Bitzer CM-RC-01 Technische Daten
KW-232-1
Instructions for mounting the CM-RC-01 add-on kit
Translation of the original document
English....................................................................................................................................................... 2
Anleitung zur Montage des CM-RC-01 Komplettierungsbausatzes
Originaldokument
Deutsch ..................................................................................................................................................... 18
Instructions de montage du kit complémentaire CM-RC-01
Traduction du document original
Français..................................................................................................................................................... 34
4VES-6Y .. 4NES-20(Y)
Installer
Monteur
Monteur
KW-232-12
Table of contents
1 Introduction............................................................................................................................................................3
2 Safety ....................................................................................................................................................................3
2.1 Also observe the following technical documents ...........................................................................................3
2.2 Authorized staff..............................................................................................................................................3
2.3 Residual risks ................................................................................................................................................3
2.4 Safety references...........................................................................................................................................3
2.4.1 General safety references.................................................................................................................. 3
3 Mounting the CM-RC-01 basic kit..........................................................................................................................4
3.1 Mounting the cable holders............................................................................................................................4
3.2 Removing the SE-B* motor protection device ...............................................................................................5
3.3 Connecting the oil heater...............................................................................................................................6
3.4 Mounting the discharge gas temperature sensor ..........................................................................................6
3.5 Mounting the oil monitoring............................................................................................................................7
3.6 Further electrical connections on the CM-RC-01...........................................................................................8
3.7 Screwing the cover onto the module housing................................................................................................8
3.8 Laying the cables...........................................................................................................................................9
4 Mounting the optional CM-RC-01 extension kits .................................................................................................10
4.1 Mounting the extension kit "Capacity control" (CRII) and "Start unloading" (SU)........................................10
4.2 Mounting the "Pressure transmitter" extension kit .......................................................................................11
4.3 Mounting the "Liquid injection" extension kit................................................................................................13
4.4 Mounting the "Additional fan" extension kit..................................................................................................14
5 Communication via BEST SOFTWARE ..............................................................................................................16
5.1 Configuration via BEST SOFTWARE ..........................................................................................................16
KW-232-1 3
1 Introduction
This document describes the procedure to follow for
mounting the CM-RC-01 compressor module add-on kit
to the compressors 4VES-6Y .. 4NES-20(Y). The de-
scription explains how to subsequently mount any com-
ponent of the basic kit and the optional extension kits to
the compressor. For electrical connection, please refer
to the Technical Information KT-230 enclosed.
Information
A prerequisite for mounting the CM-RC-01 com-
pressor module add-on kit to the compressor
models 4JE-13Y .. 4NES-20(Y) is an aluminium
terminal box!
Information
Observe the tightening torques for screwed con-
nections (see also Maintenance Instructions
KW-100)!
2 Safety
Compressor and compressor module have been built in
accordance with state-of-the-art technology and current
regulations. Particular importance has been placed on
user safety.
The notes given in the Operating Instructions for the
compressor must be followed in addition to these Main-
tenance Instructions.
Always keep the Operating Instructions and these
Maintenance Instructions in the vicinity of the refrigera-
tion system during the whole lifetime of the com-
pressor!
2.1 Also observe the following technical documents
Number Topic
KB-104 Operating Instructions ECOLINE com-
pressors
KT-150 Oil heater
KW-100 Tightening torques for screwed connec-
tions
KT-230 Compressor module CM-RC-01
2.2 Authorized staff
All work done on the compressors, the refrigeration
systems and their electronic accessories may only be
performed by qualified and authorized personnel who
have been trained and instructed accordingly. The local
regulations and guidelines will apply with respect to the
qualification and expertise of the specialists.
2.3 Residual risks
Compressors and electronic accessories may present
unavoidable residual risks. This is why any person
working on this device must carefully read this docu-
ment!
The following regulations shall apply:
• the relevant safety regulations and standards (e.g.
EN378, EN60204 and EN60335),
• generally accepted safety rules,
• EU directives,
• national regulations.
2.4 Safety references
are instructions intended to prevent hazards. Safety ref-
erences 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 hazard-
ous situation which may result in minor or mod-
erate injury.
