Refrigerated Dryer

Troubleshooting Guide

Thermo Star

More Than Air. Answers.

Online answers: http://www.air.irco.com
PHONE: 1-800-526-3615

FORM: APDD 818A

CCN: 05515580 REV A July 2002
 Contents
TOPIC Page

Component Review 2
Controller Description 5
Controller Functions 6
Temperature Scale Selection and Clear Hour Counter 6
Clear Report (Alarm Report) /
Set Last Service Date (Maintenance Area) 6
PORO (Power Out Restart Option) 7
Start Up 7
Remote Off 9
Maintain Cold Mass Function 9
Terminal Board Connection 11
Alarms and Warnings 12
Refrigerant Circuit and Troubleshooting
Hot Gas Adjustment 14
High Head Pressure (HP Alarm) 15
High Discharge Temperature (ST Alarm) 16
High Dew Point 16
Internal Protection (PI Alarm) 16
Cold Weather Shutdown (8.8 Alarm) 17
Control Fuses Blowing fu 4-7 17
Leak Checking Refrigeration System 17
Leak Checking Air to Air Exchanger 17
Refrigerant Compressor Troubleshooting 18
Three Phase Compressors 18
Checking a Hermetic Compressor Single-Phase 20
Dehydration and Vacuum Procedure: 21
Refrigerant Charging 22
Compressor Oil Housekeeping 23
Compressor Burn Out 24
Scroll Compressor Removal 25
Refrigerant Pressures and Temperatures 27

1
 Component Review

QS
This switch is the power switch for the dryer.

For the TS200 and below, this switch is the On/Off. When
turned On, this switch will start the dryer.

For TS250 and above, this switch turns the power on to the
unit, but it does not start the unit. It powers up the controller.
With switch in the On position it is impossible to open the
cabinet door.

1fu
The 1fu is a fast blow fuse installed in the incoming power
supply of the controller. It is installed to provide a degree of
protection to the controller.
5 x 20 250volt I=32ma-t Fast blow

4fu and 5fu

The 4fu and 5fu fuses are a slow blow fuse installed on the
primary side of the step down transformer. These fuses
provide a degree of protection should a short-circuit develop in
the transformer.
10.3 x 38 600volts I=1A-f Slow blow

6fu and 7fu

The 6 fu and 7fu fuse are on the 230-volt secondary side of the
transformer. These fuses provide a degree of protection to the
conductors on the primary side.
5 x 20 600volt I=630mA-t

TC1
A step-down transformer TC1 reduces the incoming line
voltage to levels suitable for the power source for the
controller. This transformer takes 460 primary voltage down to
230 secondary voltage.

KM1
The KM1 is the compressor contactor. This contactor
incorporates a 230-volt coil.

KM2
The KM2 is the fan motor contactor. This contactor
incorporates a 230-volt coil.

KA1
The KA1 coil is powered though the HP and PI switch. The
KA1 allows the controller to have an input on terminal number
4. The KA1 is a control relay with N/O and N/C contacts. The
KA2 uses a 230-volt coil.
2
KA2
The KA2 relay is used for dry contacts for alarm indications.
When an alarm occurs, the KA2 relay is energized. This
switches the position of the contacts. The KA2 uses a 230-volt
coil.

Hot Gas Bypass

As the air compressor modulates or goes online/offline, the

compressed air capacity entering the dryer fluctuates. It
should be noted that dryer loading can apply not only to
capacity changes but thermal load changes due to varying
climatic conditions. The dryer must be able to adjust to these
varying capacities and maintains performance. The 100%
modulating hot-gas bypass valve ensures optimum dew point
control under all operating conditions. The pressure actuated
design’s immediate reaction to variations in airflow
guarantees a linear pressure dew point. All models perform
within a generous range of ambient and compressed air
temperatures, ensuring optimum performance whatever the
application. In the TS dryer, refrigerant constantly flows
through the evaporator. The flow varies dependent on the
percentage of rated air capacity flowing through the dryer.

