bitzer
Short Description
compressor...
Description
The widest Screw Range Products Bitzer Screw Compressors Open Drive
- Marine - Ammonia
OS
Semi Hermetic
- Low temp. - Supermarket - Cold room - Industrial refrigeration
HS
Compact Screw
- Chiller
CSH CSW
Hermetic
- Transport - Train A/C
VSK Bitzer Intro_E –
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Today‘s focus...... Bitzer Screw Compressors Open Drive
- Marine - Ammonia
OS
Semi Hermetic
- Low temp. - Supermarket - Cold room - Industrial refrigeration
HS
( external oil separator )
Compact Screw
- Chiller
CSH (built in oil separator) Bitzer Intro_E –
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CSH Compact Screw with Integral Oil Separator High Temperature screw compressors (With built in Motor & Oil separator)
CSH
65 / 75 / 85 / 95 (Max 300HP)
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Screw Compressor Applications CSH Series 4-step Capacity Control
CR SU 25%* 50% 75% 100%
1
2
3
4
Infinite Capacity Control
Multiple Possibilities
CR1
CR2
CR SU
1
2
3
4
25 50 max min
CR3
CR4
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Screw Compressor Applications CSH Series Not advisable for > 2 circuits
+5oC
Water Cooled Liquid Chiller:
1 8
to
Single Circuit Single Compressor System – The Simplification of Application Compact
- 15oC
2
4
Bitzer-Software.lnk
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7
6
5
simplified scheme Bitzer Intro_E –
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SITE VISIT REPORT
Date : Jan 2006
Thailand – Plate Ice Machine - CSH Application : Plate Ice Machine Operating Condition: -10oC SST / 40oC SCT Refrigerant : R22 Output : 25 tons plate ice per day Economizer : No Year Installed : 2005 Compressor : 1 pcs. CSH Bitzer Screw Bitzer Model : CSH 8551-125 x 1 pcs 20 tons per day (CSH 7571-90) Contractor offer 5 years warranty
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Today‘s focus...... Bitzer Screw Compressors Open Drive
- Marine - Ammonia
OS
Semi Hermetic
- Low temp. - Supermarket - Cold room - Industrial refrigeration
HS
( external oil separator )
Compact Screw
- Chiller
CSH (built in oil separator) Bitzer Intro_E –
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Screw Compressor Application Ranges Semi-hermetic Screw Compressors HSK & HSN
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Design of Bitzer HS. Screw Compressor Single housing
CR pistons are absolutely flush with flange & rotor contour
Very large cross sections during CR operation – minimum losses Bitzer Intro_E –
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HS 85 − Transparent View
Integrated oil filter Very solid bearing arrangement
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HS. Screws – Working Principle SL
SL
ECO SU/CR
DL
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Bitzer Screws – Profile & Discharge Port
Male Rotor
Female Rotor
Discharge Port Bitzer Intro_E –
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Application Range of Screw Compressors HSK/HSN with R22
Full Load Operation with & w/o Eco Additional cooling may be required, see Applications Manuals or Selection Software
Contact Freezer Chill water ColdFlake roomIcePlant Machine IQF, Blast freezers Bitzer Intro_E –
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Current Compressor Models – Semi-Hermetic HS..
K
N
HT & MT
LT
Displacement [m3/h @ 50 Hz]
HSK5343-30
HSN5343-20
84
HSK5353-35
HSN5353-25
100
HSK5363-40
HSN5363-30
118
HSK6451-50
HSN6451-40
140
HSK6461-60
HSN6461-50
165
HSK7451-70
HSN7451-60
192
HSK7461-80
HSN7461-70
220
HSK7471-90
HSN7471-75
250
HSK 8551-110
315
HSK 8561-125
359
HSK 8571-140
HSN 8571-125
410 Bitzer Intro_E –
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Screw Compressor Application Ranges
Open Drive Screw Compressors OSK, OSN
& OSKA, OSNA
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Application Range of Screw Compressors OSK/OSN with R22
Full Load Operation with & w/o Eco Additional cooling may be required, see Applications Manuals or Selection Software
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Current Compressor Models – Open Drive OS..
