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COM-D-17-A
General
Contents
Description
The 3-D scroll compressor is a nominal 3500 rpm on 60 Hz and 2900 rpm on a 50 Hz hermetic compressor with a solidly mounted compressor assembly. The compressor is unidirectional and will only pump refrigerant when the compressor motor is wired in the proper electrical phase sequence. For R-22 applications, the compressor ships with a full oil charge. The compressor has as standard features an oil sight glass and an oil charging valve. Compressors for use with POE oils will ship less oil.
Electrical Phasing Since the scroll compressor is a unidirectional device, it must be properly phased. See Electrical Information for information on determining the proper electrical phasing. Sound Scroll compressors make a different sound than reciprocating compressors. Running a scroll compressor backwards or shutting it down can cause unusual noise. Running Backwards If the compressor is running backwards, the compressor will be noticeably noisy. Along with the noise, the discharge pressure and suction pressure will be about equal and the current draw will be substantially below the normal value expected. Switching two of the three power leads will correct this problem. Shutdown At shutdown, the gas within the scrolls expands and causes momentary reverse rotation until the check valve closes. This noise is minimal and may not occur at all conditions.
General Model Number Description General Mounting Refrigeration Connections Electrical Connections Operating Limits System Protection Controls Electrical Data Manifolded Comp. Sets System Cleanliness Evacuation & Dehydration
2 4 5 7 9 10 11 15 20 22 36 37
General
Servicing
Warnings are provided to alert the installer or service personnel of hazards that could result in personal injury or death. The instructions given in each warning appearing in this publication must be followed carefully. Cautions are provided to alert the installer or service personnel that equipment or property damage could occur if specific instructions are not followed. WARNING: NEVER REMOVE THE COMPRESSOR FROM THE UNIT WITHOUT REMOVING THE REFRIGERANT CHARGE FROM BOTH THE HIGH SIDE AND THE LOW SIDE OF THE COMPRESSOR. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH BECAUSE THE ESCAPING PRESSURIZED OIL AND REFRIGERANT MIXTURE COULD BE IGNITED BY THE TORCH FLAME. Since the scrolls flanks may seal the refrigerant pressure between the high and low side preventing pressure equalization through the compressor, it is necessary to remove the refrigerant from both the high side and the low side of the compressor before removing the compressor from the system. Shell Leak Repairs Warning: UNDER NO CIRCUMSTANCES SHOULD THERE BE ANY ATTEMPT TO REPAIR ANY HERMETIC COMPRESSOR THAT REQUIRES WELDING, BRAZING OR SOLDIERING. ANY COMPRESSOR THAT REQUIRES REPAIRS OF THIS TYPE SHOULD BE REPLACED. SERIOUS PERSONAL INJURY OR DEATH MAY OCCUR DUE TO EXPLOSION OF REFRIGERANT/AIR MIXTURE, FIRE DUE TO THE PRESENCE OF OIL UNDER PRESSURE, EXPLOSION DUE TO THE INCREASE IN PRESSURE FROM HEAT BEING ADDED TO A CLOSED VESSEL OR EXPLOSION DUE TO THE REDUCTION IN STRENGTH OF THE COMPRESSOR SHELL.
THE ONLY PARTS OF THE COMPRESSOR WHERE BRAZING IS ALLOWED ARE THE REFRIGERANT CONNECTIONS. BRAZING ON THE REFRIGERANT CONNECTIONS SHOULD ONLY BE DONE WHEN THE REFRIGERANT CHARGE HAS BEEN REMOVED, WITH THE COMPRESSOR AT ATMOSPHERIC PRESSURE AND NITROGEN BEING PURGED THROUGH THE COMPRESSOR. Oil Charge/Type The compressor ships with a full charge of mineral oil suitable for use with R-22. The amount of oil charge is listed in Table 1 - General Data. The approved oil for the Trane CSHA 3-D scroll is Trane Part Number OIL 0042. It contains a special additive and must not be substituted. When compressors are applied using refrigerants R-134A, R-404a and R-407C, a POE oil is required. When ordered for use with these refrigerants, the compressor will ship without oil. The approved POE oil is ICI Emkarate RL32HB. See Table 1- General Data for the quantity required for each compressor. Oil Level The level in the compressor sight glass that is typically referred to as the oil level is actually the level of the refrigerant-oil mixture in the compressor. It can and will vary, depending upon the operating condition of the compressor. The conditions that affect the oil level are superheat and the operating conditions. Superheat affects the oil level because it is a measure of how much liquid refrigerant is being brought back to the compressor. The more refrigerant that is brought back to the compressor, the higher the oil level. When the compressor is operating at a condition where the refrigerant is more miscible with the refrigerant, the oil level will be higher. When the operating conditions are such that the refrigerant is less miscible with the oil, the level will be lower.
