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1 2011 Emerson Climate Technologies

Printed in the U.S.A.

AE-1315 R1

Application Engineering

B U L L E T I N

Application Guidelines forCopeland ScrollTK Open Drive Compressors

AE4-1315 R2 August 2011


B U L L E T I N

SafetySafety Instructions ................................................................................................ 2Safety Icon Explanation ....................................................................................... 2Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons ...... 3Safety Statements ................................................................................................ 3

Introduction............................................................................................................. 4Nomenclature ....................................................................................................... 4Refrigerant/Lubricants .......................................................................................... 4Operating Envelope ............................................................................................. 4Liquid Injection ..................................................................................................... 4Discharge Temperature Protection ....................................................................... 5

Accumulators ....................................................................................................... 5Pressure Controls ................................................................................................ 5Directional Dependency ....................................................................................... 5Deep Vacuum Operation ...................................................................................... 5Shaft Seal ............................................................................................................. 5Belt Tension .......................................................................................................... 5Mounting Consideration ....................................................................................... 5

FiguresOperating Envelope ............................................................................................. 4Model Nomenclature ............................................................................................ 6

TK Belt Gauge Correlation ................................................................................... 7

Table of Contents

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Safety Instructions

Copeland Scroll TK open drive compressors are manufactured according to the latest U.S. and EuropeanSafety 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 instructionsshould be retained throughout the lifetime of the compressor.You are strongly advised to follow these safetyinstructions.

Safety Icon Explanation

DANGER indicates a hazardous situation which, if not avoided, will resultin death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardoussituation 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 practicesnot related to personal injury.

DANGER

WARNING

CAUTION

NOTICE

CAUTION

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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.

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 electricallylocking 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.

BURN HAZARD

Do not touch the compressor until it has cooled down.

Ensure that materials and wiring do not touch high temperature areas ofthe compressor.

Use caution when brazing system commponents.


Failure to follow these warnings could result in serious personal injury orproperty damage.

COMPRESSOR HANDLING

Use the appropriate lifting devices to move compressors.


Failure to follow these warnings could result in personal injury orproperty 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 andrefrigeration equipment must be observed.

Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

WARNING

WARNING

WARNING

CAUTION

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Introduction

The Copeland ScrollTK compressor is an open drivescroll compressor that has been developed specifically

for the truck refrigeration industry. This open drivescroll compressor has the following features that areunique and different from traditional hermetic scrollcompressors.

The scroll set and bearings are designed to operateat a range of all RPMs from 2300 to 4200.

The compressor has a lightweight aluminum bodyto minimize the overall compressor weight.

The compressor also utilizes a positive displacementoil pump to ensure adequate lubrication over theentire operating range of speeds.

The design also utilizes a state-of-the-art shaft sealto eliminate any leakage.

These modifications result in a compressor that issuitable for the most demanding transport applicationswith efficiencies and reliabilities far better thantraditional reciprocating compressors.

Nomenclature

Please refer to Figure 2.

Refrigerant/Lubricants

The TK open drive compressors are only approvedfor use with R-404A and Emerson approved POE

lubricants. Please refer to Emerson Form No. 93-11, Refrigerant/Lubricants for Use in CopelandCompressors. (The oil charged as shipped is 63 oz.)

Operating Envelope

The approved operating envelope is shown in Figure1 below. To achieve extremely high pressure ratiooperation, liquid injection will be required to avoidexcessive discharge temperature.

Liquid Injection

The open drive TK scroll compressor is provided withan injection port suitable for connection to a source

of liquid refrigerant. Internally, this port is connectedto an inner pocket of the scroll mechanism. Since thispocket is separated from the suction inlet, no loss ofcapacity or mass flow results from injecting at thispoint.

The approved liquid injection device is the Sporlandesuperheater valve, one-ton size, rated at 121 C.The bulb must be installed on the discharge line withinsix inches of the compressor outlet, and the connectionmust be fully insulated. A minimum of -12 C liquidsubcooling required for proper valve operation.

