比泽尔压缩机使用手册.pdf

1SH 170 3 CN 应用手册 Applications Manual Semi hermetic Compact Screws CSH65 CSH95 SH 170 3 CN 半封闭整体式螺杆压缩机 CSH65 CSH95 2SH 170 3 CN 目 录 1 特色 2 设计和功能 2 1 设计特点 2 2 压缩过程Vi控制 2 3 能调控制和卸载启动 2 4 液压控制 2 5 压缩机启动 2 6 无级能量调节 2 7 4级能量调节 2 8 油循环 3 润滑油 4 制冷回路中的安装 4 1 压缩机的安装 4 2 系统布置 4 3 压缩机和机组的安全运行 5 直接喷液附加冷却 5 1 LI喷嘴喷液冷却 5 2 喷液阀喷液冷却 6 外置油冷附加冷却 7 经济器运行 ECO 7 1 概 述 7 2 工作原理 7 3 带过冷循环的ECO运行 7 4 带中间压力储液器的ECO 运行 7 5 ECO回气管路消声音器 7 6 管路布置 7 7 附 件 7 8 控 制 7 9 带喷液冷却的ECO运行 8 电气连接 8 1 电机设计 8 2 压缩机保护装置 8 3 电器盒 8 4 电气元件选择 8 5 接线示意图 9 产品概要 10 技术参数 11 应用范围 12 性能数据 软件 12 1 选择压缩机 12 2 性能数据计算 13 尺寸图 页码 3 5 5 8 9 11 11 11 15 15 17 18 18 19 23 26 26 29 32 37 37 37 38 39 39 40 41 42 42 44 44 46 49 52 55 63 64 66 68 69 70 74 Contents 1 The special highlights 2 Design and functions 2 1 Design features 2 2 Compression process Vi control 2 3 Capacity control and start unloading 2 4 Hydraulic control 2 5 Starting the compressor 2 6 infi nite capacity control 2 7 4 step capacity control 2 8 Oil circulation 3 Lubricants 4 Integration into the refrigeration circuit 4 1 Mounting the compressor 4 2 System layout 4 3 Safe operation of compressor and plant 5 Additional cooling by means of direct liq uid injection LI 5 1 LI withintegral LI nozzle 5 2 LI valve 6 Additional cooling by means of external oil cooler 7 Economiser operation ECO 7 1 General 7 2 Operation principle 7 3 ECO operation with subcooling circuit 7 4 ECO operation with intermediate pressure receiver 7 5 Pulsation muffl er in ECO suction line 7 6 Pipe layout 7 7 Additional components 7 8 Control 7 9 ECO operation with liquid injection 8 Electrical connection 8 1 Motor design 8 2 Compr protection device 8 3 Terminal box 8 4 Selection of electrical components 8 5 Schematic wiring diagrams 9 Program survey 10 Technical data 11 Application limits 12 Performance data Software 12 1 Select the compressor 12 2 Determine perform data 13 Dimensional drawings Page 3 5 5 8 9 11 11 11 15 15 17 18 18 19 23 26 26 29 32 37 37 37 38 39 39 40 41 42 42 44 44 46 49 52 55 63 64 66 68 69 70 74 3SH 170 3 CN 排气量 50Hz Displacements 50Hz Semi hermetic Compact Screws CSH Series Displacements from 137 to 910 m3 h at 50 Hz 1 The special highlights The CSH Compact Screws set the worldwide standard for technical innovation and effi ciency Energy effi cient high effi ciency profi le infi nite or closely stepped capacity control optimum economiser operation Universal R134a R407C and R22 R404A R507A upon request with and without economiser ECO Compact shortest fi tting length in its performance class shut off valves its function is verifi ed by respective tests Switch compressor to part load operation CR 50 immediately before every reversing approx 15 max 20 seconds this operating condition ensures the highest possible oil pressure Maintain part load operation CR 50 after reversing until a pressure difference of at least 3 0 bar is reached After this the compressor can be switched to full load Specifi c modifi cations to the functional characteristics mentioned above may become necessary depending on the system design 26SH 170 3 CN 5 直接喷液附加冷却 在高冷凝温度或低蒸发温度的应用中 压缩机需附加 冷却 见11章应用范围 一个简单的方法是在现 有的经济器接管处进行直接喷液冷却 图9 10 为此 比泽尔提供与相应的压缩机型号匹配的特制 喷嘴 LI喷嘴 另一个替代方案是使用特制的喷液阀 针对以上两种方案的设计建议详见5 1和5 2节 5 1 LI喷嘴喷液冷却 LI喷嘴和接头作为一个整体安装在经济器端口 图 9 喷嘴经过特殊设计以使喷液量与实际需求相匹 配 替换时 拿掉原来的标准接头 密封型螺钉或 椭圆型法兰 取而代之的是带LI喷嘴的接头 同时 还需安装一个温度开关和在喷液管上电磁 阀 温度开关根据排气温度来控制电磁阀的开关 喷液管走向 为了保证供给LI喷嘴的制冷剂液体没有气泡 连接 管必需取液于水平液管 而且起始段必需首先向下 走管 见图9中上图 带LI喷嘴的接头组件 组件号 内径 CSH65 361332 06 16mm 5 8 CSH75 361332 05 16mm 5 8 CSH85 361332 04 10mm 3 8 CSH95 361332 07 10mm 3 8 5 Additional cooling by means of