K
N
HT & MT
LT R22 & HFCs
R22 & HFCs
NH3
OSK5343
OSKA5343
OSN5343
OSNA5343
84
OSK5353
OSKA5353
OSN5353
OSNA5353
100
OSK5363
OSKA5363
OSN5363
OSNA5363
118
OSK7441
OSKA7441
OSN7441
OSNA7441
165
OSK7451
OSKA7451
OSN7451
OSNA7451
192
OSK7461
OSKA7461
OSN7461
OSNA7461
220
OSK7471
OSKA7471
OSN7471
OSNA7471
250
OSK 8551
OSKA 8551
315
OSK 8561
OSKA 8561
359
OSK 8571
OSKA 8571
OSN 8571
NH3
Displacement [m3/h @ 50 Hz]
OSNA 8571
410
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Application Range of Open Drive Screws with NH3 Additional Cooling (oil cooler) required With Part Load Operation limited Application Range: see individual envelopes
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Comparison of Discharge Gas Temperatures with Single Stage Operation 260 240
to +5°C, tc 50°C
toh 20°C / *NH 3 ∆ toh 5 K Isentropic Efficiency: HFCs + HCs 0.7 (semi-hermetic) NH3 0.8 (open type compressor)
to -10°C, tc 45°C
Discharge Gas Temperature [°C]
220
to -35°C, tc 40°C
200 outside operating limits
180
outside operating limits
160 140 120 100 80 60 40 20 0 R22
R 134a
R 407C
R404A / R507A
R 410A
R 290
R 600a
R 1270
NH3*
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2-Stage Compressors & Systems Why 2-stage systems? Low temp. application / very low evaporating temperatures NH3 low mess flow charateristic will generate very high
discharge temperature at low temperature. need 2 stage, cascade system or booster systems.
2-stage systems‘s Fact are: - Is a MUST for R22 and NH3 refrigerant with low temp application - Generally increase the system efficiency - become complicated system, need precise control or high risk of failure Bitzer Intro_E –
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Example of 2-Stage Recip Compressor
2 stages – 6 cylinders recips - No unload option
6 cylinders recips - possible 66% / 33% unload
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Systems of 2-stage Reciprocating Compressors incl. Subcooler
Condenser
T CPR
MP
HP
T
Receiver
M
LP Sub Cooler
Evaporator Bitzer Intro_E –
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Cascade System +40oC
Vereinfachte Darstellung Simplified Sketch
-15oC
-40oC
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Application Range of Open Type Screws with NH3 – general overview 60 Additional Cooling
50 tc °C 40
OSKA
OSNA
(oil cooler) requiered
30
With Part Load Operation limited
20
Application Range: see individual
10 0 -10 -20 -50
OSKAB (Booster)
NH3 ∆toh < 10K) (∆
with add. oil pump
-40
envelopes
-30
-20
-10
0 °C
10
to
20 Bitzer Intro_E –
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Einsatzgrenzen R22-Booster ohne Zusatzkühlung Application Limits R22 Booster w/o Additional Cooling 20
tc [°C] Verflüssigungstemperatur Condensing Temp.
10 externe Ölpumpe erforderlich
0
additional oil pump requirerd
-10
HSKB OSKB R22
-20
toh = 10 K -30 -55
-50
-45
-40
-35
-30
-25
to [°C]
-10
Verdampfungstemperatur / Evaporating Temp. vorläufige Werte / preliminary data
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Application Limits 2-stage Reciprocating Compressors 60
tc 50 R22
40 30 R507A Highest COP Low temp 20
R404A R507A
10 toh =20°C
0 -80
-70
-60
-50
-40
-30
-20 to
4.2 Bitzer-Software.lnk
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Booster screw Compressor Models HSKB
OSKB
semi
Open type
HSKB5343-15
OSK(A)B 5341-K
HSKB5353-17
OSK(A)B 5351-K
HSKB5363-20
OSK(A)B 5361-K
R22/R404 or Ammonia NH3
HSKB6451-40 HSKB6461-40 HSKB7451-40
OSK(A)B 7451-K
HSKB7461-40
OSK(A)B 7461-K
HSKB7471-40
OSK(A)B 7471-K
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General Highlights of Bitzer Screw Compressors BITZER HS. Screw Compressors are the result of more than 20 years of experience in research, development, production and application of screw compressors. The latest step in this evolution features: Wide product range with the least No. of models Robust & long term proven construction elements 3-step capacity control from smallest to largest model
50% / 75%
Unique “low pressure bearing chamber”
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HS. Screws – Oil Management with Sealed Low Pressure Bearing Chamber Conditions: R404A / Oil POE 170 cSt SST -10°C / SDT 45°C DGT 80°C (w/o oil cooling)
Bitzer design with sealed bearing chamber: BCP 6.5 bar (abs) Solution < 5% R404A Viscosity > 20 cSt Standard design w/o seal BCP 16.5 bar (abs.) Solution 11% Viscosity 12 cSt
LP 4.4 bar (abs.)
