AK 2 Series Compressor

Transcription

1 AK 2 Series Compressor Reference Guide Commercial Refrigeration Applications

2 AK 2 SERIES COMPRESSOR AK 2 Compressor Reference Guide ECO-FRIENDLY AK 2 is optimized for use with eco-friendly refrigerant R290 (Propane), plus newly released U.S. EPA SNAP approved refrigerants, R452A, R448A and R449A. Traditional refrigerants R134a and R404A are also supported by the AK 2. PERFORMANCE New valve plate, muffler and motor designs result in improved compressor efficiency. PROVEN RELIABILITY Leverages robust design attributes developed from decades of commercial refrigeration experience with this expansion and update of the AK product family including larger bearing surfaces. SERVICE AND SUPPORT Backed by Tecumseh s network of knowledgeable applications engineers, test labs and support personnel. LOW NOISE New suction muffler and internal suspension system as well as a new rounded housing combine to deliver significant improvements in sound quality. AK 2 COMMERCIAL REFRIGERATION BEST IN CLASS The AK 2 borrows its name from Tecumseh s popular AK series compressor and there are a multitude of improvements. From the acoustically shaped housing to the refrigerant handling system and the mechanical pump kit and motor, the AK 2 has been designed to deliver high performance without sacrificing Tecumseh s industry known reputation for reliability. While increasing bearing surfaces AK 2 R290 compressor models deliver efficiencies as high as 10.5, 7.1 and 5.3 EER respectively in the expanded High/Commercial evaporating range and Low Temperature conditions. Tecumseh s new AK 2 is one of the quietest commercial refrigeration compressors produced to-date with sound power levels as low as 50 dba. 2

3 TABLE OF CONTENTS AK 2 Series Compressor... 2 Commercial Refrigeration Best in Class... 2 Typical Applications... 3 AK 2 Series Compressor Nomenclature and Serial Label... 4 AK 2 Series Compressor Dimensions... 5 Capacitor Start and Run (CSR) Motor Type... 5 Performance Specification H/CBP... 6 Performance Specification LBP... 7 AK 2 Installation Instructions... 8 TYPICAL APPLICATIONS The AK 2 has a H/CBP expanded evaporating temperature range from +5 F to +59 F (-15 C to +15 C). Models also available in LBP temperature from -40 F to +10 F (-40 C to -12 C). 3

4 AK 2 SERIES COMPRESSOR NOMENCLATURE Compressor Series Application Code 2 LBP 4 H/CBP Rating Point (Evaporating Temperature) LBP -10 F (-23.3 C) CBP +20 F (-6.7 C) HBP +45 F (+7.2 C) Capacity (Btu/h) First digit represents the number of digits in BTU capacity at ASHRAE conditions. Last two digits represent the first two digits in the Rated Btu/h capacity. In this example, four (4) total digits with the first two (82) or 8,200 Btu/h capacity. AK 2 SERIES BOM NOMENCLATURE AK U-XA 3B Refrigerant Type U R290 Y R134a/ Z R404A/R452A/ R448A/R449A Capacitor Options First Character (Run Capacitor) 1 Without Run Capacitor 2 Optional Run Capacitor 3 With Run Capacitor Voltage Code AA XA XD /60/1 200/50/1 XN /60/ /50/1 NA /60/1 FZ /50/1 A K 4 U A 1 A T A 4 0 Compressor Series Application Refrigerant Displacement Code Model Variant Voltage Country of Origin Compressor Housing Pack Type Process Code 2 LBP 4 H/CBP U R290 Y R134a/ Z R404A/R452A//R448A/R449A Cu In / Cu Cm A / 15.6 B / 17.5 C / 20.4 D / Current 2 Future 3 Future A = XA, AA D = XD, XN, NA J = FZ T Tupelo/USA 100 DCAK DCAK DCAK DCAK103 A J P Pallet Pack Single Pack Plant Use By Region, See BOM structure Model Number Code for Division of Manufacture (P) (T) Bill of Material Number AK2UCIAT101A40 AK2431U-XA3B Appropriate Refrigerant R V ~ 60Hz 100V ~ 50Hz LRA: 51.5 Electrical Rating Volts/Hertz Note: Yellow box will be in ALL labels, however flammable symbol only appears on R290 compressors. LRA (Locked Rotor Amps) Code Date Letter indicates month Next 2 digits indicate day of month. Last 2 digits indicate year 04 J A January D April G July K October B February E May H August L November C March F June J September M December C US THERMALLY PROTECTED COUNTRY OF ORIGIN: USA Compressor Serial Data Matrix Code Sequential 6 Digit Number Shift Reference (Shift code is applied at final process) Line Letters or Numbers 4

