Service Guide - BitzerPV

1 Service Guide Semi-hermetic Reciprocating Compressors This Service Guide provides answers to some of the most common questions and issues in the field. For more information on design, selection , application data and the BITZER software please refer to the BITZER website at Please consider the following safety instructions prior to attempting to repair, test, start up or diagnose any issues with BITZER compressors. Authorized Staff All work on compressors and refrigeration systems should only be performed by refrigeration personnel who have been trained and certified to perform the task at hand. General safety references: Warning! The compressor is under pressure with a holding charge of to 29 psi above atmospheric pressure. Incorrect handling may cause injury to skin and eyes.

2 Wear safety goggles while working on compressor. Do not open connections before pres-sure has been released. Caution! During operation, surface temperatures exceeding 140 F or below 32 F can be reached. Serious burnings possible. Lock and mark accessible sectors. Before working on the compressor: Switch off and let cool down. Warning! If working on the compressor after the plant has been commis-sioned: Compressor is under pressure! In case of improper handling serious injuries are possible. Release the pressure in the compressor! Wear safety goggles! CONTENTS 1 General Information Page Contact Information 4 Nomenclature (US vs. Global) 5 Serial Number Explanation 6 Quick Ship Program 7 Core Charge Return 8 Technical Support 9 2 Compressor Data C1, C2, C3 Technical Data 10 C4 Technical Data 11 B5/B6 Technical Data 12 2-Stage Technical Data 13 Dimensional Drawings & Connections 14 Application Limits 35 3 Electrical Information Maximum Operating Amps and Max MCC 46 Operating Amps 50 UL Motor Codes 54 Wiring diagrams/Power Connection 55 4 Accessories / Options Protection Devices (SE-B3, Delta PII, OLCK1)

3 59 Other Oil Monitoring Devices 65 Refrigeration Oils 66 Capacity Regulation 70 5 Spare Parts Mounting Kits 72 Oil Pumps, Valve Plates, Terminal Box Kits, Terminal Plate Kits, Complete Gasket Sets 73 Crankcase Heater and Head Fan 75 6 Preventive Maintenance / Service Operating Temperatures & Oil Guidelines 76 Switching Frequency and Vibrations 77 Tightening Torques 78 Common Wrench Sizes for Basic Service 79 Valve plate replacement instructions 80 Trouble Shooting 81 7 Technical Documents Overview 83 8 Start-Up Check List 86 BITZER North America Contact Information BITZER US, Inc 4031 Chamblee Road Oakwood, GA 30566 Phone: 770-503-9226 Fax: 770-503-9440 Email: 24hr Quick Ship Emergency Replacement Hotline for US Customers: 1-888-GO BITZER (1-888-462-4893) BITZER Canada Inc.

4 930 Selkirk Street Pointe Claire, Quebec, Canada H9R 4T7 Phone: 514-697-3363 Fax: 514-697-9768 BITZER M xico S de RL de CV Av. Adolfo L pez Mateos 221 Bodega 9 Col. Victoria Guadalupe, , 67110, M xico Phone: +52 (81) 1522 4500 Fax: +52 (81) 1522 4505 1 General Information 4 Nomenclature: US Model Number vs. Global Model Number 1 General Information Model Number4B3604PH-2NU-Y1No. of Unloaders1 or 2 Oil Type: A=AB; Y=POE; D=DryMotor Code 230/460/3Ph 60Hz ULMotor Type (High or Low temp)P=Oil Pump or S=Centrifugal DiskDisplacement (CFH@60Hz)B=Traditional or C=OctagonNumber of CylindersGlobalModel for bore x strokeMotor Horse Power2ndGeneration 5 Serial Number Significance starting 01/09/2003 The serial number contains 10 figures. The first 2 digits indicate the factory, the 3 following digits indicate the manufacturing date, and the last 5 digits are running subsequently.

5 Factory codes are the first 2 digits of the serial number (see Table 1). Date Codes are the next 3 digits that indicate the manufactur-ing date (use Table 3 for the 1st digit and Table 2 for the 2nd and 3rd digit). 1 General Information 6 Example: SERIAL NUMBER 2572100001 DIGITS 1 AND 2 DIGITS 3 TO 5 DIGITS 5 TO 10 FACTORY CODE DATE CODE SUBSEQUENT NUMBERING 25 721 00001 OAKWOOD Jan-07 Unambiguous subsequent numbering Table 3: Date Code 1986 until 1990 = Value 3 1991 until 1995 = Value 4 1996 until 2000 = Value 5 2001 until 2005 = Value 6 2006 until 2010 = Value 7 2011 until 2016 = Value 8 Table 1: Factory Codes 10 Rottenburg - Germany 11 Hailfingen - Germany 16 Schkeuditz - Germany 12 Castelo Branco - Portugal 13 Sao Paulo - Brazil 15 Milton Keynes - UK 17 Works BBR - China 18 Works Capetown - South Africa 20 Works BCB - China 21 Jawa Barat - Indonesia 22 St.

6 Marys - Austrialia 23 Sunshine, Victoria - Australia 24 Point Claire - Canada 25 Oakwood, GA - USA 27 Syracuse, NY - USA Table 2: Date Codes 2007 2008 2009 2010 2011 Jan 721 741 761 781 801 Feb 722 742 762 782 802 Mar 723 743 763 783 803 Apr 724 744 764 784 804 May 725 745 765 785 805 Jun 726 746 766 786 806 Jul 727 747 767 787 807 Aug 728 748 768 788 808 Sep 729 749 769 789 809 Oct 730 750 770 790 810 Nov 731 751 771 791 811 Dec 732 752 772 792 812 BITZER Quick Ship Program Placing your Order: Call 770-503-9226 M-F from 8am - 5pm Call 1-888-GO BITZER (1-888-462-4893) Choose from 4 Shipping Options: Next Day Delivery Second Day Delivery Standard Ground Transportation Customer Pick-Up Please provide the following information to our Customer Service Associates: Failed Model Number Serial Number Contact Name Contact Phone Number Email Address Ship to Address Is a liftgate needed?