Air to Air and Refrigerant to Air Exchangers

The air-to-air heat exchanger pre-cools the incoming air and

re-heats the out-going air, giving a high overall efficiency. This
cools the incoming compressed air, reducing the amount of
refrigeration energy needed to dry the compressed air. This
translates to lower energy costs. The reheater section raises
the temperature of the outgoing compressed air, protecting
the dew point, decreasing the relative humidity and
eliminating annoying condensation on downstream air piping.

Air-to-
Refrigerant
Demister
Exchanger

Air-to-Air Condensate
Exchanger Outlet

The large surface area in the evaporator means the TS

dryer provides dry compressed air and a low pressure
drop. The superior efficiency of the design minimizes the
3
power consumption of the dryer, saving money. A large
expansion chamber slows the compressed air down to its
critical velocity, forcing moisture to condense. This
design ensures maximum separator efficiency across the
entire flow range. Liquid water in the air is removed by a
high efficiency demister separator (vertically mounted for
optimum condensate removal). The aluminum heat
exchanger’s highly efficient operation permits exceptional
energy conservation levels. Generously sized pre-cooler,
re-heater heat exchangers, standard on all models, offer
noteworthy reductions in power consumption

4
1.0 Controller Description

1.1 Description
The TS controller controls all relative procedures in starting
and stopping the refrigerant compressor.

The controller reads the dew point in °C or °F.

The controller checks the machine and returns diagnostic

information in the presence of a malfunction.

Available functions:
- Memory storage of the last 8 messages or alarms
- Memory storage of operating hours
- Memory storage of the date of the most recent service
- “Maintain Cold Mass” function

1.2 Inputs

- Compressor high discharge temperature thermostat

- High refrigerant discharge pressure
- Remote ON/OFF function
- Dew point temperature

1.3 Outputs

- Compressor contactor
- Alarm contacts

Technical Characteristics

Min Normal Max Unit of

Measure
Power supply 207 230 253 Voltage

Power 3 VA
consumption
Working 14°F 99°F °F
temperature
ST input voltage 230 Voltage
HP input voltage 230 Voltage
LP (not used) 230 Voltage
input voltage
Remote On/Off 230 Voltage

Table 1

5
2.0 Controller Functions

The report/hour counter option can only be accessed when the

unit is turned off, but the Power On LED is on.

Press the REPORT button and hold it down for 6 seconds.

“rE” will appear.

Press the ON/OFF button to access the alarm report area.

Press the REPORT button to access current hour’s area.

In the alarm report area, the controller will flash the last
shutdown and the number one. To access the number of
hours when the last shutdown occurred, press the REPORT
button. Pressing the ON/OFF button allows you to scroll
though the last 8 events.

The controller can record up to 99,999 operating hours. The

counter is advanced at 20-minute intervals. Current operating
hours are displayed in the pages at 2-second intervals.
- First page displays Thousands; the red Alarm LED flashes
- Second page displays Hundreds; the yellow Remote Off
LED flashes
- Third page displays TENS; the green Dryer On LED flashes

To exit this area, hold down the REPORT button.

2.1 Temperature Scale Selection and Clear Hour Counter

The unit can display temperatures in either Celsius or

Fahrenheit.

1. Switch on the main switch while holding down the ON/OFF

button
2. The display will show the code “CF”
3. Press the RESET button to select the required unit of
measure
4. Switch OFF and Switch ON the main switch to store the
selection

To reset the hour counter, repeat the previous points 1-3, then
press and hold the RESET key. The counter will be
automatically returned to zero. The counter will be
automatically returned to zero if you change the display
temperature.

2.2 Clear report (Alarm Report) / Set Last Service Date

(Maintenance Area)
6
Switch On the main switch while holding down the RESET
button. This will access the Clear report function. “CL” will
display on the controller.

