ESB-135-1

Installation and
Startup Instructions
ORBIT 8 Series R410A Scroll Compressors
Content Page
1 General 1
2 Safety Instructions 1
3 Installation Procedures 2
4 Accessory Items 6
5 Compressor Installation / Preparation 7
6 Checks before Starting 7
7 Operational Checks 8
1 General
This document provides installation and startup instructions
for BITZERs ORBIT 8 Series R410A Scroll compressors.
A more complete description of the compressors and
application requirements can be found in the 8 Series
Compressor Application Manual, which is available on
BITZERs website (www.bitzerus.com).
2 Safety Instructions
WARNING !
ELECTRICAL SHOCK HAZARD
Failure to follow these safety warnings could result in serious
injury or death. All installation and servicing activity should be
performed only by trained personnel. Wear safety goggles.
Shut off all power to this equipment during installation and
service. Lock and tag all disconnect locations until work is
completed.
CAUTION !
Compressors contain oil and refrigerant under pressure.
Release pressure from both high and low side of compressor
before installation or servicing.
CAUTION !
Tube brazing and compressor operation can produce hot
surfaces. To avoid burns, allow surfaces to cool down before
continuing installation or servicing.
NOTICE
Do not remove oil drain plug as the entire oil charge could be
lost. Do not reuse drained oil that has been exposed to the
atmosphere.
1. The compressor should be inspected for shipping damage
and a claim fled with the shipping company if the com-
pressor arrives damaged.
2. Check the compressor nameplate to insure you have the
correct model and voltage for the application. Also, insure
that the maximum pressure/temperature ratings listed
on the nameplate are not exceeded during installation or
operation of the compressor.
3. Before attempting to install the compressor, be sure to
review this document in its entirety as well as all related
BITZER application literature. You should familiarize
yourself with the compressor application requirements
before continuing with the installation. The literature is
available through BITZERs website (www.bitzerus.com).
4. Insure that all work on compressor and refrigeration
systems shall be carried out only by refrigeration personnel
which have been properly trained and instructed.
Applicable safety procedures and practices should be
followed.
5. The compressor is under pressure with a holding charge of
approximately 7 psi (0.5 bar) above atmospheric pressure.
Do not open any connections before relieving the pressure
as discussed in the holding charge section below. Incorrect
handling may cause injury.
6. Safety glasses should be worn while working on
compressor.
7. Do not apply any power supply to the compressor unless
all suction and discharge valves (i.e. service valves) are
installed and opened.
8. Do not operate or provide any electrical power to the
compressor unless the terminal box cover is in place and
secured. Measurement of amps and volts during running
conditions must be taken at other points in the power
supply.
9. Do not remove terminal box cover until all electrical sources
have been disconnected.
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NOTICE
The PVE oil used in this compressor is very hydroscopic
(i.e. will absorb moisture), similar to POE oil. The compressor
should be installed quickly with limited exposure to the
atmosphere to avoid moisture contamination.
Holding Charge
The compressor is shipped under pressure with a holding
charge of dry air or nitrgen approximately 7 psi (0.5 bar)
above atmospheric pressure. Do not remove any compressor
bolts or fittings until the factory supplied holding charge has
been relieved. Exhaust the holding charge through the high
(HP) pressure connections, see Figure 2, by removing the
Schrader valve cap and depressing the internal Schrader
valve. Exhausting the holding charge via the LP pressure
connections can allow pressure to remain in the high side
of the compressor.
Rotalock / Braze Connections
The compressor may have either braze or rotalock
connections. Remove the factory supplied suction and
discharge connection caps and/or plugs. When installing
rotalock connections, torque:
Suction Rotalock 180-190 Nm (133-140 FTLB)
Discharge Rotalock 150-160 Nm (111-118 FTLB)
When brazing pipe to the rotalock valve, disassemble the
valve or wrap in a wet cloth to prevent heat damage. Remove
the teflon gasket when brazing to the rotalock fittings.
