76239218-Bitzer

The widest Screw Range Products

Semi HermeticOpen Drive Hermetic

Bitzer Screw Compressors

Compact Screw

- Marine- Ammonia

- Low temp.- Supermarket- Cold room

- Chiller - Transport- Train A/C

Bitzer Intro_E – 1

- Cold room- Industrial

refrigeration

OS HSCSHCSW VSK

Today‘s focus......

Semi HermeticOpen Drive


Compact Screw

- Marine- Ammonia

- Low temp.- Supermarket- Cold room- Industrial

- Chiller


- Industrialrefrigeration

OS HS CSH (built in oil separator)

( external oil separator )

CSH Compact Screw with Integral Oil Separator

High Temperature screw compressors(With built in Motor & Oil separator)


CSH 65 / 75 / 85 / 95 (Max 300HP)

Screw Compressor ApplicationsCSH Series

Multiple Possibilities

4-step Capacity Control Infinite Capacity Control

CR 1 2 3 4 SU25%*50%

CR 1 2 3 4SU

��

��25


CR1

CR3 CR4

CR2

50%75%100%

��25

��50

��maxmin

Screw Compressor ApplicationsCSH Series

Single Compressor System – The Simplification of Application

1

8

Water Cooled Liquid Chiller:

� Single Circuit� Compact

+5oC

to

Not advisable for > 2 circuits


4

2

3 7 6 5

� Compact

simplified scheme

- 15oC

Bitzer-Software.lnk

SITE VISIT REPORT

Thailand – Plate Ice Machine - CSH

Application : Plate Ice MachineOperating Condition: -10oC SST / 40oC SCT Refrigerant : R22 Output : 25 tons plate ice per day

Date : Jan 2006


Output : 25 tons plate ice per dayEconomizer : NoYear 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

Today‘s focus......

Semi HermeticOpen Drive


Compact Screw

- Marine- Ammonia

- Low temp.- Supermarket- Cold room- Industrial

- Chiller


- Industrialrefrigeration

OS HS CSH (built in oil separator)

( external oil separator )

Screw Compressor Application Ranges

Semi-hermetic Screw Compressors

HSK & HSN


Design of Bitzer HS. Screw Compressor

CR pistons are absolutely flushwith flange & rotor contour

Single housing


Very large cross sections duringCR operation – minimum losses

HS 85 −−−− Transparent View


Integrated oil filter

Very solid bearing arrangement

HS. Screws – Working Principle

SL SL


DL

ECO

SU/CR

Bitzer Screws – Profile & Discharge Port

MaleRotor

FemaleRotor


Discharge Port

Application Range of Screw CompressorsHSK/HSN with R22

Full Load Operationwith & w/o Eco

Additional cooling


Additional cooling may be required,see ApplicationsManuals or Selection Software

Plant Chill waterFlake Ice MachineCold roomContact FreezerIQF, Blast freezers

Current Compressor Models – Semi-Hermetic

HS..K

HT & MTNLT

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


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

Screw Compressor Application Ranges

Open Drive Screw Compressors

OSK, OSN & OSKA, OSNA


Application Range of Screw CompressorsOSK/OSN with R22

Full Load Operationwith & w/o Eco

Additional cooling


Additional cooling may be required,see ApplicationsManuals or Selection Software

Current Compressor Models – Open Drive

OS..K

HT & MTNLT

Displacement[m3/h @ 50

Hz]R22 & HFCs NH3 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 OSNA 8571 410

�

Application Range of Open Drive Screws with NH3

Additional Cooling

(oil cooler)

required

With Part Load


Operation limited

Application Range:

see individual

envelopes

Comparison of Discharge Gas Temperatureswith Single Stage Operation

160

180

200

220

240

260

Dis

char

ge G

as T

empe

ratu

re [°

C]

to +5°C, tc 50°C

to -10°C, tc 45°C

to -35°C, tc 40°C

toh 20°C / *NH 3 ∆toh 5 KIsentropic Efficiency:HFCs + HCs 0.7 (semi-hermetic)NH3 0.8 (open type compressor)

outsideoperating limits

outsideoperating limits


0

20

40

60

80

100

120

140

R22 R 134a R 407C R404A /R507A

R 410A R 290 R 600a R 1270 NH3*

Dis

char

ge G

as T

empe

ratu

re [°

C]

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.


