Trane Start to Finish R-410A Installation Manual

Installation Guide

Start to Finish™ R-410A Scroll Compressors

Model Numbers:

SFCOM090***4PSNAD SFCOM181***4PSNAD SFCOM300***4PSNAN SFCOM109***4PSNAD SFCOM182***4PSNAN SFCOM301***4PSNAN SFCOM121***4PSNAD SFCOM183***4PSNAN SFCOM360***4PSNAN SFCOM145***4PSNAD SFCOM240***4PSNAN SFCOM361***4PSNAN SFCOM156***4PSNAD SFCOM241***4PSNAN

SAFETY WARNING

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

August 2020

PART-SVN234B-EN

Introduction

Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

WARNING

CAUTIONs

NOTICE

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants—including industry replacements for CFCs and HCFCs such as saturated or unsaturated HFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation whi result in minor or moderate injury. It could also be used to alert against unsafe practices.

Indicates a situation that could result in equipment or property-damage only accidents.

ch, if not avoided, could

WARNING

Proper Field Wiring and Grounding Required!

Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state electrical codes.

WARNING

Personal Protective Equipment (PPE) Required!

Failure to wear proper PPE for the job being undertaken could result in death or serious injury. Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:

• Before installing/servicing this unit, technicians MUST put on all PP undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals, ALWAYS (Global Harmonized System of Classification and Labeling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.

• If there is a risk of energized electrical contact, arc, flash, technicians with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.

refer to the appropriate SDS and OSHA/GHS

E required for the work being

MUST put on all PPE in accordance

or

Introduction

WARNING

Follow EHS Policies!

Failure to follow instructions below could result in death or serious injury.

• All Trane personnel must follow the company’s E

nvironmen when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc. Where local regulations are more stringent than these policies, those regulations supersede these policies.

• Non-Trane personnel should always follow local lations.

regu

tal, Health and Safety (EHS) policies

WARNING

R-410A Refrigerant under Higher Pressure than R-22!

Failure to use proper equipment or components as described below, could result in equipment failing and possibly exploding, which could result in death, serious injury, or equipment damage. The units described in this manual use R-410A refrigerant which operates at higher pressures than R-22. Use ONLY R-410A rated service equipment or components with these units. For specific handling concerns with R-410A, please contact your local Ingersoll Rand representative.

WARNING

Hazard of Explosion and Deadly Gases!

Failure to follow all proper safe refrigerant handling practices could result in death or serious injury.  Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids.

WARNING

Hazard of Explosion!

Failure to follow instructions below could result in death or serious injury or equipment or property-only damage. Use only dry nitrogen with a pressure regulator for pressurizing unit. Do not use acetylene, oxygen or compressed air or mixtures containing them for pressure testing. Do not use mixtures of a hydrogen containing refrigerant and air above atmospheric pressure for pressure testing as they may become flammable and could result in an explosion. Refrigerant, when used as a trace gas should only be mixed with dry nitrogen for pressurizing units.

WARNING

Hazardous Service Procedures!

Failure to follow all precautions in this manual and on the tags, stickers, and labels could result in death or serious injury. Technicians, in order to protect themselves from p

otential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the following instructions: Unless specified otherwise, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks.

WARNING

Hazardous Conditions!

Failure to follow these instructions could result in death or serious injury or damage to the equipment. Observe and follow the “Warning” and “Notices” labels on the compressor.

NOTICE

Use Proper Charging and Crankcase Heater Operation Procedures!

Failure to utilize proper charging and crankcase heater procedure will result in compressor failure. Refer to unit Installation, Operation, and Maintenance manual and this manual for the proper procedures.

Copyright

This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes

PART-SVN234B-EN 3

Introduction

to its content without obligation to notify any person of such revision or change.

Trademarks

All trademarks referenced in this document are the trademarks of their respective owners.

Revision History

Updated for Trane Technologies.

4 PART-SVN234B-EN

Table of Contents

Model Number Descriptions . . . . . . . . . . . . . . 6

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 8

General Information . . . . . . . . . . . . . . . . . . . . 17

POE Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Oil Handling . . . . . . . . . . . . . . . . . . . . . . . 17

Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operating Envelope . . . . . . . . . . . . . . . . . . . 17

Refrigerant Type . . . . . . . . . . . . . . . . . . . . 18

Transportation, Handling, and Storage . . 18

Pre-Installation Inspections . . . . . . . . . . . 19

Repair Recommendations . . . . . . . . . . . . . 20

Mechanical Failure . . . . . . . . . . . . . . . . . . 20

Electrical Failure . . . . . . . . . . . . . . . . . . . . . . 21

Two Types of Motor Failures . . . . . . . . . 21

Removal and Installation . . . . . . . . . . . . . . . . 22

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Compressor Replacement—Tandem and Trio

Compressor Sets . . . . . . . . . . . . . . . . . . . 23

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Electrical Connections . . . . . . . . . . . . . . . . . 25

Leak Detection . . . . . . . . . . . . . . . . . . . . . . . 26

Vacuum Testing and Evacuation . . . . . . . . 27

Charging the System . . . . . . . . . . . . . . . . . . 28

Verification Before Start-Up . . . . . . . . . . . . 28

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 31

182–361 Nominal Capacity Compressor Mo-

tor Protection Module Diagnosis . . . . . . 32

Log Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Replacement Scroll Compressors . . . . . . . 34

Log Sheet for Installers . . . . . . . . . . . . . . 34

Systems Check . . . . . . . . . . . . . . . . . . . . . 35

Operating Controls Check . . . . . . . . . . . . 35

Observations . . . . . . . . . . . . . . . . . . . . . . . 35

PART-SVN234B-EN 5

Model Number Descriptions

Digit 1, 2 — Brand

SF = Start to Finish™

Digit 3, 4, 5 — Unit Type

COM= Scroll Compressor

Digit 6, 7, 8 — Nominal Capacity

090 = 85 MBtu/h 109 = 101 MBtu/h 121 = 117 MBtu/h 145 = 137 MBtu/h 156 = 158 MBtu/h 181 = 178 MBtu/h 182 = 176 MBtu/h, 115/230V Module 183 = 176 MBtu/h, 24V Module 240 = 237 MBtu/h, 115/230V Module 241 = 237 MBtu/h, 24V Module 300 = 298 MBtu/h, 115/230V Module 301 = 298 MBtu/h, 24V Module 360 = 359 MBtu/h, 115/230V Module 361 = 359 MBtu/h, 24V Module

Digit 9, 10, 11 — Electrical Code

230 = 200–230/60/3 460 = 460/60/3 575 = 575/60/3

Digit 12 — Refrigerant

2=R-22 4 = R-410A

Digit 13 — Lubricant

M= Mineral Oil P = Polyolester (POE) Oil

Digit 14 — Connection Type

R=Rotolock S = Stub Tube

Digit 15 — Motor Protection

E = External Protection N = Internal Protection

Digit 16 — Revision Level

A = Initial Release

Digit 17 — Bill of Material

D N

6 PART-SVN234B-EN

Overview

The purpose of this document is to provide installation and service information for Start to Finish™ R-410A compressors.

This document is not meant to be provide a step-by-step

ocedure, but is intended to identify procedures or

pr precautions that may be unique to a Start to Finish R-410A compressor and should be taken into account to properly and safely remove, install, and troubleshoot the compressor.