NOTICE
The system piping must be carefully designed to ensure that
under all circumstances, oil is returned to the compressor, and
as little as possible remains in the evaporator. Consult BITZER
Application Manual for further details.
Refrigerant Piping
Brazing should be accompanied with a nitrogen purge to
prevent scale and oxidation build-up. Tubing should be clean
and free of burrs, cuttings, or other material that may enter the
compressor.
Refrigerant / Oil
The GSD8 Series compressors are only approved for R410A
medium and high temperature applications. See ORBIT 8
Series Application Manual for the allowable operating
envelope and detailed application requirements.
Most compressors are shipped with a factory oil charge.
The only oil approved for the 8 Series compressors is the
PVE oil noted below. If an alternate oil is shipped with the
compressor, the oil type will be denoted by an oil label added
adjacent to the compressor sight glass. If the compressor is
shipped without oil, a No Oil Added wire tag will be added
to the oil charge fitting. See application manual for a list of all
approved refrigerant oils.
10. Follow recommended safety precautions listed on terminal
box cover label before attempting any service work on the
compressor.
11. During operation surface temperatures can exceed 275F
(135C). Severe burns are possible.
3 Installation Procedures
Transporting
Compressor should be transported either bolted down to a
wooden pallet or lifted using the lifting lugs that are welded
to the compressor as shown in Figure 1.
Figure 1 Transporting Compressor
Mounting
For most applications the compressor is isolated from the unit
with rubber grommets. For single compressor applications
the grommets are placed between the compressor and the
unit. For tandem and trio applications, the compressors are
hard mounted to base rails with rubber grommets placed
between the rails and the unit base. The available grommet
packages are listed in the accessory item summary on page 6.
The Compressor Application Manual should be referenced for
detailed mounting instructions.
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The oil level should generally remain at
1
/4 to
3
/4 up the sight-
glass. During multi (tandem/trio) operation it is possible for
the oil level to move outside this range. See the application
manual for further details on acceptable oil levels. Check the
oil level after the compressor has run for a few hours as it may
be necessary to top off the oil after startup.
The compressor should be isolated from the system before
adding or removing oil. Use only the oil access port (3) to add
and remove oil from the compressor, see Figure 2.
Oil Charge
Refrigerant Oil: Polyvinylether Oil (PVE)
Oil Volume: 179 oz. (5.3L)
BITZER Oil Type: BVC32
NOTICE
Do not charge compressor with oil through the suction/
discharge access fittings as it may result in damage to the
compressor.
Figure 2 Compressor Connection Points and Access Fittings
Access Points Thread
1. High pressure connection (HP)*
1
/8-27 NPTF, with Plug
1a. High pressure connection (HP)*
1
/8-27 NPTF, with Schrader Valve
2. Low pressure connection (LP)
1
/8-27 NPTF, with Schrader Valve
3. Oil fill port
1
/8-27 NPTF, with Schrader Valve
Connection Points Rotalock Thread Connection Brazed Connection
SL Suction gas line 2-
1
/4" 12 UNF, Rotalock only 1-
5
/8" ODF
DL Discharge gas line 1-
3
/4" 12 UNF, Rotalock only 1-
3
/8" ODF
SG Sight Glass 1-
3
/4" 12 UNF, Rotalock only
* Used for discharge gas sensor (optional, see page 7). Sensor can be installed in any of the (HP) fittings.
GSD8 295-485
Rotalock
GSD8 182-235
Rotalock
GSD8 ALL
Brazed
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The orange wires on the SE-B3 are connected between
the M1 & M2 terminals on the compressor terminal plate.
Terminals 1 and 2 on the optional SE-E1 must be connected to
M1 and M2. The incoming power from the controller is wired
in series with the compressor safeties and connected to the
module at terminal 11. Terminal 14 is wired to the compressor
contactor. Terminal 12 (optional) is wired to the alarm output.
If the motor overheats, the resistance of the internal sensors
will spike (generally over 2.5k Ohms) causing the module to
lock out requiring a manual reset.
