Bitzer CM-RC-01 Technical specifications
KW-231-1
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 ..................................................................................................................................................... 20
4JE-13Y .. 4FE-35(Y)
6JE-22Y .. 6FE-50(Y)
KW-231-12
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............................................................................................................................5
3.2 Removing the SE-B* motor protection device ...............................................................................................5
3.3 Oil heater .......................................................................................................................................................7
3.4 Mounting the discharge gas temperature sensor ..........................................................................................7
3.5 Mounting the DP1 oil monitoring device ........................................................................................................8
3.6 Further electrical connections on the CM-RC-01...........................................................................................9
3.7 Laying the cables...........................................................................................................................................9
3.8 Screwing the cover onto the module housing..............................................................................................10
4 Mounting the optional CM-RC-01 extension kits .................................................................................................10
4.1 Mounting the extension kit "Capacity control" (CRII) and "Start unloading" (SU)........................................11
4.2 Mounting the "Pressure transmitter" extension kit .......................................................................................12
4.3 Mounting the "Liquid injection" extension kit................................................................................................13
4.4 Mounting the "Additional fan" extension kit..................................................................................................16
5 Communication via BEST SOFTWARE ..............................................................................................................18
5.1 Configuration via BEST SOFTWARE ..........................................................................................................19
KW-231-1 3
1 Introduction
This document describes the procedure to follow for
mounting the CM-RC-01 compressor module add-on kit
to the compressor models 4JE-13Y .. 4FE-35(Y) and
6JE-22Y .. 6FE-50(Y). The description explains how to
subsequently mount any component of the basic kit
and the optional extension kits to the compressor. For
electrical connection, please refer to the Technical In-
formation KT-230 enclosed.
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-231-14
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 and cable ties.
• Removing the SE-B* protection device.
• Electrical connection of the oil heater to the com-
pressor module.
• Mounting the discharge gas temperature sensor.
• Mounting the oil monitoring device.
• Laying the cables and closing the cable ties.
• Closing the cover, screwing the compressor module
to the terminal box.
KW-231-1 5
3.1 Mounting the cable holders
4JE-13Y .. 6FE-50(Y):
Mount 2 cable holders each to the outer cylinder
heads and to the bearing cover.
• To this end, loosen the corresponding screws
on cylinder head and bearing cover, insert the
screws again with cable holders and tighten
them (tightening torque 80 Nm).
• Fasten the plastic clip to the cable holder and
insert a cable tie.
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.
KW-231-16
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.
• 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.
KW-231-1 7
3.3 Oil heater
• Loosen and remove the connector and cable
of the installed oil heater.
• Then plug the electric connector with its cable
(labelled "Crankcase Heater") prewired to ter-
minal strip CN4, with a seal onto the oil heater
and tighten it (tightening torque 5 Nm).
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, injection nozzle or injection valve:
!
!
NOTICE
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!
Information
Observe the different connection positions of
the discharge gas temperature sensor on 4-cyl-
inder and 6-cylinder compressors!
4-cylinder compressors 4JE-13Y .. 4FE-35(Y):
• Remove the sealing plug from the connector
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.
• Guide the cable of the discharge gas temper-
ature sensor to the compressor module as
shown in the figure.
KW-231-18
6-cylinder compressors 6JE-22Y .. 6FE-50(Y):
• Remove the sealing plug from the connector
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.
• Guide the cable of the discharge gas temper-
ature sensor to the compressor module as
shown in the figure.
3.5 Mounting the DP1 oil monitoring device
• Unscrew the plug or an existing oil sensor
from the bearing cover and clean the
threaded bore.
• Screw the oil monitoring device with O-ring
and metal gasket into the bearing cover (tight-
ening torque 75 Nm). Carefully mount the O-
ring!
• Connect the cable clip to the DP1 sensor in-
dependently of the polarity.
• Attach the connection cap and tighten the
screw (position and downward cable routing,
see figure).
Next, any optional extension kits can be moun-
ted see chapter Mounting the optional CM-
RC-01 extension kits, page 10).
KW-231-1 9
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).
• 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 Laying the cables
4-cylinder compressors 4JE-13Y .. 4FE-35(Y):
• Lay the cables along the cable holders and
use cable ties to fix them.
The figure shows the compressor with compon-
ents of the optional extension kits.
6-cylinder compressors 6JE-22Y .. 6FE-50(Y):
• Lay the cables along the cable holders and
use cable ties to fix them.
The figure shows the compressor with compon-
ents of the optional extension kits.
KW-231-110
3.8 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.