Each installation has its unique set of circumstances

which

also must be taken into account by the service technician.

Table 1. Available Start to Finish™ compressors

Model Number Service Part Number

SFCOM0905754PSNAD SFCOM090-5754AD

SFCOM0902304PSNAD

SFCOM0904604PSNAD SFCOM090-4604AD

SFCOM1095754PSNAD SFCOM109-5754AD

SFCOM1092304PSNAD SFCOM109-2304AD

SFCOM1094604PSNAD SFCOM109-4604AD

SFCOM1215754PSNAD SFCOM121-5754AD

SFCOM1212304PSNAD SFCOM121-2304AD

SFCOM1214604PSNAD SFCOM121-4604AD

SFCOM1455754PSNAD SFCOM145-5754AD

SFCOM1452304PSNAD SFCOM145-2304AD

SFCOM1454604PSNAD

SFCOM1565754PSNAD SFCOM156-5754AD

SFCOM1562304PSNAD

SFCOM1564604PSNAD SFCOM156-4604AD

SFCOM1815754PSNAD SFCOM181-5754AD

SFCOM1812304PSNAD SFCOM181-2304AD

SFCOM1814604PSNAD

SFCOM1825754PSNAN SFCOM182-5754AN

SFCOM1832304PSNAN

SFCOM1822304PSNAN SFCOM182-2304AN

SFCOM1834604PSNAN SFCOM183-4604AN

SFCOM1824604PSNAN SFCOM182-4604AN

SFCOM2415754PSNAN SFCOM241-5754AN

SFCOM2405754PSNAN SFCOM240-5754AN

SFCOM2412304PSNAN SFCOM241-2304AN

SFCOM2402304PSNAN SFCOM240-2304AN

SFCOM2414604PSNAN SFCOM241-4604AN

SFCOM2404604PSNAN SFCOM240-4604AN

SFCOM3005754PSNAN SFCOM300-5754AN

SFCOM3012304PSNAN SFCOM301-2304AN

SFCOM3002304PSNAN SFCOM300-2304AN

SFCOM3014604PSNAN SFCOM301-4604AN

SFCOM3004604PSNAN

SFCOM3615754PSNAN SFCOM361-5754AN

SFCOM3605754PSNAN SFCOM360-5754AN

SFCOM090-2304AD

SFCOM145-4604AD

SFCOM156-2304AD

SFCOM181-4604AD

SFCOM183-2304AN

SFCOM300-4604AN

Table 1. Available Start to Finish™ compressors

Model Number Service Part Number

SFCOM3612304PSNAN

SFCOM3602304PSNAN SFCOM360-2304AN

SFCOM3614604PSNAN SFCOM361-4604AN

SFCOM3604604PSNAN SFCOM360-4604AN

SFCOM361-2304AN

PART-SVN234B-EN 7

Dimensional Data

Figure 1. SFCOM090 compressors

APPLICATION SFCOM090

REFRIGERANT R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 85.1 POWER INPUT (KW) 8.67 EER (BTU/W-HR) 9.82

Note: Fittings and connection part descriptions are

shown in

8 PART-SVN234B-EN

Figure 13 and Figure 14, p. 19.

Figure 2. SFCOM109 and SFCOM121 compressors

Dimensional Data

APPLICATION SFCOM109 SFCOM121

REFRIGERANT R410A R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 101.0 117.1 POWER INPUT (KW) 10.15 11.58 EER (BTU/W-HR) 9.95 10.11

Note: Fittings and connection part descriptions are

shown in

PART-SVN234B-EN 9

Figure 13 and Figure 14, p. 19.

Dimensional Data

Figure 3. SFCOM145 compressors

APPLICATION SFCOM145

REFRIGERANT R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 137.3 POWER INPUT (KW) 13.48 EER (BTU/W-HR) 10.18

Note: Fittings and connection part descriptions are

shown in

10 PART-SVN234B-EN

Figure 13 and Figure 14, p. 19.

Figure 4. SFCOM156 compressors

APPLICATION SFCOM156

REFRIGERANT R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 158.2 POWER INPUT (KW) 15.33 EER (BTU/W-HR) 10.32

Dimensional Data

Note: Fittings and connection part descriptions are

shown in

PART-SVN234B-EN 11

Figure 13 and Figure 14, p. 19.

Dimensional Data

Figure 5. SFCOM181 compressors

APPLICATION SFCOM181

REFRIGERANT R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 177.7 POWER INPUT (KW) 17.04 EER (BTU/W-HR) 10.43

Note: Fittings and connection part descriptions are

shown in

12 PART-SVN234B-EN

Figure 13 and Figure 14, p. 19.

Figure 6. SFCOM182 and SFCOM183 compressors

Dimensional Data

APPLICATION SFCOM182 SFCOM183

REFRIGERANT R410A R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 176.2 176.2 POWER INPUT (KW) 17.36 17.36 EER (BTU/W-HR) 10.15 10.15

PROTECTION CONTROL MODULE

VAC 115/230 24

Note: Fittings and connection part descriptions are

shown in

PART-SVN234B-EN 13

Figure 13 and Figure 14, p. 19.

Dimensional Data

Figure 7. SFCOM240 and SFCOM241 compressors

APPLICATION SFCOM240 SFCOM241

REFRIGERANT R410A R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 237.4 237.4 POWER INPUT (KW) 23.46 23.46 EER (BTU/W-HR) 10.12 10.12

PROTECTION CONTROL MODULE

VAC 115/230 24

Note: Fittings and connection part descriptions are

shown in

14 PART-SVN234B-EN

Figure 13 and Figure 14, p. 19.

Figure 8. SFCOM300 and SFCOM301 compressors

Dimensional Data

APPLICATION SFCOM300 SFCOM301

REFRIGERANT R410A R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 298.2 298.2 POWER INPUT (KW) 29.75 29.75 EER (BTU/W-HR) 10.02 10.02

PROTECTION CONTROL MODULE

VAC 115/230 24

Note: Fittings and connection part descriptions are

shown in

PART-SVN234B-EN 15

Figure 13 and Figure 14, p. 19.

Dimensional Data

Figure 9. SFCOM360 and SFCOM361 compressors

APPLICATION SFCOM360 SFCOM361

REFRIGERANT R410A R410A U.L. RECOGNIZED USA & CANADA

RATED PERFORMANCE @45°/130°/20°/15°

CAPACITY (MBTU/HR) 358.9 358.9 POWER INPUT (KW) 36.10 36.10 EER (BTU/W-HR) 9.94 9.94

PROTECTION CONTROL MODULE

VAC 115/230 24

Note: Fittings and connection part descriptions are

shown in

16 PART-SVN234B-EN

Figure 13 and Figure 14, p. 19.

General Information

Table 2. Torque values

Item Torque

Rotolock equalizer nut  1-3/4 and 2-1/4

Terminal screws #10-32 X 0.5 in

Terminal stud 2.75 ± 0.25 N·m; 30 ± 2 in·lb

Terminal stud nut

Ground screw 1.90 ± 0.25 N·m; 17 ± 2 in·lb

Terminal box cover 2.15 ± 0.25 N·m; 19 ± 2 in·lb

133 ± 10 N·m; 98 ± 7 ft·lb

2.75 ± 0.25 N·m; 25 ± 2 in·lb

3.4 ± 0.25 N·m; 30 ± 2 in·lb

Note: With Rotolock fittings, always use two wrenches:

one to back-up on the sleeve and one to tighten the nut. Proper torquing of the Rotolock nut is important to ensure a leak-free joint.