A)Press the ON/OFF button to perform the Clear Report

procedure
B)Press the RESET button to bypass the Clear report and
enter the last service date set function

The Clear Report procedure:

The display will automatically show the last service date. To

exit this function press the ON/OFF button 3 times scrolling
through the last service date.

The last service date function:

a) The display will show the letters “AA” to indicate the alarm,
while the red alarm LED flashes. Press the RESET button to
increase the display value. The input range is 00-99.
b) Press the ON/OFF button to display the letters “MM” for the
month, while the yellow Off Remote LED flashes. Press
RESET to increase the current display value. The input
range is 00-12.
c) Press ON/OFF to display the letters “GG” for the day. The
green Dryer On LED will flash. Press RESET to increase
the current display value. The input range is 00-31.

Press the ON/OFF button to store the settings and quit this
function.

2.3 Start-up

2.3.1 PORO (Power Out Restart Option)

Upon re-powering, the controller will test the display and LEDS
for 3 seconds. The controller will then show the temperature
scale °C or °F for 3 seconds. The signal relay’s contacts then
close.

The controller will then check all the safeties for 5 seconds.
The controller will flash the Dryer On LED for the 5 seconds.
The refrigerant compressor will then start if all safeties are
found closed and keep the green Dryer On LED on.

2.3.2 Normal Start-Up

Upon powering, the controller will test the display and LEDS for
3 seconds. The controller will then show the temperature scale
°C or °F for 3 seconds. The signal relay’s contacts then close.
7
The controller will now wait until the ON/OFF button is pushed.
Once the button is pushed, the controller will then check all
safeties for 5 seconds. The controller will flash the Dryer On
LED for 5 seconds. The refrigerant compressor will then start
if all safeties are found closed and keep the green Dryer On
LED on.

TS250 dryers and above use a scroll compressor. A scroll

compressor is rotation sensitive.

Steps in starting up a new TS250 and above.

1. Ensure that no power is to the unit.

2. Check all wire connections.
3. Check for proper installation IE: bypass piping, clearance for
maintenance and fan exhaust.
4. Turn on power to the unit. There is no crankcase heater.
5. Check to ensure the right voltage is applied.
6. Set the main disconnect switch QS to ON so the yellow
Power On LED on the control panel illuminates.
7. Start–up the unit.
8. Check the suction indicator gauge. This should start to
move down to 5 bars. The compressor should be running
smooth.
9. If the compressor is running noticeably rough and the gauge
does not move down, the compressor has the wrong
rotation. Change two leads and restart the dryer.
10. The dryer must be started with no airflow.
11. Let the unit cool down to 40 degrees and put air to the unit.

12. Check drain valve for proper operation.

13. Record Voltage, Amps, and Pressures.

TS200 and below

1. Ensure that no power is to the unit.

2. Check all wire connections.
3. Check for proper installation, i.e., bypass piping, clearance
for maintenance and fan exhaust.
4. Turn on power to the unit. There is no crankcase heater.
5. Check to ensure the right voltage is applied.
6. Start-up the unit.
7. The dryer must be started with no airflow.
8. Check indicator to ensure unit is getting cold.
9. Put air to the unit.
10. Record Voltage, Amps, and Pressures.

8
2.4 Remote Off

2.4.1 Remote Off, Non Cycling

The Remote Off may be installed on any TS250 or larger.

The “tC” must be set for 0 for none cycling operation.

If the switch is turned off or contacts are open before the unit is
started, the Off Remote LED will be on. Pressing the ON/OFF
button a “Er” will appear in the screen and the unit will not
start. This is due to the unit not running before being shut off
remotely.

Close the remote switch and start the unit. After the unit is
started, the Remote Off switch can be turned off.

2.4.2 Maintain Cold Mass Function

Switch On the main switch while holding down the RESET

button. This will access the Clear report function. “CL” will
display on the controller. Continue to hold down the RESET
button until “CC” appears on the screen. The “CC” function
will allow the controller to maintain the heat exchanger
between temperature tA and tB by turning on and off the
compressor.

