Diagnostic
Troubleshooting
Repair
RTAC
CHHP Compressor Service and
Trouble Shooting
Order Number: RTAC-SVD02A-EN
Date: April 2004
Pueblo Built Units Only
Introduction
The purpose of this bulletin is to provide troubleshooting and repair procedures for
CHHP compressors.
NOTICE: Warnings and Cautions appear at appropriate sections throughout
this literature. Read these carefully.
WARNING:
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
CAUTION: Indicates a situation that may result in equipment or property-damage only accidents.
Compressor Operation
The CHHP (GP2) compressors are helical lobed, twin screw type with 5 lobes on the
male rotor and 6 lobes on the female rotor.
The compressor is made of cast iron, semi-hermetic construction, directly driven by a
three-phase motor. All suction gas passes through the air gap or around the motor for
cooling.
2004 American Standard Inc. All rights reserved.
Both rotors are supported on rolling element bearings and lubricated by polyolester
oil. External, high-side oil separator and oil sump are required for bearing lubrication
and injection oil. All compressors have a single oil connection point, internal oil filter
and an internal oil check valve and pressure relief valve. Oil system isolation is
accomplished by a Roto-Loc valve centrally mounted on the oil filter housing for
orientation either right or left. An oil cooler may be required for certain higher head
applications
.
Figure 1
GP2 Compressor
Motor Terminals
Discharge
Check Valve
Suction
Strainer
Female
Rotor
Female
Unloader
Piston
Motor
Rotor
Oil Control
Valve
(hidden)
Male Unloader
Piston
Male
Rotor
Oil Filter
The compressors are designed for operation in one direction only (male rotor
clockwise when viewed from the motor end). A high side check valve is provided to
minimize reverse rotation on shutdown.
Unloading is accomplished using variable/port-unloading. A male slide piston is
located above and ported to the male screw rotor. The slide piston position is oil
operated and controlled by a pair of 2-way solenoid valves, one for loading and one for
unloading. The step unloader is gas operated and controlled by a 3-way solenoid
valve.
When operating at full load, the slide piston is always unloaded first to modulate load
between 100% and 60%. The female step unloader is the last step in capacity
control and provides a single step from 60% to 30% load. The compressor must
always be started in the fully unloaded condition. After starting the compressor, the
step unloader is always loaded first and then the variable slide piston. Damage or
failure from high discharge temperatures can occur if the male loader is operating
without the female step load energized.
RTAC-SVD02A-EN
Figure 2
Compressor Capacity
Troubleshooting
Important
Environmental Concerns!
Scientific research has shown that certain man-made chemicals can affect the
earths naturally occurring stratospheric ozone layer when released to the
atmosphere. In particular, several of the identified chemicals that may affect the
ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs)
and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all
refrigerants containing these compounds have the same potential impact to the
environment. Trane advocates the responsible handling of all refrigerants
including industry replacements for CFCs such as HCFCs and HFCs.
Responsible Refrigerant Practices!
Trane believes that responsible refrigerant practices are important to the
environment, our customers, and the air conditioning industry. All technicians
who handle refrigerants must be certified. The Federal Clean Air Act (Section
608) sets forth the requirements for handling, reclaiming, recovering and
recycling of certain refrigerants and the equipment that is used in these service
procedures. In addition, some states or municipalities may have additional
requirements that must also be adhered to for responsible management of
refrigerants. Know the applicable laws and follow them.
RTAC-SVD02A-EN
WARNING
Contains Refrigerant!
System contains oil and refrigerant under high pressure. Recover refrigerant to
relieve pressure before opening the system. See unit nameplate for refrigerant
type. Do not use non-approved refrigerants, refrigerant substitutes, or
refrigerant additives.
Failure to follow proper procedures or the use of non-approved refrigerants,
refrigerant substitutes, or refrigerant additives could result in death or serious
injury or equipment damage.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing.
Follow proper lockout/tagout procedures to ensure the power can not be
inadvertently energized. Failure to disconnect power before servicing could
result in death or serious injury.
RTAC-SVD02A-EN
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Piston is stuck.
Refer to male piston repair
procedure
No
Try to manually move the
piston by removing the
male piston pressure
schrader pushing on the
piston with a rod.
Yes
Yes
When pressure is manually
relieved to suction, does
RLA remain the same?
Yes
No
Yes
If pressure remains the
same with solenoids
blocked off then it is a
leaking load solenoid.
Replace the load
solenoid
No
Leaking load solenoid or
leaking piston.
Leaking piston can only be
confirmed by blocking off
the solenoids and
rechecking the pressure. If
pressure increases with
solenoids blocked off then
it is a leaking piston. Does
pressure increase?
If the pressure is increasing
the problem could be with
the load solenoid or the
piston seal.
Increase
If pressure increases
with solenoids blocked
off then it is a leaking
piston. Refer to male
piston repair procedure
If the pressure decreases
the unload solenoid is
leaking.
Other system problems are
causing erratic control (fan
staging, charge, oil filter)
Try to manually move the
piston with suction and
discharge pressure. Does
RLA remain the same?
