Com-d-17-a August 2003 Model Csha Scroll 3

Transcript

COM-D-17-A COM-D-17-A August 2003 Model CSHA Scroll 3-D® Compressor Application Data 1 General Improved Trane 3-D® Scroll Compressor Figure 1 — How the Scroll Works The principles of operation: The suction gas is drawn into the compressor at A. The gas then passes through the gap between the rotor and stator, B, cooling the motor, C. The gas then enters the intake chamber, D, that encircles the scrolls. The oil in the suction gas is separated by changing directions and impinging on surfaces within the compressor and then draining back to the oil sump. Finally, the suction gas is drawn into the scroll assembly where it is compressed and discharged into the dome of the compressor. The dome of this compressor acts as a hot gas muffler which dampens the pulsations before the gas enters the discharge line, E. How the Scroll Compressor Works General A 3-D compressor has two scrolls. The top scroll is fixed and Inlet — First Orbit As the bottom scroll orbits, two refrigerant gas pockets are formed and enclosed. Compression — Second Orbit The refrigerant gas is compressed as the volume is reduced closer to the center of the scroll. Discharge —Third Orbit The gas is compressed further and discharged through a small port in the center of the fixed scroll. ©American Standard Inc. 1997 2 the bottom scroll orbits. Each scroll has walls in a spiral shape that intermesh. 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. Scroll Compressor Special Characteristics Scroll compressors have different characteristics, both operating and non-operating, than reciprocating compressors. Because of these differences, some equipment design and manufacturing processes may need to be reviewed. High Volumetric Efficiency/Constant Volume Device The scroll compressor is a constant volume ratio device with high volumetric efficiency. As a result, the capacity, power and current do not fall off as rapidly at high condensing and low suction temperatures as they do in a typical reciprocating compressor. 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. The scroll compressor can pull down into a vacuum quicker than a reciprocating compressor. 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. Caution Scroll compressors do not use discharge or suction valves as reciprocating compressors do. Therefore, it is not necessary to perform a pumpdown or efficiency test that pulls the compressor into a vacuum. Performing this type of test will result in a compressor failure. When checking for compressor low to high-side leaks, the compressor can be used to pump the system down, but it must not be pulled down into a vacuum. 3 General 2 Model Number Description 4 General 5 Mounting 7 Refrigeration Connections 9 Electrical Connections 10 Operating Limits 11 System Protection Controls 15 Electrical Data 20 Manifolded Comp. Sets 22 System Cleanliness 36 Evacuation & Dehydration 37 Model Number Description Model Number Nomenclature C S H A 1 5 0 K 0 * 0 0 1 2 3 4 5 6 7 8 9 10 11 12 Digit 1 — “C” Positive Displacement Refrigeration Compressor Digit 9 — Capacity Control 0 = Single Speed, no unloading Digit 2 — “S” Scroll Compressor Digit 10 — Design Sequence, Factory Assigned Digit 3 — “H” Hermetic Compressor Digit 4 — Compressor Model and Development Sequence “A” 3450 rpm vertical welded shell motor Digit 5, 6, 7 — Designates Size (Nominal Tons) 093 = 9.3 tons 100 = 10.0 tons 140 = 14.0 tons 150 = 15.0 tons Digit 8 — Voltage Designator A = 200-60-3 R = 208/230-60-3 K = 460-60-3 or 400-50-3 D = 575-60-3 X = 380-60-3 F = 220-50-3 V = 346-50-3 Y = 200-50-3 (9 and 10 ton only) 4 Digit 11 — Method of Control or Unloading 0 = Single Speed, no unloading Digit 12 — Basic Compressor Variation 0 = Stub tubes, oil charging valve, oil equalizer tube, manifold bracket A = Stub tubes, oil charging valve, no oil equalizer tube, manifold bracket B = Rotalocks with access port, oil charging valve, no equalizer tube, manifold bracket. 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 scroll’s 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. 