low pressure sides. The back pressure is thus lower,
the starting torque is reduced to the required value, and the motor can start as easily as possible. This can be par-
ticularly useful with star-delta start and short on-off cycles (short pause time) of the compressor.
Many BITZER reciprocating compressors are available with integrated start unloading. It essentially consists of a
bypass between the discharge and suction gas sides, which is controlled by a solenoid valve. Ideally, this opens
1 .. 2 s before the start, the compressor then delivers from the outlet directly into the inlet with a small pressure dif-
ference. When the motor has reached nominal speed, the solenoid valve is closed, thereby closing the bypass, and
the compressor is in normal operation.

Unloaded Normal operation

start Solenoid coil
Pressure chamber
Control piston

Bypass port

Suction gas chamber

Check valve in discharge gas line

Discharge gas temperature sensor

Fig. 42: Integrated start unloading for BITZER reciprocating compressors (example)

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For most BITZER reciprocating compressors, the following applies: If a cylinder bank is equipped with start unload-
ing, it is no longer available for capacity control. A 6-cylinder compressor can therefore be equipped with max. 3
CRII capacity regulators or with start unloading and 2 CRII capacity regulators. The capacity control range is re-
duced accordingly.
An exception are R744 compressors: Here the capacity regulators are designed as bypass and can therefore also
be used for start unloading.
For compressors for which no integrated start unloading is available, an external start unloading can be set up:
For an unloaded start, a solenoid valve is opened in the external bypass line. The compressor delivers discharge
gas via the bypass line directly to the suction gas chamber or into the suction gas line. A check valve in the dis-
charge gas line prevents discharge gas from flowing back out of the condenser. In normal operation, the solenoid
valve and thus the bypass line are closed, and the compressor delivers at normal load.

Unloaded start Normal operation

Bypass line Solenoid valve Bypass line Solenoid valve

Check valve Check valve

M16
M16

Fig. 43: External start unloading for BITZER reciprocating compressors (example)

For further information on mounting and retrofitting the start unloading see the respective Operating Instructions
and Technical Information KT-110.

Information in the BITZER SOFTWARE

If a specific compressor is selected in the BITZER SOFTWARE, the tab "Technical Data" indicates if start unload-
ing is available:

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Setting in the BEST SOFTWARE
When using the compressor module CM-RC, the module also controls the start unloading if necessary. For details,
see Technical Information KT-230.

Fig. 44: Choosing start unloading with the CM-RC in the BEST SOFTWARE. If the compressor features an integrated start unloading, select
"Start Unloading (SU)".

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Schematic wiring diagram
With reciprocating compressors, start unloading replaces one of the capacity regulators (exception: R744 com-
pressors, see above). A compressor with start unloading is depicted like this, for example:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

L1
L2
L3
PE F01 1
0
Q01 F02 K01
Q05 K03

Modbus
GND-COM

1234

RS485
CN13 CN14
24V Sup
Data–
CM-RC-01 Data+

0 .. 10V
GND PE

12
T01 Input
230V GND 2

123456
3
Signal 1 P B51 (LP/2CP5-71-49)
5VSup

CN12
2
GND 3
Signal 1 P B50 (HP/2CP5-71-47)
5VSup
PE GND

1234
CN10 CN11
Signal B02
GND
Signal
PTC

12
PTC
GND DP-1

1234
CN9
01 Signal
B60 GND B12
S01 24VSup
8

CN8
CT

12
CT
CN1 CN2 CN3 CN4 CN5 CN6
K2control
K1control

RelayNC CN7

Add. fan
Add. fan

Injection
Injection

24VSup
F04 F03
RelayC

grau/grey/gris
Supply
Supply

Heater
Heater

Signal
CN9:4

CR-1
CR-1
CR-2
CR-2
CR-3
CR-3
4A F 4A T OLC-D1

GND
GND
HPS
Q02 Q03 Q04 B60 HPS CN9:2 blau/blue B30
L N 1 2 3 4 1 2 1 N 1 N 1 N 3 N 5 N 7 N 12345678 CN9:1 braun/brown
10 11 12 2
rosa orange
S02 pink
B10 CN9:3
M12
P> E01
M01 PE
M M13
M02 1"
M 3"
M05
B03..08 M11
M1 M2
orange
orange

Q02 Q04 K13

10 12 13
Q04 Q03
12 11
Q02 Q03 Q04 K13 P10

Details zum Anschluss siehe Innenseite des Anschlusskastens. 2/2/2/9 4/4/4 5/5/5/10 12
Details concerning connections see inside the terminal box.
12 11 11
Détails sur le raccordement voir intérieur de la boîte de raccordement.

Fig. 45: ECOLINE reciprocating compressor with compressor module CM-RC-01, star-delta start and start unloading. The diagram shows the
maximum possible equipment of a 6-cylinder compressor with start unloading (solenoid valve M11) and 2x CRII capacity control (solenoid
valves M12 and M13), placed here under the compressor module CM-RC-01.

Schematic wiring diagrams for BITZER compressors are compiled in the Technical Information AT-300.

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8.2 Application with BITZER screw compressors
BITZER screw compressors are equipped with capacity control by means of control sliders or control pistons. This
allows (stepped, stepless or dual) capacity control as well as automatic start unloading through appropriate control
of the solenoid valves. For start unloading, the capacity control is set to minimum displacement, ideally before the
compressor is switched off. If this is not possible, enough time must be provided before the compressor is restar-
ted, e.g. for the control slider to move to the appropriate position (pause time). For detailed information, see the re-
spective Operating Instructions.

Suction gas

Spring

ECO
Control slider (here: 75%) Discharge gas

Fig. 46: Principle of slider control e.g. for a BITZER CS. screw compressor

With direct-on-line, star-delta and part winding start, complete unloading of the screw compressor is essential to
enable a reliable start and to avoid increased starting currents or a shutdown of the compressor!

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Comparison of starting currents
As an example, the starting currents for a typical CS. compressor are shown. The starting current indicated in the
BITZER SOFTWARE is the root mean square (RMS) value of the current. To derive this from the oscillogram, the
current must be divided by √2.
Part winding start with slider at 25% vs. 100%:

Fig. 47: Starting current (peak value) for a compressor model CSH8593-180Y with part winding start (winding partition 50% / 50%, winding type
Δ/ΔΔ) and start unloading (i.e. slider position at 25%).

Fig. 48: Starting current (peak value) for a compressor model CSH8593-180Y with part winding start (winding partition 50% / 50%, winding type
Δ/ΔΔ) without start unloading (i.e. slider position at 100%).
The compressor does not start until the 2. part winding is switched on, because only then the torque is sufficient.

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Star-delta start with slider at 25%, 50%, 75%:

Fig. 49: Starting current (peak value) for a compressor model CSH8593-140Y with star-delta start (IEC connection) and start unloading (i.e.
slider position at 25%).

Fig. 50: Starting current (peak value) for a compressor model CSH8593-140Y with star-delta start (IEC connection) and start unloading (i.e.
slider position at 50%).

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Fig. 51: Starting current (peak value) for a compressor model CSH8593-140Y with star-delta start (IEC connection) and start unloading (i.e.
slider position at 75%).

Information on measuring the real starting current: see figure 24, page 69.

Information in the BITZER SOFTWARE

If a specific compressor is selected in the BITZER SOFTWARE, start unloading is listed in the tab "Technical
Data":

Schematic wiring diagram

In screw compressors, start unloading is carried out via the capacity control, therefore it is not explicitly listed in the
schematic wiring diagram.

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