WARNING
Safety reference to avoid a potentially hazard-
ous situation which could result in death or seri-
ous injury.
DANGER
Safety reference to avoid an imminently hazard-
ous situation which may result in death or seri-
ous injury.
2.4.1 General safety references
To be observed when performing work on the
compressor
WARNING
The compressor is under pressure!
Serious injuries are possible.
Depressurize the compressor!
Wear safety goggles!
KW-232-14
When working on the electrical and/or electronic
system, please observe the following
WARNING
Risk of electric shock!
Before working on the terminal box, module
housing and electrical lines: Switch off the main
switch and secure it against being switched on
again!
Close the terminal box and the module housing
before switching on again!
!
!
NOTICE
The compressor module may be damaged or
fail!
Never apply any voltage to the terminals of CN7
to CN12 – not even for test purposes!
The voltage applied to the terminals of CN13
must not exceed 10V!
The voltage applied to terminal 3 of CN14 must
not exceed 24V! Do no apply voltage to the
other terminals!
Never apply voltage to the voltage outputs, not even for
testing.
3 Mounting the CM-RC-01 basic kit
Procedure to follow for mounting the CM-RC-01 basic
kit of the compressor module add-on kit:
• Mounting the cable holders.
• Removing the SE-B* protection device.
• Connecting the oil heater.
• Mounting the discharge gas temperature sensor.
• Mounting the oil monitoring.
• Laying the cables and closing the cable ties.
• Closing the cover, screwing the compressor module
to the terminal box.
3.1 Mounting the cable holders
Mount 2 cable holders each to the cylinder
heads (see figure).
• To this end, loosen the corresponding screws
on the cylinder head, insert the screws again
with cable holders and tighten them (tighten-
ing torque 80 Nm).
• Attach plastic clip on the outer fixtures and in-
sert cable ties.
KW-232-1 5
3.2 Removing the SE-B* motor protection device
• Loosen the screws on the cover of the com-
pressor's terminal box and remove the cover.
• Then unscrew the protective earth conductor
from the terminal box cover.
Dismount the SE-B* motor protection device
from the terminal box.
• Pull the orange motor PTC cable off the ter-
minal plate.
• Then loosen the fixing screws of the motor
protection device and remove the device.
• Put the CM-RC-01 compressor module onto
the terminal box.
• Guide the orange motor PTC cable of the
compressor module downward through the
opening in the module housing and connect it
to the terminal plate of the compressor.
• Then guide the protective earth conductor of
the compressor upward into the module hous-
ing through the opening provided in the hous-
ing.
KW-232-16
• Properly position the compressor module on
the terminal box. The long side that is
provided with the numerous cable bushings of
the compressor module must point in the dir-
ection of the suction gas valve.
• Screw the protective earth conductor onto the
module housing.
3.3 Connecting the oil heater
• Put the oil heater cable through a screwed
cable gland on the compressor module and
connect it to the CN4 terminal strip.
• Guide the oil heater cable to the compressor
module as shown in the figure.
Information
For oil heater mounting, see Technical
Information KT-150.
3.4 Mounting the discharge gas temperature sensor
After mounting new components such as discharge gas
temperature sensor, pressure transmitter, injection
nozzle or injection valve:
WARNING
Serious injuries are possible. New component
may suddenly become detached.
Check the thread.
Carefully screw in the new component. Observe
the tightening torques!
Perform a tightness test before commissioning!
KW-232-1 7
• Remove the sealing plug from the connector
on the cylinder head marked by a circle and
clean the threaded bore.
• Then screw the discharge gas temperature
sensor in (tightening torque 35-40 Nm) and
tighten the connector by hand.
3.5 Mounting the oil monitoring
Information
A prerequisite for mounting the oil monitoring is
a bearing cover with the respective connection
(M20x1.5).
Information
For further details, see Technical Information
KT-180.
Information
Delivery in a pre-setup state:
If the prism unit of the oil monitoring has been
ordered pre-assembled, the compressor will
have already been tested as a whole in the fact-
ory for pressure strength and tightness. In this
case, it will only be necessary to screw on the
opto-electronic unit and to connect it electrically.
Subsequent tightness testing will not be re-
quired in this case.
