2004 Lennox Industries Inc. Dallas, Texas KITS COMMON TO HEATING AND COOLING EQUIPMENT 504,652M 03/04 Supersedes 503,249M Litho U.S.A. COMPRESSOR REPLACEMENT KIT INSTALLATION INSTRUCTIONS FOR COMPRESSOR REPLACEMENT KIT (LB 87092B; 74M30) REPLACING TECUMSEH SF, MANEUROP MT125 AND MT144 OR HEATCRAFT CRHL 100 (10 TON ONLY) COMPRESSORS WITH A COPELAND ZR125 OR ZR144 SCROLL COMPRESSOR IN GCS16/CHA16 2553, 2753, & 3003 UNITS Shipping & Packing List Discharge plumbing parts: 1 3 Foot bulk 7/8" tubing 2 7/8" Long radius 90 elbows 2 7/8" Long radius 45 elbow 1 7/8" Formed discharge line with Schraders 2 7/8" Couplings Suction plumbing parts: 3 1 3/8" Couplings 1 3 Foot bulk 1 3/8" tubing 3 1 3/8" Long radius 90 elbow 1 1 3/8" Suction line with Schraders 2 Blue wires 2 Brown wires Miscellaneous Parts: 1.280 #70 Drill bit 4 5/16" 18 Self tapping shoulder bolts Bag assembly: 6 Schrader cores 4 Schrader valve caps 4 5/16 18 X 1 1/2" Sleeved machine screws 4 Wire ties 1 Schrader valve body 2 Wire nuts NOTE This kit contains components required for a variety of applications. All parts may not be required for some replacements. Some parts may need to be cut to length. The following parts are included with the : 4 Rubber spacers 4 Metal Mounting Tubes 1 Application Bulletin AE 1303 1 Instruction Sheet FM 2001 73 NOTE Crankcase heater must be ordered separately. Application Use this kit to replace a Tecumseh SF, a Maneurop MT125 or MT144, or a Heatcraft CRHL 100 (10 ton only) with a ZR125 or ZR144 Scroll in GCS16/CHA16 2553, 2753, or 3003 units. Requirements Before replacing a, verify that the is inoperative and rotation is correct. Follow the procedure in the Checking Compressor Failure section. If the manufacturer determines the is in working condition, a replacement fee will be charged for returned s. IMPORTANT The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFC s and HCFC s) as of July 1, 1992. Approved methods of recovery, recycling, or reclaiming must be followed. Fines and/or incarceration may be levied for noncompliance. Checking Compressor Failure Compressors fail for one of two reasons: electrical or mechanical. Refer to the service manual for troubleshooting procedures and use the following steps to determine why the has failed: A Electrical Check 1 Check thermostat for a cooling demand and make sure contactor is energized. 2 Check all fuses in the system. 3 Check for correct voltage on both line and load side of contactor. 4 Check for correct voltage at s. 5 Shut off main disconnect. Remove all wiring from s. Using an ohmmeter set on10k ohm scale, check motor windings and internal protector as illustrated in figure 1. 03/04 Page 1 504,652M
Three Phase Compressor Permanent Clean up Kit (recommended installation positions) install pressure gauges while servicing L1 L2 L3 Check L1, L2, L3 to ground Continuity = Inoperative Compressor Check L1 L2, L1 L3, L2 L3 No Continuity = Inoperative Compressor (A No Continuity reading may be due to either open overload protector or broken windings.) Figure 1 B Mechanical Check If you check the components, and find a damaged crankshaft, piston, bad valves, etc., the failure is mechanical or motor without burnout. You must replace the. Removing the Compressor WARNING Recovering the refrigerant charge from the high side only may result in the low side shell and suction tubing being pressurized. Application of a brazing torch while refrigerant remains in the system may result in ignition of the refrigerant and oil mixture check the high and low pressures before unbrazing. Determine how the failed and proceed as follows: Electrical Failure If a minor burnout occurs (little or no acid is present in the refrigerant, no sludge or carbon and only a slight odor) and the unit is equipped with shut off valves, the refrigerant may be salvaged. Follow the instructions that come with the refrigerant clean up kit. It is best not to reuse refrigerant. suction line pressure port or Figure 2 IMPORTANT Be extremely careful when checking the refrigerant. If a major burnout occurs, or if the unit is not equipped with service valves, the contaminated refrigerant must be removed from the system and replaced. To determine severity of the burnout, check the refrigerant for acidity content with one of the kits available for this purpose. 