5 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. Normal Oil Level Minimum Oil Level Oil Sight Glass Figure 2 — Oil Level - Single Compressor 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). Normal Oil Level Minimum Oil Level 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. Oil Sight Glass During Operation Oil Level Higher Normally oil does not need to be removed from the system unless it has been overcharged previously. Oil Level Lower Downstream Oil Sight Glass Upstream Oil Sight Glass Suction Gas Flow Figure 3 — Oil Level for Manifolded Compressors Table 1 — General Data OILS Oil Charge Oil Type - Mineral for use with R-22 - POE for use with R-407C, R134A TEST PRESSURES: Maximum High Side Pressure Maximum Low Side Pressure Maximum Pressure Differential TILT ANGLE Maximum Tilt Angle (Single Compressor only) CSHA093, 100 - 8.5 pt. CSHA140, 150 - 13.8 pt. Trane Part Number OIL00042 Trane Part Number OIL00078 (ICI Emkarate RL32HB) 500 psig 300 psig 200 psig 10 Degrees from Vertical REFRIGERATION CONNECTIONS CSHA 093 and 100 - Sweat CSHA 140 and 150 - Sweat Discharge - 0.875” Suction - 1.375” Discharge - 1.12” Suction - 1.625” CSHA 093 and 100 - Rotalock CSHA 140 and 150 - Rotalock Discharge - 1.25-12UNF-2A Suction - 1.75-12UNF-2A ELECTRICAL CONNECTIONS Single Speed - Power Connections Motor Winding Thermostat TORQUE VALUES Power Terminal Screw Sight Glass J-Box Cover Stabilizer Plate Mounting Bolts (Manifold Sets only) Mounting Bolts - Manifold Sets only Oil Equalizer Adapter (3 and 4 Manifold Sets only) Rotalock Nuts Screw type using #10-32 x 1/2” screws 1 /4 x 0.032 Male faston connector 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. 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. 6 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. 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. 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. Capscrew .312 Flat Washer Working Height Mounting Foot Mounting Foot Isolator Mounting Rail or Unit Base Nut Sleeve Figure 4 — Isolator Installation for Single Compressor Capscrew .375-16 x 3.00 Upper Isolator Flat Washer (1.75) Sleeve Manifold Mounting Rail Compressor (Base Plate) Flat Washer (1.75) Manifold Mounting Rail Brace Req’d For Shipping Lower Isolator Unit Base Figure 5 — Isolator Installation for Manifolded Sets 7 Capscrew Compressor .312-10 (Base x 2.00 Plate) Lock Washer Tall 1.20 Spacer 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 8 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. 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. 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. 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. Table 3 — Rotalock Connection Sizes - Single Compressors Only Compressor Nominal Size 9/10 and 14/15 9/10 and 14/15 Refrigerant Connection Discharge Suction Rotalock Size 1 1/4-12 UNF-2A 1 3/4-12 UNF-2A ID 0.75 “ 1.25” Figure 7 — Rotalock Valves 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. Comp. 9/10 - Discharge 9/10 - Suction 14/15 - Discharge 14/15 - Suction Coupling 1 1/4 -12 1 3/4 -12 1 1/4 -12 1 3/4 -12 9 Connector 0.88 ODS 1.38 ODS 1.12 ODS 1.62 ODS A 5.34 7.13 5.56 7.35 B 2.37 3.19 2.59 3.41 C 1.69 2.35 1.81 2.57 D .98 1.50 0.98 1.50 E 1.19 1.31 1.19 1.31 F .62 1.00 1.00 1.00 G 1.12 1.38 1.12 1.38 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 Ground Stud Electrical Phase Sequence T1 = A T2 = B T3 = C Figure 8 — Compressor Terminal Box Layout 10 Motor Winding Thermostat Connection 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. Figure 9 — Compressor Operating Envelope 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 11 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. 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. Compressor Compressor Figure 10a — Evaporator Above Compressor 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. Figure 10c — Evaporator Below Compressor Figure 10b — Evaporator at Same Level Compressor See Figures 10a through 10j for recommended piping configurations. Figure 10a through 10j Recommended Piping Configurations Figure 10d — Condenser Above Middle Connection 12 Operating Limits Compressor Figure 10g — Condenser Same Level Middle Connection Compressor Figure 10e — Condenser Above Bottom Connection Compressor Figure 10h — Condenser Same Level Bottom Connection Compressor Figure 10i — Condenser Same Level Top Connection Compressor Compressor Figure 10f — Condenser Above Top Connection Figure 10j — Condenser Below (Same regardless whether the connection is Middle, Bottom or Top) 13 System Protection Controls Suggested wiring diagrams illustrating the control and protection of single compressors and manifolded compressor sets are shown in Figures 11 and 12 respectively. Figure 11 — Suggested Wiring Diagram - Single Compressor 1CR LOR HPC LPC MWT OLR DTS CPLS = 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. 