If subsequently mounting the prism unit of the oil monit-
oring:
!
!
NOTICE
Risk of refrigerant loss!
Check the thread.
Carefully screw the new component in and
tighten it to the prescribed tightening torque.
Perform a tightness test before commissioning!
Mounting the prism unit
Preferably mount the enclosed prism unit, before the
compressor is mounted to the system.
• Tilt the compressor by lifting it up at the bottom of
the bearing cover in order that the oil in the oil
pocket of the bearing cover cannot drain through the
connecting bore.
• Screw the screw (M20x1,5) onto the bearing cover
and thoroughly clean the threaded bore.
• Check the inside and outside of the glass cone of the
prism unit for cleanliness and clean, if required.
• Screw the prism unit with metal gasket into the bear-
ing cover. Tightening torque 75 Nm.
• Perform a tightness test:
DANGER
Risk of bursting due to excessive pressure!
The pressure applied during the test must never
exceed the maximum permitted values!
Test pressure: 1.1-fold of the maximum allow-
able pressure (see name plate). Make a distinc-
tion between the high-pressure and low-pres-
sure sides!
KW-232-18
Mounting the opto-electronic unit
!
!
NOTICE
Risk of compressor failure!
Possible failure of the protection device
due to penetrating moisture!
Ensure that the cable connection always
faces down!
• Carefully insert the opto-electronic unit into
the prism unit up to the stop. Position and
cable routing downwards, see figure!
• Tighten the union nut of the opto-eletronic unit
by hand.
Following this, any optional extension kits can be
mounted (see chapter Mounting the optional CM-RC-01
extension kits, page 10).
3.6 Further electrical connections on the CM-RC-01
• Voltage supply of the compressor module on ter-
minal strip CN1 (115 .. 230V +10%/-15%, 50/60Hz
– Terminal 1: L
– Terminal 2: N
• Command for compressor start (release signal from
system controller).
• Optionally: Analogue signal for capacity control from
the system controller (0 .. 10 V).
Schematic wiring diagram and further information, see
Technical Information KT-230.
3.7 Screwing the cover onto the module housing
• Attach the enclosed adhesive label "CM-
RC-01" into the cover of the terminal box.
• Then screw the protective earth conductor to
the terminal box cover.
KW-232-1 9
• Put the terminal box cover on the compressor
module housing and fasten both to the ter-
minal box using the 6 enclosed screws (M5 x
70 mm).
3.8 Laying the cables
• Lay the cables along the cable holders and
use cable ties to fix them.
KW-232-110
4 Mounting the optional CM-RC-01 extension kits
Required components and procedure to follow for
mounting the optional extension kits of the compressor
module add-on kit:
• Mounting and connecting valve flanges and solenoid
valves for capacity control (CRII) and/or start unload-
ing (SU).
• Mounting and connecting the pressure transmitters.
• Mounting and connecting the liquid injection.
• Mounting and connecting the additional fan.
WARNING
The compressor is under pressure!
Serious injuries are possible.
Depressurize the compressor!
Wear safety goggles!
After mounting new components such as discharge gas
temperature sensor, pressure transmitter, injection
nozzle or injection valve:
WARNING
Serious injuries are possible. New component
may suddenly become detached.
Check the thread.
Carefully screw in the new component. Observe
the tightening torques!
Perform a tightness test before commissioning!
4.1 Mounting the extension kit "Capacity
control" (CRII) and "Start unloading" (SU)
Information
In order to allow the solenoid valves for capacity
control (CRII) and start unloading (SU) to be
mounted, the corresponding CRII and SU cylin-
der heads must already be pre-installed on the
compressor.
For safety references and installation descrip-
tions for the CRII or SU cylinder heads, includ-
ing mounting positions and exact equipment of
the cylinder banks, see Technical Information
KT-101 and KT-110.
• Remove the oval flange and seal from the
CRII/SU cylinder head and clean the sealing
surface.
• Apply a new seal, paying attention to the
guide pin positions!
• Use new screws to fasten the solenoid valve.
Alternately tighten the screws (tightening
torque 80 Nm).
Andere Handbücher für CM-RC-01
6
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