Service Guide Semi-hermetic Reciprocating Compressors

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 www.bitzerus.com. 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 7.25 to 29 psi above atmospheric pressure. Incorrect handling may cause injury to skin and eyes. Wear safety goggles while working on compressor. Do not open connections before pressure 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 commissioned: 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 1.1 Contact Information 4 1.2 Nomenclature (US vs. Global) 5 1.3 Serial Number Explanation 6 1.4 Quick Ship Program 7 1.5 Core Charge Return 8 1.6 Technical Support 9 2 Compressor Data 2.12.2 C1, C2, C3 Technical Data 10 2.2 C4 Technical Data 11 2.3 B5/B6 Technical Data 12 2.4 2-Stage Technical Data 13 2.5 Dimensional Drawings & Connections 14 2.6 Application Limits 35 3 Electrical Information 3.1 Maximum Operating Amps and Max MCC 46 3.2 Operating Amps 50 3.3 UL Motor Codes 54 3.4 Wiring diagrams/power Connection 55 4 Accessories / Options 4.1 Protection Devices (SE-B3, Delta PII, OLCK1) 59 4.2 Other Oil Monitoring Devices 65 4.3 Refrigeration Oils 66 4.4 Capacity Regulation 70 5 Spare Parts 5.1 Mounting Kits 72 5.2 Oil Pumps, Valve Plates, Terminal Box Kits, Terminal Plate Kits, Complete Gasket Sets 73 5.3 Crankcase Heater and Head Fan 75 6 Preventive Maintenance / Service 6.1 Operating Temperatures & Oil Guidelines 76 6.2 Switching Frequency and Vibrations 77 6.3 Tightening Torques 78 6.4 Common Wrench Sizes for Basic Service 79 6.5 Valve plate replacement instructions 80 6.6 Trouble Shooting 81 7 Technical Documents Overview 83 8 Start-Up Check List 86

1 General Information 1.1 BITZER North America Contact Information BITZER US, Inc 4031 Chamblee Road Oakwood, GA 30566 Phone: 770-503-9226 Fax: 770-503-9440 www.bitzerus.com Email: customerservice@bitzerus.com sales@bitzerus.com techsupport@bitzerus.com 24hr Quick Ship Emergency Replacement Hotline for US Customers: 1-888-GO BITZER (1-888-462-4893) BITZER Canada Inc. 930 Selkirk Street Pointe Claire, Quebec, Canada H9R 4T7 Phone: 514-697-3363 Fax: 514-697-9768 www.bitzer.ca BITZER México S de RL de CV Av. Adolfo López Mateos 221 Bodega 9 Col. Victoria Guadalupe, N.L., 67110, México Phone: +52 (81) 1522 4500 Fax: +52 (81) 1522 4505 www.bitzermexico.com 4 www.bitzerus.com

1 General Information 1.2 Nomenclature: US Model Number vs. Global Model Number U.S. Model Number 4B3604PH-2NU-Y1 No. of Unloaders 1 or 2 Oil Type: A=AB; Y=POE; D=Dry Motor Code i.e. 230/460/3Ph 60Hz UL Motor Type (High or Low temp) P=Oil Pump or S=Centrifugal Disk Displacement (CFH@60Hz) B=Traditional or C=Octagon Number of Cylinders Global Model Number 4G-30.2Y-2NU Identification Letter for bore x stroke Motor Horse Power 2 nd Generation www.bitzerus.com 5

1 General Information 1.3 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. Factory codes are the first 2 digits of the serial number (see Table 1). Date Codes are the next 3 digits that indicate the manufacturing date (use Table 3 for the 1st digit and Table 2 for the 2nd and 3rd digit). 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. 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 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 DIGITS 1 AND 2 FACTORY CODE Example: SERIAL NUMBER 2572100001 DIGITS 3 TO 5 DATE CODE DIGITS 5 TO 10 SUBSEQUENT NUMBERING 25 721 00001 OAKWOOD Jan-07 Unambiguous subsequent numbering 6 www.bitzerus.com

1 General Information 1.4 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? Credit Card Number (American Express / Visa / Mastercard) www.bitzerus.com 7

1 General Information 1.5 BITZER Core Charge Return Policy Contact customer service at 770-503-9226 or email customerservice@bitzerus.com for a RMA form. Please Note: A credit card number (or a PO if you have a BITZER account) is required 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 deposit. BITZER does not charge a core charge for your replacement compressor 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. 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. 8 www.bitzerus.com

1 General Information 1.6 Technical Support 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 techsupport@bitzerus.com 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. www.bitzerus.com 9

2.1 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 2KC-05.2 0.5 2.9 173 -- Yes -- 35 95 1/2 5/8 C1 2C0222SH 2JC-07.2 0.75 3.7 222 -- Yes -- 35 95 1/2 5/8 C1 2C0278SL 2HC-1.2 1 4.6 278 -- Yes -- 35 95 1/2 5/8 C1 2C0278SH 2HC-2.2 2 4.6 278 -- Yes -- 35 99 1/2 5/8 C1 2C0323SH 2GC-2.2 2 5.4 323 -- Yes -- 35 99 1/2 5/8 C1 2C0407SL 2FC-2.2 2 6.8 407 -- Yes -- 35 99 1/2 5/8 C1 2C0407SH 2FC-3.2 3 6.8 407 -- -- -- 35 103 1/2 5/8 C2 2C0484SL 2EC-2.2 2 8.1 484 -- -- -- 53 150 5/8 7/8 C2 2C0484SH 2EC-3.2 3 8.1 484 -- Yes -- 53 157 5/8 7/8 C2 2C0572SL 2DC-2.2 2 9.5 572 -- -- -- 53 150 5/8 7/8 C2 2C0572SH 2DC -3.2 3 9.5 572 -- Yes -- 53 157 5/8 7/8 C2 2C0692SL 2CC -3.2 3 11.5 692 -- Yes -- 53 157 5/8 7/8 C2 2C0692SH 2CC -4.2 4 11.5 692 -- -- -- 53 159 5/8 7/8 C3 4C0770SL 4FC -3.2 3 12.8 770 Yes -- -- 70 176 5/8 7/8 C3 4C0770SH 4FC -5.2 5 12.8 770 Yes -- -- 70 185 5/8 7/8 C3 4C0969SL 4EC -4.2 4 16.2 969 Yes -- -- 70 181 5/8 1 1/8 C3 4C0969SH 4EC -6.2 6 16.2 969 Yes -- -- 70 188 5/8 1 1/8 C3 4C1145SL 4DC -5.2 5 19.1 1145 Yes -- -- 70 188 7/8 1 1/8 C3 4C1145SH 4DC -7.2 7 19.1 1145 Yes -- -- 70 192 7/8 1 1/8 C3 4C1385SL 4CC -6.2 6 23.1 1385 Yes -- -- 70 192 7/8 1 1/8 C3 4C1385SH 4CC -9.2 9 23.1 1385 Yes -- -- 70 192 7/8 1 1/8 2 Compressor Data 10 www.bitzerus.com

2.2 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 4VC-6.2 6 24.7 1480 Yes -- Yes 92 280 7/8 1 1/8 C4 4C1480SL 4VCS-6.2 4VES-6Y 6 24.7 1480 Yes -- Yes 92 280 7/8 1 1/8 C4 4C1480PH 4VC-10.2 10 24.7 1480 Yes -- Yes 92 300 7/8 1 1/8 C4 4C1480SH 4VCS-10.2 4VES-10Y 10 24.7 1480 Yes -- Yes 92 300 7/8 1 1/8 C4 4C1761PL 4TC-8.2 8 29.4 1761 Yes -- Yes 92 289 1 1/8 1 3/8 C4 4C1761SL 4TCS-8.2 4TES-8Y 8 29.4 1761 Yes -- Yes 92 289 1 1/8 1 3/8 C4 4C1761PH 4TC-12.2 12 29.4 1761 Yes -- Yes 92 304 1 1/8 1 3/8 C4 4C1761SH 4TCS-12.2 4TES-12Y 12 29.4 1761 Yes -- Yes 92 304 1 1/8 1 3/8 C4 4C2067PL 4PC-10.2 10 34.5 2067 Yes -- Yes 92 300 1 1/8 1 3/8 C4 4C2067SL 4PCS-10.2 4PES-10Y 10 34.5 2067 Yes -- Yes 92 300 1 1/8 1 3/8 C4 4C2067PH 4PC-15.2 15 34.5 2067 Yes -- Yes 92 324 1 1/8 1 5/8 C4 4C2067SH 4PCS-15.2 4PES-15Y 15 34.5 2067 Yes -- Yes 92 324 1 1/8 1 5/8 C4 4C2397PL 4NC-12.2 12 40 2397 Yes -- Yes 92 304 1 1/8 1 3/8 C4 4C2397SL 4NCS-12.2 4NES-12Y 12 40 2397 Yes -- Yes 92 304 1 1/8 1 3/8 C4 4C2397PH 4NC-20.2 20 40 2397 Yes -- Yes 92 331 1 1/8 1 5/8 C4 4C2397SH 4NCS-20.2 4NES-20Y 20 40 2397 Yes -- Yes 92 331 1 1/8 1 5/8 2 Compressor Data www.bitzerus.com 11