The oil level will also be affected by the factors that affect oil return, such as piping design, piping velocities, velocities in the heat exchangers and the number of oil traps in the system. An overcharge of oil can be detrimental to the performance of the system. The effect on the efficiency of the system is due to an increased oil circulation rate and fouling of the heat exchange surfaces with oil. This results in the compressor operating at a balance point which is less efficient. An undercharge of oil will result in poor lubrication and eventually lead to bearing failure due to lack of lubrication. Single Compressor During operation, the oil level should be at a minimum in the bottom of the sight glass. If the oil level is above the sight glass, it must be determined if it is due to refrigerant in the compressor oil sump or an overcharge of oil before the oil is removed oil.
Multiple Manifolded Compressors The oil level can only be evaluated when all the compressors are shut off. During operation, the oil levels will vary. Generally speaking, the oil level will be highest in the last compressor in the manifolded set and lowest in the first compressor in the manifolded set. The oil must be at a minimum in the bottom of the sight glass, with the compressors shut off. If the oil level is above the sight glass, it must be determined if it is due to refrigerant in the compressor oil sump or an overcharge of oil before the oil is removed.
General
Off
Adding or Removing oil Before adding or removing oil, operate the system at full load, then proceed to pump the system down to no lower than 5 psig. This will boil off refrigerant in the oil and give a more representative oil level in the compressor(s). Normally oil does not need to be added to the compressor unless there is a leak or the system has extremely long lines and many oil traps. If you are adding oil and no oil leaks are visible, always consider the fact that the oil could be trapped in the system and may return when the compressor is operated. Normally oil does not need to be removed from the system unless it has been overcharged previously.
Oil Level Lower
Handling The compressor is equipped with a lifting lug on the upper shell to facilitate handling of only the compressor during installation. WARNING: THE LIFTING LUG MAY BE USED ONLY TO LIFT THE COMPRESSOR. IF THE UNIT IN WHICH THE COMPRESSOR IS INSTALLED IS LIFTED USING THE COMPRESSOR LIFTING LUG, THE LUG COULD BREAK, CAUSING DAMAGE TO THE UNIT AND COMPRESSOR OR CAUSING PERSONAL INJURY OR DEATH. Systems Test Pressures When pressurizing the refrigeration system, the test pressures must not exceed the following: Low side is 300 psig. High side is 500 psig. Maximum pressure differential is 200 psig. WARNING: NEVER USE OXYGEN, DRY AIR OR ACETYLENE IN PLACE OF REFRIGERANT AND NITROGEN FOR LEAK TESTING. A VIOLENT EXPLOSION MAY RESULT, CAUSING PERSONAL INJURY OR DEATH. ALWAYS USE A PRESSURE REGULATOR WHEN USING NITROGEN TO PRESSURE TEST. FAILURE TO DO SO WILL RESULT IN EXTREMELY HIGH PRESSURES WHICH COULD EXCEED THE BURST PRESSURE OF THE COMPRESSOR OR OTHER SYSTEM COMPONENTS, RESULTING IN PERSONAL INJURY OR DEATH.
Discharge - 0.875 Suction - 1.375 Discharge - 1.12 Suction - 1.625 Discharge - 1.25-12UNF-2A Suction - 1.75-12UNF-2A Screw type using #10-32 x 1/2 screws 1 /4 x 0.032 Male faston connector 25 in-lb. 28 + 2 ft-lb. 60 + 10 in-lb. 12-14 ft-lb. 20 + 2 ft-lb. 45 + 5 ft-lb. 1.25 - 110/100 ft-lb. 1.75 - 155/145 ft-lb.
Mounting
Optional resilient mounting isolators are recommended to minimize the transmission of compressor vibration to the unit. They are recommended for either single or manifolded applications. However, an individual compressor or manifolded sets can be solidly mounted to the unit, if this is a requirement for the application. Single Compressor Isolators The optional mounting kit for single compressor applications consists of four rubber isolators and four sleeves. The mounting hardware, 5/16 cap screw, washer and nut are provided by the user. Install the isolator as shown in Figure 4. For shipping, tighten the cap screws down against the metal sleeves. When the unit is placed in operation, it is recommended that the cap screws be backed off enough to let the rubber isolator expand to allow the compressor to ride freely on the rubber isolators. Manifolded-Set Isolators The mounting isolators for use with the manifolded sets are different from the isolators used for single compressor application. The isolators for the manifolded set consist of an upper and a lower isolator mounted under the compressor mounting rail, a sleeve and a spacer and washers, and cap screw. There is a different isolator kit for depending on whether there are two, three or four compressors in the manifold kit. Table 2 lists the part numbers for the isolator kits.
Table 2 Isolator Kits for Manifold Sets
Number of Manifolded Compressors 2 3 4 Isolator Kit Part 5710-0114-01-00 5710-0114-02-00 5710-0114-03-00
IMPORTANT USE OF COMPRESSOR SPACERS WITH VIBRATION ISOLATION KIT. When using the manifold isolator kit, it is important to use the spacers supplied with this kit to mount the compressors to the rails that are supplied with the manifold kit. Failure to do so will cause insufficient clearance for the upper washer and mounting hardware. These spacers are only required when using the vibration isolator kit.