direct liquid injection LI Additional cooling is required in areas of high condensing and or Iow evaporating temperatures see application limits chapter 11 This can easily be achieved by direct liquid injection at the ECO port fi gures 9 and 10 For this purpose special injection nozzles are provided LI nozzles which are specifi cally designed for the respec tive compressor models As an alternative specially designed expansion valves can be used Layout recommendations for both variants see the fol lowing chapters 5 1 and 5 2 5 1 Liquid injection with integral LI nozzle LI nozzle and adaptor are mounted as a unit directly into the ECO port fi g 9 below This nozzle is tuned by design for injection fl ow in relation to the demand For retrofi tting the standard adaptor is removed sealing screw or oval fl ange and replaced by the adaptor with LI nozzle As additional components a solenoid valve in the liquid line to the LI nozzle and a thermostat are required The thermostat opens and closes the solenoid valve depend ing on the discharge gas temperature Pipe runs To ensure a bubble free liquid supply to the integral LI nozzle the connection must be made on a horizontal section of the liquid line and the pipe should at fi rst lead downwards see fi g 9 above Kit of adaptor with LI nozzle Kit No Inlet CSH65 361332 06 16mm 5 8 CSH75 361332 05 16mm 5 8 CSH85 361332 04 10mm 3 8 CSH95 361332 07 10mm 3 8 27SH 170 3 CN 注意 振动有可能引起管子破裂 用卡箍固定电磁阀和喷液管 运行时检查振动 Attention Vibration fracures possible Fit solenoid valve and liquid line with clips Check vibration behaviour during operation 图 9 喷液附加冷却 整体式LI喷嘴 CSH95接管位于压缩机上部 Fig 9 Additional cooling by means of liquid injection design with integral LI nozzle connection is located at compressor top for CSH95 28SH 170 3 CN 喷嘴管路上的电磁阀 根据附加冷却所需最大冷量选择 见BITZER选型软件 考虑极限运行工况 最小蒸发温度 最大吸气 过热度和最大冷凝温度 电磁阀控制 通过常开触电与电机同步并由温度传感器控制 电磁阀位置 CSH65 CSH85 接管向下至少高于ECO接口20cm 见图9下 CSH95 接管可水平或垂直向下与接头相连 电磁阀温度传感器 高品质 传感器温度至少120 温度设定 ON 110 OFF 100 感温包置于排气管路 平滑并清洁排气管表面至光亮金属 在接触面上涂传热胶 用管夹固定感温包 注意热膨胀 对感温包隔热 喷液管路清洁度 喷液口直接与压缩机相连 因此必需十分干净 无 焊渣 金属屑 锈渣 磷化膜等 Solenoid valve in liquid line to LI nozzle Dimension appropriately according to maximum re quired capacity for additional cooling see BITZER Software consider the most extreme conditions that can oc cur in a real operation minimum evaporation temp erature maximum suction gas superheat and cond ensing temperature Control of the solenoid valve parallel to compressor motor via normally open con tact NO and additionally via a thermostat Positioning of the solenoid valve CSH65 CSH85 Line connection facing directly downwards min 20 cm above ECO connection fi g 9 below CSH95 Run pipe joints horizontally or downwards Thermostat for solenoid valve High quality design suitable for sensor temperatures up to 120 Temperature setting ON 110 OFF 100 Mount thermostat bulb on the discharge line Smoothen the tubes surface carefully and clean the surface to bright metal Apply heat transfer paste to the contact surface Fix the bulb fi rmly with adequate pipe clips Mind heat expansion Insulate the bulb Cleanness in liquid and injection line The injection connection at the compressor ECO con nection leads directly into the profi le area For this reason the pipes must be absolutely clean free of slags swarfs rust and phosphate coatings 29SH 170 3 CN 5 2 Liquid injection valve As an alternative to the liquid injection with integral LI nozzles specially designed expansion valves can be used for additional cooling Valve must regulate according to the discharge tem perature suitable design e g Danfoss TEAT20 Alco series 935 