2.3 B5 / B6 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.) B5 4B2707PL 4J-13.3 4JE-13Y 13 45.1 2707 Yes -- Yes 141 395 1 1/8 1 5/8 B5 4B2707PH 4J-22.3 4JE-22Y 22 45.1 2707 Yes -- Yes 141 419 1 1/8 1 5/8 B5 4B3139PL 4H-15.2 4HE-15Y 15 52.3 3139 Yes -- Yes 141 404 1 1/8 1 5/8 B5 4B3139PH 4H-25.2 4HE-25Y 25 52.3 3139 Yes -- Yes 158 448 1 1/8 2 1/8 B5 4B3604PL 4G-20.2 4GE-20Y 20 60.1 3604 Yes -- Yes 158 423 1 1/8 2 1/8 B5 4B3604PH 4G-30.2 4GE-30Y 30 60.1 3604 Yes -- Yes 158 454 1 1/8 2 1/8 B6 6B4060PL 6J-22.2 6JE-22Y 22 67.7 4060 Yes (2) -- Yes 167 470 1 3/8 2 1/8 B6 6B4060PH 6J-33.2 6JE-33Y 33 67.7 4060 Yes (2) -- Yes 167 509 1 3/8 2 1/8 B6 6B4709PL 6H-25.2 6HE-25Y 25 78.5 4709 Yes (2) -- Yes 167 494 1 3/8 2 1/8 B6 6B4709PH 6H-35.2 6HE-35Y 35 78.5 4709 Yes (2) -- Yes 167 518 1 3/8 2 1/8 B6 6B5406PL 6G-30.2 6GE-30Y 30 90.1 5406 Yes (2) -- Yes 167 503 1 3/8 2 1/8 B6 6B5406PH 6G-40.2 6GE-40Y 40 90.1 5406 Yes (2) -- Yes 167 525 1 3/8 2 1/8 B6 6B6462PL 6F-40.2 6FE-40Y 40 107.7 6462 Yes (2) -- Yes 167 527 1 5/8 2 1/8 B6 6B6462PH 6F-50.2 6FE-50Y 50 107.7 6462 Yes (2) -- Yes 167 531 1 5/8 2 1/8 2 Compressor Data 12 www.bitzerus.com

2.4 2-Stage Technical Data Tube Connections Series Model Number Global Model Number NOMINAL HP CFH (LP/HP) Single Phase Option Dual Voltage 230/460 Oil Charge (oz) Weight (lbs) DL (in.) SL (in.) BS4 S4T-5.2(Y) S4T-5.2(Y) 5 840/537 -- Yes 106 300 7/8 1 1/8 BS4 S4N-8.2(Y) S4N-8.2(Y) 8 1193/763 -- Yes 106 310 7/8 1 1/8 BS5 S4G-12.2(Y) S4G-12.2(Y) 12 1803/1151 -- Yes 158 365 1 1/8 1 3/8 BS6 S6J-16.2(Y) S6J-16.2(Y) 16 2706/1355 -- Yes 167 460 1 3/8 1 5/8 BS6 S6H-20.2(Y) S6H-20.2(Y) 20 3137/1573 -- Yes 167 485 1 3/8 1 5/8 BS6 S6G-25.2(Y) S6G-25.2(Y) 25 3602/1803 -- Yes 167 515 1 3/8 1 5/8 BS6 S6F-30.2(Y) S6F-30.2(Y) 30 4309/2152 -- Yes 167 517 1 3/8 1 5/8 2 Compressor Data www.bitzerus.com 13

2 Compressor Data 2.5 Dimensional Drawings and Connections C1 Series Series Model Number Global Model Number C1 2C 0173 SH 2KC-05.2 C1 2C 0222 SH 2JC-07.2 C1 2C 0278 SL 2HC-1.2 C1 2C 0278 SH 2HC-2.2 C1 2C 0323 SH 2GC-2.2 C1 2C 0407 SL 2FC-2.2 C1 2C 0407 SH 2FC-3.2 14 www.bitzerus.com

2 Compressor Data C1 Series Dimensions and Connection Ports For Legend Go to Page 33 All dimensions in inches Legend for connections see page 34 www.bitzerus.com 15

2 Compressor Data C2 Series Series Model Number Global Model Number C2 2C 0484 SL 2EC-2.2 C2 2C 0484 SH 2EC-3.2 C2 2C 0572 SL 2DC-2.2 C2 2C 0572 SH 2DC -3.2 C2 2C 0692 SL 2CC -3.2 C2 2C 0692 SH 2CC -4.2 16 www.bitzerus.com

2 Compressor Data C2 Series Dimensions and Connection Ports All dimensions in inches Legend for connections see page 34 www.bitzerus.com 17

2 Compressor Data C3 Series Series Model Number Previous Model Number C3 4C 0770 SL 4FC -3.2 C3 4C 0770 SH 4FC -5.2 C3 4C 0969 SL 4EC -4.2 C3 4C 0969 SH 4EC -6.2 C3 4C 1145 SL 4DC -5.2 C3 4C 1145 SH 4DC -7.2 C3 4C 1385 SL 4CC -6.2 C3 4C 1385 SH 4CC -9.2 18 www.bitzerus.com

C3 Series Dimensions and Connection Ports All dimensions in inches Legend for connections see page 34 Legend for dimensions see page 26 2 Compressor Data www.bitzerus.com 19

2 Compressor Data C4 Series Series Model Number Global Model Number Ecoline Model Number C4 4C 1480 PL 4VC-6.2 4VES-6Y C4 4C 1480 PH 4VC-10.2 4VES-10Y C4 4C 1761 PL 4TC-8.2 4TES-8Y C4 4C 1761 PH 4TC-12.2 4TES-12Y C4 4C 2067 PL 4PC-10.2 4PES-10Y C4 4C 2067 PH 4PC-15.2 4PES-15Y C4 4C 2397 PL 4NC-12.2 4NES-12Y C4 4C 2397 PH 4NC-20.2 4NES-20Y 20 www.bitzerus.com

2 Compressor Data C4 Series Dimensions and Connection Ports All dimensions in inches Legend for connections see page 34 Legend for dimensions see page 26 www.bitzerus.com 21

2 Compressor Data B5 Series Series Model Number Global Model Number Ecoline Model Number B5 4B 2707 PL 4J-13.3 4JE-13Y B5 4B 2707 PH 4J-22.3 4JE-22Y B5 4B 3139 PL 4H-15.2 4HE-15Y B5 4B 3139 PH 4H-25.2 4H-25Y B5 4B 3604 PL 4G-20.2 4GE-20Y B5 4B 3604 PH 4G-30.2 4GE-30Y 22 www.bitzerus.com

2 Compressor Data B5 Series Dimensions and Connection Ports All dimensions in inches Legend for connections see page 34 Legend for dimensions see page 27 www.bitzerus.com 23

2 Compressor Data B6 Series Series New Model Number Global Model Number Ecoline Model Number B6 6B 4060 PL 6J-22.2 6JE-22Y B6 6B 4060 PH 6J-33.2 6JE-33Y B6 6B 4709 PL 6H-25.2 6HE-25Y B6 6B 4709 PH 6H-35.2 6HE-35Y B6 6B 5406 PL 6G-30.2 6GE-30Y B6 6B 5406 PH 6G-40.2 6GE-40Y B6 6B 6462 PL 6F-40.2 6FE-40Y B6 6B 6462 PH 6F-50.2 6FE-50Y 24 www.bitzerus.com

2 Compressor Data B6 Series Dimensions and Connection ports All dimensions in inches Legend for connections see page 34 Legend for dimensions see page 27 www.bitzerus.com 25