Decrease
Change
De-energize both load and
unload solenoids.
Does piston pressure
increase, decrease or
remain constant
No
Remain Constant
With both solenoids deenergized, if the piston
pressure remains constant
the compressor has a stuck
piston or is operating
properly
No
Is RLA 70-100% at start-up?
Male Unloader Piston
Female Unloader Piston
If the female Unloader is not working properly the compressor will not load up to
100% RLA. This checkout procedure assumes that the male unloader is working
properly.
Put a gauge on to read the female piston
pressure. W hen the solenoid is energized the
piston pressure should be near discharge.
Is there near discharge pressure in the
female piston cavity?
Yes
No
Try to manually load the female by
using a gauge set to increase the
pressure in the piston cavity. The
RLA should increase approximately
30% when the female is loaded.
Did the RLA increase when the
female was manually loaded?
Female piston is stuck and
can not be replaced in the
field. Replace compressor.
Yes
Replace solenoid.
No
Female piston is stuck and
can not be relpaced in the
field. Replace compressor.
Oil control valve and Oil filter
If the oil control valve is not working properly it will act as a restriction in the oil line. A
restriction (dirty filter or non-functioning oil control valve) will cause the compressor to
be very loud and/or trip on Low Oil Flow.
Routine changing of the oil filter is not required. Figure 3 is an example plot of the
pressure drop of clean filter on a N1 compressor. The formulas below describe the oil
protection scheme.
PC = Condenser Pressure
PI = Intermediate Pressure
PE = Evaporator Pressure
For the first 2.5 minutes of operation of the circuit while the Delta P is greater than 35
Psid the Acceptable Intermediate Oil Pressure Range is:
( PC PI )
0.50 > ----------------------( PC PE )
RTAC-SVD02A-EN
After 2.5 minutes, the acceptable Intermediate Oil Pressure Range is:
( PC PI )
0.25 > ----------------------( PC PE )
Figure 3
Oil System Pressures
GP2 Clean Filter Versus Recommend Filter Replacement Line
CH530 Oil Pressure Protect Scheme Pressure Ratio
0.60
0.50
Unit Shut
Down
(Pe - PI) / (Pc - Pe)
0.40
35 psid
Minimum
System
Pressure
Differential
0.30
Start Protection Line
For 1st 2.5 Minutes of
Operation
Run Protection Line
After 2.5 Minutes of
Operation
GP2 Recommended Filter
Replacement Line
0.20
0.10
GP2 Clean Filter Line
0.00
0
20
40
60
80
100
120
140
160
180
200
Pc - Pe
RTAC-SVD02A-EN
Figure 4
Component Locations
Repair Procedures
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing.
Follow proper lockout/tagout procedures to ensure the power can not be
inadvertently energized. Failure to disconnect power before servicing could
result in death or serious injury.
Male Unloader Piston
Tools needed: Impact Wrench, 4 pieces- 1 ft. long of M16 all thread and M24 socket
1.
Do a service pumpdown and Isolate the low side (close discharge service valve
and oil line valve) including the compressor.
2.
Remove vapor.
Reclaim Refrigerant (from oil) through male piston pressure schrader.
3.
Remove solenoid coils, intermediate pressure transducer line & HPC Switch
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4.
Unbolt discharge service valve at the compressor and tie line back out of the
way.
5.
Remove Suction Line and Suction Screen.
6.
Remove motor rotor bolt using impact wrench
7.
Cover suction inlet on compressor with tape.
8.
Remove bolts that secure bearing housing to rotor housing including the one on
belly of compressor (Note: thread 3 guide rods into compressor before removing the last bolt)
9.
Separate the compressor motor and bearing housings. This can be done by
placing jacking bolts into dowel pin holes (this will force compressor to separate)
10.
Slide bearing housing no more than 5 inches (12.7 cm) away from the rotor
housing
Figure 5
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Compressor motor and bearing housings
11.
Remove the male unloader and inspect bore of both bearing and rotor housings
for debris and scaring.
12.
Remove and discard old o-ring.
13.
Install new male unloader into rotor housing
14.
Pull out the guide rods one by one to put the o-ring in place. Replace guide rods.
Put a small amount of loctite 515 on the outside of the o-ring grove.
Figure 6
O-ring grove
515
15.
Slide bearing housing back toward rotor housing until the male rotor reaches the
suctionbearing.
16.
Thread 4th guide rod into male rotor.
17.
While pushing bearing housing in, lift guide rod (slightly) until bearing housing is
flush with rotor housing.
18.
Re-install bolts and torque to 170 ft-lbs.
19.
Add drop of Loctite 271 to first two threads of motor rotor bolt.
20.
Use impact wrench to re-install motor rotor bolt.
21.
Re-install suction screen.
22.
Replace suction o-ring.
23.
Re-install suction line and torque to 175 ft-lbs.
24.
Replace discharge valve gasket.
25.
Re-install discharge service valve/line and torque to 175 ft-lbs.
