Manual Screw Condensing Units

Contents

1. Open the Packing Box and Inspections

2. Safety
3. Description of the Units
4. Installation
5. Pipeline connection
6. Electrical connection
7. Commissioning
8. Operation & maintenance
9. Trouble shooting

Thanks you for your purchasing our product. We remind you read
this manual and compressor usage manual carefully before you use
our product, and contact us anytime when you need.

1. Open the Packing Box and Inspections

Observe the package to confirm it is in good condition, no toppling and up side down occurred. If those
occurred, contact your forwarders, and inform your suppliers or the manufacturers.
Confirm the contents compared with the pack list or contract, if there are issues, contact your forwarders,
and inform your suppliers or the manufacturers.

2. Safety
2.1 mark and explanation

Attention: No harm to operators!

Attention: Attention to the safety from electricity!

Attention: Temperature over 60C, attention not touches to prevent from burning the body!

Attention: The correction fan direction!

2.2 The condensing unit can only be installed in the refrigeration system. It can be put into use only after it is
correctly installed and completely conformed to the relative national laws and regulations.
2.3 All operation of condensing unit and cooling system should be handled by qualified or authorized refrigeration
professionals, or the serious danger will be caused by incorrect operation.
2.4 The condensing unit is with 1.3~1.5 bar gauge pressure imposed before delivery, that has to be released before
operation. Man should keep away from the discharge outlet to avoid the hurt in releasing air pressure.
2.5 The temperature of the compressor or pipe line may be higher than 60℃ or lower than 0℃ in running, pay
attention to it to avoid scald or frostbite.
2.6 Opening running is prohibited for box type condensing unit
2.7 Reliable grounding protection is necessary in running.
2.8 All maintenance and repair should be made after the power is cut off.

3. Description of the Units

3.1 Unit system composition diagram:

TT

LS

Figure No Name:
1.Compressor 2.Oil separator 2.1.Oil level controller 2.2.Oil temperature controller 2.3. Oil heater
3. Check valve 4.Safety valve 5.Oil separator outlet valve 6.Oil cooler 7.Ball valve 8. Oil bypass
solenoid valve 9.Oil temperature controller 10.Oil filter 11.Ball valve 12. Oil filter 13.Oil flow
switch 14.Oil flow solenoid 15.Ball valve 16.Sight oil glasses 17.Condenser 18.Liquid receiver
19.Safety valve 20.Dry filter 21.Sight glasses 22.Ball valve 23.Ball valve 24.Solenoid 25.Filter
26.Sight glasses 27.Solenoid 28.Economizer expansion valve 29.Economizer 30.Suction filter
31.H/L P controller 32.L/P gauge 33L/P sensor 34.H/P gauge 35.Condensing pressure controller
（Control the cooling fan or cooling tower fan） 36.Stop valve 37. Packing joints 38.Oil drain valve
39.Ball valve 40.Solenoid 41.Liquid discharge valve 42. Check valve 43. Ball valve
Note: The components included differ from the unit models and the compressor types used !
Mainly as follows:
1）For the Bitzer low temperature screw compressor, there are no the number 40-43 components in above list;
2）For Bitzer compressor HP over 125, the components of No. 12, 13, 14 in the above list are built inside the
compressors.
3）There will be differences between the single compressor system and the multi compressor rack system, the
 system diagram above can just be taken for reference.
3.2 Main components
1） Compressor: Suction the evaporated refrigerant gas，then discharge it into the condenser;
2） Oil separator: The oil mixed in the discharged gas will be separated ,and the separated oil enter into oil
cooler or compressor;
3) Oil cooler: Cooling the refrigeration oil that separated from the oil separator, ensure the refrigeration oil
return to the compressor at a suitable temperature;
4) Oil filter: Filter the oil that separated from the oil separator or oil cooler, remove oil impurities;
5) Condenser: A heat releasing device, with air or water, cool the compressor discharged refrigerant gas of
high temperature and high pressure to become liquid;
6) Liquid receiver: To store the liquid refrigerant condensed by the condenser, and maintain an appropriate
reserves, according to the change of working condition of refrigeration system decrease or supplement
the refrigerant liquid in circulation. In addition, in case of repairing, the refrigerant can be collected into
the liquid receiver. For some water-cooled unit, as the condenser itself can function as the liquid receiver,
it can be saved;
7) Dry filter: It keeps the refrigerant dry, and takes the impurities in it ensuring the reliable operation of the
refrigeration system.
8) Sight glasses: With it can judge whether the refrigerant filling quantity right, whether there is water, air
in the system;
9) Economizer: Before the throttle valve to realize sub-cooling of the liquid refrigerant, thus improving the
cooling capacity of the unit;
10 ） Suction filter: Effectively remove the suction side impurities, prevent the impurities entering the
compressor;
11）Solenoid: Play in the system shutdown role to realize the unit automatic control;
12）H/L pressure protectors: When the high pressure is over or the low pressure is below their normal setting
values, the compressor is stopped, thus ensuring the normal operation of the unit.
13）Oil flow switch：When the screw compressor oil pressure is too low or lack of oil, effectively protect the
compressor;
14）Condensing pressure controller：For Air-cooled unit, can through it to control the condenser fans work to
achieve the purpose of the condensing pressure control. For Water-cooled unit, can through it to control the
cooling tower operation to realize the purpose of the condensing pressure control;
15）Liquid discharge valve: Reduce the compressor discharge temperature, to ensure the compressor
running normally;
16）Expansion valve : Throttling device, throttling the liquid refrigerant, then evaporated in the economizer,
thus reducing the temperature of the liquid refrigerant in the other way, to achieve the purpose of sub-cooling;
17）L/P sensor: Pass the low pressure signals to controller or PLC to achieve the unit capacity regulation.
3.3 Unit working principle
The screw compressor discharge high temperature and high pressure gas refrigerants into the oil
separator, under the action of the centrifugal oil separator will be effective separation of oil and refrigerant, the
separated oil into the compressor or through the oil cooling system return to the compressor; On the other hand
through the oil separator separated refrigerant gas entering the condenser, in the role of the condenser cooling,
cooling refrigerant gas into liquid refrigerant, and then into the liquid receiver, with its water and debris taken
way by the dry filter, then through liquid pipe into the evaporator system or after cooling system or passing
through cooling system before entering the evaporation system; After the evaporation of refrigerant gas through
the compressor suction line returns to the compressor.