2 Compressor Data Legend for C3, C4 Compressor Dimensions Model Number A C D1 F G H J K L 4C0770SL 4C0770SH 4C0969SL 17.01 13.78 2.95 8.7 1.65 12.36 14.21 1.46 12.05 4C0969SH 4C1145SL 4C1145SH 4C1385SL 4C1385SH 4C1480SL 4C1480SH 2.24 13.9 12.48 18.03 3.98 9.72 15.24 2.24 1.65 12.2 1.65 13.35 4C1761SL 25.55 7.36 6.34 21.97 4C1761SH 2.48 4C2067SL 4C2067SH 26.38 8.27 4.37 6.77 22.87 2.24 13.9 4C2397SL 25.55 7.36 2.48 6.34 21.97 4C2397SH 26.38 8.27 4.37 6.77 22.87 Please Note - All measurements in this table are listed in inches 26 www.bitzerus.com

2 Compressor Data Legend for B5, B6 Compressor Dimensions Model Number A D1 F G J L 4B2707PL 4B2707PH 27.28 5.94 2.64 4.41 19.72 4B3139PL 4B3139PH 29.17 7.83 3.43 21.61 4B3604PL 28 6.65 3.03 5.08 20.43 4B3604PH 29.17 7.83 3.43 21.61 6B4060PL 30.12 8.31 3.03 28.9 6B4060PH 31.3 9.49 3.43 30.08 6B4709PL 30.12 8.31 3.03 28.9 6B4709PH 31.3 9.49 3.43 30.08 10.67 6B5406PL 30.12 8.31 3.03 28.9 6B5406PH 6B6462PL 6B6462PH 31.3 9.49 3.43 30.08 28.74 15 Please Note - All measurements in this table are listed in inches www.bitzerus.com 27

2 Compressor Data 2-Stage Series Series Model Number BS4 S4T-5.2(Y) BS4 S4N-8.2(Y) 28 www.bitzerus.com

2 Compressor Data 2-Stage SB4 Series - Dimensions and Conection Ports All dimensions in inches Legend for connections see page 34 www.bitzerus.com 29

2 Compressor Data 2-Stage Series Series Model Number BS5 S4G-12.2(Y) 30 www.bitzerus.com

2 Compressor Data 2-Stage BS5 Series - Dimensions and Conection Ports All dimensions in inches Legend for connections see page 34 www.bitzerus.com 31

2-Stage BS6 Series Series Model Number BS6 S6J-16.2(Y) BS6 S6H-20.2(Y) BS6 S6G-25.2(Y) BS6 S6F-30.2(Y) For Legend Go To Pages 32-35 2 Compressor Data 32 www.bitzerus.com

2 Compressor Data 2-Stage BS6 Series - Dimensions and Conection Ports All dimensions in inches Legend for connections see page 34 www.bitzerus.com 33

2 Compressor Data Legend for Connection Positions 1 High pressure connection (HP) 2 Discharge gas temperature sensor (HP) or LI sensor 3 Low pressure connection (LP) 4 Liquid Injection: spray nozzle (LP) 4b Liquid Injection sensor (HP) 4c Liquid Injection sensor (MP / operation with a liquid subcooler) 5 Oil fill plug 6 Oil drain (magnetic screw) 7 Oil filter 8 Oil return (oil separator) 9a 9b Gas equalization (parallel operation) Oil equalization (parallel operation) 10 Crankcase heater 11 High Oil pressure connection (7/16-20 UNF Thread) 12 Low Oil pressure connection (7/16-20 UNF Thread) 14 Intermediate pressure connection (MP) Liquid injection (operation without liquid subcooler and 15 with thermostatic expansion valve) Connection for oil monitoring 16 (oil sensor or differential oil pressure switch Delta-P ) (M20 Thread) 17 Refrigerant inlet at liquid subcooler 18 Refrigerant outlet at liquid subcooler 21 Connection for oil service valve 34 www.bitzerus.com

2 Compressor Data 2.6 Application Limits Explanation of Application Limits Diagram of Semi Hermetic Reciprocating Compressors Figure 2.9.1.Simplified application limits diagram Limitations of the application limits diagram: 1-Pressure differential / pressure ratio If the pressure differential / pressure ratio of the compressor gets too low the resulting force is insufficient to properly open or close the reeds on the valve plate. This can lead to a breakage of the reeds. Furthermore the volumetric displacement decreases due to reverse expansion from the pressure chamber into the working chamber. www.bitzerus.com 35

2 Compressor Data 2-Maximum evaporating temperature If the compressor operates at an evaporating temperature close to the maximum allowed evaporating temperature the compressor delivers a high refrigerant mass flow. Hence high forces develop on bearings and drive gear. 3-Motor Load The motor load of a semi hermetic reciprocating compressor depends on the operating point. The higher the evaporating temperature and the higher the condensing temperature, the higher the corresponding motor load. 4-Maximum condensing temperature The maximum condensing temperature is limited by the saturated vapor pressure as well as the maximum allowable operating pressure on the high pressure side of the compressor. According to EN378-2 the maximum allowable operating pressure of the systems with pressure relief devices must not exceed 0.9 x maximum allowable operating pressure. 5-Minimum evaporating temperature With decreasing evaporating temperature the saturated vapor pressure of the refrigerant decreases as well. For safe operation the circuit should not be operated at pressures too much below ambient air in order to avoid penetration of ambient air into the suction side of the system through a leakage. At low evaporating temperatures the refrigerant mass flow of the compressor as well as the suction gas density are decreasing. This can possibly lead to an insufficient motor cooling as the delivered refrigerant mass flow is too low. 6-Thermal limit At low evaporating temperatures in combination with high condensing temperatures the thermal load limit of the compressor restricts the operation. There are various possibilities to extend the application limits such as water cooled cylinder heads, additional fans, restricting the allowable suction gas superheat or, in individual cases, a direct liquid injection into the suction side of the compressor. The recommended methods for additional cooling are displayed in the application limits diagram as icons. 36 www.bitzerus.com

2 Compressor Data Semi-hermetic Recips Application limits: R404A and R507A R404A / R507A 100% 2C0173SH.. 4C1385SH R404A / R507A 100% 4C1480SL.. 6B6462PH www.bitzerus.com 37

2 Compressor Data R404A / R507A 50% 2C0173SH.. 4C1385SH R404A / R507A 50% 4C1480SL.. 4B3604PH 38 www.bitzerus.com

2 Compressor Data Application limits: R134a R134a 100% 2C0173SH.. 4C1385SH R134a 50% 2C0173SH.. 4C1385SH www.bitzerus.com 39

2 Compressor Data R134a Ecoline 100% 4VES-6Y.. 6FE-50Y R134a Ecoline 50% 4VES-6Y.. 4GE-30Y 40 www.bitzerus.com

2 Compressor Data Application limits: R407A R407A 100% R407A 50% www.bitzerus.com 41

2 Compressor Data Application limits: R22 R22 100% R22 50% 42 www.bitzerus.com

2 Compressor Data Application limits: R22 LOW TEMP APPLICATIONS R22 VARICOOL SL(B) 2C0173SH.. 4C1385SH R22 LIQUID INJECTION SYSTEM 4C1480SL.. 6B6462PH LI Liquid Injection System www.bitzerus.com 43

2 Compressor Data Application limits: R407C R407C 100% Application limits legend *For R134a when SDT>130F, the oil BSE55 must be used (instead of BSE32) 44 www.bitzerus.com

2 Compressor Data 2-Stage Semi-hermectic Recips: S4T.. S6F Application limits: R404A / 507A R22 www.bitzerus.com 45

3 Electrical Information 3.1 Maximum Operating Amps (MOA) and Maximum MCC BITZER semi-hermetic reciprocating compressors are characterized by their universal applications. Our standard reciprocating compressors can be applied with R22, R404A, R507A, R134A, R407A and R407C in high, medium or low temperature applications. The compressors are equipped with highly efficient large volume electric motors. According to UL specifications, contactors and cables can be selected by either MCC and RLA or by means of the MOA (maximum operating amps) specified in the following tables. When using MCC to select contactors and cables, the value of RLA = MCC/1.40 should be used for sizing contactors. All other electrical sizing should be based on RLA = MCC/1.56. When using MOA to select contactors and cable, use UL listed circuit breakers set to trip at no more than 125% of the MOA. The circuit breaker should not be sized less than 110% of the MOA value to avoid nuisance tripping. Note: All electrical calculations are based on 3 phase at 60Hz. Table: Standard Rating Conditions (Based on 95 F [35 C] Ambient Temperature) Legend Temperature Application Designation SST SDT RGT SC Air Conditioning High Temp Refrigeration Medium Temp Refrigeration Low Temp Refrigeration H 45 F 130 F 65 F 15 F H 45 F 130 F 65 F 0 F M 20 F 120 F 65 F 0 F L -25 F 105 F 65 F 0 F 46 www.bitzerus.com