14 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. System Protection Controls Figure 12 — Suggested Wiring Diagram - Manifolded Compressors 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. 15 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. System Protection Controls NOTE: When using the optional rotalock fittings with the access port and rotalock service valves, the access fitting on the rotalock fitting can also be used for the loss of charge low pressure switch connection. Also, when using a suction line service valve on compressors that have sweat connections, locate both the loss of charge low pressure switch and the low pressure switch between the compressor and the service valve. Manifolded Sets The same guidelines apply for manifolded sets as for single compressor applications. When using a suction service valve with a manifolded compressor set, locate both the compressor protection switch and the loss of charge low pressure switch between the compressor and the service valve. Oil Pressure Controls The scroll compressor uses a centrifugal oil pump and therefore does not require the use of any oil pressure controls. No oil pressure taps are available to measure or sense the oil pressure. Other: The device must be manual reset and UL listed and Approved by the Trane OEM Compressor Group. Special Note Regarding Overloads Other Than the Trane-Supplied Overloads This includes IEC overloads or other overload devices that are part of an integral starter. Review of many of these devices has shown that they are too slow to properly protect the compressor. If a device other than the solid-state overload supplied as an accessory by Trane is to be considered for use with the scroll compressor, prior approval is required by the Trane OEM Products Group. To receive approval, you should first review the overcurrent protection requirements listed above and on the compressor data sheets with the manufacturer of the overcurrent device. The device must meet those requirements. Figure 13 — Overcurrent Protection - Trip Timing Motor Protection Controls Motor Winding Thermostat The motor winding thermostat is located within the compressor motor and the electrical terminals for this device are located in the compressor electrical junction box. The primary purpose of this control is to provide reverse rotation protection. If the compressor is incorrectly electrically phased, causing it to run backwards, the motor will heat up, causing the motor winding thermostat to open. The thermostat opens at 221 F and resets at 181 F. Overcurrent Protection The scroll compressor requires the use of an external overcurrent protection device. The requirements for the current protection device are as follows: Trip Timing: Locked Rotor — Must trip within 10 seconds on a cold start at Locked Rotor Current Running Overcurrent Protection — Must Trip within 2 minutes at 110 percent of the Maximum Must Trip current. 16 Then submit the following information to the OEM Compressor Group: 1 The manufacturer’s catalog data. 2 The manufacturer’s catalog number of the selected device. 3 Manufacturer’s 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. System Protection Controls Trane Supplied Current Overload The solid-state overload offered as an accessory meets these requirements. See Figure 13 for the trip timing and Figure 14 for the physical dimensions. Features of the Trane-provided solid state overload include: • Direct must-hold settings. • Dial markings based on actual calibration of the device. • One device for 50/60 Hz. • 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 Figure 14 — Current Overloads Relay Overload — Overload Manual Reset (“A” Frame) X13280089-01 and -02 Relay Overload — Overload Manual Reset (“B” Frame) X13280090-01 and -02 17 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. System Protection Controls Discharge Temperature Switch (DTS) Use the operating envelopes shown in Figure 9 to determine whether a discharge temperature switch is required. To determine whether or not the discharge temperature switch is required, review the compressor operating envelope, along with the operating envelope of the unit, including the low pressure switch setting and the high pressure control settings. See Figure 15 for an example. Then determine the following: 1 Can the unit operate continuously to the left of the lines labeled “Discharge Temperature limit”? If the answer is yes, then the Discharge Temperature Switch is required. 