The isolators are fastened to the unit using the 3/8-inch cap screw supplied in the isolator kit. For shipment, shipping rails or spacers are supplied that attach to the compressor mounting rails and then attach to the unit mounting base to eliminate excessive movement in shipping. Install the isolators as shown in Figure 5.
Capscrew .312 Flat Washer Working Height Mounting Foot Mounting Foot
Isolator Mounting Rail or Unit Base Sleeve Figure 4 Isolator Installation for Single Compressor Nut
Capscrew .375-16 x 3.00 Upper Isolator Manifold Mounting Rail Brace Reqd For Shipping Unit Base Sleeve
Lower Isolator
Mounting
Solid Mounting Individual Compressors If the requirement is to solid-mount the compressor, solid metal spacers are available to raise the compressor above the base to allow for clearance of the flanges on the base plate. The part number for the spacers is X04010503-02-00. A quantity of four per compressor is required. See Figure 6.
Figure 6 Spacer Solid Mount
Solid Mounting of Manifold Sets If the requirement is to solid-mount the manifold set, use the spacers that ship with the manifold kit to mount the compressor to the manifold base rails. See Figure 6 for the spacer that ships with the manifold kit. The manifold mounting rails can then be mounted solidly to the unit base.
Refrigeration Connections
Suction and Discharge Connections Single Speed The standard refrigerant connections are steel tubes suitable for sweat-type braze connections. The connection sizes are listed in General Information Table 1. Recommended braze material is Specification Number BAg-28 AWS/ AMS. WARNING ALWAYS PURGE NITROGEN THROUGH THE COMPRESSOR WHEN BRAZING THE REFRIGERANT CONNECTIONS TO THE COMPRESSOR. FAILURE TO SO COULD RESULT IN A FIRE OR AN EXPLOSION WHICH COULD RESULT IN PERSONAL INJURY OR DEATH. Caution: Whenever brazing the refrigerant piping to the compressor, always use a nitrogen purge to prevent the formation of copper oxides. The presence of copper oxides in the compressor is detrimental to the reliability of the compressor and will cause premature failure. Rotalock Fittings Optional rotalock fittings with an access port (1/4-inch flare fitting) are available as a factory-installed option. The discharge access port contains a 0.040 vent without a Schraeder valve. The suction access port does contain a Schraeder valve. See Table 3. Rotalock fittings are not available for compressors used in manifolded sets. Optional rotalock valves are available for use with the optional rotalock fittings. See Figure 7. IMPORTANT: When the optional rotalock valves are used, the system high pressure control must be connected to the access port on the rotalock fitting. For proper protection of the compressor against running into a vacuum, it is recommended that the compressor protection low pressure switch be attached to the fitting on the rotalock connection. Oil Equalizer Tube Manifolded Compressors only A 3/8-inch oil equalizer tube connection is provided on the compressors used in manifold sets. If the compressor is for a single compressor application, the oil equalizer connection is not supplied on the compressor. WARNING ALWAYS PURGE NITROGEN THROUGH THE COMPRESSOR WHEN BRAZING THE REFRIGERANT CONNECTIONS TO THE COMPRESSOR. FAILURE TO SO COULD RESULT IN A FIRE OR AN EXPLOSION WHICH COULD RESULT IN PERSONAL INJURY OR DEATH. Caution: Whenever brazing the refrigerant piping to the compressor, always use a nitrogen purge to prevent the formation of copper oxides. The presence of copper oxides in the compressor is detrimental to the reliability of the compressor and will cause premature failure.
Electrical Connections
Power Connections Caution: Use copper conductors only. Compressor terminals are not designed to accept other types of conductors. Failure to do so may cause damage to the equipment. Compressor The electrical connections are screwtype connections. The recommended method of making electrical connections is to use a ring terminal on the power wiring. Attach the terminal to the compressor terminal block using the #10-32 x 1/2-inch screws provided with the compressor. Maximum torque to be applied to the fastening screws is 25 in-lb. See Figure 8 for the Terminal Box Layout. Motor Winding Thermostat The motor winding thermostat is a part of the electrical motor protection system and must be used in all applications. The motor winding thermostat uses 1/4 x .032 male faston connections. It is recommended that tin or silver-plated connectors be used. See Figure 8 for the location of the motor winding thermostat within the compressor terminal box. The motor winding thermostat provides the primary reverse rotation protection for the compressor motor.