1 Disconnect all power to unit. Remove access the unit s panel. 2 If refrigerant is not to be reused, remove entire charge from system into a suitable container. 3 Units equipped with a low ambient control Disconnect and tape off or remove the wires that shunt the low pressure switch of the existing. The control will be installed on the first. In a few cases, the low ambient control has been installed on the first and second. The low ambient control should continue to cycle the condenser fan motor(s). 4 Disconnect wiring. See 575 Volt Compressor Removal section to disconnect wiring on 575 volt units. 5 Number wires for reference for rewiring. Page 2
1 Mechanical Failure If is operable, pump down the system according to the system pump down procedure in the Service Unit Information manual. Front seat suction and discharge valves. If is inoperable, close the suction and discharge valves and recover remaining refrigerant. Remove Slab Coil Compressors (side view) discard pipe cut suction line here 2 Follow steps 1 through 5 in the electrical failure section. CAUTION Contaminated refrigerant and oil could contain heavy concentrations of hydrochloric and hydrofluoric acid. Avoid contact with skin or clothing. Do not breathe any of the discharged gases. 12" cut discharge line here 21 1/2" unit base pan Remove the Compressor 1 Reheat and separate the discharge and suction line piping from the stubs in all applications of this kit. NOTE Remove piping from before cutting discharge and suction line plumbing; this will prevent debris from entering the system. 2 Remove and retain bolts and washers that secure the to base rails. Remove from unit. 3 Cut and discard the suction and discharge lines as shown in figure 3 for slab coil s and figure 4 for formed coil s. Figure 3 Removing 575 Volt Compressor Tecumseh SF 575 volt protection modules are located in a make up on the mounting rail near the first stage. 1 Replacing first stage Disconnect wiring to A9 protection module s M1, M2, S, and S1. Also disconnect jumpers between A9 and A10 s T1 and T2. Reconnect wiring from A9 s T1 and T2 to A10 s T1 and T2. See figure 5 and 7. Replacing second stage Disconnect wiring to A10 protection module. See figure 6. Replacing both s Disconnect jack/plug harness P81/J81 and remove A9 and A10 make up. Disconnect P81/J81 wiring connections in main unit control. See figure 7. 2 Remove appropriate module(s). Page 3
Remove Formed Coil Compressors First stage Shown cut suction line here discard pipe discard pipe cut discharge line here; retain shock loop liquid line Figure 4 Existing Tecumseh SF Motor Protector Wiring 1st Stage Compressor Changeout 2 1 A9 1st stage 6 5 remove wiring to A9; reconnect to A10 s T1 and T2 remove wires to A9 s S1 and S remove jumper wires between A9 and A10 T1 and T2 2 1 8 A10 2nd stage 10 9 7 J81 P81 Figure 5 Page 4
Existing Tecumseh SF Motor Protector Wiring 2nd Stage Compressor Changeout 2 1 4 3 A9 1st stage 6 5 remove jumper wires between A9 and A10 T1 and T2 8 A10 2nd stage 10 9 remove wiring to a10; reconnect to A10 s M1 and M2 7 J81 P81 remove wires to A10 s S1 and S Figure 6 Page 5
Compressor Protection Module 575 Volt Units Only Figure 7 Page 6
Installing the Replacement Compressor 1 Slab Condenser Coils Use the template from the last page of this instruction to mark new installation holes. Use the provided.280 #70 drill bit to drill four.280" holes. See figure 8 template for drill hole positions. New Slab Coil Base Rail Mounting Holes 2 Slab Condensing Coils Install new on base rails; orient as shown in figure 10. Formed Condensing Coils Slide s into place over newly drilled holes. Compressor Orientation Slab Coil Top View drill 4 holes with provided.280 bit filter section stage 2 blower section stage 1 7 1/2" electrical connections refrigerant piping electrical connections 3 1/2" mounting channels 7 1/2" Figure 8 2 1/2" outside edge of unit Formed Condenser Coils Center the on the base rail near previous installation. Mark location of each foot (orient s as shown in figure 