5 AK 2 SERIES COMPRESSOR DIMENSIONS Left Side View Right Side View Suction Tube B Discharge Tube Process Tube A * Housing A - Width (IN) B - Height (IN) C - Length (IN) D - Bracket (IN) E - Bracket (IN) DCAK100/ DCAK101/ Top View D Process Tube Connection Sizes (IN) E Suction Tube Process Tube Suction Tube 3/8 OD / 1/4 ID 1/2 OD / 3/8 ID Discharge Tube 3/8 OD / 1/4 ID Discharge Tube C *Refer to Sales Compressor Housing Drawing for additional drawing details. CAPACITOR START AND RUN (CSR) MOTOR TYPE* This motor arrangement uses a start capacitor and a run capacitor in parallel with each other and in series with the motor start winding (see figure). This motor has a high starting torque, runs efficiently, and is used on many applications. A potential relay removes the start capacitor from the circuit after the motor is up to speed. On AK 2 the motor is protected by an external thermal protector. *Refer to DEAK1 Drawing for specific electrical hookup and wiring diagram information Line 1 Line 2 Control Ground Compressor Unit Ground Relay Potential External Thermal Protector C S R Start Winding Main Winding 5

6 PERFORMANCE SPECIFICATION H/CBP Model AK4461Y-XA3B Voltage Disp (Cu In) AK4461Y-FZ3B /50/ AK4468Y-XA3B AK4481Y-XA3B AK4481Y-FZ3B /50/ AK4481Y-XD3B AK4510Y-XA3B /60/1 200/50/ AK4510Y-NA3B /60/ R404A/R452A/R448A/R449A AK4510Z-XA3B AK4510Z-FZ3B /50/ AK4510Z-NA3C /60/ AK4511Z-XA3B AK4511Z-XD3B AK4513Z-XA3B /60/1 200/50/ AK4513Z-FZ3B /50/ AK4513Z-XD3B /60/1 200/50/ AK4513Z-NA3C /60/ AK4516Z-NA3C /60/ R290 AK4482U-XA3B Refrig. HBP/CBP 5 F to +59 F or (-15 C to +15 C) ASHRAE AHRI EN F (7.2 C) 20 F (-6.7 C) 45 F (7.2 C) 20 F (-6.7 C) 41 F (5 C) Capacity Efficiency Capacity Efficiency Capacity Efficiency Capacity Efficiency Capacity Efficiency BTU/Hr Watts EER COP BTU/Hr Watts EER COP BTU/Hr Watts EER COP BTU/Hr Watts EER COP Watts COP 6,145 1, , ,844 1, , ,440 1, , ,090 1, , , ,750 1, ,500 1, ,500 1, , ,172 2, ,393 1, ,624 2, ,136 1, ,814 1, ,804 1, ,471 1, , , ,173 2, ,460 1, ,677 2, ,890 1, ,371 3, ,330 1, ,830 2, ,018 1, ,304 3, ,900 1, ,669 2, ,865 1, R404A 9,871 2, ,389 1, ,812 2, ,839 1, R452A 9,841 2, ,365 1, ,094 2, ,818 1, R448A/R449A 9,776 2, ,412 1, ,162 2, ,860 1, R404A 8,244 2, ,814 1, ,513 2, ,323 1, , R452A 8,339 2, ,488 1, ,623 2, ,030 1, , R448A/R449A 8,191 2, ,466 1, ,693 2, ,011 1, , R404A 10,073 2, ,198 1, ,280 2, ,565 1, R452A 9,947 2, ,357 1, ,240 2, ,811 1, R448A/R449A 9,872 2, ,581 1, ,323 2, ,011 1, R404A 10,581 3, ,861 1, ,755 2, ,263 1, R452A 10,316 3, ,402 1, ,333 3, ,851 1, R448A/R449A 10,245 3, ,574 1, ,590 2, ,005 1, R404A 11,323 3, ,017 1, ,467 3, ,403 1, R452A 11,123 3, ,922 1, ,306 3, ,318 1, R448A/R449A 10,916 3, ,948 1, ,447 3, ,341 1, R404A 12,914 3, ,837 2, ,851 3, ,139 1, R452A 12,701 3, ,950 2, ,829 3, ,241 1, R448A/R449A 12,385 3, ,950 2, ,047 3, ,241 1, R404A 10,882 3, ,058 1, ,063 2, ,440 1, , R452A 10,895 3, ,955 1, ,090 2, ,347 1, , R448A/R449A 10,726 3, ,172 1, ,226 2, ,542 1, , R404A 12,731 3, ,706 1, ,687 3, ,022 1, R452A 11,968 3, ,846 2, ,720 3, ,147 1, R448A/R449A 11,191 3, ,815 1, ,615 3, ,120 1, R404A 13,071 3, ,430 2, ,045 3, ,672 1, R452A 13,120 3, ,148 2, ,201 3, ,419 1, R448A/R449A 13,234 3, ,272 2, ,266 3, ,530 1, R404A 16,246 4, ,687 2, ,973 4, ,800 2, R452A 15,570 4, ,313 2, ,873 4, ,465 2, R448A/R449A 16,251 4, ,587 2, ,244 4, ,710 2, R290 8,238 2, ,203 1, ,834 2, ,991 1, AK4482U-FZ3B /50/ R290 6,904 2, ,930 1, ,487 1, , , AK4482U-XD3B /60/1 200/50/ R290 8,410 2, ,632 1, ,995 2, ,213 1, AK4492U-XA3B R290 9,167 2, ,050 1, ,591 2, ,490 1, AK4492U-XN3B /60/ /50/ R290 9,362 2, ,939 1, ,883 2, ,663 1, AK4511U-XA3B R290 11,028 3, ,406 1, ,558 3, ,791 1, AK4514U-NA3B /60/ R290 14,363 4, ,940 2, ,731 4, ,950 2,