from oil separator
HP 20.5 bar (abs.) Viscosity 9 cSt (14% R404A) Bitzer Intro_E –
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General Highlights of Bitzer Screw Compressors BITZER HS. Screw Compressors are the result of more than 20 years of experience in research, development, production and application of screw compressors. The latest step in this evolution features: Wide product range with the least No. of models Robust & long term proven construction elements 3-step capacity control from smallest to largest model
50% / 75%
Unique “low pressure bearing chamber” Suitable for highly efficient Economiser operation Comprehensive extent of delivery Advanced protection system Complete program of accessories (incl. oil separators, oil coolers) Independent engineering & production “know how” Bitzer Intro_E –
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General Highlights of Bitzer Screw Compressors BITZER HS. Screw Compressors are the result of more than 20 years of experience in research, development, production and application of screw compressors. The latest step in this evolution features: Wide product range with the least No. of models Robust & long term proven construction elements 3-step capacity control from smallest to largest model Unique “low pressure bearing chamber” Suitable for highly efficient Economiser operation Comprehensive extent of delivery Advanced protection system Complete program of accessories (incl. oil separators, oil coolers) Independent engineering & production “know how” Bitzer Intro_E –
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Semi-hermetic Screw Compressor Oil Circuit with HS. Series (Option)
Oil separator NO oil Deliver inside compressor
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General Highlights of Bitzer Screw Compressors BITZER HS. Screw Compressors are the result of more than 20 years of experience in research, development, production and application of screw compressors. The latest step in this evolution features: Wide product range with the least No. of models Robust & long term proven construction elements 3-step capacity control from smallest to largest model Unique “low pressure bearing chamber” Suitable for highly efficient Economiser operation Comprehensive extent of delivery Advanced protection system Complete program of accessories (incl. oil separators, oil coolers) Independent engineering & production “know how” Bitzer Intro_E –
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Semi-hermetic Screw Compressor Oil Circuit with HS. Series (Option)
Built in Motor Overload protector Oil sol valve Oil flow switch
Oil level control
Oil filter Oil thermostat Bitzer Intro_E –
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Protection & Control Devices for Screw Compressors SE-E1 (INT69VSY-II) (has to be connected as first item in the control/protection circuit) Motor Protection with Manual Reset
PTC sensors for monitoring of motor temperature
Discharge Gas Temperature Protection
Monitoring of Discharge Gas Temp. (PTC Sensor located in the Compressor Discharge Chamber)
Fail Prove of PTC-Sensor(s)
Checking of PTC Sensor Cycle (open circuit, broken line)
Checking Direction of Rotation & Phase Failures Interrupts control current and locks-out with wrong direction
Reset: Short interruption of supply voltage (L/N) for at least 5 sec. Further Details: See Applications Manual SH-100 / SH-170 / SH-500
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Protection & Control Devices for Screw Compressors
INT389R
New Generation (SE-C1) is planned to introduce early next year Bitzer Intro_E –
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Protection & Control Devices for Screw Compressors INT389R
Motor Protection with Manual (or Auto-) Reset
Function - same as INT69VSY-II
Manual reset: Short interruption of supply voltage
Auto-reset by removing link between B1/B2: 5 faults / 24h accepted
Single phasing / Phase asymmetry protection
automatic start repetition after each 30 minutes
Discharge Gas Temperature Protection
Function - same as INT69VSY
Manual reset: Short interruption of supply voltage
Auto-reset by removing link between B1/B2: 5 faults / 24h accepted Bitzer Intro_E –
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Protection & Control Devices for Screw Compressors INT389R (cont‘d)
Limitation of switching frequency The total of operating & off-time is limited to a minimum of 7 minutes Signal lamp “H2” Shortening of pause time (for service) by linking Z/B1 for approx. 2 sec. Minimum starting delay: 30 sec after shut-off (independent from running period)
Further Details: See Applications Manual SH-100 / SH-500
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Protection & Control Devices for Screw Compressors S2 B2 F5 P> F6 P< L1 L2 L3 1 2
11
L
Z
INT 389R 14