Power Connections
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Operating Limits
Discharge Temperature and Motor Temperature Limits The operating limits of the compressor define the boundaries of the operating envelope in which the compressor will operate reliably. Operation of the compressor outside of the operating envelope will decrease the operating life of the compressor. Figure 9 shows the operating envelope for the compressor for both single and manifolded applications. Voltage Utilization Ranges The voltage applied to the compressor motor terminals must be within the ranges listed in Table 4 at start-up and during running operation.
Table 4 Voltage Utilization Range
Electrical Voltage Characteristic Designator 200-60-3 A 208/230/60/3 R 380/60/3 X 460/60/3 K 575/60/3 D 200/50/3 Y (9 and 10-ton only) 220/50/3 F 346/50/3 V 400/50/3 K Voltage Utilization Range 180-220 187-254 342-418 414-508 518-635 180-220 198-254 308-381 340-460
Voltage Unbalance Voltage unbalance causes current unbalances and increases current, resulting in the motor overheating. The maximum allowable voltage unbalance is two percent. Calculate voltage unbalance as follows: % Unbalance = Max. Deviation from Average Voltage Average Voltage X 100 Example: L1Average Volts = 236 volts 236+232 + 230/3 = 232.66 L2Max. Deviation from 232 volts Average = 236-232.66 = 3.34 L3% Unbalance = 230 volts 3.34/232.66 X 100 =1.4%
Cycle Rate Limit The cycle rate limit should not exceed 12 starts per hour. The time between starts must be a minimum of five minutes. The compressor should have a minimum run time of five minutes to provide sufficient run time to cool the motor after it starts or sufficient time to return the oil from the system, whichever is greater. Note: Oil return is a function of system design and will vary depending on the system design. Refrigerant Charge Limit Refrigerant Charge Limit (RCL) is defined as the amount of refrigerant in a system which, when exceeded, requires additional measures to minimize refrigerant migration to the compressor. Table 5 lists the Refrigerant Charge Limits for the CSHA compressor.
Table 5 Refrigerant Charge Limit (RCL)
Compressor Model CSHA 093 and 100 CSHA 140 and 150 CSHA 180 and 200 CSHA 230,240 and 250 CSHA 280 and 300 CSHA 320 and 350 CSHA 400 CSHA 450 CSHA 500 CSHA 600 RCL 24 LB. 30 LB 48 LB 54 LB 60 LB 78 LB 84 LB 90 LB 108 LB 120 LB
Refrigerant Charge Limit Exceeded On systems that have more refrigerant than the RCL limit shown in Table 5, a liquid line solenoid valve and a crankcase heater are required to minimize refrigerant migration to the compressor. The liquid line solenoid valve should be mounted close to the evaporator so as to use the entire liquid line for storage. It should be wired in the control system such that it closes when the compressor shuts off and is immediately opened when the compressor starts. Caution: Operation of a scroll compressor in a vacuum will cause the fusite power terminals to arc internally and cause a motor failure. Operating the scroll compressor in a vacuum causes galling of the scroll and internal arcing of the fusite power terminals, both of which will result in a compressor failure. Crankcase Heater A crankcase heater is required on all split systems (the evaporator or condenser is located remotely from the compressor) and for units where the Refrigerant Charge Limit (RCL) is exceeded. See Table 5. A crankcase heater is used to help prevent migration of refrigerant to the compressor during the off cycle.
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Operating Limits
Liquid Line Solenoid Valves Liquid line solenoid valves are required on all split systems (the evaporator or condenser is located remotely from the compressor) and for units where the Refrigerant Charger Limit (RCL) is exceeded. See Table 5. The liquid line solenoid should be wired into the control system such that the liquid line solenoid valve opens immediately when the compressor starts and closes when the compressor stops. Pumpdown Pumpdown is not recommended. Pumpdown can cause the oil to leave the compressor during the pumpdown cycle. Also during the pumpdown period, the compressor receives marginal lubrication due to the outgassing of the refrigerant from the oil which causes foaming. Suction Line Accumulators Suction line accumulators are not required when using the scroll compressor if the guidelines above are followed for limiting the charge (Refrigerant Charge Limit). See Table 5 and Using Solenoid Valves and Crankcase heaters. Refrigerant Piping Considerations To minimize the refrigerant available to the compressor at start-up, the suction line and the discharge lines should not allow liquid refrigerant to drain by gravity into the compressor. This is especially a concern with evaporators mounted above the compressors, which can experience migration during off cycles. In either case, it is recommended that if either the evaporator or condenser is above the compressor that the suction line or discharge line be trapped to prevent the flow of refrigerant directly into the compressor. See Figures 10a through 10j for recommended piping configurations. Figure 10a through 10j Recommended Piping Configurations
Figure 10d Condenser Above Middle Connection
Compressor
Compressor
Compressor
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Operating Limits
Compressor
Figure 10e Condenser Above Bottom Connection Compressor Figure 10h Condenser Same Level Bottom Connection
Compressor Compressor
Figure 10j Condenser Below (Same regardless whether the connection is Middle, Bottom or Top)
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= Control Relay = Lockout Relay = High Pressure Control = Low Pressure Control = Motor Winding Thermostat = Overload Relay = Discharge Temperature Switch = Compressor Protect Low Pressure Switch AM = Compressor Contactor LLSLV = Liquid Line Solenoid Valve ART = Antirecycle Time Delay M = Compressor Motor T1,2,3 = Motor Terminals Tstat = Temperature Control Device SW1 = On-Off Switch-Reset Switch
NOTE 1. Under no circumstances should the CPLS be jumpered out. Doing so will not provide the compressor with protection from operating into a vacuum and will cause the compressor to fail.
