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    Dunham-Bush 127 series

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    Dunham-bush 127 Series

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    Dunham-Bush 127 series

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    110 views23 pages

    Dunham-Bush 127 Series

    Uploaded by

    Baltik2672
    Dunham-Bush 127 series

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 23
    MSC-127 Series tion, Operation ee Te met ate INTRODUCTION “To ensure satisfactory operation and to avoid costly damage to the compressor, the instalation, pro-stat checkup and star-up, as welt as maintenance, must be done by a service person who is qualified end authorized by the orginal equipment manvfacturer Start-up documentation must be provided for naw and replacement compressors at time of Installation, in order to validate the warranty Ris not the intent of this manual to give complete compressor specifcations, but ony to provide information necessary to quard against some common installation and operation problems. Oniy in regard to specttc ‘warnings and cautons wil this manual take precedence over instruction supplied by the manufacturer of the Package equipment. TABLE OF CONTENTS |. GENERAL INFORMATION ‘A. Compressor Outline Drawings B. Model Nomenclature... . Approved Refrigerants and Oi E - Oil Kare®s Program ‘Compressor Weights I INSTALLATION Receiving Inspection eee 5 ‘Compressor Storage 5 Piping Connections non 3 Liquid Injection Couns oo mE 6 Evacuation and Behan fotuninsnsenna I 9 Electrical oo sea 8 6 7 Vapor Injection System Cleaning rommpom> ‘OPERATION Operating Limits - a Gyaling tims I Ol Level... : Capacity Control Suction itor moom> W. TROUBLESHOOTING High Discharge Temperature ~ Motor Tripping on Thermal Protection ‘Low Discharge Superheat .... oo Compressor Tnpping on Low Oi Level ‘Compressor Will Net Restart Unloader Not Operating Correctly... : ‘Compressor Motor is Suspected to be Damaged 2 2 wet mat emmeoo> I. GENERAL INFORMATION Figure 1. Compressor Outline Drawing (in Inches unless specified) SEE wid ! nex wow ron | neo Ss Reine se Table 1. Comprossor Dimensions in inches (mm) Wodoe [A Tete, of e©yr]e¢fulstT«tttwt[w qonizia | 434] 198 | 20] 131 | 43 | a) a2 39 ae pas | | ay | 102) | (502) | (08) | 332) | (364) | (366) | (10) | 99) | 116) | oH | ar | a2 | 09. qareKADeK | 473 | 218 | 40 | 142] 153] 165] 48 | 43] 52 | 481%. | ye | th 1200) | (955) | (956) | oot) | (gem) | e419) | cra) | (108) | (132) | 22) i Los | |. GENERAL INFORMATION 8, MODEL NOMENCLATURE —*—7 sma] wetop 1521.50 ois Ye='a0 ‘COMPRESSOR TYPE. Wwone. 0 seat 4. CF =< vous Swe a) vous one | poses vei — FIGURE 3. Nameplate 12 15 NH F 6 W 4 K OEM BJ t commas votTasE comesuso Soe-soee ‘START METHOD 0= Doub Does 360 26N« Ong Equipment fir Rorenuitne ‘SOMPRESSOR VERON = Comet Veron morons 4s rdersead yt sep Nomnat 52 Ovemsudy 1sap snuEcTON Mone Nore {watrcelas) Ue feet (a cates) Lui Ifecon & Vapor ryocton We Vapor tyecton (ator noid) "For special engineered compressor, the indicated orton ofthe made! numbars replaced by the "SE. amber” Example: 111396127 1KOEMBJOC |. GENERAL INFORMATION ‘G. APPROVED REFRIGERANTS AND Ol, 1. Refigerants: R22, R407C, RAOAA, R507, and R134a are approved for use in ths compressor. For refigerant conversions contact the Hartlord Compressors Application Engineering Department. 