- tA temperature of compressor OFF

- tB temperature compressor ON
- tC delay time to stop the compressor following the opening
of the Remote Off contact
- dC delay time to stop the compressor when tA is reached

9
Temperature
(C°)

Compressor turns on Compressor

turns off

tB

tA

tC dC dC Time

To set the parameters:

1. Hold down the ON/OFF button and switch the power on.
2. Continue to hold down the ON/OFF button until the letters
“CC” appear
a. Press the RESET button to set tA (alarm LED flashes)
compressor OFF temperature will be displayed. Press the
RESET button to set temperature. The temperature
should be set for 3.0 °C.
b. Press the ON/OFF button to move to tB (Remote Off LED
flashes), press the RESET to set the temperature. The
temperature should be set at 9.9 °C.
c. Press the ON/OFF button to move to tC (Dryer On LED
flashes), press the RESET button to set the time. The
time should be set for a minimum time of 2 minutes.
d. Press the ON/OFF button to move to dC (Alarm, Remote
Off and Dryer On LED flashes) press the RESET button to
set the time. The time should be set for 10 minutes.
3. Press the ON/OFF to store the settings.

The cold mass function will only work if the tC time is not set
for 0. If tC is set for 0, the unit will shut off as described in
2.5.1 Remote Off non cycling.

When the remote contact is opened, the Remote Off LED will
flash for the duration time of tC and the unit will only turn off if
tA is reached.

10
 3.0 Terminal Board Connection

Supply Output Input Sensor

230 230 1 2 3 4 5 6 7 8 NTC NTC

N NTC Sensor
Compressor
Contactor Coil Common Input
N N
Low Pressure
Common Output n/c n/c (not used)
R R

Warning/Alarm Relay n/c Remote Off

R R

High Temperature
High Pressure Switch n/c n/c Switch
R R

11
4.0 Alarms and Warnings

HP – PI : High Pressure and Integral Protection Alarm

The HP-PI alarm is generated if the input to terminal 4

becomes open. This happens due to the pressure being
greater then the maximum allowed.

When the unit trips, the display will show the code HP and PI.
PI is the external overload on the TMS1650 and larger. This
overload is attached to the side of the refrigerant compressor.

Press RESET to clear the alarm

LP- Low Pressure

This alarm function is no longer installed. This alarm would

show if the terminal number 7 on the controller lost power for
three minutes.

12
ST- High Discharge Temperature Alarm

The ST alarm is shown when the refrigerant discharge

temperature exceeds 248° F. This switch is a manual reset.
Once the temperature switch is reset, pressing the RESET
button may reset the controller.
If the bulb loses it’s charge, the switch will not reset.

Ld – Low Dew Point Temperature Alarm

This alarm is generated when the temperature falls to 27° F

after a three-minute delay. When the alarm trips, the
compressor will stop. Code Ld appears on the display. The
controller will alternate between the temperature reading and
alarm code until the temperature has reached 32° F. The
controller will then read Ld continuously. Reset and restarting
the unit is not possible until the temperature has risen to 32° F.
This is a manual reset on the controller.

Hd – High Dew Point Temperature Warning

This warning is displayed when the temperature exceeds 59° F

for 3 minutes. The compressor does not stop. The display will
alternate between Hd and the temperature. The warning will
automatically reset when the temperature moves below 55° F.

AS- Sensor Fault

This warning is shown when the temperature sensor is open or

shorted. In this event, the Ld alarm and Hd warning are
inhibited. All other functions remain active.
13
EP – E-prom Error

This warning appears when the e-prom chip is faulty. All

alarms and warnings are inhibited. The controller must be
replaced.

Er – Power-On Error

The controller will display the Er warning if the ON/OFF button

is pushed when the unit has been turned off remotely.