Model Number Global Model HP kw CFH Max MCC LRA MOA 230V 460V 575V 230V 460V 575V 230V 460V 575V 2C0173SH 2KC-05.2 1/2 0.37 173 7.6 3.6 2.7 32 16 12.8 5.5 2.8 2.2 2C0222SH 2JC-07.2 3/4 0.55 222 9.4 4.5 3.3 40 20 16 7.1 3.6 2.8 2C0278SL 2HC-1.2 1 0.7 277 10.2 4.8 3.7 42 19 13 6.8 3.4 2.7 2C0278SH 2HC-2.2 1.5 1.1 277 15.5 6.3 5 54 24 17 8.7 4.4 3.5 2C0323SH 2GC-2.2 1.5 1.1 323 15.3 6.7 5.2 54 24 17 9.5 4.8 3.8 2C0407SL 2FC-2.2 1.5 1.1 406 14 6.4 5 54 24 17 9.6 4.8 3.8 2C0407SH 2FC-3.2 1.8 1.4 406 17.6 8 6.8 60 27.5 19 11.8 5.9 4.7 2C0484SL 2EC-2.2 2 1.5 484 16.8 7.6 5.6 70 28.5 20.5 11.4 5.7 4.6 2C0484SH 2EC-3.2 3 2.2 484 21.9 10.2 8.2 97 39.5 28.5 14.1 7 5.6 2C0572SL 2DC-2.2 2.5 1.9 572 18.3 9 6.6 80.5 33 23.5 13.4 6.7 5.4 2C0572SH 2DC-3.2 3 2.2 572 23.8 11.3 8 97 39.5 28.5 15.8 7.9 6.3 2C0692SL 2CC-3.2 3 2.2 692 20.9 9.8 7.9 97 39.5 28.5 16.1 8 6.4 2C0692SH 2CC-4.2 3.5 2.6 692 28.4 12.7 10.2 115.5 47.5 34 19 9.5 7.6 4C0770SL 4FC-3.2 3.5 2.6 770 28.1 12.6 9.6 115.5 47.5 34 17.9 9 7.2 4C0770SH 4FC-5.2 5.5 4 770 37.8 20.5 13.6 163 66.5 48 21.8 10.9 8.7 4C0969SL 4EC-4.2 4 3 969 31.4 14.4 11.6 142 58 41.5 20.7 10.3 8.3 4C0969SH 4EC-6.2 5.5 4 969 43.8 20.9 14.7 163 66.5 48 26.7 13.4 10.7 4C1145SL 4DC-5.2 5.5 4 1144 32.2 16.8 14 163 66.5 48 25.4 12.7 10.2 4C1145SH 4DC-7.2 7.5 5.5 1144 48.3 23.8 17.2 215 88 63.5 31.9 15.9 12.8 4C1385SL 4CC-6.2 5.5 4 1385 39 22.1 17.5 215 88 63.5 32.1 16 12.8 4C1385SH 4CC-9.2 9 6.7 1385 53.3 26.6 21.3 215 88 63.5 34.6 20 16 3 Electrical Information C1 to C3 Models www.bitzerus.com 47

Model Number Global Model Number HP kw CFH Max MCC LRA MOA 230V 460V 575V 230V 460V 575V 230V 460V 575V 4C1480P(S)L 4VC(S)-6.2 5.5 4 1480 38 19 15 150 75 60 27 13.5 10.8 4C1480P(S)H 4VC(S)-10.2 10 7.5 1480 60 30 24 222 111 89 37.2 18.6 14.9 4C1761P(S)L 4TC(S)-8.2 7.5 5.5 1761 44 22 19 180 90 72 33.1 16.6 13.2 4C1761P(S)H 4TC(S)-12.2 12.5 9.2 1761 66 33 26.4 252 126 101 45.8 22.9 18.3 4C2067P(S)L 4PC(S)-10.2 10 7.5 2067 54 27 22.4 222 111 89 39.6 19.8 15.8 4C2067P(S)H 4PC(S)-15.2 15 11 2067 76 38 30.5 294 147 117 53.4 26.7 21.4 4C2397P(S)L 4NC(S)-12.2 12.5 9.2 2397 62 31 24.8 252 126 101 47 23.5 18.8 4C2397P(S)H 4NC(S)-20.2 20 15 2397 90 45 36.8 352 176 140 63.6 31.8 25.4 4B2707PL 4J-13.2 13 9.5 2707 68 34 27 294 147 117 53 26.5 21.2 4B2707PH 4J-22.2 22 16.1 2707 96 48 38 352 176 140 69.8 34.9 27.9 4B3139PL 4H-15.2 15 11 3139 72 36 43.6 294 147 117 60.2 30.1 24.1 4B3139PH 4H-25.2 25 18.5 3139 118 59 47 436 218 174 80.8 40.4 32.3 4B3604PL 4G-20.2 20 15 3604 90 45 36 352 176 140 71.2 35.6 28.5 4B3604PH 4G-30.2 30 22 3604 140 70 56 490 245 196 98.4 49.2 39.4 6B4060PL 6J-22.2 22 16.1 4060 102 51 41 436 218 174 80 40 32 6B4060PH 6J-33.2 33 24.2 4060 156 78 62 550 275 220 105 52.6 42.1 6B4709PL 6H-25.2 25 18.5 4709 108 54 43 436 218 174 92 46 36.8 6B4709PH 6H-35.2 35 26 4709 164 82 65 550 275 220 123 61.6 49.3 6B5406PL 6G-30.2 30 22 5406 132 66 52 490 245 196 106 53.1 42.5 6B5406PH 6G-40.2 40 30 5406 220 110 88 700 350 280 150 75.1 60.1 6B6462PL 6F-40.2 40 30 6462 152 76 61 700 350 280 129 64.6 51.7 6B6462PH 6F-50.2 50 37 6462 224 112 89 950 425 340 182 92 72.8 3 Electrical Information C4, B5 & B6 Models 48 www.bitzerus.com

Model Number Global Model Number HP kw CFH Max MCC LRA MOA 230V 460V 575V 230V 460V 575V 230V 460V 575V 8C7863PH 8GC-60.2 60 44.7 7866 281 141 113 1230 513 410 226 113 91 8C9400PH 8FC-70.2 70 48.9 9402 329 164 132 1288 590 472 278 139 112 S4T-5.2 S4T-5.2 5 3.7 839/537 28 28 11.2 150 75 60 28 14 11.2 S4N-8.2 S4N-8.2 8 6 1193/763 39.2 39.2 15.7 180 90 72 34 17 11.2 S4G-12.2 S4G-12.2 12 9 1803/1151 56 56 22.4 252 126 101 48 24 19.2 S6J-16.2 S6J-16.2 16 12 2707/1355 84 84 33.6 294 147 117 62 31 24.8 S6H-20.2 S6H-20.2 20 15 3137/1573 95.2 95.2 38 352 176 140 74 37 29.6 SG6-25.2 SG6-25.2 25 18.5 3602/1803 116 116 46.4 436 218 174 86 43 34.4 S6F-30.2 S6F-30.2 30 22 4309/2152 134.4 134.4 53.5 490 245 196 81.6 51 40.8 3 Electrical Information C8 & 2-Stage Models www.bitzerus.com 49