2. Reltigerant Os: Several readily avaliable refigerant ols have been approved. The compressor is ‘Shipped with a charge of 88 ISO (300 SUS or 68 ISO) mineral refigerant oll except for R134a (NHL) ‘models uniess otherwise specified ‘Note: Synthetic ols are required for R134a, RAO7C, R4O4A, R507 and special applications. Consult Hartford ‘Comprossors Appication Engineering. Waring: Use only Hartford Compressors approved refigeration oll, Warranty will be void if oherol!is used, sted by compressor size in Table 2. Table 2. Approximate Oll Charge MODEL | U.S, GALLONS | LITERS 210K 89) 373. aa ao. 235. 1215 12.0 452 1Z16K mi a3 DOI. KARES PROGRAM Hartford Compressors recommends that an oll sample be takon from each comoressor four times per year for ‘annual operation and three times per yaar on seasonal operation such as a-conditioning. The samples are ent to a testing lab for analysis of wear metal concentration, contaminants, moisture, acd and viscosty. More sgnifcant than the actual valuas obtained in any given ol tes are the changes noted as the hours of service on the ol Increase. Hartford Compressors! OlL KARE® kit FOS3498A\. 5, COMPRESSOR WEIGHTS “Tha approximate weights for hermetic compressors are isted by model number in Table 3. For Nlanged ‘compressors, add 1701. (77 Kg} fr 1210/1212 models nd 200 Ib, (91 kg} for 1215/4218 models to the woights sted below. Tabla 4. Hormodc Comprossor Weights (uncratod) MODEL KG, ‘MODEL is [KG TZIONHFSXEK 458 THSNHFEXEK | 1265_| 575 2IONHFeWaK | 968 | ~440 TaisNHFeWaK | 1225 | S57 "pronbrewaK | 948 [431 TztgNHF6WwaK [1205 | 548, *121ONHLBVSK | 867" | 304" “ar5uHusvs< | 1109" | 04" A2TONLFaVsK | 980__| 450 ‘12TSNLFBVEK| 1250 | 568) ‘2t0NUFEvsK | 990 —|450. T216NUFevsK_|~1250__| 588. ‘satanHeexex [1020 | 454 ‘s21enHrexex_| 1260 | 573 TzIONHFewaK | 953 | ~a47 a21eNHFeWaK | 1230 | 559 “‘RIONHFEWaK | 963 | aaa] [a2tenrFewax | 1214 | 652 “D1ONHLBVEK | 684" | 402° ‘ratennevsx [120° | S09" ‘2taNLFeveK | 1002 |— 455 weianurevex | 1002 | 455] «compressor shipped iess olf Il. INSTALLATION ‘A. RECEIVING INSPECTION ‘The comprossor, whather received as part of @ unit or as a bare compressor, must be checked in the presence of the carers representative for any evidence of camage cunng shipping. Any damage or missing perts must be immediately documented with the cari. ‘Should the compressor, carton, or skid show any signs of Being dropped or mishandled, such damage must be reported since it may have caused intemal camage tothe comprassor. A damage claim should then be filed by the purchaser against the delivering carer, since all shipments are made at the purchaser's risk B. COMPRESSOR STORAGE “These compressors have hermetic motors which must be protected from contaminants, whether introduced during operation via refigerant and ol or during storage. During storage the compressor must be maintained under postive pressure. A gauge and a monthly Inspection tog are required and must be vertiable for warranty purposes. A nominal charge of ry refrigerant, or ittogen of 35 psig (241 kPa) s required. Charge must be added to maintain a minimum of 25 psig (172 kPa). Dry airis not alowable in the compressor under any circumstances. For prolonged storage, place a plastic cover over the entire compressor to protect the electrical terminal box {rom aust and other atmospheric contaminants. Also, the torques should be checked (see Table 4 & Table 6). Teble 4. Torque Values DESCRIPTION NOWINAL | TORQUE MODELS BoTsze | we-FT) ‘Sightigass o sight glass boss “14-20 Hex 8 AL ‘Vapor injection transfer tube 278-16 Hex 30, ALL Four post feed through #10.32 Soc 5 ALL ‘Suetton shipping cover: ‘18-11 Hex 20 aero PTAC “Suction shipping cover 314-10 Hex 700 21512 18K_ Discharge shipping cover ‘(8-11 Hex 2) ALL &. PIPING CONNECTIONS 4. General: The compressor is shipped witha holding charge. Gare must be taken to relieve the holding charge when tne cover plates are removed. ‘compressor is supplied wit the suction check valve. No discharge check valve is provided. Cove Plates are used for shipping purposes. 