24
N
B1 12
S3
B2
H2
Alarm Signal „Possibilities“ K1
K3T
H1
0.5 s Bitzer Intro_E –
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Protection & Control Devices for Screw Compressors Discharge Gas Sensors (Oil Temp Sensor)
PTC100 (HS, OS) PTC120 (CSH) PTC140 (Recips) PT1000 (Recips CIC) Bitzer Intro_E –
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Protection & Control Devices for Screw Compressors Oil flow switch
6 l/min (HS/OS53) 10 l/min (HS/OS64/74) Special versions for NH3 Bitzer Intro_E –
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Semi-hermetic Screw Compressor Oil Circuit with HS. Series (Option)
Water cooled oil cooler Bitzer Intro_E –
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Shell & Tube Condensers Sea Water Version TD 15 K 6,6 to 780 kW TD 10 K 4,5 to 524 kW
Standard Version TD 15 K 8 to 913 kW TD 10K 5,3 to 609 kW Bitzer Intro_E –
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Production Process - Brazing of the Tubes
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Structure of Bitzer Tubes
=> High performance because of tube‘s low fouling behaviour Bitzer Intro_E –
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HS/OS Compressor Models – Capacity Ranges
HSK (-10/45)
11 models
R404A
9 models
R404A
9 models
NH3
9 models
HSN (-35/40) OSK (-10/45)
7 models
OSN (-35/40) OSKA (-10/40) OSNA (-35/40)
7 models 0
50
100
150
200
250
300
350
400
450
500
Cooling capacity range [kW] Bitzer Intro_E –
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Bitzer HS & OS Screw Compressors The Ideal Products for Parallel Operation !! High pressure oil return Can be horizontal or vertical mount Can up to 6 compressors or more
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HS/OS – Capacity Ranges ( maximum 6 units in a rack)
Capacity ranges from 1 x HS./OS.53 >> 6 x HS./OS.7471 HSK (-10/45)
R404A
HSN (-35/40) OSK (-10/45)
R404A
OSN (-35/40) OSKA (-10/40)
NH3
OSNA (-35/40) 0
200
400
10,000 MT Cold room
600
800
1000
1200
1400
1600
1800
Cooling capacity range [kW] Bitzer Intro_E –
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Screws vs. Large Recips.
Screw compressor Or Large Reciprocating compressor?
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Screws vs. Large Recips. Advantages of Screws vs Large Recips 1) Higher Specific Capacity -- based on Displacement - higher running speed 2900 RPM vs. 1450 rpm - much smaller and compact in size, lower weight 0.56 M
75 HP motor 2 4 3
1
0.47 M
2..3 mm
6 5 7
7 Bitzer Intro_E –
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Screws vs. Large Recips. Advantages of Screws vs Large Recips 2) Potential for Economiser Operation for better efficiency - very flat performance characteristic with varying CT - higher COP hence save operating cost
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BITZER Screw Compressor Technologies Compression Process SL
SL
ECO
DL
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SL
SCREW Compressor – Compression Process DL
ECO
p
pc
po
peco
Process with Economiser Standard Process
s
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ECO Oil separator Screw compressor
TXV
Liquid subcooler
TXV Bitzer Intro_E –
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Economiser-System with Heat Exchanger 30 50°C
ECO
20
40 30
Pressure [bar]
20 10 10
8
R404A R507A
0
6 5
-10
4 -20
3
-30
2
∆h Standard
-40°C
∆h with ECO
1 0
50
100
150 200 Enthalpy [kJ/kg]
250
300
350 Bitzer Intro_E –
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SCREW Compressor Technology Arrangement of the ECO Suction Line
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HSK 7461 vs Recip with Identical Displacement -Comparison of Refrigeration Capacity 180
Refr. Capacity [kW ]
160 140 120 100 80 HSK 7461 HSK 7461 ECO Recip
60 40 20
3
VG 220 m /h SST -10°C SH 10 K R 22
0 30
40 SCT [°C]
50 Bitzer Intro_E –
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Performance Data of Reciprocating Compressors vs. Screw Compressors − Refrigerant R404A Refrigerating Capacity [kW]
100 80
VG 100 m3/h SCT 40°C SH 20 K
60 40
RECIP 20
+60%
SCREW SCREW+ ECO
10 -10
-20
-30
-40
SST [°C] Bitzer Intro_E –
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Capacity Increase with reduced SCT [%]
Performance Behaviour οf Screw Compressors with Economizer vs. Reciprocating Compressors 200 190 180 170 160 150 140 130 120 110 100
SST - 35 °C SH 20 K R 404A
RECIP SREW +ECO
20
30
40
50
SCT [°C] Bitzer Intro_E –
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Screws vs. Large Recips. Advantages of Screws vs Large Recips 3) Best parallel system – possible for rack system - simple part load 50% / 75% / 100% - Can start unload - Energy saving, low operating cost - Rack has less risk as not depend on one compressor
Note that oil equalizing is very difficult for recips rack!