Model Number Global Model Number Motor 45 F/ 130 F R22 R134a 32 F/ 130 F 0 F/ 130 F 45 F/ 130 F 32 F/ 130 F 2C0173SH 2KC-05.2(Y) 1 2.29 2.15 1.73 1.75 1.67 1.45 2C0222SH 2JC-07.2(Y) 1 2.94 2.77 2.27 2.28 2.19 1.91 2C0278SL 2HC-1.2(Y) 2 2.67 2.56 2.45 2.12 2C0278SH 2HC-2.2(Y) 1 3.79 3.61 3.03 2.93 2.83 2.57 2C0323SH 2GC-2.2(Y) 1 4.1 3.92 3.28 3.14 3.01 2.66 2C0407SL 2FC-2.2(Y) 2 3.57 3.48 3.29 2.78 2C0407SH 2FC-3.2(Y) 1 4.99 4.71 3.79 3.69 3.5 3.01 2C0484SL 2EC-2.2(Y) 2 3.96 4.03 3.73 2.96 2C0484SH 2EC-3.2(Y) 1 6.05 5.62 4.47 4.55 4.29 3.65 2C0572SL 2DC-2.2(Y) 2 4.96 4.96 4.68 3.88 2C0572SH 2DC-3.2(Y) 1 7.01 6.54 5.33 5.35 5.11 4.5 2C0692SL 2CC-3.2(Y) 2 6.03 6.03 5.66 4.73 2C0692SH 2CC-4.2(Y) 1 8.24 7.59 6.02 6.03 5.66 4.72 4C0770SL 4FC-3.2(Y) 2 6.44 6.06 5.71 4.79 4C0770SH 4FC-5.2(Y) 1 9.35 8.71 6.93 6.78 6.43 5.47 4C0969SL 4EC-4.2(Y) 2 7.15 7.27 6.72 4.94 4C0969SH 4EC-6.2(Y) 1 11.25 10.32 7.94 8.09 7.57 6 4C1145SL 4DC-5.2(Y) 2 9 9.05 8.41 6.57 4C1145SH 4DC-7.2(Y) 1 13.77 12.95 10.53 10.44 9.9 8.49 4C1385SL 4CC-6.2(Y) 2 12 11.7 10.9 8.9 4C1385SH 4CC-9.2(Y) 1 16.44 15.18 12 11.7 10.89 8.9 4C1480PL 4VC-6.2(Y) 2 10.19 10.48 9.32 6.37 0 F/ 130 F 3 Electrical Information 3.2 Operating Amps R22 & R134a Operating Amps 460V/3/60Hz 50 www.bitzerus.com

Model Number Global Model Number Motor 45 F/ 130 F R22 R134a 32 F/ 130 F 0 F/ 130 F 45 F/ 130 F 32 F/ 130 F 4C1480PH 4VC-10.2(Y) 1 15.39 14.29 11 11.13 10.19 7.84 4C1761PL 4TC-8.2(Y) 2 12.43 12.73 11.34 7.78 4C1761PH 4TC-12.2(Y) 1 19.16 17.83 13.9 13.98 12.9 10.2 4C2067PL 4PC-10.2(Y) 2 14.59 15.04 13.48 9.49 4C2067PH 4PC-15.2(Y) 1 21.72 20.07 15.48 15.7 14.38 11.07 4C2397PL 4NC-12.2(Y) 2 17.45 18.09 16.27 11.74 4C2397PH 4NC-20.2(Y) 1 26.36 24.19 18.16 18.6 17 13.14 4B2707PL 4J-13.2(Y) 2 20.2 19.62 17.32 12.59 4B2707PH 4J-22.2(Y) 1 28.25 26.24 20.12 19.85 17.83 13.89 4B3139PL 4H-15.2(Y) 2 22.9 22.24 19.43 13.72 4B3139PH 4H-25.2(Y) 1 32.89 30.6 23.8 24.05 21.63 17.19 4B3604PL 4G-20.2(Y) 2 27.33 26.25 23.02 16.24 4B3604PH 4G-30.2(Y) 1 39.84 36.76 28.92 28.31 26.09 21.02 6B4060PL 6J-22.2(Y) 2 30.04 29.2 25.84 19.15 6B4060PH 6J-33.2(Y) 1 42.53 39.51 30.26 29.83 26.75 20.67 6B4709PL 6H-25.2(Y) 2 34.07 33.09 28.91 20.72 6B4709PH 6H-35.2(Y) 1 50.37 46.91 36.52 36.91 33.2 26.47 6B5406PL 6G-30.2(Y) 2 41.15 39.52 34.65 24.29 6B5406PH 6G-40.2(Y) 1 61.06 56.48 45.16 44.31 41.25 34.48 6B6462PL 6F-40.2(Y) 2 52.75 50.53 45 34.78 6B6462PH 6F-50.2(Y) 1 77.4 72.84 60.32 58.54 54.58 47.7 0 F/ 130 F 3 Electrical Information R22 & R134a Operating Amps 460V/3/60Hz (Continued) www.bitzerus.com 51

Model Number Global Model Number Motor R404A / (R507A*) R407A 20 F/ 0 F/ -25 F/ 20 F/ 0 F/ -25 F/ 110 F 110 F 110 F 110 F 110 F 110 F 2C0173SH 2KC-05.2(Y) 1 1.84 1.7 1.48 1.79 1.63 1.41 2C0222SH 2JC-07.2(Y) 1 2.48 2.27 1.97 2.39 2.17 1.87 2C0278SL 2HC-1.2(Y) 2 2.95 2.57 2.16 2.78 2.42 2.05 2C0278SH 2HC-2.2(Y) 1 3.26 2.97 2.61 3.14 2.84 2.51 2C0323SH 2GC-2.2(Y) 1 3.56 3.2 2.74 3.4 3.03 2.6 2C0407SL 2FC-2.2(Y) 2 4.08 3.59 2.96 3.87 3.35 2.75 2C0407SH 2FC-3.2(Y) 1 4.23 3.75 3.17 4.01 3.52 3 2C0484SL 2EC-2.2(Y) 2 4.79 4.05 3.22 4.45 3.73 2.98 2C0484SH 2EC-3.2(Y) 1 5.26 4.63 3.88 4.97 4.34 3.65 2C0572SL 2DC-2.2(Y) 2 5.76 5 4.11 5.41 4.65 3.84 2C0572SH 2DC-3.2(Y) 1 5.82 5.05 4.09 5.48 4.69 3.78 2C0692SL 2CC-3.2(Y) 2 6.75 5.73 4.49 6.27 5.24 4.08 2C0692SH 2CC-4.2(Y) 1 7.09 6.15 5.03 6.66 5.71 4.68 4C0770SL 4FC-3.2(Y) 2 7.77 6.63 5.29 7.23 6.14 4.89 4C0770SH 4FC-5.2(Y) 1 8.04 7.08 5.86 7.58 6.62 5.49 4C0969SL 4EC-4.2(Y) 2 8.71 7.25 5.35 8.02 6.57 4.72 4C0969SH 4EC-6.2(Y) 1 9.48 8.12 6.37 8.84 7.48 5.83 4C1145SL 4DC-5.2(Y) 2 10.87 9.25 7.06 10.12 8.45 6.4 4C1145SH 4DC-7.2(Y) 1 11.91 10.51 8.77 11.25 9.85 8.25 4C1385SL 4CC-6.2(Y) 2 13.73 11.91 9.6 12.84 11.02 8.85 4C1385SH 4CC-9.2(Y) 1 13.73 11.91 9.59 12.84 11.01 8.85 * R507A values are approximately 3% greater than the listed 404A values. 3 Electrical Information R404A & R507A Operating Amps 460V/3/60Hz 52 www.bitzerus.com

Model Number Global Model Number Motor R404A / (R507A*) R407A 20 F/ 0 F/ -25 F/ 20 F/ 0 F/ -25 F/ 110 F 110 F 110 F 110 F 110 F 110 F 4C1480PL 4VC-6.2(Y) 2 13.18 10.63 7.46 11.77 9.29 6.26 4C1480PH 4VC-10.2(Y) 1 13.41 11.24 8.6 12.23 10.18 7.76 4C1761PL 4TC-8.2(Y) 2 15.96 12.89 9.12 14.25 11.3 7.7 4C1761PH 4TC-12.2(Y) 1 16.65 14.17 11.17 15.33 12.93 10.17 4C2067PL 4PC-10.2(Y) 2 18.64 15.15 10.84 16.79 13.37 9.38 4C2067PH 4PC-15.2(Y) 1 18.69 15.74 12.18 17.21 14.35 10.97 4C2397PL 4NC-12.2(Y) 2 22.2 18.18 13.28 19.96 16.04 11.64 4C2397PH 4NC-20.2(Y) 1 22.3 18.61 14.36 20.4 16.83 13.09 4B2707PL 4J-13.2(Y) 2 25.1 20.8 15.15 22.7 18.54 13.21 4B2707PH 4J-22.2(Y) 1 25.1 21.1 16.04 22.8 19.04 14.41 4B3139PL 4H-15.2(Y) 2 29.7 24.1 17.36 26.6 21.4 15.31 4B3139PH 4H-25.2(Y) 1 29.5 24.9 19.45 27.1 22.8 17.77 4B3604PL 4G-20.2(Y) 2 34.1 27.8 20.2 30.7 24.9 17.78 4B3604PH 4G-30.2(Y) 1 35.1 29.5 22.9 32.1 26.8 21 6B4060PL 6J-22.2(Y) 2 37.7 31.1 22.8 33.9 27.6 20 6B4060PH 6J-33.2(Y) 1 36.9 30.8 23 33.7 27.8 20.5 6B4709PL 6H-25.2(Y) 2 44.1 35.8 25.7 39.5 31.7 22.3 6B4709PH 6H-35.2(Y) 1 45.5 38.5 30.1 41.7 35.2 27.5 6B5406PL 6G-30.2(Y) 2 50.6 41.2 29.7 45.2 36.5 25.4 6B5406PH 6G-40.2(Y) 1 54 46.1 37.1 49.7 42.5 34.2 6B6462PL 6F-40.2(Y) 2 61.9 51.8 39.7 56.4 46.9 36 6B6462PH 6F-50.2(Y) 1 69.7 60.9 51.9 64.8 57.2 49.5 * R507A values are approximately 3% greater than the listed 404A values. 3 Electrical Information R404A & R507A Operating Amps 460V/3/60Hz (Continued) www.bitzerus.com 53