2. Discharge Relief Valve (not supplied as standard): This valve is required by the national and local ‘codes if discharge service valve is used. Relief valve venting must conform to local codes ang ARI requitements, MSC-127 models use a nominal 34 inch size eo at 400 psig (2760 kPa). 3, Discharge Line Check Valve: Discharge check valves must bo used when systems have ‘compressors connected in parallel, remote condensers, of muitple circus wth common ‘condensing water supply. This isto prevent refrigerant migration which degrades the viscocty af {he ol when a given compressor Is in the off cycle. Tho check valve should have a sof sat and positive seal, They are required whether the compressors have discharge servicg valves of not. Line sizes in Table 6. Il. INSTALLATION Tablo 6. Valve Kits VALVE KT. MODEL «Ss _[ PART # ‘CONMENTS Euslion Borvice Vawe | 42t0KH212K | 05367242 | Torque bale 180 Ibn (004 Nm] — 7216K/1218 |" 053572A6_| Torque bolts to 260 o-f (954 N-m) Discharge Series) 7210K/1212« | 05367241 | Torque bolts to 150 o-R (204 N-m) Valve ZABKMETGK | 05367242 | Torque bois to 150 We G04 Nem), Ralf Valve ‘ALL | -O64047A1 | Kit includes relief valves and elbow fing | ‘ischorge Check Vane | 12i0K/1272K | oss988A1 | Kitincudes check valve, gasket. spacer 1216K/1218K [_055989A2 | ring and bolts Table 6. Displacement end Line Sizes "SUCTION DISPLACEMENT “LINE SIZES. move. |~ 60 Hz. ‘SOE, ‘SUCTION | DISCHARGE ‘210K | 16,2. CFM | 262.1 MMIR_| 3 5/8" 00S | 3 1/8"ODS. 1212 | 232.7 CFM | 327.6M7HR_| _36/8"ODS [9 178" ODS. 7216K_|_27e9GrM | 392.6 MYHR | “4 178" ODS | 3.5/8" ODS. aaeK | 334.7 CFM | 408s ann | 4178" ODs | 3 5/8" ODS (D_LIQUID INJECTION Liquid injection fs used to control the compressor discharge temperature, Liquid is injected to an intermediate ‘breseure which is isolated from the compressor suction, thus having a negigibie impact on compressor capacity. Compressors require quid injection under certain operating condtons in order to provide additional motor ‘cooling oF discharge temperature control. Compressors on systems with air-cooled condensers are equipped ‘with liquid injection arcangaments as standard. Compressors on water-cooled or evaporalive-cooied systems ‘may requite liquid Injection under one or more ofthe fotowing conditions: High suction superhes High saturated discharge temperature with low saturated suction temperature ‘Continuous operation near fil unload. Unbalanced Line Vottage. Voltage over or near limits in Table 7, opepe ‘Tw tquid supply tothe TX valve or orice Ming must be subcooled to 9 minimum of 10°F (6°C) to ensure proper quid flow. Tha liquis injection piping must be steel and a sight glass is recommended prior to the restriction. “The liguid connection must be made to the main iquid supply line, downstream from the maln ftendtiar and main liquid ing eolenold valve. ‘The Iquld connection must be tothe bottom of the main iquié line, The total Tength of steel tubing connection should be Kept to a minimum. “Three type® of liquid injection are offered depending upon the compressors operaling conditions. 1, Liquid Injection with Orifice (Figure 3)- When using R22. a fixed oflce allows a continuous flow ‘of iquid tothe compressor when itis operating. This lquid injection arrangement is designed for ‘operation 16°F (46 °C) to 130°F (64.4°C) SOT and 20°F (-7°C) to 50°F (10°C) SST. Operation ‘ado of these lite with this arrangement isnot allowed Il. INSTALLATION Figure 3. Liquid injection with Orifice ‘CHECK wave yom ke SiontaLass, = oo ! 