9). Slide away from marks and drill four.280" holes. Compressor Orientation Formed Coil Top View suction and discharge connections stage 2 stage 1 Figure 10 refrigerant piping 3 Using the grommet shown in figure 11, secure the feet of the new to the base of the unit. push the rubber grommet through the hole of the s foot insert the metal tube into the grommet s hole use the bolt to secure the grommet to the unit s base Compressor Mounting Grommet flat steel washer shoulder bolt leg mounting rail Figure 11 black mounting grommet Replacement Compressor Plumbing suction and discharge connections Figure 9 electrical connections NOTE Be sure new discharge line plumbing is not binding. Shock loop allows for some play in line. IMPORTANT Fit all plumbing into place before brazing. Page 7
A First-Stage Slab Condensing Coil 1 First stage discharge line piping Fit tubing and fittings into place according to figures 12 and 13. First stage suction line piping Fit tubing and fitting into place according to figures 14 and 15. First stage Discharge Line Slab Coil Top View First stage Suction Line Front View slab Coil 1 3/8" coupling existing vertical discharge line 45 7/8" elbow front edge of base pan existing vertical discharge line 90 7/8" elbow Figure 12 First stage Discharge Line Front View slab Coil pipe unit discharge line with Schrader fittings new 7/8" discharge line suction Figure 13 First stage Suction Line Side View slab Coil 7/8" sweat discharge 90 7/8" elbow (3) required 1 3/8" suction line cut to fit front edge of base pan Figure 15 B Second-Stage Slab Condensing Coil 1 Fit tubing and fittings into place according to figures 16 for discharge line plumbing and 17 for suction line plumbing. 1 Braze tubing and fittings into place. Second stage Discharge Line Front View slab Coil existing discharge line with 1/4" flare fittings new 7/8" discharge line plumbing cut to fit 90 7/8" elbow suction Figure 16 pipe unit suction line with Schrader fittings 1 3/8" coupling existing vertical suction line Figure 14 Page 8
Second stage Suction Line Side View slab Coil 1 3/8" suction line cut to fit First stage Discharge Line Front View slab Coil existing discharge line with 1/4" flare fittings new 7/8" discharge line plumbing cut to fit 90 7/8" elbow 1 3/8" coupling suction existing vertical suction line Figure 17 C First Stage Formed Condensing Coil 1 Fit tubing and fittings into place according to figure 18 for discharge line piping and figure 19 for suction line piping. 2 Braze tubing and fittings into place. First stage Suction Line Front View slab Coil (3) required Figure 19 D Second Stage Formed Condensing Coil 1 Fit tubing and fittings into place according to figure 20 for suction line piping and figure 21 for discharge line piping. 2 Braze tubing and fittings into place. NOTE If necessary, install the furnished Schrader port in the suction line of second stage formed coil unit. Second stage Suction Line Front View slab Coil 1 3/8" suction line cut to fit pipe unit suction line with Schrader fittings 1 3/8" coupling 1 3/8" coupling existing vertical suction line Figure 18 existing vertical suction line Figure 20 Page 9
existing vertical discharge line 90 7/8" elbow First stage Discharge Line Top View slab Coil pipe unit discharge line with Schrader fittings new 7/8" discharge line suction Figure 21 Evacuation & Dehydration CAUTION Danger of equipment damage. Avoid deep vacuum operation. Do not use s to evacuate a system. Extremely low vacuums can cause internal arcing and failure. Damage caused by deep vacuum operation will void the warranty. IMPORTANT Never use compliant scroll s (as with any refrigerant ) to evacuate a refrigeration or air conditioning system! 1 Evacuate system to an absolute pressure of.92 inches of mercury, 23 mm of mercury, or 23,000 microns. 2 After system has been evacuated to absolute pressure described above, close manifold valve to center port 3 Stop vacuum pump and disconnect from gauge manifold. Attach a drum of dry nitrogen to center port of gauge manifold, open drum valve slightly to purge line, then break vacuum in system to 3 psig (20.7 kpa) pressure by opening manifold high pressure valve to center port. 4 Close nitrogen drum valve, disconnect drum from manifold center port and release nitrogen pressure from system. 