NOTE: The recommended control scheme for manifolded compressors shows the safety controls wired in series to provide the highest degree of system protection. Prior approval from the OEM Products Group is required if the compressor safety controls are wired in individual electrical circuits that allow individual compressors to operate on a manifolded set when one has failed.
High Pressure Control The scroll compressor does not have an internal relief device. It is required that a high pressure control stop the compressor operation before the discharge pressure of the compressor exceeds a maximum value of 405 psig. Consult applicable safety codes for the proper application and setting of the high pressure control for the specific unit application. The high pressure control should be a manual reset device or applied in a lockout circuit that will not allow the unit to cycle on the high pressure control.
If a discharge service valve is used in the system, the high pressure control must be located in the unit piping between the compressor and the discharge service valve. When using the optional rotalock fittings with the access port and rotalock service valves, use the access fitting on the rotalock fitting for the high pressure control connection. On manifolded compressor sets, only one high pressure control is required for the system. Locate the high pressure switch in the common discharge line. When using a discharge service valve, locate the high pressure switch between the compressors and the discharge service valve.
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1,2,3,4 CR = Control Relay LOR = Lockout Relay HPC = High Pressure Control LPC = Low Pressure Control MWT = Motor Winding Thermostat OLR = Overload Relay DTS = Discharge Temperature Switch CPLS = Compressor Protect Low Pressure Switch A,B,C,DM = Compressor Contactor LLSLV = Liquid Line Solenoid Valve ART = Antirecycle Time Delay M = Compressor Motor T1,2,3 = Motor Terminals Tstat = Temperature Control Device SW1 = On-Off Switch-Reset Switch Manifold Sets: Two-compressor sets do not use MWT, OLR, DTS, CR, ART and LLSLV 3 and 4. Three-compressor sets do not use MWT, OLR, DTS, CR, ART and LLSLV4. Four-compressor sets use as shown. See Figure 28 for proper sequencing. NOTE 1. Under no circumstances should the CPLS be jumpered out. Doing so will not provide the compressor with protection from operating into a vacuum and will cause the compressor to fail. 2. Liquid Line Solenoid valves LLSLV2,3,4 are shown for evaporator unloading only.
Low Pressure Control The Trane 3-D scroll compressor requires the use of a minimum of one low pressure switch to prevent the compressor from operating to a vacuum. A loss of charge low pressure switch is highly recommended. Compressor Protection Low Pressure Switch IMPORTANT The Compressor Protection Low Pressure Switch (CPLS) is a low pressure switch that prevents operating the scroll compressor in a vacuum. The CPLS is required to protect the compressor from arcing of the fusite terminals and galling of the
scrolls by preventing the compressor from operating in a vacuum. The recommended cutout setting is 5 psig. This low pressure switch should not be bypassed at any time, either during start-up, low ambient starts or charging of the unit. When using the optional rotalock fittings with the access port and rotalock service valves, use the access fitting on the rotalock fitting for the compressor protection low pressure switch connection. Also when using a suction line service valve on compressors that have sweat connections, locate this low pressure switch between the compressor and the service valve.
Loss of Charge and Pumpdown Termination Low pressure controls are typically used for pumpdown termination or loss of charge protection. Since pumpdown is not recommended with the scroll compressor, it is recommended that the low pressure switch be used for loss of charge protection. Low pressure switches, when applied properly, provide loss of charge protection for both slow and rapid loss of charge. When using the low pressure switch for loss of charge protection, the compressor(s) should be manually locked out when the low pressure switch opens. This will prevent rapid cycling of the compressor(s) on the low pressure switch.
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Then submit the following information to the OEM Compressor Group: 1 The manufacturers catalog data. 2 The manufacturers catalog number of the selected device. 3 Manufacturers recommended setting. 4 The trip curve showing the trip time with the device set for the proper must hold and must trip values shown in Table 6. 5 The trip curves showing the trip timing for the Locked Rotor Amps of the compressor. 6 UL Listing Number. Caution: Failure to use an approved overcurrent protection device will void the warranty of the compressor.
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Visual overload trip indicator. Tamperproof cover. Manual trip feature for checking circuitry. Secondary single phase protection.
