& rene General RTAA-SB-4 Service Bulletin ay ‘Service Literature Product Section Refrigeration Product Rotary Liquid Chillers - A/C Medel RTAA irate Tae General Service Bulicti Sequence 4 te SO™C™~™OCOSSSSSSSSCCC tbr 1997 Fie Ne. RLC-RTAA-SB-4-1091 Supersedes Subject: Slide Valve Operation and Troubleshooting Int : Tho purpose of this bulletin is to provide information that is required to troubleshoot the slide valve operator on CHHB compressors, Discussion: The Air Cooled Series R Chiller (ATAA) is designed with 2, 3, or 4 compressors, that include modulating slide valves, that vary the capacity of the compressor. ‘The slide valve is operated by a piston/cylinder assembly. The piston/cylinder assembly is powered by oil pressure that is regulated by two “normally closed” solenoid valves. These valves are called the load and unioad solenoia valves (Note: The load solenoid valve is mounted closest to the compressor motor). he coll on each solenold valve is 110 VAC. Reference Figure 1, to view a schematic of the side valve hydraulic systemFigure 1 ‘Typical Slide Valve Hydraulic System | To From Compressur oi Suction Supply | | Unloading Loading | Solenoid Valve Solenoid Valve | Slide Vatve Piston Slide Valve | | Schrader Valve Shoft PistonsCy linger Assembly Access Slide Valve Load VILLI LT. KLE LLL ELA | | | | | Compressor l Roter The microprocessor contiols uperate the load and unload solenoid valves, in response to varying demands for ‘capacity. On an increase demand for capacity, the load solenoid valve is energized (pulsing 110 volts); allowing o8 [Proesure to onter tho piston/oylindor section, moving tho piston, which moves the slide valve via the elide valve shaft ‘over the campressar rotors, and laads the camprassar. (Ona decrease demand for capacity, the unload solenoid valve is eneraized (pulsing or constant 110 VAC, which is, dopondent on the mode of the microprocessor controls), which roliovos the oll procsuro that was built up in the piston/eylinder section, retracting the piston, which pulls the slide valve via the slide valve shaft away fram the rotors, and unloads the compressor. ‘Ona hold demand for eapacity, both the load and unload solenoid valves remain deenergized, which maintains the positon of the piston and slide valve. Why Boos The Slide Valve Move? “There are four forces that act upon the elide valve/picton accombly. Soo Figure 2.Figure 2 ‘Typical Slide Valve/Piston Assembly Piston Locd | et Im Siice Varve Regulated Pressure | | | | “BPeesure Beery pic CO Discharge LLY OLLLLELES A - Slide Valve-Suction Pressure 8 - Slide Valve-Discharge Pressure - Piston-Discharge Pressure D - Piston-Regulated Pressure For example, ithe piston or shaft were not attached to the slide valve, the discharge pressure and suction pressure, present at either end of the slide valve, will force the elide valve over the rotors, and load up the comprossor. However, mere Is a piston connected to a slide valve via @ slide valve shaft. The piston provides more surface aroa, than the slide valve ends. The discharge pressure and suction pressure present at both ends of the piston, will force the piston to overcome the slide valve movement in the opposite direction, thus, pulling the slide valve away from the rotors and unload the compressor. ‘Toload and modulate the compressor, oll preesure is added and subtracted via load and unload solenaid valves to the cylinder side of the piston. This pressure balances the other 3 forces, and allows positioning of the slide valve ‘over the rotors, to obtain varying degrees of compressor capacity. Tro ting Slide tion il pressure supply to the load solenoid valve is tapped frum the bearing and rotor injection oil supply line. Dus to pressure drop of the of cooler, angle valve, oi fiter, master solenoid valve, etc, the oll prossuro cupply to the load Solenuid valve will be approximately 20 - 30 PSIG below compressor refrigerant discharge pressure. “The Schraeder valve Is mounted on the discharge end ofthe compressor, See Figure3. Oil prescureat the Schrasder valve is not proportional to the position of the slide valve, however, tho ol prossure will be whataver it takes to hold the slide valve at a given position. Tho wiring to the microprocessor, from the load and unload solenoid valve coi, ‘can be removed or jumpered to maintain 2 constant position af the valves. to prove the operation of the slide valve,Figure 3 Schraeder Valve Location on Compressor Discharge End Unload Solenoid Valve Load Solennid Valve Piston/Cylinder Assembly Access Schraeder Valve | The following tasts assume the cloctrical