7 PERFORMANCE SPECIFICATION LBP Model R404A / R452A Voltage Disp (Cu In) AK2427Z-FZ3B /50/ AK2427Z-NA3B /60/ AK2430Z-XA3B AK2430Z-FZ3B /50/ AK2430Z-XD3B /60/1 200/50/ AK2436Z-AA3B AK2436Z-FZ3B /50/ AK2448Z-AA3C AK2448Z-FZ3C /50/ AK2448Z-NA3C /60/ R290 AK2424U-XA3B AK2431U-XA3B Refrig. LBP -40 F to +10 F or (-40 C to -12 C) ASHRAE AHRI EN F (-23.3 C) -10 F (-23.3 C) -31 F (-35 C) Capacity Efficiency Capacity Efficiency Capacity Efficiency BTU/Hr Watts EER COP BTU/Hr Watts EER COP Watts COP R404A 1, , R452A 1, , R404A 2, , R452A 2, , R404A 3, , R452A 2, , R404A 2, , R452A 2, , R404A 2, , R452A 2, , R404A 3,650 1, , R452A 2, , R404A 3, , R452A 2, , R404A 4,780 1, ,493 1, R452A 4,444 1, , R404A 4,130 1, , R452A 3,676 1, , R404A 4,892 1, ,587 1, R452A 4,454 1, , R290 2, , R290 3, , AK2431U-FZ3B /50/ R290 2, , AK2431U-XN3B /60/ /50/ R290 3, , AK2447U-AA3C R290 4,651 1, ,804 1, AK2447U-NA3C /60/ R290 4,539 1, ,690 1, Tip: Use Customer Resource Tools page at for the most up-to-date Tecumseh and competitive model cross references. AK 2 SERIES COMPRESSOR INFORMATION Application HBP 8,250-14,350 7,850-13,750 CBP 4,200-7,950 4,000-6,950 LBP 2,500-4,650 2,000-3,800 Note: Capacity is in BTUs ASHRAE / AHRI ASHRAE / AHRI ASHRAE / AHRI ASHRAE / AHRI ASHRAE / AHRI R290 R404A R452A R449A 6,150-10,350 5,850-9,850 3,100-5,350 3,000-5,000 N/A 9,850-16,250 8,800-14,950 5,400-8,700 4,850-7,800 2,700-4,900 2,100-3,600 9,850-15,550 9,100-14,850 5,350-8,300 4,800-7,450 2,450-4,450 2,000-3,400 9,800-16,250 9,150-15,250 5,400-8,600 4,850-7,700 N/A 7

8 AK 2 SERIES COMPRESSOR INSTALLATION INSTRUCTIONS Typical CSR Application Removal of the Protective Cover 1 Remove the protective cover bale strap with screwdriver. 2 Remove the protective cover. Suction Tube Process Tube (not visible - backside of lower housing) Bale Strap Discharge Tube 1 Exploded View of Assembly 2 Protective Cover Sleeve and Grommet LP15 Mounting Kit Grommet Sleeve Compressor Terminal Fence Compressor Terminal Overload Protective Cover Gasket Holder Bale Strap NOTE: Potential Relay, Start Capacitor and Run Capacitor are mounted together in an electrical box or separately in the equipment s compressor compartment. 8