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Screws vs. Large Recips. Advantages of Screws vs Large Recips 4) Less Noise - Twin screw rotors not touching each other, can even rotate a 75HP screw with hand - less wear and tear, hence longer life time - less vibration – run like a smooth 10 cylinders recips - reduce chance of pipe fracture and system leakage - no need discharge muffler
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Screws vs. Large Recips. Advantages of Screws vs Large Recips 5) Less moving parts - No working valves to fail - more tolerence to liquid slugging - Improve reliability and durability - BITZER screw‘s design life is 15 years!
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Screws vs. Large Recips. Advantages of Screws vs Large Recips 6) Easy Maintenance - Oil cleaness - oil temperature check - bearing check
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Screw Compressors (HS & OS) Service and Maintenance Works
Oil Filter – & Replacement
change after first 50...100 h (operating hours) recommended
check all 5.000 h (or yearly respectively)
must be replaced when pressure drop > 0.5 bar
Oil Change
with HCFC and HFC refrigerants
not necessary when using suction line fine filter (10 µm)
mandatory with contaminated systems and with acid formation
with NH3 (unsoluble lubricants)
first change after 100 h (oil and oil filter)
add oil if requested -- change all 5.000 h (or yearly respectively)
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Screw Compressors (HS & OS) Service and Maintenance Works
Oil Solenoid Valve
Check diaphragm all 5.000 h (or yearly respectively)
when deformed: change diaphragm and back-up ring (fitting position !!)
check system and eliminate causes of oil migration into compressor
Replacement after 100.000 h recommended
Oil Flow Switch
Check all 5.000 h (or yearly respectively)
Replacement after 100.000 h recommended
Discharge Check Valve
Check all 5.000 h (or yearly respectively)
Replacement after 20.000 .. 40.000 h recommended Bitzer Intro_E –
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Screw Compressors (HS & OS) Service and Maintenance Works
Shaft Seal
Leakage tolerable up to 0,05 cm3/h
Check intervalls -- depending on application
AC all 5.000 h
MT & LT all 10.000 h
Replacement after 20.000 .. 40.000 h recommended
Pressure Relief Valve
Maintenance free
Opening pressure differential ∆p = 28 bar Tightness check recommended after actuation ( High pressure cut-out)
Replacement after 100.000 h recommended
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Screw Compressor Ball Bearings Inspection and Replacement Intervalls Replacement Intervals for a preventive maintenance see table on next slide
The total life span potential for normal operation of the bearings is not reached
Due to occasional deviations from normal operating conditions like
Lack of oil
Less oil viscosity caused by wet operation
Insufficient suction superheat
Thermal Overload
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Screw Compressor Ball Bearings Inspection and Replacement Intervalls Inspection / replacement intervall recommendations -- operating hours (h) Refrigerant
AC application
MT
LT
R134a
1)
10.000 / 50.000 --
10.000 / 50.000
--
R22, R407C
1)
10.000 / 40.000
10.000 / 40.000
10.000 / 50.000
R404A, R507A
1)
10.000 / 40.000
10.000 / 40.000
10.000 / 50.000
R717
1)
10.000 / 40.000
10.000 / 40.000
10.000 / 50.000
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Screws vs. Large Recips. Disadvantages of Screws vs Large Recips Cost!! Usually higher investment cost for small capacity but more economy for larger capacity But BITZER‘s screw is relatively small in sizes hence sometimes it‘s not more expansive than Large Recips compressors
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Lubricants for Screw Compressors – Overview Oil type
Refrigerant
Compressor type
Oil injection temperature
B 100 (Alkyl Benzene)
R22
HS.53/64/74 OS.53/74
max. 80 °C max. 80 °C
B 150 SH (Complex Ester)
R22
HS.53/64/74 OS.53/70/74
max. 100 °C max. 90 °C
R22
CSH, HSKC
inside: max. DGT 120°C
R134a/R404A/R507A
HS.53/64/74 OS.53/74 CSH, HSKC
max. 100 °C max. 90 °C inside: max. DGT 120°C
OS.A 53/74 OS.A 53/70/74 OS.A 53/74
max. 50 °C max. 60 °C max. 60 °C
B 320 SH (Complex Ester) BSE 170 (Polyol Ester)
R134a, R407C Clavus 32/46 (MO) Clavus 68 (MO) SHC 226E (PAO)
NH3
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