POE Oil

Table 3. Factory oil charge

Nominal Capacity Pints Liters Part Number

090 6.3 3.0 OIL00078, OIL00080

109–156 7.0 3.3

181 7.6 3.6 OIL00078, OIL00080

182–301 14.2 6.7 OIL00078, OIL00080

360–361 15.2 7.2 OIL00078, OIL00080

Notes:

1. OIL00078—1 quart container

2. OIL00080—1 gallon container

3. Oil amount and type is also pri

nted on the nameplate.

OIL00078, OIL00080

The oil should be visible through the oil sightglass both during operation and when the compressor(s) is off. Oil level slightly below the sightglass, but still visible is acceptable.

Single compressor. The oil level should be stable in the

sightglass.

Tandem and trio compressors. •Operation—The oil

level will vary depending on the operating condition.

• Unloaded condition

—The running compressor will

have a higher oil level than the off compressor(s).

• Loaded condition

—Oil should be visible through all

of the compressor sight glasses. Some may have a higher level than others, but this is not abnormal.

—After several minutes, the oil levels should be the

• Off same in each compressor and should be visible in the sightglass. This is the best method to determine if the system has sufficient oil.

Units overcharged with oil will operate with degraded

erformance and co

p

uld lead to compressor damage.

Operating Envelope

The compressor must be operated within the published operating envelope.

Oil Handling

POE oil is very hygroscopic, which means it absorbs moisture very readily. Therefore, it is important to properly handle the oil.

POE Oil handling guidelines

• Always use the smallest container size required for the job requirements.

• Always leave the oil container tig of use

.

• Do not reuse oil that has been opened.

htly sealed until time

Oil Level

Figure 10. Compressor oil label

PART-SVN234B-EN 17

R410A Operating Map - Superheat 20F

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

-30 -20 -10 0 10 20 30 40 50 60 70

Evaporating temperature (°F)

Condensing temperature (°F)

R410A Operating Map - Superheat 20F

General Information

Figure 11. Operating envelope

Refrigerant Type

Start to Finish™ compressors are approved for use with R-410A refrigerant only. Any use of hydrocarbon refrigerants or air is strictly prohibited!

Heavy Objects!

Failure to follow instructions below or properly lift unit could result in unit dropping and possibly crushing

Transportation, Handling, and Storage

operator/technician which could result in death or serious injury, and equipment or property-only damage. Ensure that all the lifting equipment used is properly rated for the weight of the unit being lifted. Each of the

The compressor must be handled in the vertical position (maximum 15-degree offset from vertical). Should the compressor be handled in an upside down position, its suitability for its use can not be guaranteed.

Improper Handling!

Improper handling of the compressor resulting from being handled or transported in the upside position, dropped or tipped over could result in internal damage to the compressor and it is recommended that the compressor not be put into service.

Damage to compressor or packag to the shipper immediately.

Use a proper method of lifting the compressor, both lifting ears must be used with a spread

18 PART-SVN234B-EN

NOTICE

ing should be

er bar.

reported

cables (chains or slings), hooks, and shackles used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift.

For approximate compressor weight, see

WARNING

Table 4, p. 19.

General Information

Oil equalizer Rotolock connection fitting

1/4 Schrader port

Oil drain valve

Sightglass

Oil equalizer Rotolock connection fitting

1/4 Schrader port

Sightglass

Spreader bar use is recommended to better balance the compressor.

Figure 12. Lifting compressor with spreader bar

lifting hooks with close clasps.

Use

Table 4. Compressor weight with full oil charge

Nominal Capacity Weight (lb)

090 128

109–121

145 148

156 152

181 155

182–183 234

240–241 238

300–301 337

360–361 362

142

Figure 13. Nominal capacity 182–361

Figure 14. Nominal capacity 090–181

The compressor and its packaging must not be exposed to rain and/or corrosive, flammable atmosphere.

The compressor must not be stored in an environment less than -31°F (-35°C) or to exceed +160°F (+71°C).

Pre-Installation Inspections

Check the following before using the compressor:

• Compressor for visible shipping damage.

• Compressor is the correct mo

del/part number.

• Compressor is the correct voltage.

• Compressor ship-with items:

– Restrictors for use with tandem and trio

compressors.

®

– Oil equalizer Teflon

gaskets.

WARNING

R-410A Refrigerant under Higher Pressure than R-22!

Failure to use proper equipment or components as described below, could result in equipment failing and possibly exploding, which could result in death, serious injury, or equipment damage. The units described in this manual use R-410A refrigerant which operates at higher pressures than R-22. Use ONLY R-410A rated service equipment or components with these units. For specific handling concerns with R-410A, please contact your local Ingersoll Rand representative.

PART-SVN234B-EN 19

Oil equalizer Rotolock connection fitting

Oil equalizer lines

TANDEM

TRIO

General Information

Suggested area to cut the refrigerant lines so that they can be reinstalled

Figure 15. Tandem and Trio

Other modification may cause oil return issues and lead to compressor failure. Cut the lines in a convenient place, remove the compressor, and then unbraze the lines from the compressor. On reinstallation, reinstall lines to compressor and reassemble the cut lines utilizing a slip coupling. See to cut the

Figure 16. Suggested areas to cut refrigerant lines

Figure 16 for suggested area

discharge and suction l

ine.

Repair Recommendations

WARNING

Hazard of Explosion and Deadly Gases!

Failure to follow all proper safe refrigerant handling practices could result in death or serious injury.  Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids.

Mechanical Failure

Replace only the failed compressor in a tandem or trio set.

Important: On tandem or

20 PART-SVN234B-EN

and discharge lines must NOT be modified, except for the use of slip joint couplings.

trio assemblies, the suction

Minimize system and compressor open times to avoid excessive moisture absorption by the POE oil. Maximum suggested open time is 15 minutes.

Drain and replace oil in all the non-failed compressors.

Note: Fo

The 182–361 nominal capacity compressor has an with a Schrader® valve that can be used to remove the oil (see

Replace unit liquid line filter-drier. T part of controlling moisture in R-410A POE oil systems.

Reuse the compressors mounting isolators or mounting spacers that a assembly.

Braze the compressor into connections ar silver, with paste flux to make the copper tube connections to the compressor.

r 090–181 nomnial capacity compressors, this requires removing through the oil equalizer Rotolock fitting (see

Figure 14, p. 19). Use a dedicated device for

removing oi device with clean oil prior to use.

Figure 13, p. 19).

re used with the existing compressor

e copper-plated steel. Use BAg-28, 40%

oil using a suction device

l. It is good practice to flush the suction

his is a very important

the system. Compressor

oil drain

General Information

Nominal Capacity “X” Distance

090–181 10 inches

182–361 tandem 16 inches

182–361 trio 25 inches

X Minimum Distance

Proceed as described in the following sections:

•

“Leak Detection,” p. 26

• “Vacuum Testing and Evacuation,” p. 27

• “Charging the System,” p. 28

• “Verification Before Start-Up,” p. 28

Electrical Failure

Replace only the failed compressor in a tandem or trio set.