2 When transitory operation can occur to the left of the line labeled “Discharge Temperature Limit,” you many want to consider using the Discharge Temperature Switch. Consult the Trane OEM Products Group. Table 6 — Scroll Compressor Electrical Data If it has been determined that the application requires a Discharge Temperature Switch for a manifolded compressor set, each compressor in the set requires the use of a Discharge Temperature Switch. Compressor Model/ Voltage 093 and 100 200/60/3 LRA Max. Rated Load Amps Max. Must Trip Current Overload Must Hold Setting Overload Amp Range Overload Part Number Overload Model Number 269 42.6 59.7 53 33-66 X13280090-01 222/251 42.2 59.1 52 33-66 X13280090-01 380/60/3 142 22.4 31.4 28 15-30 X13280089-01 460/60/3 117 18.4 25.8 23 15-30 X13280089-01 575/60/3 94 14.8 20.7 18 15-30 X13280089-01 200/50/3 219 36.4 51 45 33-66 X13280090-01 220/50/3 180 32.6 45.7 40 22-44 X13280089-02 346/50/3 114 20.8 29.1 25 15-30 X13280089-01 400/50/3 110 17.9 25.0 22 15-30 X13280089-01 958L109 442U 958L109 442U 958L109 440U 958L109 440U 958L109 440U 958L109 442U 958L109 441U 958L109 440U 958L109 440U 140 and 150 200/60/3 409 63.5 88.9 79 50-100 X13280090-02 337/376 62.2 87.1 77 50-100 X13280090-02 380/60/3 215 33.4 46.8 41 22-44 X13280089-02 460/60/3 178 27.6 38.6 34 22-44 X13280089-02 575/60/3 143 22.1 30.9 27 15-30 X13280089-01 220/50/3 283 48.9 68.4 61 33-66 X13280090-01 346/50/3 180 31.0 43.5 38 22-44 X13280089-02 400/50/3 174 27 38.0 33 22-44 X13280089-02 208/230/60/3 208/230/60/3 958L109 443U 958L109 443U 958L109 441U 958L109 441U 958L109 440U 958L109 442U 958L109 441U 958L109 441U Figure 15 — Example: Determining Requirement for Discharge Temperature Switch 18 System Protection Controls Figure 16 shows the discharge temperature switch and Figure 17 provides mounting, location and installation instructions. Figure 16 — Discharge Temperature Switch 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 Figure 17 — Discharge Temperature Switch Installation 19 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. 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. 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. Table 7 — Contactor Selection Compressor 093 and 100 140 and 150 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 * 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 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. 20 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 21 Manifolded Compressor Sets General The manifolding of compressors allows the use of scroll compressors in larger scroll compressor sets in the 18 to 60-ton range. Manifolding of compressors also allows for the use of capacity control. The guidelines for applying the compressors in a manifolded set are the same as those for individual compressors except as covered in the following sections. See Table 9 for available compressor combinations. A manifolded compressor set consists of the compressors listed in Table 9 plus a manifold kit which contains mounting rails, stabilizer bar(s) to tie the compressors together (two compressor sets only), discharge line, oil equalizer lines and a suction line that incorporates the exclusive passive oil return system, mounting spacers and necessary hardware to assemble the compressors into a manifolded compressor set. The components necessary to manifold the compressors (listed in Table 10) ship as a kit for installation and assembly by the customer. Table 10 lists the ordering numbers for the manifold kits. Table 9 — Manifold Set Configurations and Connection Sizes Size 180 190 200 230 240 250 280 300 320 350 400 450 500 600 CSHA 093 2 1 CSHA 100 CSHA 140 CSHA150 1 2 1 1 1 1 1 1 2 2 2 1 2 1 1 2 3 2 4 2 *Refer to data sheets for dimensions and weights. Table 10 — Manifold Kit Ordering Numbers Size 180, 190 and 200 230, 240 and 250 280 and 300 320, and 350 400 450 500 600 Ordering Number 5710-0047-01 5710-0048-01 5710-0049-01 5710-0109-01 5710-0110-01 5710-0111-01 5710-0112-01 5710-0113-01 22 Table Number Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Suction Conn. (in) 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 Discharge Conn. (in) 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 Figure* 19 19 19 20 20 20 21 21 22 22 23 24 25 26 Manifolded Compressor Sets Sight Glass Oil Charge Valve .25 Flare 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. 