7 Credit Card Number (American Express / Visa / Mastercard) 1 General Information 7 Contact customer Service at 770-503-9226 or email for a RMA form. Please Note: A credit card number (or a PO if you have a BITZER account) is re-quired for the replacement compressor and core deposit. We will call you back with a delivery confirmation ASAP. Once a Return Material Authorization (RMA) form is filled out, we will also arrange to have your failed compressor picked up. BITZER will pay the freight back to the factory and, as soon as it arrives at the Atlanta area plant, we will issue you a credit against your core depos-it. BITZER does not charge a core charge for your replacement com-pressor if you adhere to the following procedures: 1. After receiving your replacement compressor, you have 2 weeks to contact us to schedule the pick up of your core.

8 If you fail to do so BITZER will execute the core charge on your current PO. 2. The compressor should be shipped fully sealed: Use blank offs or the Service valves shipped with replacement compressor. 3. Attach Return Material Authorization form to the compressor. Your RMA form will be issued when placing your order. BITZER Core Charge Return Policy 1 General Information 8 If there has been more than one failure in a system, speak to an application engineer: Contact technical support at 770-718-2900 or email Please provide as much of the following information as possible: Model number Serial number Refrigerant Voltage Evaporating SST or Pressure Condensing SDT or Pressure Return Gas Temperature Liquid Subcooling / Liquid Temperature Discharge gas temperature Amp draw Oil pressure See back page for start-up check list.

9 Technical Support 1 General Information 9 C1, C2, C3 Technical Data Tube Connections Series Model Number Global Model Number NOMINAL HP CFM CFH CR Ready Single Phase Option Dual Voltage 230/460 Oil Charge (oz) Weight (lbs) DL (in.) SL (in.) C1 2C0173SH 173 -- Yes -- 35 95 1/2 5/8 C1 2C0222SH 222 -- Yes -- 35 95 1/2 5/8 C1 2C0278SL 1 278 -- Yes -- 35 95 1/2 5/8 C1 2C0278SH 2 278 -- Yes -- 35 99 1/2 5/8 C1 2C0323SH 2 323 -- Yes -- 35 99 1/2 5/8 C1 2C0407SL 2 407 -- Yes -- 35 99 1/2 5/8 C1 2C0407SH 3 407 -- -- -- 35 103 1/2 5/8 C2 2C0484SL 2 484 -- -- -- 53 150 5/8 7/8 C2 2C0484SH 3 484 -- Yes -- 53 157 5/8 7/8 C2 2C0572SL 2 572 -- -- -- 53 150 5/8 7/8 C2 2C0572SH 2DC 3 572 -- Yes -- 53 157 5/8 7/8 C2 2C0692SL 2CC 3 692 -- Yes -- 53 157 5/8 7/8 C2 2C0692SH 2CC 4 692 -- -- -- 53 159 5/8 7/8 C3 4C0770SL 4FC 3 770 Yes -- -- 70 176 5/8 7/8 C3 4C0770SH 4FC 5 770 Yes -- -- 70 185 5/8 7/8 C3 4C0969SL 4EC 4 969 Yes -- -- 70 181 5/8 1 1/8 C3

10 4C0969SH 4EC 6 969 Yes -- -- 70 188 5/8 1 1/8 C3 4C1145SL 4DC 5 1145 Yes -- -- 70 188 7/8 1 1/8 C3 4C1145SH 4DC 7 1145 Yes -- -- 70 192 7/8 1 1/8 C3 4C1385SL 4CC 6 1385 Yes -- -- 70 192 7/8 1 1/8 C3 4C1385SH 4CC 9 1385 Yes -- -- 70 192 7/8 1 1/8 2 Compressor Data 10 C4 Technical Data Tube Connections Series Model Number Global Model Number Ecoline Model Number NOMINAL HP CFM CFH CR Ready Single Phase Option Dual Voltage 230/460 Oil Charge (oz) Weight (lbs) DL (in.) SL (in.) C4 4C1480PL 6 1480 Yes -- Yes 92 280 7/8 1 1/8 C4 4C1480SL 4 VES-6Y 6 1480 Yes -- Yes 92 280 7/8 1 1/8 C4 4C1480PH 10 1480 Yes -- Yes 92 300 7/8 1 1/8 C4 4C1480SH 4 VES-10Y 10 1480 Yes -- Yes 92 300 7/8 1 1/8 C4 4C1761PL 8 1761 Yes -- Yes 92 289 1 1/8 1 3/8 C4 4C1761SL 4 TES-8Y 8 1761 Yes -- Yes 92 289 1 1/8 1 3/8 C4 4C1761PH 12 1761 Yes -- Yes 92 304 1 1/8 1 3/8 C4 4C1761SH 4 TES-12Y 12 1761 Yes -- Yes 92 304 1 1/8 1 3/8 C4 4C2067PL 10 2067 Yes -- Yes 92 300 1 1/8 1 3/8 C4 4C2067SL 4 PES-10Y 10 2067 Yes -- Yes 92 300 1 1/8 1 3/8 C4 4C2067PH 15 2067 Yes -- Yes 92 324 1 1/8 1 5/8 C4 4C2067SH 4 PES-15Y 15 2067 Yes -- Yes 92 324 1 1/8 1 5/8 C4 4C2397PL 12 40 2397 Yes -- Yes 92 304 1 1/8 1 3/8 C4 4C2397SL 4 NES-12Y 12 40 2397 Yes -- Yes 92 304 1 1/8 1 3/8