Drain and replace the oil in all the non-failed compressors.

Reuse the compressors mounting isolators or mounting

rs that are

space assembly.

Braze compressor into the system. Compressor connections are copper-plated steel. Use silver, with paste flux to make the copper tube connections to the compressor.

Important: On

Minimize system and compressor open times to avoid excessive suggested open time is 15 minutes.

Test the acid condition of the oil in the compressors using

acid

test kit. Use Part Numbers KIT06815, CHM00414,

an and KIT06754.

Two Types of Motor Failures

Light. If oil test kit is negative and oil is only slightly

discolored, treat in the same manner as a mechanical failure.

Severe. If oil test kit is positive with strong pungent odor

and dark oil, drain and replace oil in all of the non-failed compressors.

Reuse the compressor mounting isolators or mounting

rs that are

space assembly.

This type of failure requires changing both the suction and

iquid line

l facilitate changing filter-driers, if required.

Install the suction filters no closer than the distance listed in the table following from the centerline

p. 20).

PART-SVN234B-EN 21

used with the existing compressor

BAg-28, 40%

tandem or trio assemblies, the suction and discharge lines must not be modified, except for the use of slip joint couplings. Other modification may cause oil return issues and lead to compressor failure. Cut the lines in a convenient place, remove the compressor then unbraze the lines from the compressor. On reinstallation, reinstall lines to compressor and reassemble the cut lines with a slip coupling. See

r suggested area to cut the discharge

fo

p. 20

and suction

moisture absorption by the POE oil. Maximum

used with the existing compressor

filter-driers. Use replaceable filter-drier cores to

line.

Figure 17. The distance is measured

of the suction inlet tee (see

Figure 16,

Braze compressor into the system. Compressor connection silver, with paste flux to make the copper tube connections to the compressor.

Proceed as described in the following sections:

•

“Leak Detection,” p. 26

• “Vacuum Testing and Evacuation,” p. 27

• “Charging the System,” p. 28

• “Verification Before Start-Up,” p. 28

Figure 17. Minimum distance b

1. Use acid removal type filter-drier cores in both the suction filter and liquid line filter drier.

2. Change when the pressure drop exceeds 4 psig.

s are copper-plated steel. Use BAg-28, 40%

efore installation

suction line filter

182–361 nominal capacity models

Test oil after 24 hours of operation. Change filter-drier again if required. If oil is still acid, drain and replace oil in all the non-failed compressors.

After system is clean, test kit in su

ction clean up filter-drier and replace the liquid line drier

with standard filter drier cores.

dicates okay, remove the

090–181 nominal capacity models

Since these compressors do not have an oil drain valve, it is recommended that after 24 hours of operation, the filterdrier cores be replaced with acid removal filter-drier cores. Operate the system for another 24 hours before changing to remo filter-drier in the liquid line.

ve the suction filter-drier and install a standard

of

Removal and Installation

WARNING

Removal

Refrigerant under High Pressure!

Failure to follow instructions below could result in an explosion which could result in death or serious injury or equipment damage. System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use nonapproved refrigerants, refrigerant substitutes, or refrigerant additives.

Pressurized Burning Fluid!

Failure to follow these instructions could result in death or serious injury. Before opening a system, you must remove refrigerant from both the high and low sides of the system. If the pressure is not removed from both sides of the system, pressure could still exist in the system. If a torch is used to unbraze the tubing, the refrigerant and oil mixture could ignite.

WARNING

Contains Refrigerant! R-410A Refrigerant under Higher Pressure than R-22!

Failure to use proper equipment or components as described below, could result in equipment failing and possibly exploding, which could result in death, serious injury, or equipment damage. The units described in this manual use R-410A refrigerant which operates at higher pressures than R-22. Use ONLY R-410A rated service equipment or components with these units. For specific handling concerns with R-410A, please contact your local Ingersoll Rand representative.

WARNING

Hazard of Explosion and Deadly Gases!

Failure to follow all proper safe refrigerant handling practices could result in death or serious injury.  Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids.

Only qualified personnel should install or repair refrigeration systems. If you are not qualified, seek the services of qualified personnel. The steps listed below are not meant to be an exact step-by-step procedure, but are intended to identify procedures or precautions that may be unique to a Start to Finish™ compressor and should be taken into account to properly and safely remove and install the compressor. Each installation has its unique set of circumstances which must be considered by the service technician to perform a safe and successful compressor replacement.

22 PART-SVN234B-EN

Hazardous Voltage w/Capacitors!

Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Verify with an appropriate voltmeter that all capacitors have discharged.

For additional information regarding the safe discharge of

capacitors, see PROD-SVB06*-EN.

• Prior to removing the compressor, open th disconnect and place a lock on the disconnect to prevent someone else from accidentally applying power to the unit while it is under repair.

• Completely recover the refrigerant fr om the refrigerant

t being rep

circui atmosphere! Use Responsible Refrigerant Practices. If adding or removing refrigerant, the service technician must comply with all Federal, State, and local laws.

Before removing the electrical connections on the

mpressor u

co power on:

• Compressor power terminals.

• Compressor motor protection module.

• After confirming the absen electrical connections.

– Mark the electrical wires so they can

– 090–181 nominal capacity com

• Remove oil prior to compressor

– 182–361 Nomi

se a voltmeter to check for the absence of

on the same terminal on the replacement compressor to prevent improper phasing.

bl

ocks are marked: T1 is marked red, T2 is marked

blue, and T3 has no mark (see

–361 nominal capacity compressors have an

• 182 oil drain

WARNING

e unit

aired. Do not release refrigerant to the

ce of power, r

removal:

nal Capacity Compressors

valve (see

Figure 13, p. 19) that allows

emove the

be placed back

pressor terminal

Figure 21, p. 26).

Removal and Installation

oil to be drained out of the compressor. After the refrigerant has been recovered, pressurize the system with nitrogen to help remove oil from the compressor.

• If the

– 090–181 Nominal Capacity Compressors

Note: F

• Fo

• If

Tip: Befor

compressor, apply flux to the joint. This will aid in the flow of the braze material and help keep the joint clean for rebrazing. After fluxing, heat the joint evenly to slightly higher temperature than the melting temperature of the filler material. At this point, the two parts of the assembly should be easily separated.

• Refrigerant Connection Removal

– Single compressor—Cut the refrigerant lines in a

co slip couplings. Then, unbraze the line from the compressor and reuse it when the replacement is installed.

• Whe

• T

compressor is in a tandem or trio set, place a catch pa connection on the compressor to catch the oil from the oil equalizer tube or compressor when the oil equalizer tube is removed.

r 090–181 nominal capacity compressors, oil removal requires using a suction or pump device through the oil equalizer Rotolock fitting, see with clean oil prior to use.

the compressor is in a tandem set, place a catch pan unde connection fitting on the compressor to catch the oil from the compressor when the oil equalizer tube is removed. Refer to

p. 19

connection fitting.

e removing the existing tubing from the

nvenient

on the cap of the compressor with a spreader bar (see

he lifting device must be rated to handle the

weight compressor

n under the oil equalizer Rotolock

or excess oil removal, the Schrader valve in the lower part of can be used. If more oil or the complete oil charge needs to be removed, use the following procedure.

