COMPRESSOR REPLACEMENT PROCEDURE - Bard …

1 COMPRESSOR REPLACEMENTPROCEDUREM anual No.:2100-003 ESupersedes2100-003 DFile:Volume I, Tab 1 Date:06-25-02 Bard Manufacturing CompanyBryan, Ohio 43506 Since ahead just as planned Copyright 2002 General InformationThree Phase Scroll CompressorStart Information .. 1 Steps to Replace COMPRESSOR .. 1 Suction and Discharge Tube Brazing .. 2 Conclusion .. 4iCONTENTST ablesTable 1 Air Contitioner Liquid LineFilter Driers (Directional) .. 3 Table 2 Heat Pump Liquid LineFilter Driers (Bidirectional) .. 3 Table 3 Sunction Line Filter Driers .. 3 Table 4 Additional Refrigeration Requirements.

2 4 FiguresFigure 1 Brazing Diagram .. 3 Figure 2 Typical A/C Filter Drier Locations .. 5 Figure 3 Typical Self-Contained H/PFilter Drier Locations .. 5 Figure 4 Typical Split System H/PFilter Drier Locations .. 5 manual 2100-003 Page 1 GENERALB efore replacing any COMPRESSOR , make absolutely surethat it is the COMPRESSOR that is at fault. Problems withthe external electrical components are many timesdiagnosed as a faulty note the information below on three phase PHASE SCROLL COMPRESSORSTART UP INFORMATIONS croll compressors, like several other types ofcompressors, will only compress in one rotationaldirection.

3 Direction of rotation is not an issue withsingle phase compressors since they will always startand run in the proper , three phase compressors will rotate in eitherdirection depending upon phasing of the power. Sincethere is a 50-50 chance of connecting power in such away as to cause rotation in the reverse direction,verification of proper rotation must be of proper rotation direction is made byobserving that suction pressure drops and dischargepressure rises when the COMPRESSOR is rotation also results in an elevated sound levelover that with correct rotation, as well as substantiallyreduced current draw compared to tabulated of proper rotation must be made at thetime the equipment is put into service.

4 There is nonegative impact on durability caused by operating threephase Compliant Scroll compressors in the reverseddirection. However, after several minuted of operationthe COMPRESSOR s internal protector will operation for over one hour may have anegative impact on the : Some units are equipped with a PhaseMonitor that will automatically governwhether the COMPRESSOR contactor can beactivated. Check the unit wiring diagramand installation three phase ZR*3 compressors are wired identicallyinternally. As a result, once the correct phasing isdetermined for a specific system or installation,connecting properly phased power leads to the sameFusite terminals should maintain proper direction of rotation of the motor may be changedby reversing any two line connections to the 1.

5 If the COMPRESSOR tries to start and cyclesoverload:A. Measure line voltage at the unit terminals atthe moment of start. It must be within theoperation voltage range as sown on the unitserial plate. If it is less than the minimumvoltage shown, check all electricalconnection and branch wire Check to determine whether the runcapacitor is good and of the correct the capacitor if in If a start capacitor and start relay areemployed, check out these If there are no starting components used onthe system, connect a start kit of the correctsize temporarily to the COMPRESSOR the COMPRESSOR motor now starts and runsokay, install start kit the COMPRESSOR does not try to start and blowsfuses:A.

6 Remove the wiring from the compressorterminals and check for ground betweeneach terminal and the COMPRESSOR Check for continuity between the commonterminal C and run terminal R , andbetween the common terminal C and startterminal S . If either one of these checksshow continuity and the other does not, oneof the motor windings is open. If neithershow continuity and a check betweenterminal R and terminal S showcontinuity, both motor windings are intactand the internal overload is open.(Normally, any time the COMPRESSOR housingis cool enough to hold your hand tightagainst, the overload should be closed.)

7 Step 2. It is essential to establish the type of compressorfailure that has occurred before any furtherwork can take If there was a mechanical failure that wouldcause a no pump condition (any situationwhere the motor starts and runs okay butlittle or no refrigerant is pumped), thesystem cleanup PROCEDURE can be the COMPRESSOR and proceed toStep 2100-003 Page 2If the COMPRESSOR failure resulted from someform of an electrical failure, the COMPRESSOR hasundergone a burnout condition of some degreeof magnitude. It is essential to determine thetype and extent of the burnout before the newcompressor is Through the service ports, sample therefrigerant for the characteristic acrid odorof a Recover the system refrigerant charge usingcorrect recovery procedures and send therefrigerant to any authorized Remove the burned COMPRESSOR .

8 Userubber gloves when handling contaminatedparts if there is any likelihood of contactingthe oil or If the discharge line shows no evidence ofsludge and the suction stub is likewiseclean, or perhaps has some light carbondeposits, the burnout occurred while thecompressor was not rotating. Contaminantsare, therefore, largely confined to thecompressor housing and a singleinstallation of liquid and suction linefilter-driers will probably suffice to cleanup the If the sludge is evident in the discharge line(and very likely also found in the suctionline) the COMPRESSOR motor burned whilerunning.

9 Sludge and acid has been pumpedthroughout the system and several changesof the liquid and suction filter-driers willprobably be necessary to cleanse 3. System suffering running burnouts will alsorequire additional cleansing of various pipingand components, and even this may not rule outthe possibility of having to replace An extensive burnout condition may clogthe screen and/or the capillary tubing,orifice or TXV requiring The reversing valve may becomeinoperative or sluggish due to sludge andacid action attacking the moving parts andtheir bearing It is highly probable that the accumulatorbleed orifice would be plugged on a severeburnout.

10 And is recommended that theaccumulator be replaced as it is practicallyimpossible to assure the reliability andperformance of the accumulator eventhough it has been flushed 4. An evaluation should be made to determinewhat the system fault that caused the burnoutwas and take the necessary steps to correct Check all electrical components (capacitors,relays, overload, etc. where applicable).Check the contacts of the Install the new COMPRESSOR . Make sure thatthe REPLACEMENT COMPRESSOR is exactly thesame as the defective one, or a substituteauthorized by the following information is to be noted forinstallation of the REPLACEMENT AND DISCHARGE TUBEBRAZINGC ompliant Scroll compressors have copper plated steelsuction and discharge tubes.