2. Liquid Injection with TX Valve (see Figure 4) - This type utlizes an expansion valve to control the liquid feed to the compressor, reacting to and controling the discharge tomperature. This TX valve ‘must be adjusted to maintain @ maximum discharge temperature of 170°F (76°C) and a minimum ‘lscharge superveat of 20°F (11°C) under al condilons, This method Is spaciieg for we Iypes of ‘pplications: v2 be 809 —_ assfiry 17% unbalance, curent>65/HA 3 [ Fault unjosdod unbalance: > 25% unbelance, 40°MHAC curont < 65°MHA ‘4 | Fauit-imoropor phase sequanoa/iswiro S| Fault over temperaure 6 | Fault- out of range of MIA calibration — "7 | Faut- unvoaded unbalance: >50% unbalance, culront = 40MHA ‘g____| Fauit= phase logs: 60% unbaiance ll. INSTALLATION Figure 10. 11 2ACE Motor Protector Wiring Diagram —— 4H eompntoon 2) Oil Level Sensor: The compressor is equipped with an optical level switch to protect the ‘compressor from low oil ovel. See Figures 8 and 8 for wiring diagrams, A fuse Is ‘rovided on the terminal board to protect the switch from fuctuetions in contro volage. ‘Soe Tabto 11 for fuse specifications, Wire the hot lead to the white sensor lead. Wire the lead to load fo the yellowed (115/290 Voi) lead. The black load Is wired through a resistor dct tothe unloader ‘common (no other wing is required fr the black lend), Table 14. Terminal Board Replacement Kite CONTROL | TERMINAL | OIL SENSOR | OW SENSOR | _OILTSTAT VOLTAGE | STRIPPART# | PART# | FUSE RATING | FUSE RATING Ti5V ‘0538885, 95682041 150A. 300A Dany ‘O53B28A6 ‘555202, O7eA. 1507. 6) Sump Heater: The compressors ol sump heater must be energized at least 24 hours Dror fo start up oF sump heated to a minimum of 80°F (17°C) above ambient. Under ‘Normal operation the heater should be energized when the compressor Is not running. The unit should never be left in service ifthe sump heater is Inoperstve, 8), Unloader Coits: The comprassor is equipped with a 3-way solenoid valve for ‘compressor capacity contol. The two solenoid vaives are wired to the compressor terminal box. The “load” cols marked "A" the “unload” col is masked °E 1) Oil Thermostat: The thermostat will open at 240°F. Itis 2 secondary thermal protection ‘vice preventing the compressor from operating at excessive temperatures, I. INSTALLATION G.VAPOR INJECTION “This ows a single compressor to operata in a 2-stago rafigorant cyclo resulting in incroasod capacty and Improved system elciency. Several contigurations are possible, Dut the lofowing examples are most common: Direct Expansion (DX) Sublcooler (Figura 14): Liquid rerigerants taken from the liquid Ene of the ‘condenser, trough an expansion valve, to a hoat exchanger. The refrigerant bols-off at an Intermediate pressure and is irjectad info the vapor injecton port. The cooted fd may be the bafance of the high pressure fiqud refrigerant fom the condenser or an independent "stde” oad. 1 Figure 11. Vapor Infection with Direct Expansion (DX) Subcooler | 4+ 378 008 Layo magcron Ue wo wetieo PE 1 3/8 005 10 EVAPORATOR METHOD “A*- fo bo used whon tquid to tho tube in tube subcodter has less than 10°F (8°C) subcooting. METHOD B"- sto bo usod whon liquid fo the tube in tube subcooior has more then 10°F (6°C) subcooting. Il. INSTALLATION 2. Flash Tank (Figure 12}: This is 2 flooded vasse! at an intermediate prossure where 2-phese ‘efigerant enters from the st expansion device and is soparated. The saturated vapor exis the top ‘ofthe tank and i injected into the vapor injection port, The saturated qu forms a liquid soal atthe ‘bottom of the tank and is then expanded ino the evaporator. The lash tank arrangement hes the benefit of maximum possible systern efficiency, bul with added complications ofa flooded vessel and contol, Figure 12. Vapor injection with Flash Tank (Flange Connection) If vapor injection is used, some added precautions must be token. 