Figure 14, p. 19. Flush the suction device

r the oil equalizer Rotolock

for the location of the oil equalizer Rotolock

location that allows reassembly with

n removing the compressor use both hooks

Figure 12, p. 19).

the compressor shell

Figure 14,

as listed in

Table 4, p. 19.

There are special considerations that are unique to replacing compressors in a tandem or trio set:

1. Only replace the failed compressor.

2. On tandem or trio assemblies, the discharge lines must not be modified, except for the use of slip-joint couplings. Other modifications may cause oil return issues and lead to compressor failure. Cut the lines in a convenient place, remove the compressor, and then unbraze the lines from the compressor. On re-installation, reinstall lines to compressor and reassemble the cut lines using a slip coupling. Refer to to cut the

Tip: Before removing the existing tubing from the

3. Change oil in all compressors in the tandem or trio

mpressors whenever there is a failure.

co

a. 182–361 Nominal Capacity—Use the oil charging

b. 090–181 Nominal Capacity—Remove the oil

Important: So

discharge and suction line.

compressor, apply flux to the joint. This will aid in the flow of the braze material and help keep the joint clean for re-brazing. After fluxing, heat the joint evenly to slightly higher temperature than the melting temperature of the filler material. At this point, the two parts of the assembly should be easily separated.

lve on the compressor.

va

equalizer fitting and use a suction or pump device to remove the oil from the compressor through the oil equalizer tube opening. A suction type device should be used to remove oil from the compressor.

require a restrictor be placed in the suction inlet to balance the oil levels. Refer to unit Installation, Operation, and Maintenance manual for correct size and location of restrictor. The restrictors are packaged in a bag with a label with the part number and diameter required (see The internal diameter in millimeters is Ø31. The restrictor is also marked on the face with both the extension number, last three digits of the part number, and diameter. For the previous example, the restrictor would be marked 010-31. Without the proper restrictor installed, the compressor oil level balance will not be correct.

Figure 16, p. 20 for suggested area

me mult

part number is X17311028010 and the

iple compressor configurations

suction and

Figure 18, p. 24).

Compressor Replacement—Tandem and Trio Compressor Sets

Definitions:

• Tandem—Two compressors on a sing circuit.

• Trio—Three compressors on a single refriger circuit.

PART-SVN234B-EN 23

le refrigerant

ant

Incorrect Restrictor Size and Location!

Failure to install the correct size restrictor or in the correct position will lead to improper oil levels in the compressor. This could result in a compressor failure due to low oil level.

NOTICE

Removal and Installation

4. It will be necessary to use an oil catch pan under the oil equalizer connection to catch the oil when the connection is loosened and removed.

Figure 18. Restrictor label

Installation

WARNING

Hazardous Voltage w/Capacitors!

Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Verify with an appropriate voltmeter that all capacitors have discharged.

For additional information regarding the safe discharge of capacitors,

Hazard of Explosion and Deadly Gases!

Failure to follow all proper safe refrigerant handling practices could result in death or serious injury.  Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids.

• Only qualified personnel should install or repair refrigeration systems. If you are not qualified, seek the services of qualified personnel.

• Pressure tests must be performed by qualified

rsonnel.

pe

• T

he replacement compressor contains a nitrogen charge of 5 psig. Before opening the connections on the compresso Schrader fitting on the shell to slowly release the nitrogen charge in the compressor.

see PROD-SVB06*-EN.

WARNING

r, connect a 1/4-inch service hose to the

• Remove the suction plug before the discharge plug to avoid oil spray while opening the compressor.

• Keep exposure to the atmosphere at a minimum due to

E oil. Remove th

PO install the compressor. Plug other compressor on tandem or trio compressors.

fore removing the oil equalizer connection ca

Be

• place a can pan under the Rotolock fitting as the compressor oil level is above the Rotolock connection. Oil must be added to the compressors after installation.

a. Removal Instructions

Tip: Be

fore removing the existing tubing from the compressor, apply flux to the joint. This will aid in the flow of the braze material and help keep the joint clean for rebrazing. After fluxing, heat the joint evenly to slightly higher temperature than the melting temperature of the filler material. At this point, the two parts of the assembly should be easily separated.

b. Installation

c. Preparation:

i. For proper capillary action to occur, the tube and

e fitting must be free of oil, grease, burrs, and

th

oxide contamination. To remove the oil and

grease a commercial solvent or denatured

alcohol can be used. The surface may be

properly cleaned by brushing with a stainless

shell brush or by a stiff rubbing with emery clo th.

Wipe the joint clean to remove small foreign

particles such as emery dust, by wiping the

surface with a clean cloth. Once the surfaces are

clean, be careful not to touch them as oil from

the skin will contaminate the surfaces.

ii. Pre-fit the existing tubing into

check that it has full insertion into the

compressor fitting. For compressors that have a

suction restrictor located in the suction inlet,

ensure that the tube is inserted completely such

that the suction restrictor fits tightly against the

end of the compressor suction connection.

iii. Apply flux with a brush

compressor connecting tubing, taking care to

evenly apply the flux around the entire diameter.

Care must also be taken not to get the flux inside

of the tubing as this may result in contamination

of the refrigerant system.

iv. Reinsert the tube into the

connection. If the tubing does not stay fully

in ser ted , it mu st be rest rai ned t o prev ent it fro m

backing out of the compressor connection

during the brazing process.

d. Brazing Technique

i. If possible, use a double-side torch while

zing.

bra

e rubber plugs only when ready to

,

p

the compressor to

to the outside of the

compressor

24 PART-SVN234B-EN

Removal and Installation

2

ii. Use 40% silver brazing alloy with flux.

iii. Start heating the tube first. Evenly heat th

location 1 (see red color. Wh good indicator of when the proper brazing temperature has been reached. Continue heating the tube until the flux passes the “bubbling” temperature range and becomes quiet, completely fluid, and transparent—it should have the appearance of clear water.

iv. Direct the flame from the tube to the fitting,

enly heating it until the flux that may be

ev remaining in the fitting is also completely fluid.

v. Sweep the torch between the

tube, locations 1 and 2 (see mo

st of the heat being applied to the heavier and slower-heating fitting until the tube and fitting reach and maintain a uniform heat in both parts.

Figure 19. Brazing locations 1 and 2

vi. Pull the flame slightly back and feed the brazing

aterial in between the fitting and the tube. If

m the joint has been properly heated, the braze material should flow around and into the joint.

Important: The he

filler; the heat from the torch flame should not be what melts the filler.

vii.Once the braze material has flowed around and

the joint, briefly move the torch

into fitting to ensure complete capillary action into the joint.

viii.Check the joint to visually ensure that the braze

material is

e. Post-Braze

Figure 19), until it reaches a dull

en using flux, this color is also a

fitting and the

Figure 19), with

ated base metal should melt the

completely around

the joint.

NOTICE

e tube,

around the

Installation, Operation, and Maintenance manual for proper size and location of the restrictor.

• When brazing refrigerant connections, protect mpressor b

co damage.

• When brazing, always use a nitrogen purge to prevent

the formation of copper oxide contamination that can damage the compressor.

• The 182–361 nominal capacity compressor has

internal check valve. When pressurizing the system, it is important to never allow the low-side pressure to exceed the high-side pressure by more than 5 bar (72 psig). Such a pressure differential could result in compressor over a two-minute time period to allow sufficient time for the internal pressures in the compressor to equalize.

ody and terminal box from torch heat

an

damage. Also, slowly rai

se the pressure

Electrical Connections

WARNING

Hazard of Explosion and Deadly Gases!