70

90

110

130

150

170

ondensingTemperature

(F)

Extended

Envelope

For Mul-

Normal

Operang

Envelope

Extended

Envelope

-10

10

30

50

-80 -60 -40 -20 0 20 40

C

EvaporangTemperature (F)

Temp Unit

Figure 1 Operating Envelope

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Discharge Temperature Protection

CAUTION

Compressor head temperatures can be very hot.Care must be taken to ensure that wiring or othermaterials which could be damaged by thesetemperatures do not come into contact with

these potentially hot areas.

Discharge Temperature Protection is required for lossof charge and other system conditions where excessivedischarge temperature can occur. A thermostat/thermistor is supplied in the top cap for this reason.The thermostat has a cut-out temperature of 147 +/- 3C and a cut-in temperature of 61 +/- 11 C. It is ratedfor up to 24 VAC.

Accumulators

An accumulator is required on any compressor systemwith a refrigerent charge over 9 lbs. Excessive liquidfloodback or repeated flooded starts will dilute the oilin any compressor causing inadequate lubrication andbearing wear. Proper system design will minimize liquidfloodback, thereby ensuring maximum compressor life.

Pressure Controls

Both high and low pressure controls are required withthe following set points. The low pressure setting mustbe 10 PSIA or greater. High pressure controls must beset no higher than 468 PSIA.

Directional Dependency

Scroll compressors are directional dependent , i.e.they will compress in one direction only. Engine drivencompressors are designed to only operate in theproper direction. When operated in the electric motorstandby condition, the possibility exists that a 3-phasemotor could be wired to operate in the wrong direction.The controller must be equipped with a phase sensingrelay that will prevent operation in the wrong direction.

Although operation of the scroll in the reverse directionfor brief periods of time is not harmful, continuedoperation could result in a failure.

The application requires the use of phase detectionand correction device. Direction of rotation is shownby arrows cast onto the compressor body.

Deep Vacuum Operation

A low pressure control is required for protection againstdeep vacuum operation. (See the section on PressureControls for the proper set point.)

Operation in a deep vacuum will cause severeoverheating and wear on the scroll members.

Shaft Seal

Maximum low-side pressure without leak or distortion(through the casting and gasket/seal joints) is 402PSIA. Damage to the shaft seal may occur if adifferential pressure of greater than 300 PSI is appliedfor longer than 60 seconds.

Belt Tension

Excessive belt tension can cause premature wear andresult in leakage of the shaft seal. Premature wearand failure of the lower bearing (ball bearing) may alsooccur due to excessive belt loading. Therefore, themaximum belt tension should be such that a maximumof 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 willcause the oil pump to lose its ability to supply adequatelubrication. Therefore, the maximum tilt angle for thecompressor is 20 from horizontal in any direction.

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OPEN DRIVE SCROLL COMPRESSORMODEL NOMENCLATURE

X X X X - X X X X - X X X - X X X

COMPRESSORFAMILY SERIES

T- Open Drive

APPLICATION RANGEK - Thermo King only

SCROLL DISPLACEMENT

MODEL SERIES VARIATIONS

Number assigned to indicatemajor design variation withinany one family series

OIL TYPE

E - P.O.EL - No OilBlank - Std. Min Oil

MODEL BODY TYPE

L - Body MountedB - Bracket MountedF - Flange Mounted

SHAFT RPM

@ Ratingcondition in 100's

SHAFT RPM MULTIPLIER

C = 100

PRODUCT VARIATIONS

Number will be assigned as follows:

1. Numbers - 001 through -099 are reserved formodel number basics

2. Number -200 indicates a standard compressor3. 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.

Figure 2 Nomenclature

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TK Belt Gau ge C orr elati on

Note: This is for a se rpentine be lt.

0

50

100

150

200

250

300

350

400

450

500

30.0 35.0 40.0 45.0 50.0 55.0 60.0 65.0 70.0 75.0 80.0

TK Gauge Number

BeltTensioninTwoLegsofBelt(lbf)

TK Belt Gauge CorrelationNote: This is for a serpentine belt.

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 orservices described herein or their use or applicability. Emerson Climate Technologies, Inc. reserves the right to modify the designs or specifications of such products at any time withoutnotice. Emerson Climate Technologies, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance ofany Emerson Climate Technologies, Inc. product remains solely with the purchaser and end-user.

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