Application Engineering Application Engineering

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August 2011

Application Guidelines for Copeland Scroll TK Open Drive Compressors

Table of Contents Safety Safety Instructions................................................................................................ 2 Safety Icon Explanation ....................................................................................... 2 Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons...... 3 Safety Statements ................................................................................................ 3 Introduction............................................................................................................. 4 Nomenclature ....................................................................................................... 4 Refrigerant/Lubricants .......................................................................................... 4 Operating Envelope ............................................................................................. 4 Liquid Injection ..................................................................................................... 4 Discharge Temperature Protection ....................................................................... 5 Accumulators ....................................................................................................... 5 Pressure Controls ................................................................................................ 5 Directional Dependency ....................................................................................... 5 Deep Vacuum Operation ...................................................................................... 5 Shaft Seal............................................................................................................. 5 Belt Tension .......................................................................................................... 5 Mounting Consideration ....................................................................................... 5 Figures Operating Envelope ............................................................................................. 4 Model Nomenclature ............................................................................................ 6 TK Belt Gauge Correlation ................................................................................... 7

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Application Engineering B
Safety Instructions Copeland Scroll TK open drive compressors are manufactured according to the latest U.S. and European Safety Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These instructions should be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety instructions. Safety Icon Explanation

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DANGER WARNING CAUTION NOTICE CAUTION

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.

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Application Engineering B U L L E T I N
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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

WARNING

ELECTRICAL SHOCK HAZARD Disconnect and lock out power before servicing. Discharge all capacitors before servicing. Use compressor with grounded system only. Molded electrical plug must be used when required. Refer to original equipment wiring diagrams. Failure to follow these warnings could result in serious personal injury.

WARNING

PRESSURIZED SYSTEM HAZARD System contains refrigerant and oil under pressure. Remove refrigerant from both the high and low compressor side before removing compressor. Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system. Use only approved refrigerants and refrigeration oils. Personal safety equipment must be used. Failure to follow these warnings could result in serious personal injury.

WARNING

BURN HAZARD Do not touch the compressor until it has cooled down. Ensure that materials and wiring do not touch high temperature areas of the compressor. Use caution when brazing system commponents. Personal safety equipment must be used. Failure to follow these warnings could result in serious personal injury or property damage.

CAUTION

COMPRESSOR HANDLING Use the appropriate lifting devices to move compressors. Personal safety equipment must be used. Failure to follow these warnings could result in personal injury or property damage.

Safety Statements Refrigerant compressors must be employed only for their intended use. install, commission and maintain this equipment. All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed.

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Application Engineering B
Introduction The Copeland Scroll TK compressor is an open drive scroll compressor that has been developed specically for the truck refrigeration industry. This open drive scroll compressor has the following features that are unique and different from traditional hermetic scroll compressors. The scroll set and bearings are designed to operate at a range of all RPMs from 2300 to 4200. The compressor has a lightweight aluminum body to minimize the overall compressor weight. The compressor also utilizes a positive displacement oil pump to ensure adequate lubrication over the entire operating range of speeds. The design also utilizes a state-of-the-art shaft seal to eliminate any leakage. These modications result in a compressor that is suitable for the most demanding transport applications with efciencies and reliabilities far better than traditional reciprocating compressors. Nomenclature Please refer to Figure 2.

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Refrigerant/Lubricants The TK open drive compressors are only approved for use with R-404A and Emerson approved POE lubricants. Please refer to Emerson Form No. 9311, Refrigerant/Lubricants for Use in Copeland Compressors. (The oil charged as shipped is 63 oz.) Operating Envelope The approved operating envelope is shown in Figure 1 below. To achieve extremely high pressure ratio operation, liquid injection will be required to avoid excessive discharge temperature. Liquid Injection The open drive TK scroll compressor is provided with an injection port suitable for connection to a source of liquid refrigerant. Internally, this port is connected to an inner pocket of the scroll mechanism. Since this pocket is separated from the suction inlet, no loss of capacity or mass ow results from injecting at this point. The approved liquid injection device is the Sporlan desuperheater valve, one-ton size, rated at 121 C. The bulb must be installed on the discharge line within six inches of the compressor outlet, and the connection must be fully insulated. A minimum of -12 C liquid subcooling required for proper valve operation.