• Put the terminal box cover on the compressor
module housing and fasten it using the 6 en-
closed screws (M5 x 70 mm).
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, injection nozzle or injection valve:
KW-231-1 11
!
!
NOTICE
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!
After mounting all components of the liquid injection
system:
!
!
NOTICE
After assembly work on the compressor, there is
a risk of oil or refrigerant leakage
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).
!
!
NOTICE
Risk of compressor damage!
Use only suitable original solenoid coils!
• Press the solenoid coil onto the armature until
it engages.
• Insert the electric connector of the device and
screw it down (tightening torque 5 Nm).
Two completely equipped compressors, a 4-cyl-
inder type (left) and a 6-cylinder type (right) are
shown in the figure as examples. Arrangement
and equipment of the cylinder heads depending
on the equipment version ordered.
KW-231-112
• Shorten the cables as needed, pass them
through the cable glands on the compressor
module into the module housing and connect
them to the CN6 terminal strip.
If no additional extension kits are mounted:
• Proceed with the other electrical connections on the
CM-RC-01 (see chapter Further electrical connec-
tions on the CM-RC-01, page 9).
• Lay the cables and close the cable ties (see chapter
Laying the cables, page 9).
• Screw the protective earth conductor onto the ter-
minal box cover and attach the cover to the module
housing (see chapter Screwing the cover onto the
module housing, page 10).
4.2 Mounting the "Pressure transmitter" extension kit
!
!
NOTICE
The two pressure transmitters must not be inter-
changed. They differ by the component number
engraved in the component:
High pressure transmitter: 2CP5-71-47.
Low pressure transmitter: 2CP5-71-49.
Information
Alternative mounting position for discharge gas
temperatures exceeding 135°C:
Connect the pressure transmitters to the dis-
charge gas line, as close as possible to the
valves using one refrigerant hose each. Length
of the refrigerant hose: at least 200 mm to avoid
overheating of the transmitter.
4-cylinder compressors 4JE-13Y .. 4FE-35(Y):
• Remove the sealing plugs from the connect-
ors marked by rectangles and clean the
threaded bores.
• Screw the enclosed screwed nipple (low pres-
sure transmitter) resp. T-piece (high pressure
transmitter) with Schrader valves into the
threaded bores.
• Then screw the high pressure transmitter
(2CP5-71-47) into place at the HP position
and the low pressure transmitter
(2CP5-71-49) at the LP position (tightening
torque 35-40 Nm). Do not insert a blanking
plate between screwed nipple and pressure
transmitter, since this will prevent the
Schrader valve from opening!
KW-231-1 13
• Snap the connector into place and guide the
cable to the compressor module.
6-cylinder compressors 6JE-22Y .. 6FE-50(Y):
• Remove the sealing plugs from the connect-
ors marked by rectangles and clean the
threaded bores.
• Screw the enclosed screwed nipple (low pres-
sure transmitter) resp. T-piece (high pressure
transmitter) with Schrader valves into the
threaded bores.
• Then screw the high pressure transmitter
(2CP5-71-47) into place at the HP position
and the low pressure transmitter
(2CP5-71-49) at the LP position (tightening
torque 35-40 Nm). Do not insert a blanking
plate between screwed nipple and pressure
transmitter, since this will prevent the
Schrader valve from opening!
• Snap the connector into place and guide the
cable to the compressor module.
• Connect the cable of the high pressure trans-
mitter to terminal strip CN12, terminals 1, 2, 3
(designation "pdis") on the compressor mod-
ule.
• Connect the cable of the low pressure trans-
mitter to terminal strip CN12, terminals 4, 5, 6
(designation "psuc") on the compressor mod-
ule.
• Pay attention to the correct cable connec-
tions!
If no additional extension kits are mounted:
• Proceed with the other electrical connections on the
CM-RC-01 (see chapter Further electrical connec-
tions on the CM-RC-01, page 9).
• Lay the cables and close the cable ties (see chapter
Laying the cables, page 9).
• Screw the protective earth conductor onto the ter-
minal box cover and attach the cover to the module
housing (see chapter Screwing the cover onto the
module housing, page 10).
4.3 Mounting the "Liquid injection" extension kit
Information
Use an open ring spanner for mounting the in-
jection nozzle to the injection line!
For further information, see Technical Informa-
tion KT-130.
After mounting new components such as discharge gas
temperature sensor, injection nozzle or injection valve:
KW-231-114
!
!
NOTICE
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!
After mounting all components of the liquid injection
system:
!
!
NOTICE
After assembly work on the compressor, there is
a risk of oil or refrigerant leakage
Perform a tightness test before commissioning!