To reset the module, the power supply must be interrupted for
at least 5 seconds. The SE-E1 module is an optional upgrade
in compressor protection. It provides motor thermal overload
protection exactly the same as the SE-B3 module, but adds
the following additional protection features:
Reverse Rotation Protection checks the rotation direction
during the first 5 seconds after a compressor start.
Phase Loss Protection checks for phase loss during first
5 seconds of operation. Locks out for 6 minutes if phase
loss is detected. A manual reset is required (interrupt power
for at least 5 seconds) if three phase failures are detected
within 18 minutes or 10 phase failures during 24 hours.
Electrical Wiring
The motor protection for the 8 Series compressors and
electrical terminal plate wiring are discussed below. The
standard compressor shipment will include the SE-B3
protection module (SE-B2 and SE-E1 are optional). Consult
the compressor wiring diagram on the underside of the
terminal box cover along with the diagrams below for correct
compressor wiring.
NOTICE
Running the compressor in reverse (reverse rotation) will cause
compressor damage. Insure compressor is wired for correct
rotation.
Compressor must be phased for correct rotation. See Startup
Procedures at end of this document for reverse rotation test.
Motor Protection
Figure 3 below shows the wiring of the electronic motor
protection module.
Figure 3 Electrical Wiring Schematic
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Terminal Plate Wiring
Figure 4 shows a schematic of the terminal plate. Ring
terminals should be added to the incoming power wires and
affixed to the L1, L2 & L3 terminal plate power connections
using the screws shipped with the compressor.
Recommended Ring Terminal:
1
/4"/M6 stud size, insulated ring terminal
Ring Terminal Connection Torque:
M6 screw, Torque: 4.5-5.1 NM (40-45 in-lbs)
Ground Lug
M8 Hex Nut, Torque: 4.5-5.1 NM (40-45 in-lbs)
Testing Module after Installation
To test the control module after compressor installation, the
service technician should conduct the following tests:
All testing should be conducted with main compressor
power and control power supply to liquid solenoid(s)
locked-out.
Remove one of the leads from either M1 or M2 on the
compressor terminal plate.
Provide power to the module (control power only)
and confirm that the control voltage appears between
terminal 12 and N on the device (i.e. device has tripped).
NO voltage should appear between terminal 14 and N.
Figure 4 Terminal Plate Wiring
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4 Accessory Items
Mounting Kits
In order to reduce sound/vibration transmittal to the surrounding structure, it is recommended that all compressors be mounted
using rubber isolation mounts. Different isolation mounts are required for single and multi compressor installations as summarized
in Table 1.
Table 1: BITZER Rubber Isolation Mounting Kits
Description BITZER Part Number
Single Compressor Application 37002001
Multi-Compressor (i.e. tandem / trio) 37002101
Note: Mounting kits contain 4 of each: rubber grommets, washers, spacers. The mounting bolt (not included) requirements will depend on the
application. The sleeve is sized for
3
/8" (9.5 mm) diameter fastener
Rotalock Service Valves and Connection Adapters
These parts are only applicable to compressors that ship with rotalock connections. A variety of valves and connectors are
available for the compressor as summarized in Table 2 below.
Table 2: BITZER Rotalock Kits
Rotalock Standard Service Valves
Application Thread Connection Connection Size Part Number
Discharge Port* 1
3
/4" 12 UNF 1-
3
/8" rotalock valve 361321-11
Suction Port 2
1
/4" 12 UNF 1-
5
/8" rotalock valve 361321-12
Rotalock Standard Braze Adapter Fittings
Application Thread Connection Connection Size Part Number
Discharge Port* 1
3
/4" 12 UNF 1-
3
/8" rotalock braze adapter 366000-07
Suction Port 2
1
/4" 12 UNF 1-
5
/8" rotalock braze adapter 366000-22
* Can also be used for Sight Glass connection.
Oil Heater
A bellyband heater is an optional accessory item, see application manual for application recommendations and requirements.
Table 3: 8 Series Bellyband Heaters
Description Wattage (W) Voltage (V/1Ph) BITZER Part Number
Band heater, metal strap 140 120 343255-01
Band heater, metal strap 140 240 343255-02
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Insure low and high pressure switches (LPS / HPS) are set
appropriately for the application.