FS- Out of Range

FS indicates that the measured temperature exceeds the rtd

normal temperature range. 14° F - 99° F

5.0 Refrigeration Circuit and Troubleshooting

5.1 Hot Gas Adjustment

Remove all air from the unit. Let the unit run 5 minutes with no
load.

Turn the hot gas valve clockwise to increase pressure and

counter clockwise to reduce the pressure. The hot gas is set
to 70 PSIG.

This gives a 37° F dew point setting.

14
5.2 High Head Pressure (HP Alarm)

The high discharge pressure switch de-energizes the coil on

KA1. This opens the contacts to terminal number 4 on the
controller.

Possible causes are:

1. High ambient temperature

2. Condenser dirty
3. Inlet temperature too high
4. Flow rate too high
5. Fan does not work (Fan switch or motor)
6. Incorrect start up (Started with air flow though the dryer)
7. Refrigerant charge incorrect (Overcharged)
8. Defective head pressure switch
9. Clogged filter dryer (High temperature differential across
filter)
10. Blocked capillary (High temperature differential across
capillary)

If R407c is charged in the vapor form it will cause the head

pressure problems.
If the fan switch is running above 260 this will cause the
refrigerant to break up into its different parts and cause the
head pressure switch to trip.

15
5.3 High Discharge Temperature (ST alarm)

1. Refrigerant leak: The heat of compression of the refrigerant

compressor will cause the discharge temperature to rise due
to the lack of refrigerant,
2. Compressor not pumping (no pressure differential between
suction and discharge)
3. Clogged filter dryer (high temperature differential across
filter)
4. Blocked capillary (high temperature differential across
capillary)

5.4 High Dew Point

The indicator will move into the red on smaller units and the Hd
will alarm on the TS250 and larger units at 59 °F.

Reasons:

1. High ambient and high inlet temperatures causing an

excessive thermal load.
2. Wrong rotation of the Scroll compressor TS250 and above
a. The gauge on the front panel should move down to the 70
PSIG or 4.8 Bars on start-up.

5.5 Internal Protection (PI Alarm)

TS1600 and above use an external thermo-amperometric

protection. (Three phase compressors)

L1/L L2/N S1 S2 M1 M2

L1 and L2 are power in to the overload.

S1 and S2 are the temperature sensor.

M1 and M2 are the contacts that open to break the connection

going to coil that energizes the coil to KA1. KA1 closes the
contacts going to terminal number 4 on the control board.

There is 30-minute delay before the switch will reset. This is

an automatic reset.
The controller will need to be reset even if the overload resets
automatically.

16
5.6 Cold Weather Shutdown (8.8 alarm)

If the controller will not start and shows 8.8 on the LED, the
ambient or inlet air temperature is too low. This unit will not
start if the ambient temperature is below 32°F.

5.7 Control Fuses Blowing fu4-7

Short circuit on secondary side. A shorted coil most likely

causes this. Check drain valve coil as well as contactor and
relay coils.

5.8 Leak Checking

Never use colored dye to leak check a refrigeration

system. Use of a dye may invalidate the unit’s warranty.

The recommended tool for leak checking is an electronic leak

detector. (38034161)
Starting at the top of the unit and working downwards. Moving
the detector 2 inches per second. Refrigerant is heavier then
air and will fall to the base of the unit causing false alarms.

5.9 Leak Checking Heat Exchanger

Refrigerant Leak Checking

1. Check drain valve to see if any refrigerant is detected.
2. Pull a vacuum on the refrigerant side of the heat exchanger.
3. Apply air to the air side of the exchanger. If air enters the
exchanger, the leak is confirmed.

Air to Air Leak Checking

1. Pour water into the inlet of the dryer.
2. If water comes out the outlet then there is a leak in the
exchanger.

17
6.0 Refrigerant Compressor Troubleshooting

6.1 Three Phase Compressors

Checking Ohms Resistance

The ohms resistance should be close to the same on all three

phases.

