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Please read this manual carefully before installing, commissioning or operating the BDP2
ATEX
The BDP2 without optional level sensor has no ignition sources and therefore it does not meet the definition of
devices according to the ATEX Directive 94/9 / EC. The basis for this is an risk assessment of ignition sources
according EN 13463-1, chapter 5.2. Even during possible occurring malfunctions there are no own potential igni-
tion sources present.
Terms of warranty
To prevent accidents and for the safe operation of the refrigerant plant no modifications or alterations may be
carried out to the BDP2 without written approval by TH. WITT Kältemaschinenfabrik GmbH.
All information for the safe operation and maintenance of the BDP2 is based on our experience and is to the best
of our knowledge.
Our liability or warranty is excluded, if:
The instructions in this manual are not adhered to
The BDP2 and its equipment were operated incorrectly or the handling was not in accordance with the
mentioned procedures
The BDP2 is used for purposes other than that for which it was intended to
Safety devices were not used or disconnected
There have been modifications made without written approval
The safety requirements were not adhered to during installation or operation
Instruction Manual
BDP2
Intended use
The automatic oil return system BDP2 is solely intended to return refrigerant oil
in a refrigeration or heat pump system.
Safety requirements
Any work with refrigeration systems must be carried out by trained and knowl-
edgeable personnel. All safety regulations / EC-Material Safety Data Sheets and
codes of practice concerning the use of refrigerants must be adhered to.
Under no circumstances are the indicated temperature- and pressure-limitations
on the data plate to be exceeded!
From Rev. i of 07.01.2019, the 25 bar version of the BDP is safety approved up
to 120° C. However, a continuous operation at temperatures above 75° C consid-
erably decreases the lifetime of the Teflon materials used in the BDP. During
normal operation, these temperatures should not occur (see chapter 11).
Applicable standards and regulations for installing or operating refrigeration
plants, e.g., EN 378 must be adhered to.
Before work is carried out and screws are loosened, it
is important pressure has been entirely released from the BDP2
housing.
When opening the BDP2 a sudden evaporating of trapped refrigerant
may occur. Therefore, special attention must be paid to wearing pro-
tection clothing and safety glasses.
Revision: 16.02.2022
W 3552-6.02_160222_en
Page 1 / 21
MWi

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Summary of Contents for Witt BDP2

  • Page 1 To prevent accidents and for the safe operation of the refrigerant plant no modifications or alterations may be carried out to the BDP2 without written approval by TH. WITT Kältemaschinenfabrik GmbH. All information for the safe operation and maintenance of the BDP2 is based on our experience and is to the best of our knowledge.
  • Page 2 (R290), propylene / propene (R1270), butane (R600) and isobu- tane (R600a) as well as their usual refrigerant oils, there is a BDP2 in specific embodiments. When using non- soluble oils (particularly at below -30°C) the viscosity should ensure flowability at any time (see 6.1.1).
  • Page 3 Instruction Manual W 3552-6.02_160222_en BDP2 Page 3 / 21 TIGHTENING TORQUE FOR SCREW CONNECTION The screw connection of the BDP is tightened with a torque of 25 Nm. Dimensions and connections BDP2 inlet inlet Hot gas connection discharge Hot gas...
  • Page 4 Revision: 16.02.2022 Instruction Manual W 3552-6.02_160222_en BDP2 Page 4 / 21 optional equipment Threaded connection G1“ EA32/G1“-I EA32/G1“-II (for installation to a (Including threaded (Including threaded connection G1”) different brand valve) connection G1”) 25 bar & 40 bar Part no. 6435.AJ0F00 Part no.
  • Page 5 Revision: 16.02.2022 Instruction Manual W 3552-6.02_160222_en BDP2 Page 5 / 21 Flow Sight Glass Part no. 4551.AH3100 25 bar & 40 bar Spare Parts Set of gaskets inlet Part no.: 3552.006001 Mechanical valve Set of gaskets KW Part no.: 3552.002006 Part no.: 3552.006002...
  • Page 6 Revision: 16.02.2022 Instruction Manual W 3552-6.02_160222_en BDP2 Page 6 / 21 Check valve Hot gas connection Gasket 10/18x2 Centellen Art.-Nr.: 6434.ACOD 00 O-ring – Neopren 19 x 4 –70SH KW: O-Ring – LT170 19x4 – 70 SH Art.-Nr.: 5632.1A9AHK Check valve 3 bar REMARK Part no.: 3552.000042...
  • Page 7: Description Of Operation