3 Electrical Information 3.3 UL Motor Codes Compressor Model C1, C2, C3 C4, B5, B6, 2-Stage(S4-S6) Motor Code Nominal Voltage Voltage Range Motor Connection 2EU 208 / 230 208-230 1 Phase 2DU 208 / 230 208-230 D 4SU 460 440-480 Y 5SU 575 575 Y 2NU 208/230 208-230 2NU 460 440-480 Y/YY (Dual voltage) Y (Dual voltage) 3PU 380 360-400 Y/YY 4PU 460 440-480 Y/YY 5PU 575 575 Y/YY Legend: Y or S = Star wiring D = Delta wiring P = Part winding N = Dual Voltage U = UL approval Y/YY = part winding option available Note: All motor information listed for 60Hz 54 www.bitzerus.com

3.4 Wiring Diagrams / Power Connection Direct Start 2NU Motor 230V or 460V/3/60Hz 3 Electrical Information ATTENTION! Terminals B1-B2, M1-M2 and cables 1-2 must not come into contact with supply or control voltage. www.bitzerus.com 55

3 Electrical Information Direct Start 4PU Motor 460V/3/60HZ & 5PU Motor 575V/3/60 ATTENTION! Terminals B1-B2, M1-M2 and cables 1-2 must not come into contact with supply or control voltage. 56 www.bitzerus.com

3 Electrical Information Direct Start 2DU 230V/3/60HZ, 4SU 460V/3/60HZ & 5SU 575V/3/60HZ ATTENTION: Do not supply voltage at the PTC terminals www.bitzerus.com 57

3 Electrical Information Direct Start 2EU 1 Phase (UL) Legend A = Comp. control circuit CA = Start capacitor CB = Run Capacitor JP = Field installation jumper (req'd) RY = Start relay T1/T2 = From compressor contactor B1/B2 = Remove B1/B2 to enable "automatic reset" mode ATTENTION: Do not supply voltage at the PTC terminals 58 www.bitzerus.com

Protection Module INT: SE-B3 (Motor) OLC-K1 (Oil) Delta-P II (Oil) Part Number Picture 347035-01 347318-07 (110V) 347318-06 (230V) 347318-11 4 Accessories/Options 4.1 Protection Devices Protection Module Part Numbers and Pictures www.bitzerus.com 59

4 Accessories/Options SE-B3 When installing a dual voltage INT, the service tech should conduct the following tests to ensure proper operation: WITH THE POWER OFF, remove one of the leads from either M1 or M2 on the compressor terminal board. Turn on the power and confirm that the control voltage appears between terminal 12 and N on the device. If an optional signal light (H1) is used, it should be illuminated. NO voltage should appear between terminal 14 and N. Please Note: After supplying power between L and N, there will be a 3-second time delay. Manual Reset A manual reset function prevents the compressor from restarting and eliminates short cycling. This can be reset by briefly interrupting the supply voltage for 5 seconds, either by means of the main switch or by a reset push-button which can be installed in the supply line. Automatic Reset In exceptional cases, the lockout function can be cancelled by removing the link between B1-B2. The compressor then restarts automatically after cooling down. This modification is only permissible if the cycling rate is limited to 6-8 starts per hour by using an additional time-lag relay or timer. Note: INT trips at 4500Ω The typical resistance at ambient conditions for M1 and M2 is 150Ω - 650Ω. 60 www.bitzerus.com

4 Accessories/Options Oil Monitoring Devices: Delta-P II: Monitors oil pressure differential of compressors with oil pumps OLC-K1: Optically monitors oil presence at the crankshaft of centrifugal disk (Octagon S ) compressors Technical Features: The Delta-P II and OLC-K1 consists of two parts: a sensor unit and an electronic unit. Because the mechanical component screws separately into the BITZER housing, the hermetically sealed electrical piece can be replaced without refrigerant or oil loss. Device Trip: Delta-P II: If the differential oil pressure drops below 9.5 ± 2 psid (for any amount of time) a red light will illuminate on the front of the electrical unit. If the pressure remains below for 9.5 ± 2 psid for longer than the allowable time (see chart below) then the output relay opens (stopping the compressor). OLC-K1: If there is no oil present for any amount of time in the oil pocket (center of front bearing cap), a red light will illuminate on the front of the electrical unit. If no oil is sensed for longer than the allowable time (see chart below) then the output relay opens (stopping the compressor). Delta-P II / OLC-K1: In case the supply voltage is too low or if the electronic unit is not properly mounted, the device will lock out after 5 seconds. The LED at the front end of the electronic unit will flash. www.bitzerus.com 61

4 Accessories/Options LED indications: LED is off: Sufficient oil supply LED is on (red): Insufficient oil supply (presently) LED is flashing (red): Fault (Voltage or installation) Manual Reset Interrupt power supply for at least 5 seconds. Note: Always try to diagnose the issue in the event of an oil trip instead of repeatedly resetting it. (Tip: View the red LED indicator to see if oil is intermittently dropping out) Wiring (see following page): The Delta-P II and the OLC-K1 have identical wire connections: Brown and Blue are the main power and used for resetting. Gray and Orange are the relay (should be in series with the control circuit). They will close when there is power to the unit and the oil supply remain sufficient (see chart for trip delays) Pink is the alarm part of the relay. Gray and Pink will close during an oil trip or when there is no power to the unit. Violet is a run proof to start timing sequences. This must have power only when the compressor is on (typically uses the N.O. auxiliary contacts of compressor contactor). Troubleshooting Tip: If there is a similar compressor adjacent, unscrew electrical units and temporarily swop to see if issue stays with compressor or device. Delay Times Delta-P II OLC-K1 After Compressor Starts 5s 90s In Operation 90s 5s 62 www.bitzerus.com

SE-B OLC-K1 DELTA PII 4 Accessories/Options SE-B3, Delta-PII, OLC-K1 Wiring Diagram www.bitzerus.com 63

4 Accessories/Options Legend for SE-B, Delta-PII, OLC-K1 wiring diagram 64 www.bitzerus.com

Compressor Model (CFH) C1 (0173-0407) C2 (0484-0692) C3 (0770-1385) C4 (1480-2397) B5 - B6 (2707-6462) 2-Stage (S4-S6) Other Oil Monitoring Devices and adaptors Oil Safety Type Part Number Oil Float Adapter 990-8000-02 Mechanical Oil Float 794-0201-05 Oil Float Adapter 990-8000-02 Mechanical Oil Float 794-0201-05 Oil Float Adapter 990-8000-02 Mechanical Oil Float 794-0201-05 Lubrication Type Centrifugal Disk Centrifugal Disk Centrifugal Disk MP54 860-3002-01 Pump P545 860-3003-01 Pump Mechanical Oil Float 794-0201-05 Both MP54 860-3002-01 P545 860-3003-01 Oil Float Adapter 990-8000-01 Mechanical Oil Float 794-0201-05 Mechanical Oil Float PN# - 794-0201-05 4 Bolt - 3 Bolt Oil Float Adapter PN# - 990-8000-01 Pressure differential Minimum Nominal - - - - - - 9psi Pump 9psi 20-35 psi 20-50 psi Sight Glass Oil Level 1/4 to 3/4 Full Thread - 3 Bolt Oil Float Adapter PN# - 990-8000-02 4 Accessories/Options 4.2 Other Oil Monitoring Devices and Adaptors Part Numbers www.bitzerus.com 65