101 B Sporlan Y1037 Temperature setting 100 110 Mount valve bulb on the discharge line Smoothen the tubes surface carefully and clean the surface to bright metal Apply heat transfer paste to the contact surface Fix the bulb fi rmly with adequate pipe clips Mind heat expansion Insulate the bulb Pipe runs To ensure a bubble free liquid supply to the liquid injec tion valve the connection must be made On a horizontal section of the liquid line and the pipe should at fi rst lead downwards see fi g 10 above Attention Vibration fractures possible Fit injection valve solenoid valve and liquid line with clips Check vibration behaviour during operation Fitting of the liquid injection valve at the compressor CSH65 CSH85 Line connection facing directly downwards to the adapor min 20 cm above injection connection of the compressor ECO see fi gure 10 below CSH95 Run pipe joints horizontally or downwards 5 2 喷液阀喷液冷却 喷嘴喷液冷却的替代方案是使用特制的喷液膨胀阀 阀门的开度必需通过排气温度来进行控制 推 荐的有 Danfoss公司的TEAT20 Alco公司的 935 101 B Sporlan 公司的Y1037 温度设定 100 110 感温包置于排气管路 平滑并清洁排气管表面至光亮金属 在接触面上涂传热胶 用管夹固定感温包 注意热膨胀 对感温包隔热 喷液管走向 为了保证供给LI喷嘴的制冷剂液体没有气泡 连接 管必需取液于水平液管 而且起始段必需首先向下 走管 见图10中上图 注意 振动有可能引起管子破裂 用卡箍固定电磁阀和喷液管 运行时检查振动 压缩机端喷液阀的安装 CSH65 CSH85 接管直接向下与接头相连 至少高于ECO接口 20cm ECO 见图10下 CSH95 接管可水平或垂直向下与接头相连 30SH 170 3 CN 图10 喷液阀附加冷却 CSH95接管位于压缩机上部 Fig 10 Additional cooling by means of liquid injection via expansion valve connection is located at compressor top for CSH95 减振消音器 由于喷液管直接连接在ECO端口 压缩区的脉冲 压力在某种情况下会产生共振 可能会振坏喷液 阀 为经济器运行专门设计的减振消音器可保 Pulsation muffl er Due to a direct connection of the injection port ECO and the rotor profi le area gas pulsations may result in resonance vibrations depending on certain operation conditions This can damage the injection valve The pul 31SH 170 3 CN 护喷液阀 技术细节 组件号和安装建议见第 7章 喷液管路清洁度 喷液口直接与压缩机相连 因此必需十分干净 无 焊渣 金属屑 锈渣 磷化膜等 喷液阀冷量计算 使用BITZER选型软件 考虑在实际运行中的极限工况 最低蒸发温度 最大吸气过热和最大冷凝温度 喷液阀选择的其它条件 喷射点的压力 对R134a 比吸气压力高大约2 3 bar对R407C R22 比吸气压力高大约2 5 3 5 bar 决不要选择过大的喷液阀以防湿运行 喷液管上其它元件 电磁阀 与压缩机同步通断电 直接安装在喷液阀前面 必要时使用卡箍固定 精细过滤器 如需 视液镜 带膨胀阀的喷液冷却 详见第7 9章 带喷液的经济器运行 一节 sation muffl er for ECO operation should be used to pro tect the valve Technical details kit numbers and mounting recommendations see chapter 7 Cleanness in liquid and injection line The injection connection at the compressor ECO con nection leads directly into the profi le area Therefore the pipes must be absolutely clean free of slags swarfs rust and phosphate coatings Calculating the cooling capacity of the liquid injec tion valve with the BITZER Software consider the most extreme conditions to be expected during actual operation min evaporating temperature max suction gas superheat and condensing tempera ture Further conditions for valve selection Pressure at the injection point R134a approx 2 3 bar above suction pressureR407C R22 approx 2 5 3 5 bar above suction pressure Never size the valve too large Danger of wet operation Additional components in the liquid line Solenoid valve energize parallel to compressor motor place directly in front of injection valve fi t with clips if necessary Fine fi lter if required Liquid sight glass Liquid injection with expansion valve see chapter 7 9 ECO operation with liquid injection 32SH 170 3 CN 6 Additional cooling by means of external oil cooler The application of an external oil cooler air water or refrigerant cooled compared to liquid injection provides an additional extension of the application limits and even better effi ciency When calculating an oil cooler worst case operating conditions must be considered under observation of the application limits min evaporating