    6.1.2 soluble oils / systems using synthetic refrigerants It is also possible to return oil that is carried over from the compressor with the BDP2 when using soluble refrig- erant oils. In systems, using synthetic refrigerants the supply line to the BDP2 should be connected to an oil-rich phase –...
  • Page 8 (see “system schematic”, 6.10, tapping point B). In both cases, the control line that is fed from a solenoid valve should be installed near to the BDP2, because larger quantities of condensate may collect in front of the solenoid valve, but only refrigerant vapor is allowed for the cycle.
  • Page 9 BDP2 Page 9 / 21 If a fine filter (e.g. WITT oil-filter ÖF) is required in the oil return line depends on the execution/cleanliness of the entire system. This should be evaluated by the design engineer. We recommend to install a sight glass after the heat exchanger. This will enable the proper observation of the oil return.
  • Page 10 Tapping Point B = Hot gas supply through regulating valve EE3 or EE6 and Hot gas solenoid valve DN3 at WITT high side float regulator HR or HS = heat exchanger WITT DWR, if required with oil filter = return position piston compressor...
  • Page 11 Allow sufficient space for inspection and servicing. Provide at least 20 cm underneath the BDP2 for easy removal. Furthermore, a diameter of at least 20,6 cm space should be considered in order to be able to rotate the BDP2 in the G1”...
  • Page 12 Revision: 16.02.2022 Instruction Manual W 3552-6.02_160222_en BDP2 Page 12 / 21 Assembly of sealing joints It is not possible to make a general statement about tightening torques for connections with seals because they depend on various factors depending on the application.
  • Page 13 Revision: 16.02.2022 Instruction Manual W 3552-6.02_160222_en BDP2 Page 13 / 21 8.1.1 Recommendations for tightening torques The specified tightening torques are recommendations for the sealing connections of the BPD2, which were de- termined under the following boundary conditions: • - Ambient temperature 20°C •...
  • Page 14 Revision: 16.02.2022 Instruction Manual W 3552-6.02_160222_en BDP2 Page 14 / 21 component position descripiton Key width Tightening torque O-Ring 28 x 5 25 Nm G1“ Threaded ring SW 41 Cylinder screw 56 Nm SW 10 M12 x 55 — A2-70...
  • Page 15: Operation

    The hot gas solenoid valve should be activated over a period of 1 to 10 minutes– depending on the size of the BDP2 and the system concept (time or demand control) – to push the liquid content out of the BDP2. The timer...
  • Page 16 The BDP2 is designed to operate without the need of regular maintenance work. In case of contamination, it is possible to disassemble the BDP2 for cleaning or replacement of parts. During re- assembly all gaskets should be replaced.
  • Page 17 5. Carefully release the pressure of the BDP2 It is fairly easy to release the pressure inside the BDP2 by using a service valve right in front of the hot gas connection. Refrigerant gas can be drained into a bucket of water. This service valve is also suita- ble to evacuate the BDP2 upon re-assembly.
  • Page 18 12.5.1 Disassembly of the valve mechanism In case the valve mechanism should be pushed out, e.g., when clean- ing the BDP2, it is important to first remove the circlip at the bottom (see picture). Thereafter, the valve head of the BPD2 should be placed on an appro- Plastic rod priately sized tube (or similar).
  • Page 19 The filling level sensor is installed in the highest place inside the BDP2-container. When the oil reaches the level of the sensor, the LEDs change their colour from green to yellow and the solenoid valve inside the hot gas line opens, by which the oil discharge is released.
  • Page 20 The necessary discharge time can quite easily be observed and optimized through an inspection glass at the outlet of the BDP2. The next cycle must not take place at the end of the discharge, in order to give the BDP2 sufficient time for refilling (see figure 6.6).
  • Page 21 14.4 INTERNAL PISTON STUCK IN UPPER POSITION Orifice of the valve mechanic blocked See chapter 12.2 Dis-assemble BDP2 and clean the internal parts Internal contamination prevents proper piston movement 14.5 TOO MUCH OR NOT ENOUGH RETURNED OIL Incorrect positioning of the supply connection See chapter 6.1 &...

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