4 Accessories/Options 4.3 Refrigeration Oils Guiding values for changing refrigeration oils Total acid number (TAN) (ppm) Water content (ppm) Designation Manufacturer Oil Type New Oil Oil acidified Oil change necessary New oil Oil change necessary HFC (R134a, R407C, R404A, R507A, R407a...) BSE32 2 BITZER POE 0,05 0,2 50 200 BSE55 BITZER POE 0,03 0,2 50 200 HFC (R22,...) B5.2 2 BITZER MO/AB 0,04 0,07-50 HCFC (R290, R1270,...) Arctic Exxon SHC226E 2 Mobil PAO - 0,1-80 Clavus G68 Shell MO 0,04 0,1-80 Ammonia (R717), Ammonia - DME (R723) Clavus 68 2 Shell MO 0,04 - - 100 CO 2 (R744) BSE85K 2 BITZER POE 0,02 0,1 30 150 BSE60K BITZER POE 0,03 0,1 30 150 Legend PAO = poly alpha olefin POE = polyol ester MO/AB = mineral oil/alkyl benzene MO = mineral oil 2 Standard charge 2 Change filter drier 4 Change oil and filter drier 66 www.bitzerus.com

Model 2C 4C 4B 6B 8C 2x.2 4x.2 6x.2 (x=t,n,p, H,G, F) Compressor Type Semi-hermetic Open Drive Semi-hermetic S4 - S6 2 Stage I to VII Slow Open Drives Refrigerant Temperature Oil Type R134A/R407C/R404A/R507A/R407A L BSE32 (L) BSE55 R22 (R12/R502) All B5.2 R124A All S68 R410A All BSE55 R134A/R407C/R404A/R507A/R407A L BSE32 (L) BSE55 R22 (R12/R502) All B5.2 NH3 (R717) All (L) - These oils are for low temperature applications, with a high condensing temperature Clavus G68 R404A/R507A L BSE32 R22 L B5.2 R22 L B5.2 R134A/R407C/R404A/R507A/R407A All BSE32 (L) BSE55 CO2 Semi-hermetic R744 (CO2) Subcritical BSE85K 410A Semi-hermetic R410A All BSE55 4 Accessories/Options BITZER Approved Oils www.bitzerus.com 67

4 Accessories/Options Oil Part Numbers and Temperature Ranges Oil Part Numbers BITZER Oils Lubricant type 5 gallon 1 gallon 1 quart B5.2 MO/AB 793-3150-34 793-1150-24 793-1150-04 BSE32 POE 793-1031-24 793-1031-34 793-1031-04 BSE55 / BSE 68G Legend: MO = Mineral Oil AB = Alkylbenzene Oil POE = Polyolester Oil 1 gallon = 3.78 liters POE 793-1068-34 793-1068-04 Clavus G68 MO 915119-03 915119-01 S68 AB 793-3300-34 793-3300-24 BSE85K POE 915128-01 (10liters) 915128-03 (5liters) 915128-02 (1liter) H M L Temperature Ranges t e > 30F t e > 20F t e < 20F (L) t e < 20F & t c >130F t e = saturated suction temp t c = saturated discharge temp Note: When changing oil, remove the oil strainer to inspect and clean. 68 www.bitzerus.com

4 Accessories/Options Approved Alternative Oils BITZER oil Alternative oil Manufacturer B5.2 (AB 150) Zerice S46 Exxon Mobil Zerice S68 Exxon Mobil Zerol 150 Petrosynthese Clavus SD2212 Shell Reniso SP46 Fuchs Reniso SP32 Fuchs BSE32 (POE 32) Clavus R32 Shell RL32 H Uniquema SEZ32 Fuchs Castrol Icematic SW32 Deutsche BP EAL Arctic 22 CC Exxon Mobil EAL Arctic 32 Exxon Mobil Solest 31-HE CPI BSE55 / BSE68G Solest 68 CPI (POE 68) SE55 Fuchs Castrol Icematic SW68 Deutsche BP RL68 S Uniquema Clavus R68 Shell EAL Arctic 68 Exxon Mobil S68 (AB 300) Alkyl 300 BVA For more information see KT-500 & KT-510 www.bitzerus.com 69

4 Accessories/Options 4.4 Capacity Regulator The BITZER capacity control is based on the principle of suction shut -off. Hereby the suction-side gas flow to the individual cylinder bank is shut off by means of a control piston. In Full-load operation the compressor delivers on all cylinders. The solenoid coil is DE-ENERGIZED. The gas ports in the valve plate and cylinder head are opened. In Part-load operation the pistons of the switched-off cylinder bank run idle without gas pressure. The solenoid coil is ENERGIZED, the suction port in the corresponding cylinder head is shut off by means of a servo valve. Application limits with part load operation With capacity regulator operation the temperature level rises due to: reduced refrigerant mass flow, reduced motor cooling and electrical and mechanical losses. Therefore the application ranges of the capacity controlled compressors are restricted to some extent. Attention! For low temp applications and open drive reciprocating compressors the use of capacity control is restricted. 70 www.bitzerus.com

4 Accessories/Options Capacity regulator head kit (w/gasket and stem) part numbers: Compressor Model Unloader Head Kit (w/ gasket & stem) Part Number: 2C0770-4C1385 302367-01 4C1480-4C2397 302355-12 4B2707-6B6462 302355-10 Possible Combinations for CR Heads: Compressor Type Possible residual capacity Number of capacity regulators 4-Cylinder 50% 1 6-Cylinder 66% 1 66% - 33% 2 4-Cylinder Tandem* 75% - 50% - 25%** 1(2*) 83% - 50% - 33%** 1(2*) 6-Cylinder Tandem* 83% - 66% - 50%** - 33%** -17%** 2(4*) * In case of base load sequence change, each compressor side must be equipped with the same number of regulators. ** One compressor side shut off. This operation mode should be preferred in view of operating reliability and compressor life. www.bitzerus.com 71

5 Spare Parts Information 5.1 Mounting Kit Part Numbers Compressor Model Hard Mounting Kits Rubber 2C0173-2C0407 313095-01 370000-19 2C0484-4C1385 313095-01 370000-20 Compressor Model Installation Location Spring Crankcase Mounting Color Side Kits Motor Side Color 4C1480-4C2397 308001-59 370003-05 Yellow 370003-06 Green 4B2707-4B3604PL 308001-62 370004-01 Brown 370004-02 Red 4B3604PH - 6B6462 308001-61 370004-01 Brown 370004-03 Blue S4T-5.2, S4N-8.2 308001-63 370003-05 Yellow 370003-06 Green S4G-12.2 308001-60 370004-01 Brown 370004-01 Brown S6J-16.2 308001-62 370004-01 Brown 370004-02 Red S6H20.2-S6F-30.2 308001-61 370004-01 Brown 370004-03 Blue Note for C4, B5, B6 Models - Hard mount parallel applications 72 www.bitzerus.com

Compressor Model Number Oil Pump Valve Plate (w/ Gaskets) Terminal Box Kit Terminal Plate Kit Complete Gasket Set 2C0173 N/A 304055-04 343509-01 343428-01-3LD 372834-01 2C0222 N/A 304055-05 343509-01 343428-01-3LD 372834-02 2C0278 N/A 304055-01 343509-01 343428-01-3LD 372830-01 2C0323 N/A 304055-02 343509-01 343428-01-3LD 372830-02 2C0407 N/A 304055-03 343502-41 343428-01-3LD 372830-03 2C0484 N/A 304059-01 343502-41 343428-01-3LD 372835-01 2C0572 N/A 304059-03 343502-41 343428-01-3LD 372835-02 2C0692 N/A 304059-04 343502-41 343428-01-3LD 372835-03 4C0770 N/A 304059-02 343502-41 343428-01-3LD 372835-04 4C0969 N/A 304059-01 343502-41 343428-01-3LD 372835-05 4C1145 N/A 304059-03 343502-41 343428-01-3LD 372835-06 4C1385 N/A 304059-04 343502-41 343428-01-3LD 372835-07 4C1480PH/L 362503-01 304063-02 308002-58 345507-02 (9LD) 372841-04 4C1761PH/L 362503-01 304063-04 308002-58 345507-02 (9LD) 372841-03 4C2067PH/L 362503-01 304063-06 308002-58 345507-02 (9LD) 372841-02 4C2397PH/L 362503-01 304063-08 308002-58 345507-02 (9LD) 372841-01 5 Spare Parts Information 5.2 Oil Pump, Valve Plate, Terminal Box Kit, Terminal Plate Kit, Complete Gasket Set Part Numbers See page 80 for valve plate installation instructions www.bitzerus.com 73