temperature max suction gas superheat max condensing temperature operation mode capacity control ECO Calculate oil cooler capacity by using the BITZER Soft ware Connecting an external oil cooler Connections for external oil coolers are located on the back side of the compressor below the discharge shutoff valve oval or rectangle fl ange pos 11 in dimensional drawing CSH65 CSH75 Replace the oval fl ange by a pipe adaptor option of connections 16 mm 5 8 kit No 367905 01 CSH85 CSH95 Remove the rectangle fl ange and screw in two nipples option of connections 22 mm 7 8 kit No 367905 02 6 外置油冷附加冷却 与直接喷液冷却相比 采用外置油冷冷却 风冷 水冷或制冷剂冷却 可以扩大压缩机的应用范围甚 至提高效率 在计算油冷却器时 应考虑应用范围内的最恶劣运 行工况 最低的蒸发温度 最大的吸气过热度 最高冷凝温度 运行模式 能量调节 经济器 使用BITZER选型软件计算油冷负荷 外置油冷的连接 外置油冷的连接口位于压缩机后侧排气截止阀下方 外形尺寸图中位置11 椭圆或矩形法兰 CSH65 CSH75 拆去椭圆形法兰 装上管件接配器 选配 接管直径 16mm 5 8 组件号367905 01 CSH85 CSH95 拆去矩形法兰 旋上两个接头 选配 接管直径 22mm 7 8 组件号367905 02 图11 外置油冷的连接位置 电磁阀和油过滤器 按需 Fig 11 Connecting positions of external oil cooler Solenoid valve and oil fi lter if required 33SH 170 3 CN 传感器位置 温度设定 通 常 最 大 Sensor position Temperature setting nominal maximum 风冷油冷却器的风扇 Fan of an air cooled oil coller 油冷温控器 排气管线 Temperature regulator for oil cooler Discharge gas line 旁通阀或水路控制阀 排气 30K tc max 90 By pass valve or water control valve Discharge gas line 40K tc max 100 油冷的安装位置尽量靠近压缩机 管路设计要求避免停机后形成气囊和油流回压缩 机 安装油冷与压缩机水平或低于压缩机 由于增加了油回路的容积 油冷 冷却管路 可 能需要在油管路上安装一个电磁阀以避免停机后 油回流至压缩机 该电磁阀应离压缩机的回油口 尽可能的近 同时电磁阀的通断应与主接触器的 常开触点保持同步 建议安装如下额外附件 视油镜 监测油流 手动球阀 在进出口安装以便维护 油过滤器 最大网孔尺寸25 m 在油冷 位置较远或部件清洁度不能保证时使用 若额外注油量不超过压缩机标准注油量的10 同时能够保证冷却回路各组件清洁度 则上述额 外措施可以省略 其它非标设计均需单独审核 油冷必需有油温控制 温度设定见下表 Install oil cooler as close as possible to the compressor Piping design must avoid gas pads and any drainage of oil into the compressor during standstill install the oil cooler preferably at compressor level or below Due to the additional oil volume cooler piping a sole noid valve may be necessary in the oil line This is to avoid oil migration into the compressor during standstill The solenoid valve must be installed close to the compressor s oilinlet connection and it s electric cont rol should be parallel to the contactor s normally open contact Recommended additional components sight glass to monitor oil fl ow manual shut off ball valves in both feed and return lines for ease of service oil fi lter max 25 m mesh size in case of remote oil cooler or if cleanliness of components is not guaranteed Up to an additional oil volume cooler and piping of 10 of the compressor s standard oil charge and as sured cleanliness of components and pipes the above mentioned additional measures can be omitted Devi ating layout criteria must be secured by individual checks Oil coolers must be controlled by thermostats see table for temperature settings 1 1 34SH 170 3 CN 图12 例 水冷式油冷 Fig 12 Example water cooled oil cooler 为使冷却回路中的油快速升温和减少压降 在以 下情况需设计油旁通回路 甚或在停机时加热 油冷 停机期间油冷中油温可能降到20 以下 油冷和连接管路的油容量大于压缩机的油充 注量 油冷与冷凝器为一体 油路旁通阀应具有能根据温度进行调节的功能 如使用电磁阀间歇控制 要求使用高精度且具有 最小幅差的温度开关 有效温度波动 120 For rapid heating of the oil circuit and minimising the pressure drop with cold oil an oil by pass or even heat ing the cooler during standstill is mandatory under the following conditions the oil temperature in the cooler drops below 20 during standstill the oil volume of cooler plus oil piping exceeds the compressor s oil charge the oil cooler is an integral part of the condenser coil The by pass valve should have a temperature respon sive modulating control function The use of a sole noid valve for intermittent control requires highest sen sitivity of the control thermostat and a minimai switch