23 Manifolded Compressor Sets Typical Sight Glass Oil Charge Valve .25 Flare Figure 20 — 23-25 Ton Manifold Set Table 12 — 5710-0048-01-00 — CSHA230, 240 and 250 Item # ** ** 1 2 3 4 5 6 7 8 40 68 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 5707-2750-01-00 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. 24 Manifolded Compressor Sets 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 Manifolded Compressor Sets Sight Glass Sight Glass Figure 22 — 32-35 Ton Manifold Set Table 14 — 5710-0109-01-00 — CSHA320 and 350 Item # ** ** 36 37 39 40 41 6 22 23 7 8 24 25 26 80 81 76 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 Lock Washer- Compressor Mounting Oil Equalizer Line Bracket Oil Equalizer Line Clamp Screw 6-32 x .38 Equalizer Clamp Oil Equalizer Line Compressor (9/10 to 9/10) Oil Equalizer Line Compressor (9/10 to 14/15) Oil Equalizer Line Sight Glass Adapter (middle compressor) Schraeder Valve Core - Discharge line fitting Schraeder Valve Cap - Discharge line fitting Compressor Shipping Shim (2 per location) Screw Shipping Shim .38-16 x 2.00 Washer Shipping Shim .44 ID x 1.75 OD Part Number By Description By Description By Description X04010503-02-00 X25030007-01-0 X22016000-00-0 X22040400-00 4356-9483-01-00 X32030401-08-0 X25530033-10-0 X020800622-01-0 X02080629-01-0 X17310606-01-0 X17550004-00-0 X150900054-00-0 4356-9590-01-00 X25014900-00-0 X22010002-00-0 QTY 1 1 2 12 12 12 12 3 3 3 1 1 1 1 1 8 4 4 **indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits. 26 Manifolded Compressor Sets Typical Sight Glass Sight Glass Figure 23 — 40-Ton Manifold Set Table 15 — 5710-0110-01-00 — CSHA400 Item # ** ** 36 37 39 40 41 6 22 23 7 8 24 32 33 80 81 76 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 Lock Washer - Compressor Mounting Oil Equalizer Line Bracket Oil Equalizer Line Clamp Screw 6-32 x .38 Equalizer Clamp Oil Equalizer Line Compressor (9/10 to 14/15) Oil Equalizer Line Compressor (14/15 to 14/15) Oil Equalizer Line Sight Glass Adapter (middle compressor) Schraeder Valve Core - Discharge line fitting Schraeder Valve Cap - Discharge line fitting Compressor Shipping Shim (2 per location) Screw Shipping Shim .38-16 x 2.00 Washer Shipping Shim .44 ID x 1.75 OD Part Number By Description By Description By Description X04010503-02-00 X25030007-01-0 X22016000-00-0 X22040400-00 4356-9483-01-00 X32030401-08-0 X25530033-10-0 X020800608-01-0 X02080609-01-0 X17310606-01-0 X17550004-00-0 X150900054-00-0 4356-9590-01-00 X25014900-00-0 X22010002-00-0 QTY 1 1 2 12 12 12 12 3 3 3 1 1 1 1 1 8 4 4 **indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits. 27 Manifolded Compressor Sets Sight Glass Sight Glass Figure 24 — 45-Ton Manifold Set Table 16 — 5710-0110-01-00 — CSHA450 Item # ** ** 36 37 39 40 41 6 22 23 7 8 24 32 33 80 81 76 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 Lock Washer - Compressor Mounting Oil Equalizer Line Bracket Oil Equalizer Line Clamp Screw 6-32 x .38 Equalizer Clamp Oil Equalizer Line Compressor (14/15 to 14/15) middle to left Oil Equalizer Line Compressor (14/15 to 14/15) middle to right Oil Equalizer Line Sight Glass Adapter (middle compressor) Schraeder Valve Core - Discharge line fitting Schraeder Valve Cap - Discharge line fitting Compressor Shipping Shim (2 per location) Screw Shipping Shim .38-16 x 2.00 Washer Shipping Shim .44 ID x 1.75 OD Part Number By Description By Description By Description X04010503-02-00 X25030007-01-0 X22016000-00-0 X22040400-00 4356-9483-01-00 X32030401-08-0 X25530033-10-0 X020800606-01-0 QTY 1 1 2 12 12 12 12 3 3 3 1 X02080609-01-0 1 X17310606-01-0 X17550004-00-0 X150900054-00-0 4356-9590-01-00 X25014900-00-0 X22010002-00-0 1 1 1 8 4 4 **indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits. 28 Manifolded Compressor Sets Typical Sight Glass Sight Glass Figure 25 — 50-Ton Manifold Set Table 17 — 5710-0112-01-00 — CSHA500 Item # ** ** 43 44 46 47 48 4 28 29 5 6 7 38 37 52 80 81 76 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 Lock Washer - Compressor Mounting Oil Equalizer Line Bracket Oil Equalizer Line Clamp Screw 6-32 x .38 Equalizer Clamp Oil Equalizer Line Compressor (14/15 to 14/15) Oil Equalizer