9 Compressor Port Locations Process Tube Bale Strap Suction Tube Discharge Tube Protective Cover NOTE: Reference Tecumseh Engineering Policy Bulletin EP-16 when applying AK 2 Series and other direct suction compressors in Cube Ice Machine applications. Refer to the Library - Engineering Policies section of our website ( Terminal Pin Orientation Common Run Start CAUTION: Safety First! Note: Never energize the system unless; 1. The protective cover is securely fastened, and 2. The compressor is properly connected to ground.! WARNING Never service, repair, or troubleshoot unless you are qualified to perform these functions. Improper servicing can lead to serious injury or death from fire, electrical shock, or explosion. Electrical Wiring Diagram - CSR 115 or 230 Volt - Schematic Wiring Diagram CSR or CSR Start Capacitor Assist ELECTRICAL COMPONENTS Use only new electrical components specific for this compressor model. 9

10 GENERAL INSTALLATION INSTRUCTIONS * Prior to removal of current compressor please refer to Tecumseh s Service Handbook to verify compressor requires replacement. The Service Handbook is available online at * Tubing sizes and orientation may vary between compressors and applications. * Use only electrical start components supplied with this replacement compressor. Do Not Reuse Electrical Components! Use Only New Electrical Components. * Tecumseh recommends using provided replacement mounting grommets and hardware. * Install a properly sized filter-drier for the system being serviced. * Evacuate to a minimum of 500 microns. Always use a vacuum gauge to measure vacuum levels. CAUTION: SAFETY FIRST * DO NOT INSTALL, service, repair, or troubleshoot an air conditioning or refrigeration system without proper certification and approval from authorities (Local, State, Federal). * YOU MUST have the necessary knowledge, training and equipment. * DISCONNECT ELECTRICAL POWER before removing the protective cover of any electrical terminal. * DO NOT RE-CONNECT electrical power unless the protective covers of all electrical terminals are in place and securely fastened. * DO NOT OPERATE compressor or connect electrical power, unless it is connected to ground. * DO NOT RESET A BREAKER or replace a fuse without first checking for ground fault (short circuit to ground). * An open fuse or tripped circuit breaker is a strong indication of a ground fault, also known as a short circuit to ground. * If a ground fault does exist, keep the power off and find and repair. Use only a Mega Ohmmeter ( megger ) or a Hi-potential ground tester ( Hi-Pot ) to check for a ground fault. A conventional ohmmeter will not reliably detect an insulation breakdown causing the ground fault. * Never expose system to leak test pressures greater than 150 psig (11.4 bar abs). * Never overcharge system with refrigerant. Overcharging with refrigerant may lead to excessive pressures and rupture of terminal block may occur. Always use proper charging techniques and limit charge amounts to those specified on the system equipment serial label or in the original equipment manufacturer s service information. * Contact with refrigerant, mixtures of refrigerant and oil, or other chemicals can cause a variety of injuries including burns and frostbite. * Oil and refrigerant can spray from compressor electrical terminals and be ignited by electricity or other sources of ignition causing serious INJURY or DEATH. NEW INSTALLATION TIPS * Upon receipt of your new compressor check for damage from shipping. Report any damage immediately to your local Tecumseh Authorized Wholesaler. * Check the name plate for correct voltage, phase, frequency, and refrigerant for the intended use BEFORE installation. * Check compressor windings for correct ohm s readings and short circuit to ground BEFORE installation. Keep the following in mind: - Power to unit must be off - Removing wires to expose terminals can lead to mis-wiring, replace correctly - Securely replace protective cover * Warning labels are provided to inform and protect persons servicing Tecumseh equipment. Care must be taken not to damage or destroy labels during installation. Damaged or missing labels should be replaced with approved labels from your Tecumseh Authorized Wholesaler. * This compressor is shipped with a holding charge of nitrogen or dry air. Remove the holding charge only after the equipment has been installed with connecting tubing and a new filter-drier installed. Purge the holding charge thru a service port. DO NOT leave the unit open to the atmosphere for an extended period of time, to do so will contaminate the oil and cause excessive evacuation time, and could cause premature failure. * Be sure to use clean, refrigeration tubing with both ends sealed. * Remove discharge tube hang tag prior to brazing. Cut, form and braze tubes carefully to avoid getting dirt and/or metal filings into the lines. When sizing suction and liquid lines, consult the refrigerant line sizing section of the Tecumseh Hermetic Service Handbook, or use the Tecumseh refrigerant line sizing app located at 10