When doing an ohms test no power should be applied to the

circuit. The preferred method is to take the wires off the
terminal post and check the ohms at the terminal post. Expect
as the horsepower goes up that the average resistance
readings will go down.

Under NO Circumstance should you be able to read any

resistance going to ground with the wires disconnected. To test
resistance to ground, one should scratch the paint off a point
on the compressor and use this point to get an accurate
reading to ground.

Checking Amp Draw

The amp draw should be within 10% on each phase. You

should check the voltages before making any conclusions.
The amp draw should never be over nameplate.

Causes of high amp draw

1. Shorted winding
2. Mechanical problem
3. Short in the control circuitry
This is why it is important to isolate the compressor for the
control circuitry when checking resistance (see Table 2).

18
 Resistance Table

Model Run to Start to Run to Voltage CCN

Start Common Common
TS250- 8.6 8.6 8.6 460/3/60 38003653
400
TS500 5.94 5.94 5.94 38003661

TS700- 4.03 4.03 4.03 38003679

800
TS1000- 2.72 2.72 2.72 38003687
1200
TS1400 1.79 1.79 1.79 38003695

TS1650- 1.11 1.11 1.11 38003703

2000
TS2400 1.02 1.02 1.02 38003711

TS3000 0.83 0.83 0.83 38003729

Table 2

19
6.2 Checking a Hermetic Compressor, Single-Phase

When checking a single-phase motor it must be understood

that there are different types of single-phase motors.

Checking the ohms of a single-phase compressor.

The Capacitor Start Type Compressor

The highest ohms readings will be between the start and run
windings. This reading will be the sum of both sets of windings.
The third post will be the common post. The ohms readings
between the run and common windings will be the lowest. The
ohms reading between the start and common will be higher
than the run and common by 2:1 ratio or 3:1 ratio. See Fig. 1
for example.

The Split Phase Compressor

Again the highest readings will be between the start and run
windings. The third post will be the common and the reading
will also be the sum of the windings. The ohms readings
between the run and common will be the lowest. The ohms
readings between the start and common will be higher than the
run and common by 4:1 ratio or 5:1 ratio. See Fig. 1 for
example.

When doing an ohms test no power should be applied to the

circuit. The preferred method is to take the wires off the
terminal post and check the ohms at the terminal post. Expect
as the horsepower goes up that the average resistance
readings will go down.

Under NO Circumstance should you be able to read any

resistance going to ground with the wires disconnected. To test
resistance to ground, one should scratch the paint off a point
on the compressor and use this point to get an accurate
reading to ground.

For the sake of comparison, the same horsepower compressor

was used for this example.

Figure 1
Start-up amp draw
Start Start to Run to run amp start amp
to run common common draw draw
Split 19.5 16 ohms 3.5 ohms 10.5 to 6 to 0
Phase ohms 2.5 amps amps

Capacitor 10.5 7 ohms 3.5 ohms 12 to 2.5 8 to 0

start ohms amps amps
20
Checking Amp Draw on a Single-Phase
It is generally known that the starting current will be 300% to
500% higher than running current.

At start-up, the run windings will be the windings that have the
greatest variance. This will also vary from the type of
compressor one is working on. See amp draw on same two
compressors Fig.1.

If amp draw is higher than 140% of nameplate, something is

wrong. Make sure the line voltage is within 10% of the
nameplate before drawing any conclusions.

Causes of high amp draw

1. Shorted winding
2. Mechanical problem
3. Short in the control circuitry
This is why it is important to isolate the compressor for the
control circuitry when checking resistance (see Table 3).