Compressor Valve Plate Model Number Oil Pump (w/ Gaskets) Terminal Box Kit Terminal Plate Kit (9 Lead) Complete Gasket Set 4B2707PH/L 362503-02 304051-01 343502-13 345501-10 372811-02 4B3139PL 362503-02 304051-02 343502-13 345501-10 372811-03 4B3139PH 362503-02 304051-02 343502-13 345501-10 372811-06 4B3604PH/L 362503-02 304051-03 343502-13 345501-10 372811-04 6B4060PH/L 362503-02 304051-01 343502-13 345501-10 372811-05 6B4709PH/L 362503-02 304051-02 343502-13 345501-10 372811-07 6B5406PH/L 362503-02 304051-03 343502-13 345501-10 372811-08 6B6462PH/L 362503-02 304051-15 343502-13 345501-10 372811-09 2-Stage Series -LP / LP(mid) / HP S4T-5.2 362503-01 304017-03/ --/ 01 343502-06 345501-10 372817-01 S4N-8.2 362503-01 304017-02/ --/ 01 343502-06 345501-10 372817-01 S4G-12.2 362503-02 LP:304016-07 HP:304018-01 343502-13 345501-10 372818-01 S6J-16.2 362503-02 304016-05/ 09/ 01 343502-13 345501-10 372816-01 S6H-20.2 362503-02 304016-06/ 10/ 02 343502-13 345501-10 372816-02 SG6-25.2 362503-02 304016-07/ 11/ 03 343502-13 345501-10 372816-03 S6F-30.2 362503-02 304016-08/ 12/ 04 343502-13 345501-10 372816-04 5 Spare Parts Information 74 www.bitzerus.com

5 Spare Parts Information 5.3 Crankcase Heater and Head Fan Crankcase Heater Part Numbers Compressor Model Watts Control Voltage Part Number 2C0173-2C0407 60 110V 892-0060-01 220V 892-0060-02 2C0484-4C1385 120 110V 892-1120-01 220V 892-1120-02 4C1480-4C2397 120 110V 892-1120-13 220V 892-1120-14 4B2707-8C9400 140 110V 892-1140-01 220V 892-1140-02 S4T-5.2 - S4N-8.2 100 110V 892-0100-01 220V 892-0100-02 S4G12.2 - S6F-30.2 140 110V 892-1140-01 220V 892-1140-02 Head Fan Part Numbers Compressor Head Fan Control Voltage Head Fan Kit Model Bracket Kits 110V 415-2100-15KIT 2C0173-2C0692 208V 415-2100-28KIT 0705468 460V 415-2100-46KIT 110V 415-2100-15KIT 4C0770-4C1385 208V 415-2100-28KIT 0705467 460V 415-2100-46KIT 110V 415-2100-15KIT 4C1480-4C2397 208V 415-2100-28KIT 0705466-KIT 460V 415-2100-46KIT 110V 415-2100-15KIT 4B2707-4B3604 208V 415-2100-28KIT 0705465-KIT 460V 415-2100-46KIT 110V 415-2100-15KIT 6B4060-6B6462 208V 415-2100-28KIT 0705464-KIT 460V 415-2100-46KIT www.bitzerus.com 75

6 Preventive Maintenance / Service 6.1 Operating Temperatures and Oil Guidelines Guide values for operating temperatures* Suction gas superheat Discharge gas temperature 2 Stage Intermediate (middle) pressure superheat Operating Temperatures min. typical min. *Values in practice depend much on operating conditions (A/C, medium temp., low temp.) and refrigerant! Please check individual cases with the selection software or BITZER. Note: Compressor/Oil Pump rotates in both directions. Guide values for oil maintenance ~15 F 20-30 F 40 F above condensing temp. (50 F for R22) max. 250 F; measured at discharge line min. ~40 F+subcooler saturation temp; measured at bulb on MP line Oil temperatures - on Start-up** Oil temperatures - Operating Oil pressure differential Oil change Oil Guidelines typical min. 25-35 F above ambient 95 F (min. 55 F > SST) max. 170 F min. 9.5 ± 2 psi (see pg 61-62 for oil monitoring devices) Every 3 years or 10000 hrs of operation **Oil heater recommended. Note: When changing oil, remove the oil strainer to inspect and clean. 76 www.bitzerus.com

6 Preventive Maintenance / Service 6.2 Switching Frequency and Vibrations Switching frequency and minimum running time Nominal Motor (HP) Starts per hour Minimum running time (min) Vibrations on the high pressure side Vibrations on the high pressure side of refrigeration systems are mainly caused by: Pulsations, Structure-borne vibrations, Frame design / basement Pulsations Pulsations (longitudinal gas vibrations on the high pressure side) are created by the discharge process of the gas out of the cylinders. Their amplitude and frequency depend on: Compressor speed Number of cylinders Cylinder alignment recommended maximum up to 7.5 10 20 2 up to 20 8 12 3 above 20 6 6 5 Refrigerant properties (pressure, temperature and sonic speed) Critical discharge gas vibrations can be found if the frequency of the oscillating gas column in a straight discharge tube section gets into resonance with the natural frequency of the pipework. In the worst case this could result in a fracture of the piping. The length of the pipe segment with a resonance frequency corresponding to the natural frequency of the gas flow is designated as "critical pipe length". www.bitzerus.com 77

6 Preventive Maintenance / Service 6.3 Tightening Torques for Screw Fixings of Non-Aluminum Reciprocating Compressors A. Normal bolts M5 M6 M8 M10 M12 M16 M20 Units Without flat gasket With gasket B. Special bolts 7 9 23 42 80 150 ---- Nm 5 7 17 31 59 111 ---- lb ft ---- 16 40 80 125 220 220 Nm ---- 12 30 59 92 162 162 lb ft Sealing plugs lb ft Nm 1/8"-27 NPTF 7..10 10..13 1/4"-18 NPTF 15..17 20..23 3/8"-18 NPTF 31..35 42..47 1/2"-14 NPTF 47..51 64..69 3/4"-14 NPTF 72..80 98..108 Oil drain lb ft Nm M22 100..114 135..155 M26 114..129 155..175 Sight glass lb ft Nm M6 6 8 M6 8 11 1 1/8"-18 UNEF (Thread) 37..44 50..60 Oil Pump lb ft Nm M8 17 23 Shut-off valve and flanges lb ft Nm M8 18 25 M10 37 50 M12 74 100 M16 110 150 M18 147 200 M20 147 200 Screws at terminal lugs at 68F lb ft Nm M4 1 2 M6 4 6 M8 7 10 M10 15 20 Rotor screws lb ft Nm M10 15 20 M12 15 20 M16 44 60 PLEASE NOTE: DO NOT OIL GASKETS TIGHTEN SCREWS CROSSWISE AND AT LEAST IN TWO STEPS (50/100%) 78 www.bitzerus.com

6 Preventive Maintenance / Service 6.4 Common Wrench Sizes for Basic Compressor Service Bolt Metric Wrench Size (mm) Metric size in inches (decimal) Metric size to closest inch (1/16 )* M5 HHC 8mm 0.315 5/16 M6 HHC 10mm 0.394 3/8 M8 HHC 13mm 0.512 1/2 M8 SHC 6mm (Allen) 0.236 1/4 M10 HHC 17mm 0.669 11/16 M10 SHC 8mm (Allen) 0.315 5/16 M12 HHC 19mm 0.748 3/4 M12 SHC 10mm (Allen) 0.394 3/8 M16 HHC 24mm 0.945 15/16 * SAE standard equivalent wrenches may be used as a substitute for metric wrenches. Use caution as bolt may strip from incorrect tool size use. Legend HHC = Hex Head Cap SHC = Socket Head Cap www.bitzerus.com 79

6 Preventive Maintenance / Service 6.5 Cylinder head and valve plate replacement guidelines 1. Remove cylinder head bolts. 2. If a capacity regulator (unloader) is installed, remove the bolts holding the unloader stem as they are part of the cylinder head bolts. 3. Remove the cylinder head. 4. Remove the valve plate and inspect for damage. 5. Install a new valve plate gasket 6. Install a new valve plate. -Note: the new valve plate may look different than the original (number of discharge reeds and diameter of holes may vary) - this is normal and will not affect performance. -Use the dowel/guide pins to align and hold the gasket and valve plate correctly. 6. Install a new head gasket 7. Replace the cylinder head, tighten the screws crosswise and in at least two steps. Torque the screws to the appropriate force listed on page 78. 80 www.bitzerus.com