4. Installation
4.1 The declining angle of the units in transporting and installing must not be over 45℃. Be especially careful
when handling to avoid damage to persons or injured the units!
4.2 Check if the units is intact, loose fasteners, repair those can be repaired in time!
4.3 The compressor condensing units must be installed in level in the place that can support the units’ weight,
avoiding the high temperature and moisture place. It should be covered with sunshine tent to shelter straight
sunshine or raindrop if it is in the open.
4.4 Firm the units to the basis of cement by the foot expansion bolts fastening .
4.5 The units must be installed with sufficient space around for operation and maintenance of the unit
4.6 Installation for the air cooled condenser
1）Air-cooled condenser should be installed in a well-ventilated place away from direct sunlight;
2）In order to prevent vortex wind, each condenser around at least one meter more enough space;
3）In order to prevent bubbles, the condenser should be installed at the top of the unit;
4 ） For using multiple condenser units, air-cooled condenser should be used in the form of parallel, from the
discharge manifold branch pipes respectively into each condenser, and then the condenser of the liquid pipe on
the summary to the discharge liquid pipes;
4.7 Installation for the water cooled unit
When installing water-cooled unit, should be choose enough cooling tower, water pump and pipeline to meet unit
cooling needs. Pay attention to the quality of the cooling water, prohibited to use of strong acid or alkaline, turbid
cooling water.

5. Pipeline connection
5.1 The requirement of the pipe line for refrigeration system
Match the refrigeration system according to the units’ inlet and outlet pipe diameters or the calculated diameters
for the liquid supply pipe and suction pipe lines.
Connect the refrigeration system with clean, moistureless copper pipes, in case steel pipes has to be used, it must
be seamless type and the rust in it has to be cleaned.
The pipe lines between the unit and the evaporator should be as short and simple as possible and less elbows. If
the elbows have to be used, their diameter has to be bigger ones.
For the flared mouth connections, the mouth must be smooth and burr free; For the brazing connection, the dry
Nitrogen has to be used to remove the oxide skin; for the valves, precaution has to be taken to protect it from
being burnt.
5.2 The pipeline connection between the units and air cooler condenser
The horizontal pipe of the exhaust pipe should be not less than the slope of 1/100 and set the slope sloping down
the condenser side;
A liquid receiver Bend has to be set when condenser is on the top over the units.
The pipeline connection between the units and evaporator
① No less than 1/100 of slope for the discharge line horizontal section and slope to the condenser side;
② When using multiple V-type condenser in parallel with the condenser should take over the way as diagram
below:

5.3 Pipeline connection between the unit and the evaporator:

① No less than 0.02 of slope for the suction line before the Compressor has to be set sloping down the
compressor to ensure that the oil can flow back into the compressor in operation as figure 1;
② A U-shape oil return elbow has to be set, U-shape elbow should be as small as possible and a standing part has
to be made with its top over the evaporator;（See Figure 1）
③ When suction pipe arraying above the evaporator, a U-shape elbow has to be set on the evaporator suction
pipe for each group（See Figure 1）;
④ When suction pipe arraying under the evaporator, an inverted U-shaped elbow has to be set on the suction pipe
line, to prevent the unit stops running, the evaporator refrigerant liquid flow into the unit, causing the compressor
liquid strike; （See Figure 3）
⑤ When the unit with capacity regulation running, should consider its suction pipe design can not only satisfy the
 maximum working capacity, but also must meet the minimum working capacity, should use double suction risers
to ensure that the pressure loss within the allowable range, and make the lubricating oil can be flow back to the
compressor; (See Figure 4）
⑥ In case the unit is located above the evaporator, an inverted U-shaped elbow has to be set for every 4 m on
suction line (See Figure 5)
⑦ The pipelines should be fixed and supported firmly to prevent vibration of the line.
⑧ Heat insulation has to be made for the suction line to prevent condensation and abnormal overheating.

2/100

to units cooler
to units

cooler cooler

cooler

Fig 1 Fig 2

above Evp.

cooler to units

cooler

cooler
to units

Fig 3
4m

to units
4m

cooler
cooler

Fig 4 Fig 5

5.4 The requirement of the water cooling pipe line for water cooled units
The connection for the cooled water system of the units should follow the principle of that the water will always
goes in the condenser from the below inlet and goes out of the condenser from the upper pipe mouth.
A target flow switch is recommended for no water protection of the system.
The connection for the water cooled condenser is shown as diagram below:

TARGET FLOW SWITCH CHECK VALVE

PUMP

Condenser

VIBRATION ELIMINATOR

Oil cooler

6. Electrical connection
6.1 The standard power supply of the condenser is 220V±10%、50Hz or 3P 380V±10%、50HZ(Except for
special circumstances, the wiring should be confirmed in advance)
6.2 Only Qualified, appropriate capacity electrical components, wiring and reasonable electrical control can be
used, or it will lead to serious compressor failure.
6.3 The electrical connection should be done only by qualified electrical professionals;
6.4 Cable connection with the compressor must be made strictly according to the specification. Wrong connection
will ruined the compressor motor.
6.5 In case the crankshaft case heater is used, it requires being on in compressor stop and being off in compressor
operation
6.6 The units should be properly grounding connected.
6.7 If the electrical control box is equipped, read its manual carefully before electrical installation and operation.

7. Commissioning
7.1 The refrigerating system must be cleaned with dry nitrogen gas to rid of the dust, oxidizes in the pipes, System
not clean may result in abnormal running of the refrigerating system, or it may even ruined the compressor.
7.2 Refrigerant oil filling.
1) Oil type:

Refrigerant
Compressor Brand
R22 R404A/R507A
ZB Screw B100 BSE170
Hanbell screw HBR-B03 HBR-B05
 Check the compressor nameplate for the information.
2）Oil filling quantity: The oil separator oil volume+ Oil cooler oil volume+ The capacity of the oil pipeline+ The
refrigerant circulation amount of the oil in the circuit(About 1 ~ 2% of the refrigerant filling quantity);
Oil separator oil volume can see oil nameplate or oily cent operating instructions;
3）The refrigeration system can be vacuumed before filling oil, closed filling segment, then the oil can directly
into the oil separator. When filling oil, the oil solenoid valve on the liquid discharge pipeline should be
closed(It is prohibited to oil directly into the compressor).
7.3 Open all the valves in the refrigerating system, Test the system with pressure by dry nitrogen with 2.4Mpa of
high pressure and 1.5Mpa in the low pressure, and keep the pressure 24h. It should be no leakage in the system. In
case the condensing units have inner pressure before the installation, then it can save the test. The pressure has to
be imposed gradually lest the gauges are damaged.
7.4 The oxygen is not permitted absolutely to make the test, for it may result in explosion, and hurt.
7.5 System vacuuming:
1) Release the pressure in the system, close all mouths in the system, and pump the air out from the high pressure
side and low pressure side simultaneously with vacuum pump until the pump is over 150 Pa.
2) Under the condition of vacuum, the liquid discharge pipeline solenoid should be closed.
3）Under the condition of vacuum ,the oil heater on the oil separator should be connected .
Attention: It is prohibited to pump vacuum with the compressor, which may burnt the compressor. And
don’t use mega meter, or electrify the compressor in vacuum status, that may burn the compressor down.
7.6 Refrigerant filling:
1） After the vacuuming process, fill the refrigerating system with specified refrigerant. The refrigerant filling
has to be made in liquid through the bypass hole of the liquid supply valve of the liquid receiver.
2） If the amount cannot be up to the standard set-up, the refrigerant can be put in through the suction pipe of the
compressor. In filling from the suction side, the R22 refrigerant has to be in gas state; For R404A refrigerant,
it can be filled in liquid state gradually, or too much liquid refrigerant mix with the oil, leading to compressor
failure.
3） When filling refrigerant, the oil separator of oil heater should be in working condition.
7.7 Checking before the unit is started
1）Before operation, please check if the electrical connection is right, all the valves open, or there will be danger in
it.
2 ） Set the value for all the control components at the right, such as mechanical type pressure controller, relay
operation current, cold room temperature control etc. Wrong setting may impact the normal operation of the units.
3）Please check the refrigerant status by the sight glass on the liquid line.
4）Before operation, Should be turned on the oil separator oil heater, ensure that the oil should be higher than the
ambient temperature of about 15-20K.
5）Please make sure oil solenoid valve is closed. Attention: If due to wrong operation made screw compressor is
filled with oil, the oil should be evacuated; it is prohibited to start screw compressor with oil.
7.8 Checking after the unit is started
1 ）Please check the screw compressor turning direction ,if not correct should adjust that timely, Not long time
reversal.
2）Observe the oil discharge pipeline sight glasses, if not have oil flow within five seconds, should stop the unit
immediately, check whether the oil solenoid valve, oil stop valve is open.
3）After the unit is started and running, check the oil level in the oil separator, the reasonable oil level should be
in the range of the oil separator of oil sight glass.
4）Check the fan turning direction of the condenser and air-cooled oil cooler right or not. If not correct should
adjust that timely.
5 ） Please check the refrigerant status by the sight glass on the liquid line. Tell if there is bubble or moisture.
Bubble means refrigerant not sufficient, have to add until no bubble being seen.
6 ） After the unit is started and running, check if the condensing pressure, evaporation pressure, discharge
temperature, oil temperature and current is right.
7）Observe and test if the oil switch, pressure controller and other protection devices can act normally.
Attention: In the trial operation, whenever abnormality is found, it is necessary to stop the unit and check it
immediately.
8. Operation & maintenance
8.1 The units should not be used outside their working conditions, or the compressor may be damaged.
8.2 In the winter low temperature operation, to prevent the condensing pressure over low, the regulation by
condenser fans or cooling water flow can be considered.
8.3 A regular check to the units should be made to see the operation normal or not after the units run normally.
Stop the unit for check and repair if there is any thing not in order.
8.4 To keep the units run efficiently, a regular clean to the dust on the condenser surface should be made. No sharp
tools or corrosive liquid has to be used for the cleaning of the water cooled condensers.
8.5 Should be observed the refrigerant oil in the separator, suggest new unit replace oil filter core after running
50-100hours. If it shows black or degraded quality, replace it timely.
8.6 The refrigerant should be kept in the liquid receiver or shell and tube condenser and shut off the discharge
cut-off valves for compressor when the unit will not run for a long term,
8.7 For water cooled units, if they are not to be used in the winter, the water inside has to be drained to prevent it
from freezing breaking.

9. Trouble shooting
Trouble Reason Action
Compressor No power in the main line, phase lack Check and repair.
 start failure Check control circuit and repair or
Control trouble.
replace the troubled components.
Compressor motor burnt. Replace the compressor.

Compressor Unreasonable control setting. Reset the value.

stop soon after Abnormal system pressure. Check and repair.
start Compressor axis sticking. Replace the compressor.
Condenser fan or pump trouble Repair or replace.
Serious stain (or water stain) on the
Clean.
condenser surface.
Drainage air not complete, air or other
Pump vacuum again.
H pressure too gas in the system
high Too much refrigerant injected. Discharge some refrigerant.
Environment temperature too high or Control the environment temperature or
cooling water lack. enlarge the cooling water.
The compressor outlet valve or liquid
Open the valves completely.
receiver valve not open well.
System leakage and not enough
Check leak, repair, filling refrigerant.
H pressure refrigerant.
too low Too thick frost or dirt on the evaporator Clean or defrosting.
Too much air flow in the condenser Control the air flow
Load too heavy. Decrease load or Selection inappropriate
L pressure too The expanding valve supply too much Check the temperature sensor ball,
high liquid. adjust the overheating.
Insoluble gas in the system. Release the air or insoluble gas.
No clean inside system and the filter
Replace the core.
blocked.
Water in the system, and the
Replace the core.
expanding valve ice blocked.
L pressure too
Too thick frost or dirt on the evaporator Clean or defrosting.
low
Evaporator fan trouble. Replace the evaporator fan.
The expanding valve trouble. Adjust the over heat or change the valve.
Check the leak and repair and filling
Too little refrigerant injection.
refrigerant.
Oil flow alarm Oil dirty, filter blocked. Change the oil and oil filtering core.
 Oil temperature too low Check the oil heater.
Oil solenoid or oil flow switch trouble Replace
Oil level too low Filling refrigerant.
Unit Vibration Loose nut in the bottom foot Tighten the bolting.