Failure to follow all proper safe refrigerant handling practices could result in death or serious injury.  Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids.

NOTICE

Clean Flux From Joint!

Flux is corrosive and could lead to long-term problems and equipment damage if not properly removed. Quench the joint with water or a wet rag while the joint is still hot—but below 900°F—to shock off the flux. If not cleaned off, flux could hide leaks.

• Tandem (two compressors) and trio c (three compressors) with uneven compressor combinations requires the use of restrictor(s) to balance the oil level in the compressor. Refer to unit

PART-SVN234B-EN 25

ombinations

Removal and Installation

BROWN

BLUE

BLACK

L1

M2

L3

L2

M1S2S1NL

L1

L3

L2

A

C

B

L1 L3L2

M2M1NL POWER SUPPLY

MODULE INPUT

VOLTAGE

CONTROL

CIRCUIT

PHASING TO BE CONNECTED AS SHOWN TO PREVENT REVERSE ROTATION

Blue dot

indicating T2

(Phase B)

Red dot

indicating T1

(Phase A)

Unmarked

T3

(Phase C)

182–361 Nominal Capacity

Before removing wires, mark them so that they can be

• put back on the same terminal when the new compressor is installed.

• Ensure that the compressor model terminals are installed on the correct terminals (see

• If the compressor is not wired properly, it wi within five seconds.

• Proper torque for the terminal screws is 25 in·lb.

Note: Wh

• Before st

en equipped with terminal stud with a nut,

torque the nut to 30 ±

2 in·lb.

arting the compressor

phasing with a phase sequence meter similar to an Ideal-Sperry Model 61-520.

Figure 20. 182–361 nominal capacity wiring diagram

Figure 20).

, ch

eck the electrical

ll shut of

Figure 21. 090–181 nominal capacity wiring diagram

f

• Ensure that the compressor model terminals are installed on the correct terminals (see

• Proper torque for the terminal screws is 25 in·lb.

Note: When

equipped with terminal stud with a nut,

torque the nut to 30 ± 2 in·lb.

Figure 21).

NOTICE

Improper Power Phasing!

Operating the compressor with improper phasing could

090–181 Nominal Capacity

The terminal blocks are marked with red and blue dots for phase identification. Compressor terminal T1 is red, compressor terminal T2 is blue, and compressor terminal T3 is unmarked. Depending on the unit type, several methods of marking the wires may be used, colored wires, wire color marks on the wire or wire numbers to indicated the proper location of the wire on the compressor terminal block.

If the wires are not marked, ensure that you mark them

rior to removing them so that they can be reinstalled in

p the same position.

26 PART-SVN234B-EN

cause compressor failure. Check phasing before starting compressor.

•

Before starting the compressor, check the electrical phasing with a phase sequence meter similar to an Ideal-Sperry Model 61-520.

Leak Detection

WARNING

Hazard of Explosion!

Failure to follow instructions below could result in death or serious injury or equipment or property-only damage. Use only dry nitrogen with a pressure regulator for pressurizing unit. Do not use acetylene, oxygen or compressed air or mixtures containing them for pressure testing. Do not use mixtures of a hydrogen containing refrigerant and air above atmospheric pressure for pressure testing as they may become flammable and could result in an explosion. Refrigerant, when used as a trace gas should only be mixed with dry nitrogen for pressurizing units.

Removal and Installation

WARNING

Hazardous Pressures!

Failure to properly regulate pressure could result in a violent explosion, which could result in death or serious injury or equipment or property-only-damage. When using dry nitrogen cylinders for pressurizing units for leak testing, always provide a pressure regulator on the cylinder to prevent excessively high unit pressures. Never pressurize unit above the maximum recommended unit test pressure as specified in applicable unit literature. See maximum recommended unit test pressure below.

Pressure Testing

• Use industry-standard and EPA-accepted techniques for testing.

• Pressure tests must be performed by qualified

rsonnel.

pe

• U

se tools especially designed for

• Do not exceed the high-side and low-side pressures listed on th

• If no test pressure value is listed on the nameplate of the unit, a pressure acceptable.

e unit nameplate.

of no more than 150 psig is

leak testing.

NOTICE

Overpressure Damage!

Failure to follow these instructions could result in compressor damage. Do not pressurize the low side of the compressor by more than 5 bar (72 psig) higher than the high side of the compressor within less than two minutes.

• The 182–361 nominal capacity compressor has an in

ternal check valve. When pressurizing the system, it is important to never allow the low side pressure to exceed the high side pressure by more than 5 bar (72 psig). Greater pressure differen compressor damage. Also slowly raise the pressure over a 2-minute time period to allow sufficient time for internal pressures in the compressor to equalize.

• Pressure decay testing can be used to check for gross leaks but

• After pressurizing the system use an R-410A leak detection devi

will not be able to detect the l

ce to detect and locate leaks.

tial could result in

ocation of a leak.

WARNING

Hazardous Voltage w/Capacitors!

Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Verify with an appropriate voltmeter that all capacitors have discharged.

For additional information regarding the safe discharge of

capacitors, see PROD-SVB06*-EN.

NOTICE

Compressor Motor Damage!

Failure to follow instructions below could cause compressor motor damage. Never use the compressor as a vacuum pump. Never meg-ohm test or apply power to the compressor while it is in a vacuum.

• Ensure that there is no voltage being applied to the compressor terminals.

• Evacuate the unit to 500 microns.

• Hold vacuum for 30 minutes.

• Rapid pressure rise indicates a the leak.

• Slow pressure rise indicates on

– A small leak, indicated by a continuous rise in

pressure.

– Moisture in the system, indicated by

pressure and leveling-out at a pressure equivalent to the moisture level. If this occurs, break the vacuum with dry nitrogen and repeat evacuation process to 500 micron.

• Once system is leak-tight, connect compressor re the vacuum procedure, break vacuum with dry nitrogen and evacuate to 500 microns. The vacuum should be able to be maintained for four hours. Isolate the vacuum reads the system pressure.

• Vacuum must be measured in the refrigeration system and n

pump so that the vacuum gauge only

ot at the vacuum pump.

leak; locate and repair

e of two possibilities:

a slow rise in

peat

Vacuum Testing and Evacuation

• Use the procedure as described in the unit

Operation, and Maintenance

• If no other information is available, use the following information.

PART-SVN234B-EN 27

manual.

Installation,

Removal and Installation

Charging the System

WARNING

Hazardous Pressures!

Failure to follow safety precautions below could result in a sudden rise of pressure possibly resulting in a violent explosion which could result in death or serious injury. If a heat source is required to raise the tank pressure during removal of refrigerant from cylinders, use only warm water or heat blankets to raise the tank temperature. Do not exceed a temperature of 150°F. Do not, under any circumstances apply direct flame to any portion of the cylinder.

Use R-410A refrigerant only! Follow the instructions in the un

Installation, Operation, and Maintenance manual for

it

proper charging methods.

If there are no instructions available, use

• Evacuate the unit as described in

Evacuation,” p. 27

• Ensure that the oil level is at least 1/2-sight glass in the compressor

• Do not use the compressor to pull refrigerant into the system.