ing differential effectivetemperature variation 120 35SH 170 3 CN 图13 例 风冷式油冷 A 独立换热器 B 与冷凝器一体 Fig 13 Example air cooled oil coolers A separate heat exchanger B integrated into condenser coil 风冷式油冷 可采用开关型调节或风扇无级调速进行油温控制 设定点见上表 允许传感器温度 120 在油冷和冷凝器做成一体的情况下 旁通阀同时起 到油温控制的作用 设定点见上表 允许运行和 或 传感器温度 120 Air cooled oil cooler Temperature control by thermostatic switching on and off or stepless speed control of the cooler fan see table for set point admissible sensor temperature 120 In case of condenser integrated oil coolers the by pass valve simultaneously controls the temperature see table for set point admissible operating and or sensor tem perature 120 36SH 170 3 CN 图14 例 热虹吸式油冷 Fig 14 Example thermosiphon oil cooling 热虹吸式油冷 制冷剂冷却 通过制冷剂流量调节阀或旁通阀控制油温 设定点 见表 第33页 允许运行和传感器温度 120 图14 例举了一个冷凝器后带储液器的管路布置 也可用带泵或喷射器的热虹吸循环来进行油冷却 详情备索 Thermosiphon oil cooling cooling by refrigerant Temperature control either by thermostatic regulation valve for refrigerant feed or by pass valve see table for set point admissible operating and sensor temperature 120 As an example fi gure 14 shows a layout variation with a primary receiver after the condenser An alternative layout of the thermosiphon circuit as well as refrigerant circula tion by means of a pump or an ejector is also possible information upon request 37SH 170 3 CN 图15 与滑阀一体的ECO接口 带ECO的压缩过程Fig 15 ECO port with integrated control slider compression process with ECO 7 经济器运行 ECO 7 1 概述 CSH螺杆压缩机的标准设计中已提供经济器 ECO 运行的可能 在这种模式中通过过冷循环或两次节 流循环制冷量和效率都得到提高 相对于普通应用 模式 尤其是在高冷凝温度下优势明显 这种整体式螺杆机独特的特点是经济器喷液口与滑 阀做成一体 图14 这使得压缩机在任何负荷下 都可进行过冷循环运行 其它品牌带固定ECO进气 口的螺杆压缩机在部分负荷时 ECO回气口常常会 与吸气区域相通 从而不起作用 7 2 工作原理 螺杆压缩机的压缩过程是单向的 见第2 2 节 这 样就可在螺杆腔布置一个额外的吸气口 这个位置选 在吸气终了压力且有上升处 通过这个接口可以吸 入额外的质量流量 这对吸气量仅有微小的影响 7 Economiser operation ECO 7 1 General CSH screw compressors are already provided for ECO operation in the standard design With this operation mode both cooling capacity and effi ciency are improved by means of a subcooling circuit or 2 stage refrigerant ex pansion There are advantages over the conventional ap plication particularly at high condensing temperatures A unique feature of the compact screws is the ECO channel integrated into the control slider fi g 15 This enables to operate the subcooling circuit regardless of the compressor load condition Screw compressors with a fi xed ECO suction position have this frequently located in the suction area of the rotors during part load and then has no effect 7 2 Operation principle With screw compressors the compression process oc curs only in one fl ow direction see chapter 2 2 This fact enables to locate an additional suction port at the rotor housing The position is selected so that the suc tion process has already been completed and a slight pressure increase has taken place Via this connection an additional mass fl ow can be taken in which has only a minimal effect on the fl ow from the suction side 38SH 170 3 CN 图16 带过冷循环的ECO系统Fig 16 ECO system with subcooling circuit ECO入口的压力值与两级压缩的中间压力相似 这 意味着系统中可以增加额外的过冷循环或中间容器 两级节流循环 这种方法可通过额外液体过冷实现 更高的制冷量 同时压缩机功率输入也有相对较小 的增加 因为吸气压力升高 整个工作过程效率变 得更高 7 3 带过冷循环的ECO运行 该运行模式使用一个热交换器作为液体过冷器 冷 凝器来的一部分制冷剂通过膨胀装置进入过冷器 蒸发并吸收逆向的制冷剂 被过冷 的热量 过 热蒸汽通过压缩机的ECO接口与从蒸发器来的 The pressure level at the ECO suction point is similar to the intermediate pressure with 2 stage compressors This means that an additional subcooling circuit or in termediate pressure receiver for 2 stage expansion can be integrated into the system This measure achieves a signifi cantly higher cooling capacity through additional liquid subcooling At the same time there is a relatively Iow increa