Maximum RLA and Overload Settings The Maximum RLA values shown in Table 6 are based on the NEC requirement that the must-trip current must not exceed 140 percent of the compressor rated load amperage. The
Maximum RLA values are determined by using the following equation: Max. RLA = Max. Must Trip Current/ 1.40. The Must-Hold Overload setting is 125 percent of the Maximum RLA value. The overload settings in Table 6 are for the Trane-supplied overload device only.
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79 77 41 34 27 61 38 33
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Switch Rating Inductive Load 120V - 34.8 LRA 5.8 FLA 240V - 17.4 LRA 2.9 FLA Resistive Load 120V - 10 Amps 240V - 5 Amps
NOTE: 1. Therm-O-Disc 37TJ Series. 2. Part to be clean and free from foreign material. 3. Thermostat to open at 265 F 8 F and close at 220 F 11 F. 4. Silver Contacts
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Electrical Data
Phase Sequencing The scroll compressor is a unidirectional compressor and must be correctly electrically phased to operate properly. Should the scroll compressor be incorrectly phased it is designed to run backwards without damaging itself. However, the compressor will not pump refrigerant and will eventually trip on the motor winding thermostat. If a phase sequence meter is not available, the quickest way to check for the correct electrical phasing is to start the compressor after the system has been properly evacuated and charged with refrigerant. Using a set of refrigerant gauges, measure the discharge and suction pressures. The discharge pressure should increase and the suction pressure should decrease. The current draw should appear to be normal. If the compressor is incorrectly electrically phased, the discharge and suction pressure will be about equal, the current draw will be low (approximately 1/2 the expected value) and the compressor will be noisy. To correct an incorrectly phased compressor motor, switch two of the three electrical connections and start the compressor again and again check the refrigerant pressures and current draw. Maximum Trip Current This is the current at which the current overcurrent protection device must take the compressor off-line. The Maximum Trip Current is determined at the minimum voltage within the voltage utilization range. Maximum Trip Current is listed in Table 6. Locked Rotor Amps The Locked Rotor Amp (LRA) rating is used to select electrical devices such as fuses, contactors and circuit breakers for compressor protection. Consult UL and NEC unit requirements for the proper selection of these components. Locked Rotor Amps are listed in Table 6. Maximum Rated Load Amps Maximum Rated Load Amps for the compressor is defined as Maximum Trip Current/1.40. This definition is based on the NEC requirement that the Maximum Trip Amps can not exceed 140 percent of the RLA. Must Hold Overload Setting The Must Hold Overload Setting is 125 percent of the Maximum Rated Load Amps. The overload setting is dependent on the type of overload used. In this case, it is the specific setting for Furnas Class 958 Overload used with the Trane scroll compressor.
Table 7 Contactor Selection
Compressor 093 and 100 Voltage 200/60/3 208/230/60/3 380/60/3 460/60/3 575/60/3 200/50/3 220/50/3 346/50/3 400/50/3 200/60/3 208/230/60/3 380/60/3 460/60/3 575/60/3 220/50/3 346/50/3 400/50/3 Max. Rated Load Amps 42.6 42.2 22.4 18.4 14.8 36.4 32.6 20.7 17.8 63.5 62.2 33.4 27.5 22.0 48.8 31.0 27 Locked Rotor Amps 269 222/251 142 117 94 219 180 114 110 409 337/376 215 178 143 283 180 174 Inductive Load Contactor Rating Amps* 50 50 30 25 25 40 40 25 25 75 75 40 30 30 50 40 30
Compressor Starter Type The scroll compressor is suitable for across-the-line start only. Table 7 lists the recommended contactor by compressor size and voltage.
* The Locked Rotor Amperage (LRA) rating of the contactor must exceed the LRA of the compressor.
Determining Current Draw at Other Than 460 Volts The current draw for the 460 volt application is listed in the performance curves. To determine the current draw for other voltages, multiply the 460 volt current draw by the appropriate factors listed in Table 7. Use the corrected current draw values to size fuses, wires and electrical components.