• Charge liquid refrigerant into unit—either into the condenser or liquid receiver, if so eq

uipped.

• Charge as much of the unit refrigerant charge as possible before

• Do not charge liquid refrigerant into the low side of the compressor without the compressor runn amounts of liquid may be metered through refrigerant gauges into the suction line while the compressor is operating.

• If the unit is equipped with suction and discharge

ice valves, close them du

serv procedure.

Water chi

• pumps while charging the unit to prevent freezing the evaporator.

ller units

.

starting the compressor.

—Alw

ays operate the chilled water

these guid

“Vacuum Testing and

the high-side of the

ring the charging

elines:

ing. Small

NOTICE

Improper Crankcase Heater Operation! Exception to 8-hour Minimum Crankcase Heater Operation Time!

Failure to follow this instruction could result in a compressor failure. Apply power to the crankcase heater for a minimum of 8 hours prior to startup of the compressor!

If the compressor is a replace and has been charged in accordance with either the procedures in the unit IOM or

p. 28

in this manual, the compressor could be immediately started after charging the system. Th that the refrigerant has not had sufficient time to migrate to the compressor and cause potential damage upon startup. The system should set for no more 8 hours or overnight h

eater operation. If the time exceeds 8 hours or the unit sits overnight, the crankcase heater must be operational for a minimum of 8 hours prior to starting the compressor.

If liquid refrigerant was charg side during the charging procedure, damage could still occur.

with a refrigerant charge without crankcase

ment for a failed co

“Charging the System,”

e reason for this is

ed into the suction or low

mpressor

Verification Before Start-Up

Follow the instructions in the unit

and Maintenance

available, use these guidelines:

•

Before starting the unit, verify that all service valves open.

• Energize the crankcase he before starting the compressor

28 PART-SVN234B-EN

manual. If there are no instructions

Installation, Operation,

ater a mi

nimum of 8 hours

are

Startup

Follow the instructions in the unit Installation, Operation, and Maintenance

available, use these guidelines:

Equipment Damage!

Failure to follow guidelines below could result in equipment damage.

• Never start the compressor without refrigerant in the system.

Never bypass the low pressure switch to start the unit.

•

• Monitor oil level for 60 minutes to ensure that oil returns from the system.

• Check system pressures and tempe the y are in line with unit design pressures. Refer to the unit

Installation, Operation, and Maintenance manual

for this information.

• To top off the unit, charge liquid refrigerant may added

slowly thr

by done only when the compressor is operating.

• Do not overcharge the unit.

• Recommended system full load superheats—unless

ecified differently in the unit

sp

and Maintenance

•Measure the oil sump superheat. Oil sump superheat should be g calculated as follows:

Oil Sump Superheat = Oil Sump Temperature – Saturated Suction

• Measure thermocouple on the bottom of the compressor,

eferably in the center, and insulate it. Calculate sump

pr superheat. If less than 20°F, recheck the expansion valve superheat and increase it. Low sump superheat is indicated by foaming compressor oil.

• After fully charging the unit, recheck all pressure,

eratures, and electrical readings.

temp

• Ensure that the compressor protection module and power supply wires are installed on the correct terminals (see

• Proper torque for the terminal screws is 25 in·lb.

Note: Wh

manual. If there are no instructions

NOTICE

ratures to ensure

ottling it into the suction line. Th is must be

Installation, Operation,

manual—is 16°F–20°F.

reater than 20°F. Oil sump superheat is

Temperature

the oil sump temperature by placing a

Figure 20, p. 26 and Figure 21, p. 26).

en equipped with terminal stud with a nut,

torque the nut to 30 ± 2 in·lb.

PART-SVN234B-EN 29

Maintenance

Check the unit Installation, Operation, and Maintenance manual for specific instructions.

Operating conditions must always remain within the operating ran

• Operating pressures (suction and discharge pressure).

• Operating temperatures (suction, discharge, and

quid).

li

• Operating parameters (compressor superheat, subcooling amperage).

• Check all of the following on a regular basis:

– System operating conditions.

– System refrigerant charge level.

– Oil levels and oil color.

Hazardous Voltage w/Capacitors!

Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Verify with an appropriate voltmeter that all capacitors have discharged.

For additional information regarding the safe discharge of capacitors,

ge of the compressor. This includes:

, oil sump superheat, voltage, and

WARNING

see PROD-SVB06*-EN.

• Check electrical season).

• C

heck unit operating controls.

30 PART-SVN234B-EN

connections (prior to startup each

Troubleshooting

Important: Check the unit Installation, Operation, and

Maintenance

information regarding diagnosis and causes.

manual for additional

WARNING

Hazardous Service Procedures!

Failure to follow all precautions in this manual and on the tags, stickers, and labels could result in death or serious injury. Technicians, in order to protect themselves from p

otential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the following instructions: Unless specified otherwise, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks.

Compressor will not start

• Refer to the unit

Maintenance

and corrective action.

• Verify:

– Compressor voltage is correct.

82–361 nominal capacity compressors

1

–

protection module is the correct voltage.

– All safety switches are closed.

– All the contacts on the contactor are pulled in.

90–181 nominal capacity compressors

–

0

internal motor overloads may be open. Disconnect power to the unit and disconnect the wires from the compressor terminals. With an ohm meter, check to ensure that there is resistance between T1-T2 and T3.

Compressor will not build up pressure

• 090–181 nominal capacity compressor is wired incorrectly

amps. Shut the compressor off immediately. Running in this condition for more than 5 seconds may damage the compressor.

–361 nominal capacity compressor is wired

•

182 incorrectly

• Check to ensure that any bypass valves in the system are not open.

• Four-way reversing valve may be stuck and not switched properl

Installation, Operation, and

manual for possible diagnostics codes

—Moto

—The

—It will be noisy and draw 1/2 the expected

.

y bypassing from the high side to the

r

low side of the system; this situation is indicated by an extremely warm suction inlet to the compressor.

60–361 nominal capacity compressors contain an

•

3 internal pressure relief that may have opened.

take two to three hours to reset. The oil sump will be very warm and the compressor will be trippe the motor protection module. This is caused by a very high 625–715 psid difference between the high side

w side of the system. This could occur with either

and lo a blocked high side or low side.

It may

d out on

Abnormal running noise

• Compressor is running backwards—Immediately shut off the compressor and check wiring and proper phasing.

• Excessive floodback—The superheat should be a minimum should be at least 20°F above the saturated suction temperature. Measure the sump temperature at the bottom center of the compressor. Chillers with electronic expansion valves may operate with lower superheats; check the unit

Maintenance

• Compressor is full of liquid on st heater eith eight hours, or it is defective.

• Mechanical damage to the compressor has occurred— Check compressor motor protection module or other unit electrical protection devices such as circuit breakers.

of 16°F at full load and oil sump temperature

Installation, Operation, and

manual for proper operating superheats.

artup—The crankcase

er was not energized for a minimum of

compressor amperage. It may also trip the

High-pressure control opens

• Check the unit

Maintenance

and corrective action.

• Also check for:

– Defective condenser fan motors or controls.

– Dirty air-cooled or wate

– Restricted air flow.

– Insufficient water flow.

– System overcharged with refrigerant. Check

superheat

– Non-condensables in the system.

