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Revision:  09/2014  

W 3552-6.02e.E 

Page 1 / 16              MWi 

 
 

Instruction manual 

BDP2 

Please read this manual carefully before installing, commissioning or operating the BDP2 
 

1. 

INTENDED USE 

The automatic oil return system BDP2 is solely intended to return refrigerant oil in a 
refrigeration or heat pump system. 

2. 

SAFETY REQUIREMENTS  

Any work with refrigeration systems must be carried out by trained and knowledge-
able 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! 
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. 

 

 
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 ac-
cording EN 13463-1, chapter 5.2. Even during possible occurring malfunctions there are no own potential ignition 
sources present. 

 

3. 

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 

 

Summary of Contents for BDP2

Page 1: ...ring pro tection clothing and safety glasses 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 ac cording EN 13463 1 chapter 5 2 Even during possible occurring malfunctions there are no own potential ignition sources present...

Page 2: ... DWR WITT oil fine filter ÖF G1 4 Level switch or Level switch with heating element t0 30 C no ATEX approval 5 TECHNICAL DATA 5 1 PRESSURE TEMPERATURE RANGE max permissible pressure Ps at t0 100 max permissible pressure Ps at t0 75 Test pressure PT BDP2 25 bar 1 00 bar to 25 00 bar between 10 C and 75 C 1 00 bar to 18 75 bar between 10 C and 60 C 41 00 bar BDP2 40 bar 1 00 bar to 40 00 bar between...

Page 3: ...003002 25 bar KW Art Nr 3552 002101 25 bar KW Art Nr 3552 002102 BDP2 38 BDP2 03 to BDP2 38 25 bar Part no 3552 002003 25 bar 40 bar Part no 3552 003003 40 bar 25 bar KW Art Nr 3552 002103 Hot gas connection Oil discharge Hot gas connection Hot gas connection Oil discharge Oil discharge Required diameter for installation D 206 Optional level switch Optional Level switch Optional level switch Oil i...

Page 4: ...0 SS G1 II for installation to a Including threaded Including threaded different brand valve connection G1 connectionG1 25 bar Part no 6435 AF0F01 Part no 4111 AA8MJA Part no 4111 AA8MKA 40 bar Part no 6435 AF0F01 Part no 4111 AA8MJD Part no 4111 AA8MKD Adapter with gas equalization line Level switch incl adapter O Ring Part no 3552 000009 25 bar 40 bar Part no 3552 005010 25 bar 40 bar Level swit...

Page 5: ...ative Check valve 1 bar Part no 3552 000043 O ring Neopren 19 x 4 70SH KW O Ring LT170 19x4 70 SH Art Nr 5632 1A9AHK Gasket 10 18x2 Centellen Art Nr 6434 ACOD00 Gasket 80 100x2 Centellen Art Nr 3552 000006 O ring Neopren 75 87x2 62 70SH O ring Neopren 28x5 70SH KW O ring LT170 28x5 70 SH Optional level switch Heating element for level switch Part no 4651 140601 Check valve 3 bar Part no 3552 00004...

Page 6: ...ter evaporation of the remaining liquid refrigerant should be equivalent to the amount that is carried over from the compressor passing the oil separator In common systems operated with synthetic refrigerants the amount of oil dissolved in the refrig erant is approximately 3 miscibility gap should be considered 6 2 REFRIGERANT OIL MIXTURE SUPPLY Oil respective refrigerant oil mixture must enter th...

Page 7: ...en evaporated before returned to the compressor The heating capacity should be adequately selected such that any liquid refrigerant is completely evaporated Sufficient time for evaporating should also be con sidered when an optional level senor is used to control the cycle WITT flow through evaporator DWR or small oil collectors heated electrically or with hot gas are proven for this purpose see s...

Page 8: ... In systems with synthetic refrigerants the control cycle has to be adjusted depending on the operation time and may need up to 10 cycles per hour depending on the oil carry over of the compressor When operating an ammonia system a small BDP2 is normally suitable with 1 to 6 cycles per day If the refrigeration heat pump system is operated with only one compressor or multiple compressors with one o...

Page 9: ...l control Tapping Point A Hot gas supply through regulating valve EE3 or EE6 and Hot gas solenoid valve DN3 at oil separator 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 DWR heat exchanger WITT DWR if required with oil filter X return position piston compressor Y return position screw compressor ...

Page 10: ...ake sure the cylinder screws are tightened again with a torque of 56 Nm Before installation the G1 threaded ring of the BDP2 should be turned all the way down The threaded ring together with the O ring acts as a stuffing box screw connection When the BDP2 is entirely screwed into the existing G1 connection the BDP2 should be positioned and sealed with the threaded ring O ring Therefore the threade...

Page 11: ... sure any dirt is flushed out off the system It is recommended to wait until the oil of the compressor has been changed for the first time to make sure most of the dirt is removed Check that the max allowable pressure is not exceeded see data plate the pressure in the BDP2 housing cannot increase more than 3 bar above the lowest possible pressure in the compressor suction line particularly during ...

Page 12: ...ring re assembly all gaskets should be replaced Besides the following recommended test there is no further work required 12 1 FUNCTION CONTROL During operation the proper functioning of the internal piston mechanical valve can be recognized when the piston moves down Due to the internal damping it is not easy to recognize when the piston is moving up A side glass behind the BDP2 is recommended to ...

Page 13: ...DP2 from the G1 coupling 12 5 CLEANING THE BDP2 To clean the BDP2 it is sufficient to take the valve head off by unscrewing the container Then it is possible to re move any dirt by blowing out with air or rinsing the internals 12 5 1 DISASSEMBLY OF THE VALVE MECHANISM In case the valve mechanism should be pushed out e g when cleaning the BDP2 it is important to first remove the circlip at the bott...

Page 14: ...cessful inspection and cleaning the check valve can be re assembled Check the system for tightness see 12 5 1 13 OPTIONAL LEVEL SWITCH no ATEX approval 13 1 SCOPE OF SUPPLY DIMENSIONS There are two options available standard level switch for BDP2 and for operating temperatures below 30 C level switch for BDP2 with heating element The scope of supply includes level switch including connector plug H...

Page 15: ...self sealing 3 Screw the level switch into the adapter 4 Fit the o ring on to the adapter 5 Insert the level switch with adapter and o ring in the intended tap hole of the BDP2 6 Start up the BDP2 13 5 START UP When starting up the BDP2 with level switch it is necessary to check that the time to push out the content is suffi cient see also 6 9 The time required to push out the content is determine...

Page 16: ... Orifice hole in the internal piston is blocked Clean the orifice see 12 2 and 12 4 14 2 CYCLE DOES NOT WORK Not sufficient hot gas pressure Open the regulating valve of the hot gas line e g the top service valve on the high side float regulator Solenoid valve in the hot gas line does not open Check solenoid valve and its control Liquid in the hot gas line See chapter 6 4 BDP2 connections mistaken...

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