Line Compressor (9/10 to 14/15) Oil Equalizer Line Compressor (9/10 to 9/10) Oil Equalizer Line Sight Glass Adapter (middle compressors 1-14/15 and 1-9/10) Schraeder Valve Core - Discharge line fitting Schraeder Valve Cap - Discharge line fitting Compressor Shipping Shim (2 per location) Screw Shipping Shim .38-16 x 2.00 Washer Shipping Shim .44 ID x 1.75 OD Part Number By Description By Description By Description X04010503-02-00 X25030007-01-0 X22016000-00-0 X22040400-00 4356-9483-01-00 X32030401-08-0 X25530033-10-0 X02080606-01-0 X020800623-01-0 X020800630-01-0 X17310606-01-0 QTY 1 1 2 16 16 16 16 4 4 4 1 1 1 2 X17550004-00-0 X150900054-00-0 4356-9590-01-00 X25014900-00-0 X22010002-00-0 1 1 12 6 6 **indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits. 29 Manifolded Compressor Sets Sight Glass Sight Glass Figure 26 — 60-Ton Manifold Set Table 18 — 5710-0113-01-00 — CSHA600 Item # ** ** 43 44 46 47 48 4 28 29 5 7 38 32 53 80 81 76 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 Lock Washer - Compressor Mounting Oil Equalizer Line Bracket Oil Equalizer Line Clamp Screw 6-32 x .38 Equalizer Clamp Oil Equalizer Line Compressor (14/15 to 14/15) used with compressors that use item 38 Oil Equalizer Line Compressor (14/15 to 14/15) Oil Equalizer Line Sight Glass Adapter (middle compressors 1-14/15 and 1-9/10) Schraeder Valve Core - Discharge line fitting Schraeder Valve Cap - Discharge line fitting Compressor Shipping Shim (2 per location) Screw Shipping Shim .38-16 x 2.00 Washer Shipping Shim .44 ID x 1.75 OD Part Number By Description By Description By Description X04010503-02-00 X25030007-01-0 X22016000-00-0 X22040400-00 4356-9483-01-00 X32030401-08-0 X25530033-10-0 X02080606-01-0 QTY 1 1 2 16 16 16 16 4 4 4 2 X020800609-01-0 X17310606-01-0 1 2 X7550004-00-0 X150900054-00-0 4356-9590-01-00 X25014900-00-0 X22010002-00-0 1 1 12 6 6 **indicates items that are provided as an assembly and are not called out for specifically on the drawing included with the kits. 30 Manifolded Compressor Sets 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. Manifolded Sets 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 are different isolator kits depending on whether there are two, three or four compressors in the manifold kit. Table 19 lists the part numbers for the isolator kits. 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. Table 19 — Isolator Kit Manifolded Sets Number of Manifolded Compressors 2 3 4 Isolator Kit Part 5710-0114-01-00 5710-0114-02-00 5710-0114-03-00 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. 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 Flat Washer (1.75) Sleeve Manifold Mounting Rail 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. Capscrew Compressor .312-18 (Base Compressor x 2.50 Plate) Lock (Base Washer Plate) Flat Washer (1.75) Manifold Mounting Rail Brace Req’d For Shipping Lower Isolator Unit Base Figure 27 — Isolator Installation Manifolded Sets 31 Tall 1.20 Spacer - pn x04010503010 Manifolded Compressor Sets Starting Compressors Simultaneously Although compressors can be started simultaneously, the obvious disadvantage is that the inrush amperage is high. If the power supply is not robust enough, a voltage reduction could occur at start-up, causing problems such as lights dimming. This would be similar to starting a large compressor across the line. Another consideration is that the lower the voltage, the higher the inrush, 208/230 and 200 volt compressors have higher locked rotor values than 460 volt compressors, making the potential for low voltage problems even greater. Another consideration is the response of the refrigeration system. When large changes occur rapidly, it takes the system longer to settle out and reach operating equilibrium. The more components in the system such as thermal expansion valves, the longer it takes to reach equilibrium. Incremental Start of Compressors This is the preferred manner to start compressors on a manifold set. Incrementally starting compressors reduces inrush amperage. This is similar to starting a large compressor using part winding start, where only a portion of the winding is initially energized and then after one second or less, the other part of the winding is energized. The advantage to having multiple compressors is that they can be staged on individually at whatever time sequence is desired. A timing sequence can be chosen that both reduces inrush and minimizes system refrigerant system fluctuations. If inrush is the only concern, a minimum of one second between compressors starts is recommended. Ramping up compressor capacity reduces refrigeration system fluctuation. When smaller changes are made over a larger time period, the refrigeration system components experience less radical change and have a better chance of reaching operating equilibrium quicker than starting all the compressors at once. This improves system operation and control. 