circuits to the load/unload solencid valve coils are curect and operative. ‘An aurtibie “click” can be heard when the vaive is energized, and the magnetism created by an energized coil will attract the tip of a pocket screwdriver. Insure the valves are electrically correct before procooding, Load and Unload Solen: A. Connect a gauge to the piston/cylinder access Schraedar valve and start compressor. R_ Apply constant power to load solenoid valve coll. Leave unload solenoid valve coil attached to microprocessor Pressure shauid rise to within 20.20 PSIG of condenser pressure, provided microprocessor docs not energize unloed solenoid valve, due to a limit or temperature canta. I pressure fails ta rise, suspect one of the following: 1. Clogged oi fiter 2. Plugged load solenoid valve 3. Leaking unload solenoid valve (verify there is no signal from controls to be eneraized). @C. Disconnect power from both solenoid valve colls. Pressure should maintain. if pressure drons, suspect a leaking load solenoid valve. D. Energize unioad solenoid valve, until pressure drops to about halfway between suction and condenser pressures. then insure that power is not applied to both valves. Pressure should maintain. If pressure rises, suspect a leaking pad solenoid valve. If pressure drops, suspect a leaking unload solenoid valve E. Put constant power to unload solenoid valve coll. Disconnect power to load solenoid valve coil. Pressure should drop to suction pressure, it pressure does not drop, suspect a plugged unload solenoid valve. If either a leaking load or unload solenoid valve is suspected of a problem, a piece of shimstock can be placed ‘between the valve and the gasket, sealing off the ports of the valve. This will essentially isolate the valve from the ‘system, to confirm diagnosis of a leaking solenoid vaive, either a plugged load or unload solenoid valve is suspected, replacement of valve is required to confirm diagnosis, Slide Valve Movement Ifthe load/unload solenoid valves operate property, but the compressor motor amperage fails to rise, oF fal, in response to commands from the oad/unload solenoid valves, the slide valve piston could be hesitantto move. This, usually happens when the compressor is first put nto service, and the rings on the piston have not been “broke-in” yet To move slide valve, perform the following sequence: 1 The discharge pressure can be increased to acquire more pressure to move the slide valve. Disconnect wiring to several condenser fan motor contactor coils, in order to achieve 350-370 PSIG condenser pressure. Typically, this will provide sufficient power to move a “hesitant” slide valve piston. 2+ Ifthe slide valve is stil falling to move, an extra 20-0 PSIG that is lost, via the oil cooler circuit, can be acquired by deenergizing the load solenoid valve, and temporarily connect a refrigerant service gauge set, between the compressor refrigerant discharge Schraeder valve and the Schraeder valve for the pistan/cylinder assembly. The valve on the gauge set can be used to simulate the toad solenold valve. 3. Ifthe slide valve stil fails to move, access to the top of the piston can be gained, through the Schraeder valve piston/cylinder access port, by using the folowing procedure: [A Isolate compressor via compressor suction and discharge service valves B, Relieve pressure on compressor down to 2 PSIG. C. Remove complete piston/cylinder access Schraeder valve. (Note: The threads on this valve is sealed with loctite Care must be taken to not damage, or break valve off when removing) D. Insert a smooth rod (to prevent damage to pipe threads), that has a diameter of no more than 5/16" (.e..Philips screwdriver) If slide valve is in the unloaded positon, insert the rod (approximately 3/4) to make contact with the piston. Next, push on the piston and the slide valve should move to the loaded position. Table 1 lists the stroke lengths of the various compressors and slide valves. A slight tap with a hammer may be required to get the piston moving,Table 1 le Valve Stroke Lengths ‘Compressor Slide Valve Stoke Length | CHHB 070 inches e@ CHHB OBS | ‘3.25 inches CHHB 10u ‘3 inches E. Toretum the piston to the unloaded position, add pressure to the compressor, via the suction service valve. This pressure wil be on the back side of te piston, thus, causing hs movement back to the unloaded postion. ‘ F. Repeat steps D adn E to insure ree movement of slide valve/piston assembly. G. Evacuate any portion of the compressor that non-condensibles may have entered. H. Open service valves and put compressor back into operation. JH