5 Reconnect vacuum pump to manifold center port hose. Evacuate system to an absolute pressure less than.197 inches of mercury, 5 mm of mercury, or 500 microns, then turn off vacuum pump. If absolute pressure rises above.197 inches of mercury, 5 mm of mercury, or 500 microns within a 20 minute period after stopping vacuum pump, repeat evacuation. If not, evacuation is complete. If excessive moisture is present, evacuation process may be required more than once. 6 After evacuation has been completed, close gauge manifold service valves. Disconnect vacuum pump from manifold center port and connect refrigerant drum. Pressurize system slightly with refrigerant to break vacuum. Miscellaneous A General WARNING Never use oxygen to pressurize refrigeration or air conditioning system. Oxygen will explode on contact with oil and could cause personal injury. When using high pressure gas such as nitrogen or CO 2 for this purpose, be sure to use a regulator that can control the pressure down to 1 or 2 psig. 1 Oil and install provided valve cores where necessary after brazing; ensure pressure sensing devices have a depressor tee. 2 Reconnect all pressure sensing devices on the new suction and discharge lines. Cap off the unused pressure taps. 3 Reconnect wiring according to diagram on unit. 4 Install crankcase heater as low on as possible. Tighten to 25 ft. lbs. Wire new crankcase heater to line side (L1 & L3) of contactor. NOTE Ensure crankcase heater voltage listed on the heater matches voltage listed on the. 5 Oil level should be at halfway point in sight glass (if provided) when unit is not operating. If necessary, you may remove oil from the oil port 6 Use provided wire ties to secure all wiring away from the discharge line. Start Up & Run Check 1. Before starting new, check contacts on starter or contactor and replace, if needed. IMPORTANT Crankcase heater should be energized 24 hours before unit start up to prevent damage as a result of slugging. 2. Set thermostat for a cooling demand. 3. Check that amps and volts match values listed on nameplate. 4. In applications where a major burn-out has occurred or where a replaceable filter/drier element has been installed in clean-up kit: Page 10
Check pressure drop across filter/drier in clean-up kit. The initial pressure drop should be approximately 2 to 3 psi. If pressure drop increases to between 9 and 10 psi, replace filter/drier cartridge. Repeat until pressure drop remains steady at 2 to 3 psi. After approximately 48 hours of run time, an oil sample should be taken and an acid test made. If oil proves acid free and clean, pump system down, remove filter/drier element from shell of clean up kit, and replace with fresh filter/drier element. If acid is still present in oil sample, replace liquid and suction line filter/driers. Repeat until system is contaminant free. 5. Install seal caps on unused pressure tap fittings. 6. Complete return goods tag. Be sure to include model number and serial number. NOTE See Lennox Return Policy for warranty replacements. Three Phase Compressor Rotation Three-phase scroll s must be phased sequentially to ensure that the rotates and operates correctly. When the starts, a rise in discharge and drop in suction pressures indicate proper phasing and operation. If discharge and suction pressures do not perform normally, follow the steps below to correctly phase in the unit. 1 Disconnect the power to the unit. 2 Reverse any two field power leads to the unit. 3 Reconnect the power to the unit. The discharge and suction pressures should operate at their normal start-up ranges. NOTE Compressor noise level will be significantly higher when phasing is incorrect. The unit will not provide cooling when is operating backwards. Continued backward operation will cause the to cycle on internal protector. Page 11
NEW SLAB COIL BASE RAIL MOUNTING HOLES DRILL NEW BACK HOLE 9 11/16" FROM FRONT HOLE EXISTING HOLE EXISTING HOLE DRILL NEW BACK HOLE 9 11//16" FROM FRONT HOLE Page 12 DRILL NEW FRONT HOLE DRILL NEW FRONT HOLE OUTSIDE EDGE OF UNIT