� 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

Example of 2-Stage Recip Compressor


2 stages – 6 cylinders recips- No unload option

6 cylinders recips- possible 66% / 33% unload

Systems of 2-stage Reciprocating Compressors incl. Subcooler

CondenserReceiver MPHP

MT T


Sub Cooler

Evaporator

CPR

LP

MT T

Cascade System

Vereinfachte DarstellungSimplified Sketch

-15oC

+40oC


-40oC

Application Range of Open Type Screwswith NH3 – general overview

40

30

tcOSKA

60

OSNA

50°C

Additional Cooling

(oil cooler)

requiered

With Part Load


20

10

0

-50 -40 -30 -20 -10 to 0 °C 10

OSKAB(Booster)

20

with add.oil pump

-10

-20

NH3(∆∆∆∆toh < 10K)

Operation limited

Application Range:

see individual

envelopes

Einsatzgrenzen R22-Booster ohne ZusatzkühlungApplication Limits R22 Booster w/o Additional Cooling

20

0

tc [°C]

10

Ver

flüss

igun

gste

mpe

ratu

rC

onde

nsin

g T

emp.

externe Ölpumpe erforderlich

additional oil pump requirerd


-10

-20

-30-55 to [°C]-50 -35-40-45 -25-30 -10

�toh = 10 K

HSKBOSKBR22

Verdampfungstemperatur / Evaporating Temp.

vorläufige Werte / preliminary data

Ver

flüss

igun

gste

mpe

ratu

rC

onde

nsin

g T

emp.

requirerd

Application Limits2-stage Reciprocating Compressors

50

40

tc

R22

60


30

20

10

0-80 -70 -60 -50 -40 to-30 -20

R404AR507A

toh =20°C 4.2

R507AHighest COPLow temp

Bitzer-Software.lnk

Booster screw Compressor Models

HSKBsemi

OSKBOpen type

R22/R404 orAmmonia NH3

HSKB5343-15 OSK(A)B 5341-K

HSKB5353-17 OSK(A)B 5351-K

HSKB5363-20 OSK(A)B 5361-K

HSKB6451-40


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

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

General Highlights of Bitzer Screw Compressors



� 3-step capacity control from smallest to largest model

� Unique “low pressure bearing chamber”50% / 75%

HS. Screws – Oil Management with Sealed Low Pressure Bearing Chamber

Conditions: R404A / Oil POE 170 cStSST -10°C / SDT 45°CDGT 80°C (w/o oil cooling)

Bitzer design withsealed bearing chamber:

BCP 6.5 bar (abs)Solution < 5% R404AViscosity > 20 cSt

Standard design


from oil separator

HP 20.5 bar (abs.)Viscosity 9 cSt (14% R404A)

Standard design w/o sealBCP 16.5 bar (abs.)Solution 11% Viscosity 12 cSt

LP 4.4 bar (abs.)









� 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”

50% / 75%

Semi-hermetic Screw CompressorOil Circuit with HS. Series

(Option)


Oil separator

NO oilDeliver insidecompressor


(Option)

Built in Motor Overload protector


Oil levelcontrol

Oil thermostat

Oil flowswitch

Oil sol valve

protector

Oil filter

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)

Protection & Control Devices for Screw Compressors


(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



INT389R

New Generation (SE-C1)is planned to introduce early next year

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

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.



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

S2

F5

F6

B2

P>

P<



Alarm Signal „Possibilities“

H1

L1L2L312

11

24 14

INT 389R

12N

L Z

B1

B2

S3

H2

K1 K3T

0.5 s

Discharge Gas Sensors (Oil Temp Sensor)



PTC100 (HS, OS)PTC120 (CSH)PTC140 (Recips)PT1000 (Recips CIC)

Oil flow switch



6 l/min (HS/OS53)10 l/min (HS/OS64/74)

Special versions for NH3


(Option)


Water cooled oil cooler

Shell & Tube Condensers

Sea Water VersionTD 15 K 6,6 to 780 kWTD 10 K 4,5 to 524 kW


Standard VersionTD 15 K 8 to 913 kWTD 10K 5,3 to 609 kW

Production Process - Brazing of the Tubes


Structure of Bitzer Tubes


=> High performance because of tube‘s low fouling b ehaviour

HS/OS Compressor Models – Capacity Ranges

OSK (-10/45)

HSN (-35/40)

HSK (-10/45) R404A

R404A

11 models

9 models

9 models


0 50 100 150 200 250 300 350 400 450 500

OSNA (-35/40)

OSKA (-10/40)

OSN (-35/40)

OSK (-10/45)

Cooling capacity range [kW]

R404A

NH3

7 models

7 models

9 models

9 models

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


HS/OS – Capacity Ranges ( maximum 6 units in a rack)

OSK (-10/45)

HSN (-35/40)

HSK (-10/45) R404A

R404A

Capacity ranges from 1 x HS./OS.53 >> 6 x HS./OS.74 71


0 200 400 600 800 1000 1200 1400 1600 1800

OSNA (-35/40)

OSKA (-10/40)

OSN (-35/40)

OSK (-10/45)

Cooling capacity range [kW]

R404A

NH3

10,000 MT Cold room

Screws vs. Large Recips.