Installation, Operation, and

manual for possible diagnostics codes

d condensers.

r-coole

and system subcooling.

Low-pressure control opens

• Check the unit

Maintenance

and corrective action.

• Also check for:

– Defective evaporator fan motors, belts, or controls.

– Defective TXV valve.

– Plugged liquid line filter.

Installation, Operation, and

manual for possible diagnostics codes

PART-SVN234B-EN 31

Troubleshooting

– Liquid line solenoid valve does not open (if so

equipped).

– Dirty evaporators, either air-to-air or water-to-air.

– Restricted airflow.

– Insufficient evaporator water flow.

– System undercharged with refrigerant. Check

em superheat and subcooling.

syst

Compressor short cycling

• Check the unit

Maintenance

and corrective action.

• Also check for:

– Defective unit controls—maximum 12 starts per

r.

hou

– Compressors cycling on safety controls.

– Unit oversized.

– Building load is light—this is likely to occur

building occupancy

Installation, Operation, and

manual for possible diagnostics codes

ior to

pr

.

Motor protector module resets

• Type: Manual

Fault modes:

– Phase sequence

– Phase loss

– Multiple motor temperature overload cycles.

Reset—Remove power from mo

• Type: Auto with five-minute 4500 ohms)

Fault modes:

– Over current

– Running phase loss

– Motor over temperature (manual reset required

fter 2-5 auto reset cycles)

a

Reset—Auto-reset

ors resistance drops below 2750 ohms. Although

sens module will reset automatically the compressor(s) may not because the protection module may be wired in a safety lockout circuit.

occurs when motor temperature

dule for five sec

delay (sensors exceed

onds.

Incorrect phase sequence

Incorrect phase sequence protection—compressor will run approximately five seconds and trip off, pending the motor protection module is correctly wired into the system safety circuit. If the motor is believed to be incorrectly phased; change two of the three wires.

PTC Overheat (motor over temperature/over current)

• Compressor motor drawing too much current.

• Defective compressor; look for dark oil in sightglass.

• Low voltage (voltage outside the nominal voltage); voltage utilization range is printed on compressor nameplate.

• Unbalanced voltage—must not exceed 2% imbalance.

• Motor PTC thermistor resistance above 4500 ohms will cause the motor protector to open. The motor protector will reset at resistance below 2750 ohms. A five-minute time delay is active after cool down until the maximum number of auto reset cycles has been reached. The module will then be locked out until it is manually reset.

±

the

10% range from

NOTICE

Excessive Voltage on PTC Sensors!

Failure to follow these instructions could cause thermistor failure, resulting in a compressor replacement. Do not measure the motor PTC sensors with a device rated at more than 3 Vdc.

• When measuring the PTC sensors, do not use a meter with gr

eater than 3 Volt.

360–361 nominal capacity compressor

• valve has opened.

• Phase loss.

• Defective contactor.

• Loose or poor electrical co or contactor.

nnections at the compressor

internal relief

182–361 Nominal Capacity Compressor Motor Protection Module Diagnosis

WARNING

Hazardous Service Procedures!

Failure to follow all precautions in this manual and on the tags, stickers, and labels could result in death or serious injury. Technicians, in order to protect themselves from p

otential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the following instructions: Unless specified otherwise, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks.

If M1-M2 contacts are open, proceed as follows:

1. Check motor protection module for the correct input oltage on terminals L and N. Voltage applied to

v

32 PART-SVN234B-EN

module must match module input voltage as printed on module nameplate.

2. Check wire connection tightness.

3. Try to reset the module (i five seconds).

4. If, after reset, module M1-M2 closes, determine which fault caused module to tri

5. If M1-M2 remains open, proceed as follows:

Disconnect PTC thermistors from S1and S2 terminals,

d measure the resistance of the PTC using a device

an with a maximum output of 3 volts.

• Resistance = ∞.

Open PTC open; replace compressor.

• Resistance = 0 ohms

PTC shorted; replace compressor.

• Resistance >2750 ohm

Wait until the motor has cooled down and

nce is less than 2750 ohms; reconnect and

resista try to reset motor protector. Diagnose problem that caused motor over temperature.

• Resistance = 150 ohms < R< 1250 ohms

Normal resistance value for PTC ambient

emperature.

t

nterrupt power for

p.

Troubleshooting

Test the module within the terminal box

1. Disconnect L-N voltage supply.

2. Disconnect S1-S2 PTC circuit on the module.

3. Disconnect M1-M2 safety circ

4. Apply a resistance between 150 and 1250 ohms across S1-S2. This simu

5. Reconnect L-N voltage supply. Ensure that the voltage

L-N has been disabled for at least 5 seconds. This

to will reset the module.

6. Check M1-M2 with ohmmeter.

7. M1-M2 closed—Module okay.

8. M1-M2 open—Module defective.

lates a functional, cool motor.

uit control contacts.

PART-SVN234B-EN 33

Log Sheet

Replacement Scroll Compressors

Complete and retain a record in the job file for future reference.

Log Sheet for Installers

Job Name:

Job Address:

Equipment Model Number:

Equipment Serial Number:

Compressor Model Number:

Compressor Serial Number:

Startup Date:

Table 5. System operating data

Refrigeration Data Circuit 1 Circuit 2 Circuit 3 Circuit 4

Suction Pressure/Saturation Temp

Suction Line Temperature

Suction Superheat (2-1)

Discharge Pressure

Discharge Line Temp

Liquid Line Pressure/Saturation Temp

Liquid Line Temp

Liquid Subcooling (6-7)

Table 6. Electrical data

Unit Voltage L1-L2 L2-L3 L1-L3

Table 7. Compressor Amperage

Compressor #1 #2 #3 #4 #5 #6 #7 #8

T1 amps

T2 amps

T3 amps

Compressor Model 8 Digit Number

Table 8. Oil sight glass (when available)

Compressor #1 #2 #3 #4 #5 #6 #7 #8

Level

Condition

M=Manifold/S=Single

Compressor Model 8 Digit Number

34 PART-SVN234B-EN

Table 9. Condenser

Type Air Cooled Water Cooled

Entering Temperature

Leaving Temperature

Ambient Not Applicable

Number of Fans ON

Clean (Yes/No)

Not Applicable

Table 10. Evaporator

Type DX-Air DX-Water

Entering Temperature

Leaving Temperature

CFM/GPM

Clean (Yes/No)

Chiller pressure drop Not Applicable

Systems Check

Suction Line Filter Drier Installed



Pressure Drop After 1 Hour:



PSIG After 4 Hours:



Liquid Line Filter Changed



Oil Changed



Acid Check



If System Includes Liquid Line Solenoid, Verify Proper Opening/Closing



Log Sheet

Operating Controls Check

Low Pressure Control



High Pressure Control



Contactor



Replaced



Checked



Verify Proper Cycling of Unit Via Temperature Controls



Observations

Service Technician: Date:

PART-SVN234B-EN 35

Trane - by Trane Technologies (NYSE: TT), a global climate innovator - creates comfortable, energy efficient indoor environments for commercial and residential applications. For more information, please visit trane.com or tranetechnologies.com.

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

PART-SVN234B-EN 17 Aug 2020

Supersedes PART-SVN234A-EN (Jan 2017)

Trane Start to Finish R-410A Installation Manual

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Frequently Asked Questions

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