Resistance Table

Model Start Run to Start to Voltage CCN

number to run common common
TS50-75 8.7 1.4 7.3 110 38003554

TS100 8.5 1.2 7.4 110 38003562

TS150 10.8 2.7 7.3 230 38003596

TS200 7.6 2.1 5.5 230 38003604

TS250- 3.24 1.18 2.06 208/230 38003612

325 /1/60

Table 3

6.3 Dehydration and Vacuum Procedure

This procedure describes the minimum operations that have to

be done in order to obtain a reliable dehydration and vacuum
of the cooling system.

Dehydrate the circuit by pulling it under vacuum using the

double vacuum procedure.

First evacuation:

Fit the vacuum hose to vacuum pump and the refrigerant

system and evacuate the system until a minimum vacuum is
21
reached of 1500 microns. Use a large diameter hose to
connect the vacuum pump to the system and keep it as short
as possible.

Flush system:
Break the vacuum with nitrogen at 5psi.

Second evacuation:
Pull down the entire system to 500 microns and hold for 10
minutes with minimal rise in microns. A large rise would be a
sign of a leak.

Warning:
Do not run compressor while under vacuum as it may
cause the compressor motor to short out.

6.4 Refrigerant Charging

This procedure describes the minimum operations that need to

carried out to successfully charge TS dryers with the correct
quantity of refrigerant.

Equipment:
-Filling cylinder R407C
-Service manifold with high and low pressure gauges
-Filling hoses (no loss fitting)
-Weight scale
-Micron gauge for testing vacuum

General: Before charging be sure that refrigeration system is

dehydrated and vacuumed.

Warning: Never exceed the normal charge. In cases of

overfilling, the compressor can be seriously damaged by
liquid slugging.

Filling Procedure for TS dryers

1. Connect the service manifold to the suction valve on the

compressor for low pressure and to the valve on the liquid
receiver for the high pressure (If receiver is available, if not use
another high side port). This should already be done during
the evacuation process.

2. Connect the yellow service line to the refrigerant-charging

bottle, which should be placed on a suitable scale for weighing
the charge. Open the valve on the charging bottle.
22
3. Establish the correct amount of R407C to be added to the
system from the nameplate.

4. The yellow charging hose should have no loss fittings. If the

hose does not have no loss fittings, the hose will need to be
purged first.

5. With the charging bottle on the scale, open the high side
gauge valve. (Normally the refrigerant flows by itself into the
system, if not, you can warm up the charging bottle) Do not
use a torch! Always charge R407C in liquid form!

If the flow of refrigerant stops before the unit is fully charged,

follow these next steps. You should have at least 90% of the
full charge in the system, if not, the system was not properly
charged or evacuated.

a. Close the high side valve.

b. Calculate how much more will be needed too fully charge

the system.

c. Always charge R407C in liquid form.

d. Start the unit.

e. Open the suction-side valve and weigh in the rest of the

charge.

6. Once the unit is fully charged, close the valves on the

gauges and on the charging bottle.

7. Start the unit if not already running.

*8. Fully back seat the service valves.

9. Remove the gauges and refit the appropriate caps. Use

Loctite 542 on Schrader valve connections caps.

*If compressor is installed with service valves

6.5 Compressor Oil Housekeeping

For normal working conditions there is no need to remove or

add oil to a compressor. Remember, an excess of oil is as
dangerous as a lack of oil. Where there has been a severe oil
leak, only add original polyol ester compressor oil.

Adding oil must be done on the suction side with a special oil
pump to overcome the refrigerant pressure. Follow the pump
23
directions or, for special help, call the Customer Service
Department in Davidson. (1-800-526-3615)

What to do when the refrigeration compressor motor

“burns out”

A motor “burn out” can produce several aggravating reactions

which can “spread” within the refrigeration circuit.
There are very often chain reactions. For example, a reaction
that produces a small quantity of hydrochloric acid would
increase electrical conductivity that will then induce arcing.
The resulting high temperature at the arc point causes a
concentration of acids and further breakdown of winding
insulation.

The replacing of a “burnt out” compressor without the complete

system being thoroughly cleaned previously further aggravates
this phenomenon.