32 The actual staging of a unit can be accomplished by the following devices: • An electronic temperature control that has built-in interstage time delay. • Preprogrammed unit controllers designed for a specific unit application. • Programmable control modules, where you program in the control the logic • Standard temperature control devices in combination with mechanical relay logic. Compressor Capacity Control Sequencing Capacity control is a benefit of having multiple compressors manifolded together on a compressor refrigerant circuit. When using this capability, some guidelines regarding the sequencing of the compressors must be followed to assure that the oil return system designed as part of the manifold piping works properly. The guidelines are as follows: Dual Compressor Manifold Sets Either compressor can be lead or lag on dual compressor manifold sets. Manifolded Compressor Sets Three and Four Compressor Manifold Sets There is a set sequence that must be followed to assure proper oil return to the compressors. The sequence is shown in Figure 28. Oil Levels The oil level can only be evaluated when the all the compressors are shutoff. 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 minimum oil level with the compressors shut-off is at the bottom of the oil sight glass. Figure 28 — Operating Sequence — Three and Four Compressor Manifolded Sets Three Compressor Manifold Set Suction Gas Flow Step 1 - Compressor C Step 2 - Compressor A & B Step 3 - Compressor A, B & C Four Compressor Manifold Set Suction Gas Flow Refrigerant Piping The same guidelines for single compressors apply to multiple compressors. See Figures 10a to 10j for suggested piping configurations. For connection sizes, see Table 9. Material Selection The following components are required for customer assembly: 1 Compressors — specify voltage and tonnage. Choose the appropriate compressors from Table 9 and the appropriate manifold assembly kits from Table 10. A quantity of one is required per manifold assembly. 2 Overloads — a quantity of one per compressor is required. See Table 5 for the proper overload. 3 Discharge Temperature Switch (if required) — a quantity of one per compressor. The customer must provide the clamp and insulation. See the guidelines under System Protection Controls. 4 System Protection Controls — high pressure switch (quantity of one per manifold set) and low pressure switch. See the guidelines under System Protection Controls. Step 1 - Compressor A Step 2 - Compressors C & D Step 3 - Compressors B, C & D Step 4 - Compressors A, B, C, D Figure 29 — Oil Level — Manifolded Compressors Off Normal Oil Level Minimum Oil Level Oil Sight Glass During Operation Oil Level Higher Oil Level Lower Downstream Oil Sight Glass Upstream Oil Sight Glass Suction Gas Flow 33 Manifolded Compressor Sets Manifold Kit Assembly Procedure Dual Compressor Sets 1 Mount the compressor mounting rails to the unit base, using the vibration isolators and associated hardware. 2 Mount the compressors on the rails as detailed on the scroll manifold assembly drawing, using the spacers. (Note: When using the vibration isolation kits, use the spacers provided in the mounting isolator kit), lock washers, washers and screws provided. Place the oil equalizer line support brackets under the washers. Note 7 on the drawing identifies the proper placement of the compressor feet on the base rail. Torque the mounting bolts to 20 + 2 ft. lb. 3 Mount the stabilizer plate to the compressor with nuts and bolts. Torque the bolts to 12-14 ft. lb. 4 Loose-fit the suction, discharge and oil equalizer lines to the stubs on the compressor. Clamp the oil equalizer line to the bracket prior to brazing. 5 After loose-fitting the refrigerant piping lines, braze them to industry standards. Recommended braze material is Specification Number BAg-7 AWS/ AMS. Note: Purge with nitrogen to prevent the formation of oxides that are detrimental to system cleanliness and reliability. 