Is the motor protection module installed, wired and
functioning properly (test per instructions on page 5)?
Are the shut-off / isolation valves open?
Reverse Rotation Check
Before starting the compressor and letting it run, correct
rotation must be checked. Operation of the compressor in
the wrong direction for more than a few minutes can lead to
a compressor failure. In order to monitor for reverse rotation
a pressure gauge should be added to the discharge port
and monitored while the compressor is bump-started.
The discharge pressure must rise when the compressor starts.
If reverse rotation is found, two of the motor leads should be
reversed to achieve proper rotation.
5 Compressor Installation / Preparation
Be sure to follow installation instructions covered in
this document, including: compressor mounting, piping
connections, oil charging and electrical wiring instructions.
6 Checks before Starting
Insure all wiring connections to the compressor terminal
plate and related components (i.e. circuit breaker,
contactor) are tight.
Insure oil level is
1
/4
3
/4 up the sight glass.
Test installation, wiring and operation of all compressor
safeties. The safeties must lock the compressor out when
they trip.
Figure 5 Discharge Gas Sensor
Table 4: Discharge Gas Sensor
Description BITZER Kit Part Number
140C Discharge Gas sensor (PTC) 347023-06
The sensor kit includes everything required to mount and wire the sensor into the PTC control circuit (Figure 3). The sensor has a
1
/8" NPTM threaded connection designed to be screwed into the discharge access fitting (1a) as shown in Figure 5.
ALL Brazed &
GSD8 295-485
Rotalock
GSD8 182-235
Rotalock
Oil heater
installed here
(optional)
Discharge Gas Sensor
A discharge gas sensor is an optional accessory item,
see application manual for application recommendations
and requirements. The sensor provides over-temperature
protection for the compressor when wired in series with
the motor PTCs (see electrical drawings in Figure 3). The
protection module will lock the compressor out if the
discharge temperature exceeds 285F (140C).
7 Operational Checks
An initial check should be made of the following parameters after the compressor starts. A second set of readings should be taken
once the operation has stabilized (typically 20 30 minutes after startup). These readings should be recorded for future reference.
Operating Parameter Acceptable Level Notes
Oil Level**
1
/4 -
3
/4 Sight Glass Extended range approved for tandem/trio applications.
Low (suction) Pressure 35 psig (2.4 bar) Low pressure switch must be set no lower than 35 psig (2.4 bar).
High (discharge) Pressure 610 psig (42 bar) High pressure switch must be set no higher than 625 psig (43 bar).
Max Differential Pressure
(Discharge Suction)
609 psig (42 bar) Internal Relief Valve may open at differential pressures (high to low) that
exceed 609 psi (42 bar).
Max Discharge
Temperature
250F (120C) Temperature on discharge pipe, measured within 4" of the service valve
adapter fittings, must be less than 250F (120C).
Max Return Gas
Temperature
65F (18C)* Temperature on suction pipe, measured within 4" of the service valve must
be less than 65F (18C).
Min Superheat 10F (5 K) Suction superheat at the compressor inlet should generally be maintained
at or above 10F (5 K). Lower superheat settings may be applicable for
certain applications.**
Amp Draw** See performance data Measured amp draw should be compared to amp draw from BITZER
Software or performance data. Unbalance 2%.
Voltage** +/- 10% of Nominal Voltage unbalance should be 10%.
Compressor Cycling** 6 starts per hour Compressor cycling rate should be less than 6 starts per hour with a
minimum run-time of 3 minutes.
* Or as limited by the operating envelope.
** See application manual for further details.
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Bitzer US, Inc.
4031 Chamblee Road, Oakwood, GA 30566, U.S.A.
Tel +1 770 503-9226 Fax +1 770 503-9440
www.bitzerUS.com sales@bitzerus.com
NOTICE
During the running-in period scroll compressors show
an increase in performance. In case of performance tests
a running-in period must be considered.
See BITZER Software for details.