1. The vapor injection portis another means of liquid refigorant entaring the compressor. which een ‘cause compressor damage resulting from quid stroas. lad in tha vapor injection ba to pravart ror hackepin st 3. The liquid line feeding the lash tank or subcooler must be completely closed at shutdown to prevent liquid entering the compressor or slugging the compressor at startup. ‘4. The fash tank or subcooler must not alow the vapor injection port to be directly exposed to dlscharge pressure, This can result in excessive intanal loads possibly damaging the compressor. #4. SYSTEM CLEANING ‘The system should be cleaned per the package manufacturers recommendations. Fikers and deer cores shoule be changed and an acis test performed. I the ol ig acici, change the ol, and repeat the acid tast Process. Take an oll sampla and send for analysis gee |. General Information, section D, Olt Kate Program). Ill. OPERATION ‘A.OPERATING LIMITS ‘Specific operating mits are shown in Tables 12, and 13. These limits must be siricty observed. Any ‘application outside these tite miziout explicit writen approves trom Harford Comproosors wl vid the warranty. Table 12. Operating Limits sat MINIMUM | MAXIMUM move. __| Rerricerant [“-F [ *c [| "re | °c FRONHFEXEK | Revmao7e | OF | Tec | sor | 10°C TBioNHFEWaK™ | Razma07e | 20°F | -7°C 10°C T2toNHFEWaK" | _R2wRAOTC | 20°F | -7°C 10°C. "PTONHLBVEK. Ride ovr | -18°0 | 50°F | 10°C T2TONLFEVEK | RZQIRSOTIRAOAA | OF FC T21NUFEVSK | R2URSOTIRAOSA | 50°F aC T2I2NHFOXEK | RZDRAOTC [OF 0 2IaNHirewak | AZ2iRAO7C | 20°F 10°C. TRIaNHFEWaK" | _RzamRA07C | 20°F 10 "Te1aNHLBVK. Riga OF 70° “2I2NLFOVSK | RZDIRSOTIRAOIA |_ OF 7C. “RI2NUFEVEK | R22IRSOTIRAOSA | “50°F eC "1215NHF6X6K Ra2Rao7e | OF 10° TaisNHFewaK= | ReamRaoTC | 20°F 10°C “DIENHFEWSK™ | Rz2iR407C | 20°F 10°C 1215NHLVEK Rise OF 10°C ZIENLFEVSK | ROORSO7IRGOAA | OF. ro “ZIBNUFEVEK | RZ2IRSO7IRAOGA | “50°F HEC “a1eNHFexex | RzwmRao7G | OF 10°C. marc | 145" | exe "2ieNHFewaKe | ReamRao7C— | 20" 70°C were | 115" | 46°C i2reNHFeWaK™ | Razmaor® | 20°F 10°C ec | Ho | as'c T2TENHLEVSK. RiS¢0 OF. 10°C were | 145" | 63°C *NHIF6W4 and “NHFEWS" models can operate down to 10°F (-12°C) SST. however, the maximum allowable SDT is 105°F (40°C) Table 13. Operating Limits GWiUM DISCHARGE PRESSURE aTOPSIG | 2625 P= [MAXIMUM SUCTION TEMPERATURE ‘20°F are. IMAXIMUM DISCHARGE TEMPERATURE ZO OC, {MINIMUM DISCHARGE SUPERHEAT 20°F 1 [MINIMUM SUCTION AND DISCHARGE DFFERENTIAL | ‘40 pSiO | *210 4Pad IMINI/UM DIFFERENTIAL FOR UNLOADER OPERATION | ¢0 PSD | _420xPad * The compressor can safely operate with less than 30 psld (210 kPad) for a maximum of 3 minutes. ‘B._GYGLING LIMITS ‘To maxirize the life of wear components, cycling should be minimized: 41. Starting: The compressor must not be stopped and started more than 4 times in one hour. 2. Unloading!Losding: The slide-vatva should not travel a full stroke more than once every tree minutes, OPERATION SOL LEVEL, “The sight glass on the side of the compressors used to determine the oi evel In which the comereesor can ‘safely operate. It's extremly important thatthe compressor 's never slarted with the ail level over tne sight ‘lass. Ifthe lovelis above the glass pror to start-up, suffcient of must be drained untl the levels al the center ‘of the sight lass. il fevel