Screw compressor Or

Large Reciprocating compressor?


Large Reciprocating compressor?

Advantages of Screws vs Large Recips1) 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


0.47 M

75 HP motor

13

2

4

5

77

6

2..3 mm

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



- higher COP hence save operating cost

BITZER Screw Compressor TechnologiesCompression Process

SL SL


DL

ECO

SL

DL

SCREW

Compressor –

Compression

Process


ECO

pc

pecopo

p

s

Process withEconomiser

StandardProcess

ECO

Screw compressor

Oil separator


TXV Liquid

subcooler

TXV

8

10

20

30

Pre

ssur

e [b

ar]

0

10

20

30

40

50°CECO

Economiser-System with Heat Exchanger

R404AR507A


0 50 100 150 200 250 300 3501

2

3

4

56

Pre

ssur

e [b

ar]

Enthalpy [kJ/kg]

-40°C

-30

-20

-10

0

∆∆∆∆h Standard

∆∆∆∆h with ECO

R507A

SCREW Compressor TechnologyArrangement of the ECO Suction Line


HSK 7461 vs Recip with Identical Displacement --

Comparison of Refrigeration Capacity

100

120

140

160

180

Ref

r. C

apac

ity [k

W]


0

20

40

60

80

100

30 40 50

SCT [°C]

Ref

r. C

apac

ity [k

W]

HSK 7461

HSK 7461 ECO

Recip

VG 220 m3/h SST -10°C SH 10 K R 22

Performance Data of Reciprocating Compressors vs. Screw Compressors − − − − Refrigerant R404A

100

Ref

riger

atin

g C

apac

ity [k

W]

VG 100 m3/h SCT 40°C SH 20 K

80

60

40


10

-10 -20 -30 -40

RECIP

SCREW

SCREW+ECO

SST [°C]

Ref

riger

atin

g C

apac

ity [k

W]

20 +60%

Performance Behaviour οοοοf Screw Compressors with Economizer vs. Reciprocating Compressors

150160170180190200

RECIP

Cap

acity

Incr

ease

with

re

duce

d S

CT

[%]

SST - 35 °C SH 20 K R 404A


100110120130140150

20 30 40 50

SREW+ECO

SCT [°C]

Cap

acity

Incr

ease

with

re

duce

d S

CT

[%]

Advantages of Screws vs Large Recips3) 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



- Rack has less risk as not depend on one compressor

Note that oil equalizing is very difficult for reci ps rack!

Advantages of Screws vs Large Recips4) 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


5) Less moving parts- No working valves to fail- more tolerence to liquid slugging



- more tolerence to liquid slugging - Improve reliability and durability- BITZER screw‘s design life is 15 years!


6) Easy Maintenance- Oil cleaness- oil temperature check



- oil temperature check- bearing check

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)


� 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)


� Discharge Check Valve

� Check all 5.000 h (or yearly respectively)

� Replacement after 20.000 .. 40.000 h recommended


� 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




� Pressure Relief Valve

� Maintenance free

� Opening pressure differential ∆p = 28 bar

� Tightness check recommended after actuation ( High pressure cut-out)


Screw Compressor Ball BearingsInspection and Replacement Intervalls

Replacement Intervals for a preventive maintenancesee 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

Screw Compressor Ball BearingsInspection 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

Disadvantages of Screws vs Large RecipsCost!!

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

Lubricants for Screw Compressors – Overview

Oil type Refrigerant Compressor type Oil injection tem perature

B 100 R22 HS.53/64/74 max. 80 °C(Alkyl Benzene) OS.53/74 max. 80 °C

B 150 SH R22 HS.53/64/74 max. 100 °C(Complex Ester) OS.53/70/74 max. 90 °C

B 320 SH(Complex Ester) R22 CSH, HSKC inside: max. DGT 120 °C


(Complex Ester) R22 CSH, HSKC inside: max. DGT 120 °C

BSE 170 R134a/R404A/R507A HS.53/64/74 max. 100 °C(Polyol Ester) OS.53/74 max. 90 °C

R134a, R407C CSH, HSKC inside: max. DGT 120°C

Clavus 32/46 (MO) NH3 OS.A 53/74 max. 50 °CClavus 68 (MO) OS.A 53/70/74 max. 60 °CSHC 226E (PAO) OS.A 53/74 max. 60 °C

76239218-Bitzer

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