11 * Whenever possible, pitch the suction line downward in the direction of flow, approximately 1/2 for each 10 ft length, to aid in oil drainage. Avoid line lengths in excess of 100 ft. Contact Tecumseh Technical Service for assistance. * When you open the system, complete the service operation as quickly as possible so it will not be exposed to the air longer than necessary. * Once all connections have been made, leak test with regulated dry nitrogen or other approved gas to a pressure not to exceed 150 psig (11.4 bar abs). Repair any leaks and leak test again. * When system is leak free, connect a vacuum pump capable of at least 500 microns vacuum to both sides of the system. Evacuate to at least 500 microns for a minimum of 30 min. Vacuum levels should be measured with an electronic gauge. * Do not operate the compressor without a charge in the system. Operating the compressor without a charge in the system can damage the hermetic terminals. To avoid serious injury or death from terminal venting with ignition, DO NOT energize the compressor unless the protective cover is securely fastened. * CAUTION!!! Only use refrigerant indicated on serial label when charging the system. Using a different refrigerant can lead to excessive system pressure and/or an explosion. Use of a refrigerant other than the serial label refrigerant will void the warranty. COMPRESSOR REPLACEMENT TIPS * Disconnect all electrical power supplies to the system, making sure all power legs are open. (NOTE: The system may have more than one power supply.) * Be sure all refrigerant is recovered before removing the compressor. Attempting to remove the compressor before removing all refrigerant from the system can cause a sudden release of refrigerant and oil. Among other things, this can cause a variety of injuries including burns and frostbite, a fire, and expose the service person to toxic gas. * Install a properly sized filter-drier for the system being serviced. * Use only regulated dry nitrogen or dry nitrogen with trace amounts of the serial label refrigerant to purge and/or leak test the system to a pressure not to exceed 150 psig (11.4 bar abs). PED REQUIREMENTS Standards series EN apply only to loads <150g of flammable fluids. R290 for a load>150g: Apply the ISO 5149 / EN 378. We recommend to make a risk analysis (refer to EN standard) and also avoid the refrigerant accumulation in case of leakage in potentially ignition source zones. By the refrigeration system design, the protective cover environment must not be in an explosive atmosphere. Compliance Statements and Incorporation: This compressor is designed for installation in machines in accordance with the machinery directive 2006/42 / EC. They comply with the low voltage directive 2006/95 /EC and Directive PED 97/23 /EC. Commissioning is only permitted if the assembly was performed in accordance with these instructions and if the machines meet the regulations. Consistent with the PED, all Class II compressors are tested under a higher air pressure or equal to the required 1.1 PS according to Annex C 13.2 of EN standard. The compressor free internal volume is 4.5 L. For information: 1.1 * Ps = 17.2 bar for R290. Maximum allowable pressure: this is the maximum refrigerant saturation pressure, at 46 O C ambient temperature, in the shell, compressor off. Limit the refrigerant charge in order not to exceed the maximum allowable pressure (read the label). Application signage: refrigerant used and its mass must be completed. In case of A2, A2L or A3 refrigerant, the flammability logo will be visible and legible. Steam Effect caution: can occur when water enters into the refrigerant circuit. The compressor will behave as a steam generator and motor temperature will increase pressure beyond the maximum operating pressure. The use of a safety pressure switch is a way to limit the pressure rise in the compressor shell. In order to continually improve its products, TECUMSEH reserves the right to modify this manual without notification. QUESTIONS AND SUPPORT Tecumseh Tech Support: or technical.service@tecumseh.com Tecumseh reserves the right to change any information in this publication at any time. This document is not intended to replace the training required for professional service personnel, or replace other information available from refrigeration and air conditioning equipment manufacturers. The information in this document is intended to assist service personnel in safely installing and servicing Tecumseh AK 2 compressor. Mounting and tubing connections are likely to differ from original installation. Careful review of current application requirements is essential. IT IS THE RESPONSIBILITY OF THE SERVICE PERSON TO ASSURE THEY HAVE PURCHASED A REPLACEMENT PRODUCT WHICH MEETS THE NEED OF THE APPLICATION. Failure to do so may result in misapplication requiring immediate or subsequent additional compressor replacement. 11

12 TECUMSEH COMPRESSOR COMPANY LLC NORTH AMERICAN HEADQUARTERS SALES AND MARKETING 5683 Hines Drive Ann Arbor, MI ph.: ph.: CANADA SALES 200 Elm Street Aylmer, Ontario N5H 2M8 ph.: fax: TECHNICAL SERVICES ph.: North America: Canada: For more information on products by Tecumseh, please visit our website Tecumseh Products Company LLC. All Rights Reserved. Publication TP-019, Rev 11/17