Table 8 Current Adjustment Factors
Nominal Motor Voltage 200/60/3 208/230/60 460/60/400/50 @ 380/50 @ 415/50 @ 400/50 @ 460/60 575/60/3 380/60/3 220/50/3 346/50/3 Adjustment Factor at Nominal Volts 2.3 See Figure 18a and b 1.01 0.80 0.96 1.00 0.80 1.21 1.74 1.11
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Electrical Data
Figure 18a 208/230 Volt Current Draw Correction Factors 10 Ton 208/230 Volt Adjustment Factor
Figure 18b 208/230 Volt Current Draw Correction Factors 15 Ton 208/230 Volt Adjustment Factor
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22
Sight Glass
Figure 19 18-20 Ton Manifold Set Table 11 5710-0047-01-00 CSHA180, 190 and 200
Item # ** ** 1 2 3 4 5 6 7 8 40 62 66 67 73 74 Description Discharge Manifold Assembly Suction Manifold Assembly Mounting Rails Spacers - Compressor Mounting Screw .31-18 x 1.50 - Compressor Mounting Washer .31 ID x 1.50 OD - Compressor Mounting Oil Equalizer Line Bracket Oil Equalizer Line Clamp Screw 6-32 x .38 Equalizer Clamp Oil Equalizer Line Lock Washer - Compressor Mounting Top Plate Nut Top Plate - Hex Lock .31-18 Bolt - Top Plate .31-18 x .62 Shipping Brace Screw - Shipping Brace Part Number By Description By Description 5707-0908-01-00 X04010503-02-00 X25030007-01-0 X22016000-00-0 4356-9483-01-00 X32030401-08-0 X25530033-10-0 X02080628-01-0 X22040400-00 5707-2700-01-00 X28020400-00-0 X25040251-10-0 5707-0772-01-00 X25110002-00-00 QTY 1 1 2 8 8 8 2 2 2 1 8 1 4 4 2 6
**indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits.
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Sight Glass
Oil Charge Valve .25 Flare Figure 20 23-25 Ton Manifold Set
**indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits.
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Sight Glass
Oil Charge Valve .25 Flare Figure 21 28-30 Ton Manifold Set Table 13 5710-0049-01-00 CSHA280 and 300
Item # ** ** 1 2 3 4 5 6 7 8 40 62 66 67 73 74 Description Discharge Manifold Assembly Suction Manifold Assembly Mounting Rails Spacers - Compressor Mounting Screw .31-18 x 1.50 - Compressor Mounting Washer .31 ID x 1.50 OD - Compressor Mounting Oil Equalizer Line Bracket Oil Equalizer Line Clamp Screw 6-32 x .38 Equalizer Clamp Oil Equalizer Line Lock Washer - Compressor Mounting Top Plate Nut Top Plate - Hex Lock .31-18 Bolt - Top Plate .31-18 x .62 Shipping Brace Screw - Shipping Brace Part Number By Description By Description 5707-0908-01-00 X04010503-02-00 X25030007-01-0 X22016000-00-0 4356-9483-01-00 X32030401-08-0 X25530033-10-0 X02080629-01-0 X22040400-00 5707-2767-01-00 X28020400-00-0 X25040251-10-0 5707-0772-01-00 X25110002-00-00 QTY 1 1 2 8 8 8 2 2 2 1 8 1 4 4 2 6
**indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits.
25
Sight Glass
Sight Glass
**indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits.
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Typical
Sight Glass
Sight Glass
**indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits.
27
Sight Glass
Sight Glass
**indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits.
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**indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits.
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Sight Glass
Sight Glass
**indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits.
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The isolators are fastened to the unit using the 3/8-inch cap screw supplied in the isolator kit. For shipment, shipping rails or spacers are supplied that attach to the compressor mounting rails and then attached to the unit mounting base to eliminate excessive movement in shipping. Install the isolators as shown in Figure 27. Solid Mounting of Manifold Sets If the requirement is to solid mount the manifold set, use the spacers that ship with the manifold kit to mount the compressor to the manifold base rails. See Figure 6 for the spacer that ships with the manifold kit. The manifold mounting rails can then be mounted solidly to the unit base. Compressor Tilt Angle Trane manifolded compressors have been tested with the compressor on a level base (0 percent tilt angle). If manifolded sets need to operate at other than level conditions, the OEM manufacturer is responsible for qualifying the compressor manifold sets for operation. Contact the OEM Compressor Group for test criteria and requirements. Compressor Start Sequence During the design of the unit, consideration needs to be given on how to start multiple compressors. Multiple compressors can be either started simultaneously or incrementally.
IMPORTANT USE OF COMPRESSOR SPACERS WITH VIBRATION ISOLATION KIT. When using the manifold isolator kit, it is important to use the spacers supplied with this kit to mount the compressors to the rails that are supplied with the manifold kit. Do not use the spacers that are provided with the manifold kit. Failure to do so will cause insufficient clearance for the upper washer and mounting hardware. These spacers are only required when using the vibration isolator kit.
Capscrew .375-16 x 3.00 Upper Isolator Manifold Mounting Rail Brace Reqd For Shipping Unit Base Sleeve
Capscrew Compressor .312-18 (Base Compressor x 2.50 Plate) Lock (Base Washer Plate) Flat Washer (1.75) Manifold Mounting Rail Tall 1.20 Spacer - pn x04010503010
Lower Isolator
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Step 1 - Compressor A Step 2 - Compressors C & D Step 3 - Compressors B, C & D Step 4 - Compressors A, B, C, D
Oil Level Lower Downstream Oil Sight Glass Upstream Oil Sight Glass Suction Gas Flow
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Figure 30 Oil Equalizer Adapter - Three and Four Compressor Manifolded Set
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System Cleanliness
System cleanliness is one of the most important factors that affect system and compressor reliability. System contamination can cause both mechanical and electrical failures. There are several sources of system contamination. Some of these are as follows: 1 Copper oxides formed when refrigerant piping is not purged with nitrogen. 2 Refrigerant piping chips, burrs and brazing flux. 3 Processing residue and metal chips from the evaporators and condensers. 4 Metal chips and wire brush strands from processing of other system components. 5 Contamination in refrigeration tubing which is left uncapped during assembly. 6 Moisture and air. 7 Processing chemical and oil used to manufacture and clean other system components such as copper tubing, evaporator and condensers. In addition, field-erected systems are subject to all the dirt and systems contamination of the typical jobsite. It is highly recommended that suction line filter driers as well as a liquid line filter drier be installed to protect systems that are field-erected and for other units that are prone to contamination.
