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574-930_CommScrollGuide_12222 C
O M M E R C I A L
M
O D E L S
A
P P L I C A T I O N
G
U I D E
C
ARLYLE
C
OMMERCIAL
S
CROLL
C
OMPRESSOR 1
Table of Contents
This application guide contains much of the same information as that in the
standard scroll product guide, however special attention should be paid to
Section 4, as the commercial line has unique requirements.
Section 1.0
Describes the operating characteristics of the scroll compressor to familiarize the system
designer with its features and key components.
Section 2.0
Provides a detailed explanation of the design specifications of the CARLYLE commercial
scroll compressor.
Section 3.0
Contains guidelines for the system designer, to assist in the successful application of the
compressor.
Section 4.0
System Requirements/Controls
Section 5.0
Provides guidelines for incorporating scroll compressors in the assembly process at the
manufacturing site.
Section 6.0
Details techniques for servicing scroll compressors in the factory or field environment.
Section 7.0
Describes the excessive liquid floodback test procedure, used to determine the need for
suction accumulators. 2
1.0 Scroll Compressor Functional Description
1.1 Key Components
1. Discharge Plenum
2. Upper Shell
3. Fixed Scroll
4. Orbiting Scroll
5. Crankcase
6. Stator Winding
7. Eccentric Shaft
8. Lower Bearing Ring
9. Lower Bearing
10. Thrust Washer
11. Magnet
12. Oil Tube
13. Shell
14. Rotor
15. Stator
16. Counterweight
17. Electric Terminal
18. Terminal Cover
19. Suction Baffle
20. Slider Block
21. Separator Plate
22. Discharge Tube
23. Check Valve
Figure 1-1
Scroll Compressor Components
A cutaway view of the scroll compressor with key components labeled is shown in
Figure 1-1. The motor stator is rigidly attached to the shell. The rotor is shrunk onto the
eccentric shaft. The shaft is supported by two bearings, one in the crankcase and the
second below the motor.
1
2
3
4
5
6
7
8
22
21
19
20
18
17
16
15
14
13
23
11
10
12
9 General Compressor Specifications
2.1 Condensing & Evaporating Temperature Ranges
The operating envelope for CARLYLE commercial scroll compressors is shown in Table 2-1
where the condensing and evaporating temperatures represent the range for steady-state
operation. Under transient conditions, such as start-up and defrost conditions (for heat
pump applications), the compressor may operate outside this envelope for short periods.
Table 2-1 Operating Ranges
TEMPERATURE RANGE
°F
°C
Evaporating
-25 to 55
-31.7 to 12.8
Condensing
80 to 155
26.7 to 68.3
Maximum Discharge
280
137.8
2.2 Insulation Resistance/Dielectric Strength
The insulation resistance shall be greater than 1 mega-ohm when measured with a 500 volt-
direct current mega-ohm tester.
Each compressor motor is tested at the factory with a high potential voltage (hi-pot) above
the UL requirement of [(2 x Rated Voltage + 1000) X 1.25] for longer than the 1 second
required. The leakage current must be less than 0.5 mA.
CARLYLE commercial scroll compressors are configured with the motor below the pump
assembly located at the top of the shell. As a result, the motor is partially immersed in
refrigerant and oil. The presence of refrigerant around the motor windings will result in lower
resistance values and higher leakage current readings. These readings are not cause for
concern and do not indicate a faulty compressor. It is recommended to operate the system
for a brief period of time to redistribute the refrigerant throughout the system, and then
retest the compressor for insulation resistance or current leakage.
2.3 Residual Moisture
Every compressor is dehydrated, evacuated, and charged with dry nitrogen at the factory
prior to shipment. Maximum residual moisture level is 500 mg (0.0176 oz).
2.0 Key Features of CARLYLE Scroll Compressors
3 4
2.4 Oil Charge Levels
The compressors are charged with oil at the factory to the levels shown in Table 2-2.
Alkylbenzene oil is used for R-22 models. The oil type is either Sontex SA32 with 1.5%
Syn-O-Ad or Zerol 150 with 1.5% Syn-O-Ad. R-407C models use POE oil, HATCO FRL
32ST, ISO viscosity grade 32. If additional oil charge is added for in-service conditions, use
only the oils noted above.
Table 2-2 Oil Charge Levels
Model
Oil Charge ml (fl. oz.)
Recharge ml (fl. oz.)