4-cylinder compressors 4JE-13Y .. 4FE-35(Y):
The 4-cylinder compressors are equipped with
an injection nozzle:
• Before installation, make sure that the injec-
tion nozzle is clean.
• Then remove the sealing plug (1/8 NPTF) and
screw the injection nozzle into place (tighten-
ing torque: 10-13 Nm).
• Wrap Teflon tape around the conical thread
(1/8 NPTF) to seal it.
• Screw the injection valve into place. It comes
premounted to the connecting line (including
screwed joints) leading to the injection nozzle.
• To avoid undefined vibrations and tensions in
the connecting line, secure the injection valve
through the fixing plate on the cylinder head.
• To this end, loosen the corresponding screw
on the cylinder head and tighten it again with
the fixing plate inserted (tightening torque: 80
Nm).
• Press the solenoid coil onto the armature until
it engages.
• Insert the electric connector of the device and
screw it down (tightening torque 5 Nm).
Information
Due to the position of fixing plate and
pipe clip on the cylinder head, the direc-
tion of pipe entry into the valve needs to
be considered for installation.
KW-231-1 15
6-cylinder compressors 6JE-22Y .. 6FE-50(Y):
The 6-cylinder compressors are equipped with
two injection nozzles:
Information
Make a brazing joint between liquid line
and injection valve before definitely
mounting the fixing elements.
• Before installation, make sure that the injec-
tion nozzles are clean.
• Then remove the sealing plugs (1/8 NPTF)
and screw the injection nozzles into place
(tightening torque: 10-13 Nm).
• Wrap Teflon tape around the conical thread
(1/8 NPTF) to seal it.
• Screw the injection valve into place. It comes
premounted to the forked connecting line (in-
cluding screwed joints) leading to the injection
nozzles.
• To avoid undefined vibrations and tensions in
the connecting line, secure the injection valve
by means of two fixing plates on the upper
part and on the side of the cylinder head (see
red marks in the figure).
• To this end, loosen the corresponding screws
on the cylinder head and tighten them again
with the fixing plates inserted (tightening
torque: 80 Nm).
• Then screw the connecting line into the
thread of the nozzles and tighten while hold-
ing the nozzle element with an open ring
spanner.
• Press the solenoid coil onto the armature until
it engages.
• Insert the electric connector of the device and
screw it down (tightening torque 5 Nm).
KW-231-116
• Shorten the cables as needed, pass them
through the cable glands on the compressor
module into the module housing and connect
them to the CN6 terminal strip.
If no additional extension kits are mounted:
• Proceed with the other electrical connections on the
CM-RC-01 (see chapter Further electrical connec-
tions on the CM-RC-01, page 9).
• Lay the cables and close the cable ties (see chapter
Laying the cables, page 9).
• Screw the protective earth conductor onto the ter-
minal box cover and attach the cover to the module
housing (see chapter Screwing the cover onto the
module housing, page 10).
4.4 Mounting the "Additional fan" extension kit
!
!
NOTICE
When mounted, the additional fan hides the lift-
ing eyes of the compressor!
The lifting eyes cannot be used for lifting the
compressor when the additional fan is installed.
Do not mount the additional fan before installing
the compressor in the system!
Information
For details, see Technical Information KT-140.
• Pass the cables through the cable glands on
the compressor module into the module hous-
ing and connect them to the CN5 terminal
strip.
• Proceed with the other electrical connections
on the CM-RC-01 (see chapter Further elec-
trical connections on the CM-RC-01, page 9).
• Screw the protective earth conductor onto the
terminal box cover and attach the cover to the
module housing. Procedure see chapter
Screwing the cover onto the module housing,
page 10.
KW-231-1 17
4-cylinder compressors 4JE-13Y .. 4FE-35(Y):
• Loosen the relevant screws on the cylinder
head and replace them with the enclosed
threaded bolts.
• Then fit the fixing plates on the threaded bolts
and fasten them using spring washers and
nuts (tightening torque 80 Nm).
• Use the enclosed spacer washers, screws
and nuts (see small figure) to fasten the fan
feet of the pre-assembled fan.
6-cylinder compressors 6JE-22Y .. 6FE-50(Y):
• Loosen the relevant screws on the cylinder
head and replace them with the enclosed
threaded bolts.
• Then fit the fixing plates on the threaded bolts
and fasten them using spring washers and
nuts (tightening torque 80 Nm).
KW-231-118
• Use the enclosed spacer washers, screws
and nuts (see small figure) to fasten the fan
feet of the pre-assembled fan.