34 Contact the OEM Products Group for additional information if required. Three and Four Compressor Sets 1 Mount the compressor mounting rails to the unit base using the vibration isolators and associated hardware. 2 On a three-compressor set and on the middle two compressors of a fourcompressor set, it is necessary to remove the oil sight glass(s) and replace with an adapter for connecting the oil equalizer line. • Tilt the compressor back to remove the sight glass. • Install the oil equalizer tube adapter. See Figure 30. • Torque the adapter to 45 + 5 ft. lb. • It maybe necessary to drain some oil out of the compressor so that it does not run out of the adapter. 3 Mount the compressors to the rails as detailed on the scroll manifold assembly drawing, using the spacers. Note: When using the vibration isolation kits, use the spacers provided in the mounting isolator kit, lock washers, washers and screws. Place the oil equalizer line support brackets on the washers. Note 7 on the drawing identifies the proper placement of the compressor feet on the base rail. Torque mounting bolts to 20 + 2 ft. lb. Manifolded Compressor Sets 4 Loose-fit the suction, discharge and oil equalizer lines to the stubs on the compressor. Clamp the oil equalizer line to the bracket prior to brazing. 5 After loose-fitting the refrigerant piping lines, braze to industry standards. Recommended braze material is Specification Number BAg-7 AWS/ AMS. 6 It is recommended to use a wet rag on the oil equalizer adapter when brazing the oil tube to the adapter to prevent damage to the “O” ring. 7 Purge with nitrogen to prevent the formation of oxides that are detrimental to system cleanliness and reliability. The discharge line assembly contains two access ports. One is for connection of the high pressure control and the other is for use with a Schraeder valve to allow access to the high side for checking discharge pressures. Only one Schraeder valve core is provided. If one of the discharge ports is not used for the high pressure control, install a Schraeder valve core into the fitting. Figure 30 — Oil Equalizer Adapter - Three and Four Compressor Manifolded Set 35 Alternate Manifolded Compressor Configurations If the standard compressor configuration for manifolded compressors does not fit your needs, please contact the OEM Products Group for recommendations on alternative configurations. The user must supply the piping, mounting rails and other hardware for these alternative configurations. Alternative configurations must be approved by the Trane OEM Products Group. 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. 36 Evacuation and Dehydration For a refrigeration system to work properly, it must be free of air and moisture. The process by which air and moisture are removed is known as “Evacuation and Dehydration.” Moisture and air are harmful to the system because they increase the condensing temperature, raise the discharge gas temperature, cause oil and refrigerant breakdown and cause the formation of acids. Acids are corrosive to the components in the refrigerant system, including the piping, refrigerant specialties and the compressor mechanical and electrical components. The elevated temperatures can also cause copper plating that can cause mechanical failure of the compressor. Figure 31 — Evacuation Dehydration Chart 37 The recommended method for “Evacuation and Dehydration” is to evacuate both the high side and low side to 500 microns or less. To establish that the unit is leak-free, use a standing vacuum test. The maximum allowable rise over a 15-minute period is 200 microns. If the rise exceeds this, either there is still moisture in the system or a leak is present. See Figure 31. 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 38 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 39 The Trane Company North American Commercial Group 3600 Pammel Creek Road La Crosse, WI 54601-7599 http://www.trane.com An American Standard Company Since The Trane Company has a policy of continuous product improvement, it reserves the right to change design and specification without notice. Library Product Literature Product Section Product Model Refrigeration Compressors 000 Literature Type Sequence Date Data Catalog 17 August 2003 File No. Supersedes Ordering No. PL-RF-COM-000-D-17-897 COM-D-17 COM-D-17-A 40