SR_78
2129 (72)
1952 (66)
SR_81
2366 (80)
2188 (74)
SR_94
SR_109
2662 (90)
2484 (84)
SR_120
2.5 Starting Voltage
At a temperature of 20°C (68°F) or above, the compressor will start at 90% of the lowest
nameplate voltage when measured near to the compressor with the compressor energized.
Voltage should NOT be measured directly at the compressor terminals under energized
conditions with the terminal cover removed. Prior to energizing, verify that leads and
terminal connectors are in proper working condition. The closest point of safe terminal
voltage measurement is typically at the load side of the contactor.
2.6 Internal Motor Protection
CARLYLE commercial scroll compressors are protected by internal line breaks mounted on
the motor windings. These protectors are automatic reset devices containing a snap action
bimetal switch.
Internal protectors respond to over current and high temperature. They are designed to
interrupt motor current under a variety of fault conditions. In three-phase compressors
these devices also provide protection during primary and secondary single-phase
conditions.
2.7 Dimensions
An outline drawing depicting overall dimensions of the compressors is shown in Figure 2-1.
For more detailed information refer to the specific product specification document for your
model. 5
Figure 2-1 Compressor Outline Dimensions
Note: All dimensions are in millimeters. ( ) Denotes inches.
Crankcase Heater to be
located between 17 mm to
42 mm above bottom of
foot (0.67 in. to 1.65 in. )
95.25
(3.75)
190 .5
(7.50)
232 .0
(9.13)
190 .5
(7.50)
232 .0
(9.13)
4 x Ø19.5
(0.768)
31°
65°
K
L
J
69.7
(2.74)
B
F
C
E
Suction Line
G
Ø
A
7.2
(0.28)
Discharge Line
H
D
MODEL
A
B
C
D
E
F
G
H
J
K
L
SR78 TO
511.3
484.3
28.83 / 28.65
22.48 / 22.31
SR81
(20.13)
(19.07)
(1.125) I.D. x
(0.88) I.D. x
184.1
286.4
93.0
350.2
119.5
124.6
133.1
(7.25)
(11.28)
(3.66)
(13.79)
(4.70)
(4.91)
(5.24)
SR94 TO
517.6
490.6
16.7 (0.65)
22.3 (0.88)
SR120
(20.38)
(19.31)
DEEP
DEEP 6
3.1 General
The successful application of scroll compressors is dependent on a good match between
the system design and the compressor. A poorly matched system will result in the
compressor running beyond the limitations specified in this manual. This may result in poor
performance and/or reduced reliability.
3.2 Sound Levels
3.2.1 At Start-Up
During the start-up transient it is natural for the compressor sound levels to be slightly
higher. Scroll compressor models exhibit very little start-up transient sound. If the
compressor is mis-wired in 3-phase models, the compressor will run in the reverse
direction. The reverse rotation is characterized by an objectionable sound from the
compressor. This can be corrected by disconnecting power and switching any two
power leads at the unit contactor. NEVER switch leads directly at the compressor.
3.2.2 Normal Running
Scroll compressors are designed with optimized discharge ports and wrap geometry
to control the sound levels of each compressor. Properly designed shock loops for
suction and discharge connecting tubes will enhance the sound level benefit of the
scroll, as well as reduce vibration and premature tube breakage. (Tube design and
testing information is available from the Application Engineering Department).
The use of a sound shield is not required, but is acceptable if an application
requires it.
3.3 Voltage Range
Running voltage measured at the compressor between terminals should be within ± 10%
of the nominal rated voltage of the compressor to ensure continued operation.
For three-phase applications the voltage measured at the compressor terminals for any
phase should be within ± 2% of the average for all phases.
Warning: For safety reasons, these voltage measurements should be at the unit contactor,
not at the compressor terminals. Always keep the terminal cover in place when the
compressor is energized.
3.4 Refrigerant
The CARLYLE commercial scroll compressor was designed to operate with Refrigerant-22
(using Alkylbenzene oil) and R-407C (using polyolester oil) (see product bulletin).
3.0 System Design Considerations 7
3.5 Evaporating Temperature Range
The minimum continuous saturated suction temperature is -31.7°C (-25°F), which
corresponds to a pressure of 50.9 kPa (7.39 psig) for R-22 and 25.5 kPa (3.7 psig) for
R-407C. The maximum continuous saturated suction temperature is 12.8°C (55°F), which
corresponds to a pressure of 638.4 kPa (92.56 psig) for R-22 and 590.5 kPa (85.6 psig)
for R-407C. During transient conditions