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Index
Figures
Page No.
Figure 1 How the Scroll Works ........................................................................ 2 Figure 2 Oil Level Single Compressor ............................................................. 5 Figure 3 Oil Level Manifold Compressors ....................................................... 6 Figure 4 Isolator Installation Single Compressor ............................................. 7 Figure 5 Isolator Installation Manifold Sets ..................................................... 7 Figure 6 Spacer Solid Mount .......................................................................... 8 Figure 7 Rotalock Valves ................................................................................. 9 Figure 8 Compressor Terminal Box Layout ................................................... 10 Figure 9 Compressor Operating Envelope .................................................... 11 Figure 10 Recommended Piping Configurations ............................................ 12 Figure 11 Suggested Wiring Diagram Single Compressor ............................. 14 Figure 12 Suggested Wiring Diagram Manifold Compressors ........................ 15 Figure 13 Overcurrent Protection Trip Timing Requirements .......................... 16 Figure 14 Current Overload ............................................................................ 17 Figure 15 Example Requirement for Discharge Temperature Switch .............. 18 Figure 16 Discharge Temperature Switch ....................................................... 19 Figure 17 Discharge Temperature Switch Installation ..................................... 19 Figure 18 208/230 Volt Current Draw Correction Factors ................................. 21 Figure 19 18 Through 20-Ton Manifold Set ..................................................... 23 Figure 20 23 to 25-Ton Manifold Set ............................................................... 24 Figure 21 28 to 30-Ton Manifold Set ............................................................... 25 Figure 22 32 to 35-Ton Manifold Set ............................................................... 26 Figure 23 40-Ton Manifold Set ........................................................................ 27 Figure 24 45-Ton Manifold Set ........................................................................ 28 Figure 25 50-Ton Manifold Set ........................................................................ 29 Figure 26 60-Ton Manifold Set ........................................................................ 30 Figure 27 Isolator Installation Manifold Sets ................................................... 31 Figure 28 Operating Sequence 3 and 4 Compressor Manifold Sets ................ 33 Figure 29 Oil Level Manifold Compressors ..................................................... 33 Figure 30 Oil Equalizer Line Adapter ............................................................... 35 Figure 31 Evacuation and Dehydration Chart ................................................. 37
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Index
Tables
Page No.
Table 1 General Data ....................................................................................... 6 Table 2 Isolator Kits Manifold Sets .................................................................. 7 Table 3 Rotalock Connection Sizes .................................................................. 9 Table 4 Voltage Utilization Range .................................................................. 11 Table 5 Refrigerant Charge Limit ................................................................... 11 Table 6 Compressor Electrical Data ............................................................... 18 Table 7 Contactor Selection .......................................................................... 20 Table 8 Current Adjustment Factors .............................................................. 20 Table 9 Manifold Set Configurations and Connection Sizes .......................... 22 Table 10 Manifold Kit Ordering Numbers ....................................................... 22 Table 11 Manifold Kit Components CSHA 180 and 200 ................................... 23 Table 12 Manifold Kit Components CSHA 230,240 and 250 ............................ 24 Table 13 Manifold Kit Components CSHA 280 and 300 ................................... 25 Table 14 Manifold Kit Components CSHA 320 ................................................ 26 Table 15 Manifold Kit Components CSHA 350 ................................................ 27 Table 16 Manifold Kit Components CSHA 400 ................................................ 28 Table 17 Manifold Kit Components CSHA 500 ................................................ 29 Table 18 Manifold Kit Components CSHA 600 ................................................ 30 Table 19 Isolator Kits Manifold Compressors .................................................. 31
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The Trane Company North American Commercial Group 3600 Pammel Creek Road La Crosse, WI 54601-7599 http://www.trane.com An American Standard Company
Library Product Section Product Model Literature Type Sequence Date File No. Supersedes Ordering No.
Product Literature Refrigeration Compressors 000 Data Catalog 17 August 2003 PL-RF-COM-000-D-17-897 COM-D-17 COM-D-17-A
Since The Trane Company has a policy of continuous product improvement, it reserves the right to change design and specification without notice.
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