26.
Replace teflon seal for fitting of oil valve entering compressor.
27.
Re-install oil valve entering compressor.
Use the following table to review the parts involved in this repair.
Description
Part Number
Male unloader
VAL08037 - M1
VAL08138 - M2
VAL08184 - N1
VAL08185 - N2
10
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Description
Part Number
O-ring for bearing to rotor housing - N Frame
RNG01699
O-ring for bearing to rotor housing -M Frame
RNG01698
Teflon seal for oil valve entering compressor
CPL00934
Discharge valve gasket
GKT02706
Suction O-ring
RNG01414
Suction O-ring
RNG01415
Oil Return line fitting and O-ring
ADP00909
RNG01697
Male solenoid gasket
GKT03466
Female solenoid gasket (need 3)
RNG01397
Oil control valve and Oil filter
Tools needed: 2 deep well socket, 3/16 hex head and M12 socket.
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1.
Lock Circuit out.
2.
Isolate and reclaim the compressor.
3.
Reclaim refrigerant from oil filter cavity through the oil pressure schrader on oil
filter housing.
4.
Assure that pressure is relieved from oil filter housing cavity by loosening the
bolt over the brass washer (see Figure 4).
5.
Remove the oil filter housing cover.
6.
The filter should slide out freely.
7.
Remove the valve using the 2 inch socket.
8.
Exercise the new valve. It should move freely.
9.
Replace the valve using the 2 socket.
10.
Replace the oil filter.
11.
Replace the oil housing cover and torque to 70 ft-lbs
12.
Tighten oil filter housing bolts to 170 ft.-lbs.
13.
Refill the oil filter cavity oil.
14.
Evacuate filter housing through oil pressure schrader on oil filter housing.
11
15.
Open all valves.
Figure 7
Oil Control Valve
Verify 2 o-rings
Description
Part Number
Oil Filter
FLR01650
Valve
VAL07307
Gasket
GKT03852
Schrader
VAL07306
Oil Charging Procedure
The GP2 is designed to have the entire oil charge delivered through the schraeder
fitting on the side of the compressor oil filter cavity. The purpose of adding oil in this
location is to provide the compressor with sufficient oil immediately upon start and to
purge the filter cavity, oil shutoff valve and oil line to separator of any vapor that could
prevent adequate oil flow at startup.
Like many machines, an excessive oil charge can cause operational problems. Special
care should always be taken to avoid adding extra oil. The symptoms of an oil over
charge are as follows:
EXV is open wide
Liquid Level is low
Flashing in the Sight Glass
Little or no Discharge Superheat
These symptoms may occur in one or both circuits. Oil overcharge should not be
confused with an undercharge of refrigerant which may exhibit the first three
symptoms but will be accompanied by high Discharge Superheat.
12
RTAC-SVD02A-EN
Units that exhibit the symptoms of an oil overcharge at high loads may still run fine at
light loads. An oil overcharged unit may result in an evaporator limit warning or even a
low liquid level or low evap temp (LRTC) diagnostic. An oil overcharged unit may
exhibit increased approach temperatures and decreased overall unit efficiency.
Discharge Check Valve
Figure 8
Check Valve
Shaft
Retainer
Seal
Washer
Nut
The figure above shows the correct check valve assembly. If you see the white seal
when looking into the discharge port, the check valve is assembled incorrectly.
1.
Lock Circuit out.
2.
Isolate and reclaim the compressor.
3.
Unbolt discharge service valve at the compressor and tie line back out of the
way.
4.
Remove check valve support.
5.
Remove check valve.
6.
The new check valve will come un-assembled.
7.
Assemble it as shown in the Figure 8. Torque nut to 38 ft-lbs.
8.
Re-install check valve.
Be careful not to damage the seat of the check valve by dropping it into place.
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9.
Re-install check valve support.
10.
Re-install discharge service valve and torque to 175 ft-lbs.
Description
Part Number
Check Valve Kit
KIT08032
Discharge Service Valve Gasket
GKT02706
13
Figure 9
Compressor
Male
Unload
HPC
Connection
Male
Load
Suction Pressure
Schrader
Male
Unloader
Piston
Schrader
Intermediate Oil
Pressure
Transducer
Female
Solenoid
Female
Unloader
Piston
Pressure
Schrader
Oil Charging
Schrader
Oil Filter Pressure
Relief Plug
Questions
Contact the Product Technical Service department in Pueblo, Colorado with questions
regarding this Service Bulletin. They can be reached at techservicepueblo@[Link]
or 888-244-5537.
Trane
A business of American Standard Companies
[Link]
For more information contact your local district
office or e-mail us at comfort@[Link]
Literature Order Number
RTAC-SVD02A-EN
File Number
SL-RF-RLC-RTAC-SVD02A-EN-0404
Supersedes
New
Stocking Location
Electronic Only
Trane has a policy of continuous product data and product improvement and reserves the right to
change design and specifications without notice. Only qualified technicians should perform the
installation and servicing of equipment referred to in this bulletin.