Then lay the cables and close the cable ties (see
chapter Laying the cables, page 9).
5 Communication via BEST SOFTWARE
• Mobile device
– equipped with the operating system Windows 7 or
newer
– with Bluetooth interface or USB port
– with BEST SOFTWARE installed
The BEST SOFTWARE can be downloaded for
free from the BITZER website (www.bitzer.de).
• For communication via the USB port:
– Plug the BEST interface converter into the com-
pressor module (CN14) and the mobile device.
– Control the compressor via the analogue connec-
tion (CN13). Simultaneous capacity control via the
Modbus connection is not possible.
Setting up communication
• Switch the mobile device on and start the
BEST SOFTWARE (1).
• Click the NEW button (2).
• Select CM-RC-01 (3).
• Click the CONNECT button (4).
The following selection appears: BEST INTERFACE CON-
VERTER or BLUETOOTH.
• If you select BEST INTERFACE CONVERTER:
Click the CONNECT button.
The compressor module is now connected to the
mobile device.
Fig.1: Connecting the CM-RC-01 to the BEST SOFTWARE
• Select FIRMWARE UPDATE (1) and BROWSE (2)
(see figure 2, page 19).
• Browse the folder (...\BEST\Firmware\CM-RC-01) to
find new firmware.
• Start firmware update and wait until successful up-
date is confirmed. Click OK to confirm (3).
• If you select BLUETOOTH (firmware update via
Bluetooth not possible!):
A list of all available devices appears.
• Select CM-RC-01.
• Click the CONNECT button.
KW-231-1 19
• Enter Bluetooth password. Factory setting from firm-
ware version 2.6.58.00 on: "8670", previous ver-
sions: "2"
The CONFIGURATION menu appears with the MAIN SETUP
window. The compressor module is now connected to
the mobile device.
Fig.2: Updating the firmware
5.1 Configuration via BEST SOFTWARE
Information
For further information on operating parameter
monitoring, electrical connection and communic-
ation via BEST SOFTWARE, see Technical In-
formation KT-230.
Configuration via BEST SOFTWARE (see figure 3,
page 19)
At least the following parameters need to be set / selec-
ted in the CONFIGURATION menu:
• Compressor type.
• Refrigerants.
• Motor starter function.
• Serial number of the compressor.
Depending on the installed equipment, the following ad-
ditional parameters may have to be enabled:
• Type of start unloading.
• Additional fan.
• Liquid injection.
• CRII capacity control and the number of capacity
regulators installed.
• Monitoring of application limits.
• Low pressure and high pressure switches.
Once you have set all parameters, transfer the settings
to the device.
Fig.3: Transferring user settings to the compressor module
KW-231-120
Inhaltsverzeichnis
1 Einleitung.............................................................................................................................................................21
2 Sicherheit.............................................................................................................................................................21
2.1 Zusätzlich folgende technische Dokumente beachten ................................................................................21
2.2 Autorisiertes Fachpersonal ..........................................................................................................................21
2.3 Restgefahren ...............................................................................................................................................21
2.4 Sicherheitshinweise.....................................................................................................................................21
2.4.1 Allgemeine Sicherheitshinweise ...................................................................................................... 21
3 Montage des CM-RC-01 Basis-Bausatzes..........................................................................................................22
3.1 Kabelhalter montieren..................................................................................................................................23
3.2 Motorschutzgerät SE-B* entfernen ..............................................................................................................23
3.3 Ölheizung.....................................................................................................................................................25
3.4 Druckgastemperaturfühler montieren ..........................................................................................................25
3.5 Ölüberwachung DP1 montieren...................................................................................................................26
3.6 Weitere elektrische Anschlüsse am CM-RC-01...........................................................................................27
3.7 Kabel verlegen.............................................................................................................................................27
3.8 Deckel auf das Modulgehäuse schrauben...................................................................................................28
4 Montage der optionalen CM-RC-01 Erweiterungsbausätze................................................................................28
4.1 Erweiterungsbausatz "Leistungsregelung" (CRII) und "Anlaufentlastung" (SU) montieren.........................29
4.2 Erweiterungsbausatz "Druckmessumformer" montieren .............................................................................30
4.3 Erweiterungsbausatz "Kältemitteleinspritzung" montieren ..........................................................................31
4.4 Erweiterungsbausatz "Zusatzventilator" montieren .....................................................................................34
5 Kommunikation über die BEST SOFTWARE ......................................................................................................36
5.1 Konfiguration mit der BEST SOFTWARE....................................................................................................37
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