should be montored after start-up to ensure ol returning rom the system does not rise above the sight {less nor trip the ol level sensor. The compressor can safely operate withthe oll evel below the sight glass as the ol level sensor wil protec the compressor against a low oil condition. D__CAPAGITY CONTROL, 1. Unlosder Operation: The compressor is equipped with twa solenoid valves to control ading end unloading of the compressor slide-valve. Loading is accompllshed when high pressure ailis ‘supplied tothe unioader piston. Unioading is accomplished when the urlosder piston cavity fe ‘rained to suction pressure, The slce-valve wil hold its positon when the unlcadr piston i Isolated. See Figure 13 for unioader schematic and Table 14 for sequence of eolenois actuation, Figure 13. Unloader Schematic Ill. OPERATION Table 14. Solenold Actuation Solenoid A Solenoid B Normally Closed | Normally Open Unload ‘OFF: ‘OFF: Load ‘ON, ON, Hold ‘OFF ON, 2. Unloader Rates: The unlogdr rates aro determined by fixed offfces, which control the oad and Unload sequence. The rates of loading and unloading ara 30 1060 eaconds. 3, Fiel6 Unioader Checks: There are two schrader valves on the unloader pad, which allow three Pressures fo be measured inside of the compressor fr start-up and trouble-shooting purposes. ‘2), Suction Schrader Valve (located on the side ofthe unloader): Suction pressure can be read from this addtional schrader valve while the compressors in the "HOLD" positon, This is used for ‘measuring the suction pressure afer or downstream of the suction fier ) Piston Cavity Schrader Valve (located on the face of the unloader): Discharge pressure ‘can be read when the compressor I In the load positon. The most accurate reading is. ‘whan the compressor is Inthe Tull-“oaded positon. Suction pressure is read when the Unloader sn the “UNLOAD” position. This is most accurately maasured when the ‘compressor is in the fullyunloaded postion. E, SUCTION FILTER ‘The compressor is equipped with a removable sucton filer. Pressure drop across this filer must be checked thin the frst sevoral hours aftorstar-up and whenever exceseiva pressure drop is suepected. To determine the pressure drop, a diferenval pressure gauge should bo used. Ifa standard gauge Is used, fret connect ‘downstream end then upstream from the fiter. Using the pad mounted untoader, the downstream pressure (low prassure) can be determined by conducting {the “Sucton Proseure” check in the Field Unioader Check Section. The upstream pressure can be read from ‘the Schraeder valve located on the suction boss. “The fitr should be changed whon there aro cortan changes in the pressure drops. See Table 15 for tess. pressure drops. Excessive prossute drop across the for could be due to molstue freezing on the fiter Material causing @ substantial loss of capacity. In this caso tho dryer blocks inthe condenser lgui line wit feed fo be replaced. Tablo 18. Pressure Drops Requiring 2 Filter Change MODEL PSD Pad 1210. 15 10 eas 20. 14 1218. 25 7 Roplacemant Fitar Kits: Hartford Compressors Part #054145AS for 1210K and 1212K Models; Part +8084 145A8 for 1216K and 1218K Models. These Kit includes suction fiter, o-ring, check-vaive gasket, suction ‘gasket, and instructions. IV. TROUBLESHOOTING ‘A. High Discharge Temperature + Check for excaceive euction euperheat ‘+ Check quid injection arrangement for proper operation + Check refrigerant charge. ‘B. Motor Tripping on Thermal Protection Discharge temperature too high. (6e0 A) Excessive current drew. ‘Voltage is unbalanced or outside of tits Bad sensor—

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