170

150

130

Condensing Temperature (F)

110

90

Normal Operang Envelope Extended Envelope For MulTemp Unit

Extended Envelope

70

50

30

10

-10 -80 -60 -40 -20 0 20 40

Evaporang Temperature (F)

Figure 1 Operating Envelope

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Application Engineering B
CAUTION
Compressor head temperatures can be very hot. Care must be taken to ensure that wiring or other materials which could be damaged by these temperatures do not come into contact with these potentially hot areas. Discharge Temperature Protection is required for loss of charge and other system conditions where excessive discharge temperature can occur. A thermostat/ thermistor is supplied in the top cap for this reason. The thermostat has a cut-out temperature of 147 +/- 3 C and a cut-in temperature of 61 +/- 11 C. It is rated for up to 24 VAC. Accumulators An accumulator is required on any compressor system with a refrigerent charge over 9 lbs. Excessive liquid oodback or repeated ooded starts will dilute the oil in any compressor causing inadequate lubrication and bearing wear. Proper system design will minimize liquid oodback, thereby ensuring maximum compressor life. Pressure Controls Both high and low pressure controls are required with the following set points. The low pressure setting must be 10 PSIA or greater. High pressure controls must be set no higher than 468 PSIA. Directional Dependency Scroll compressors are directional dependent , i.e. they will compress in one direction only. Engine driven compressors are designed to only operate in the proper direction. When operated in the electric motor standby condition, the possibility exists that a 3-phase motor could be wired to operate in the wrong direction. The controller must be equipped with a phase sensing relay that will prevent operation in the wrong direction.

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Discharge Temperature Protection

Although operation of the scroll in the reverse direction for brief periods of time is not harmful, continued operation could result in a failure. The application requires the use of phase detection and correction device. Direction of rotation is shown by arrows cast onto the compressor body. Deep Vacuum Operation A low pressure control is required for protection against deep vacuum operation. (See the section on Pressure Controls for the proper set point.) Operation in a deep vacuum will cause severe overheating and wear on the scroll members. Shaft Seal Maximum low-side pressure without leak or distortion (through the casting and gasket/seal joints) is 402 PSIA. Damage to the shaft seal may occur if a differential pressure of greater than 300 PSI is applied for longer than 60 seconds. Belt Tension Excessive belt tension can cause premature wear and result in leakage of the shaft seal. Premature wear and failure of the lower bearing (ball bearing) may also occur due to excessive belt loading. Therefore, the maximum belt tension should be such that a maximum of 200 lb. force is applied to the shaft. Refer to Figure 3 for belt tension guidelines. Mounting Consideration Excessive tilting or leaning of the compressor will cause the oil pump to lose its ability to supply adequate lubrication. Therefore, the maximum tilt angle for the compressor is 20 from horizontal in any direction.

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Application Engineering B U L L E T I N
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OPEN DRIVE SCROLL COMPRESSOR MODEL NOMENCLATURE

OIL TYPE E - P.O.E L - No Oil Blank - Std. Min Oil PRODUCT VARIATIONS Number will be assigned as follows: 1. Numbers - 001 through -099 are reserved for model number basics 2. Number -200 indicates a standard compressor 3. Numbers -201 through 299 will be assigned for all other variations of a given model

MODEL SERIES VARIATIONS Number assigned to indicate major design variation within any one family series.

APPLICATION RANGE K - Thermo King only

MODEL BODY TYPE L - Body Mounted B - Bracket Mounted F - Flange Mounted

XXXX-XXXX - XXX - XXX

SHAFT RPM MULTIPLIER COMPRESSOR FAMILY SERIES T- Open Drive MODEL SERIES VARIATIONS Number assigned to indicate major design variation within any one family series C = 100

SHAFT RPM @ Rating condition in 100's

SCROLL DISPLACEMENT

Figure 2 Nomenclature

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Application Engineering B U L L E T I N
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TK Belt Gau ge C orr elati on Note: TK This is for a se rpen tine be lt. Belt Gauge Correlation

500 450 Belt Tension in Two Legs of Belt (lbf) 400 350 300 250 200 150 100 50 0 30.0

Note: This is for a serpentine belt.

35.0

40.0

45.0

50.0

55.0

60.0

65.0

70.0

75.0

80.0

TK Gauge Number

Figure 3 TK Belt Gauge Correlation

The contents of this publication are presented for informational purposes only and they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. reserves the right to modify the designs or specications of such products at any time without notice. Emerson Climate Technologies, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Climate Technologies, Inc. product remains solely with the purchaser and end-user.

2011 Emerson Climate Technologies Printed in the U.S.A.