The presence of any impurities within the system would

contaminate the new compressor, so reducing it’s working life.

Cleaning after a motor “burn out”

1. Reclaim the refrigerant from the unit.

2. Replace the liquid line filter dryer and compressor (follow
change procedures).
3. Add suction line filter with Schrader taps for pressure drop
inspection. The suction line filter dryer should be added to
the unit after the suction accumulator if installed. Shut-off
valves should be installed if the filter is installed for
temporary installations or if the cores are expected to be
replaced.
4. Cleaning of the expansion valve may be needed on extreme
burn outs.
5. Do normal vacuum procedures.
6. Recharge the unit using charging procedures.
7. Check the suction line filter pressure drop after one hour of
operation. The pressure drop should be no greater then 2 psi
on a permanent installation, 6 psi on temporary installation.

6.6 Compressor Replacements

-Check the new compressor before going to the job site for
proper electrical and refrigeration performance characteristics.

-Perform an ohms test before installing a new compressor.

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-Before replacement, find the cause of failure and carry out
corrective actions. If such analyses and repairs are not done,
repetitive failure will occur.

-In cases of a motor failure, check the system for acids and
perform burn out procedures.

-Use only new rubber grommets supplied with new compressor

for installation.

-If piping needs to be modified, use only dehydrated and

sealed refrigerant copper tubing.

-Check the unit for leaks.

-Perform acid tests on all compressor failures to ensure acids

are not present in the system.

-Install new filter dryers and suction line filter if needed.

6.7 Scroll Compressor Removal

Caution! Before opening a system, it is important to remove all

the refrigerant both high and low side. If the refrigerant charge
is removed from a scroll-equipped unit by recovering high side
only, it is possible for the scrolls to seal, preventing pressure
equalization through the compressor. This may leave the low
side shell and suction line pressurized. If a brazing torch is
then applied to the low side while the low side shell and suction
line contains pressure, the pressurized refrigerant and oil
mixture could ignite when it escapes and contacts the brazing
flame. To prevent this occurrence, it is important to check both
the high and low side with manifold gauges before unbrazing.

If the compressor removal is required, the compressor

should be cut out of the system rather than unbrazed.

To disconnect: Reclaim refrigerant from both the high and low

side. Cut tubing near compressor.

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To reconnect:
1. Recommended brazing materials: 45+ silver solder with
flux.
2. Insert tubing stubs into fitting and connect to system with
tubing connectors.
3. Be sure both tube fitting I.D. and O.D. are clean prior to
assembly. If oil film is present, wipe with denatured alcohol.
Dichloro-Trifluoroethane or other suitable solvent.
4. Using a double-tipped torch to apply heat in Area 1. As
tube approaches brazing temperature, move torch flame to
Area 2.
5. Heat Area 2 until braze temperature is attained, moving
torch up and down and rotating around tube as necessary to
heat tube evenly. Add brazing material to joint to flow braze
material around circumference.
6 After braze material flows around joint, move torch to heat
Area 3. This will draw the brazing material down the joint. The
time spent heating Area 3 should be minimal.

As with any brazed joint, overheating may be detrimental to the

final result.

It is important to flow nitrogen through the system while brazing

all joints during the system assembly process.

In the case of a motor burn out, the majority of contaminated

oil will be removed with the compressor. The rest of the oil is
cleaned through use of suction and liquid line filter dryers.

It is recommended that the suction accumulator be replaced if

the system contains one.

Rotalock Torque Values

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 6.8 Refrigerant Pressures and Temperatures
Suction temperature
39 ° F to 52° F Super heated Gas
Suction Pressure
70 PSIG

Discharge line superheated gas

130° F - 170° F

Hot Gas

Discharge line
240 PSIG to
180 PSIG Suction Line
Flash gas
70 PSIG
33°F to 35°F

Discharge line subcooled

liquid 104°F or below Filter dryer
Capillary tube

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