Copeland Screw TM

Compressors
Mechanical Guidelines for
SHL & SHM Models using
ESC-201 Control System
Contents:

• Start-Up Procedure
• Operating Specifications
• Maintenance
• Trouble Shooting Guidelines
 Start-up Procedures

Factory Checks 6. With a set of pressure gauges, place the low

pressure gauge on the compressor suction and
1. General testing of the rack control circuit. the high pressure on the discharge side of the
compressor. Open the suction service valve one
2. Test the safety inputs and alarm outputs on each quarter of the way. Open the discharge service
of the ESC 201’s. (See the ESC 201 Form No. valve all the way. As the system charge increases
2001-81 manual for the individual test proce- open the suction service valve the rest of the
dures). way.

3. Pressurize the rack and check for leaks. 7. Start the compressor; one of the following obser-
vations could be made on the gauges. The first
could be a drop in the suction gauge with a rise
Start-up Procedure in the discharge; this indicates the compressor
running in the proper direction. The other obser-
1. Charge the oil separator and oil cooler(s) with the vation could be the suction gauge rises and the
specified oil for the system. discharge remains at the same level as before
the compressor was started. This indicates that
2. Energize the rack control circuit and energize the the compressor is running in reverse. Also you
oil separator heaters (Temperature range for the should have a rotation alarm on the ESC 201,
this indicates that the rotation switch has opened
heater operation is on at 100°F off at 125°F) 12 up. To correct an improper rotation condition the
to 24 hours prior to startup. following changes must be performed. First swap
two phases around on the power conductor for
3. Close the ball valve between separator and con- that compressor. The next item that will have to
denser. Then open up the oil line ball valves to be corrected is the phase leads to the ESC 201.
each of the compressors. Taking one compressor The corresponding leads to the power conductors
at a time, open the oil solenoid valve (by jumping it will need to be swapped at the ESC 201 phase
out). Pressurize the oil separator with refrigerant. connections.
Observe the oil line sight glass; when you see oil
entering the sigh glass, de-energize the oil line 8. Restart the compressor; the ESC 201 should
solenoid valve. This is very important for open check ok after 2 seconds the oil and economizer
drive screw compressors; the above procedure solenoid valve terminals C9 and C11 will be
will help prevent damage to the compressor’s energized.
shaft seal. After all the compressor oil lines have
been charged the ball valve between the separa- 9. The safety functions for the compressor should
tor and condenser can be reopened. be rechecked to insure that all of the safeties are
working properly between the compressor and the
4. For open drive compressors only. Check the ESC 201. Please refer to the ESC 201 manual
couplings for the proper installation and that the for the proper method for testing the compressor
keys have been installed properly; check the set safeties.
screws for tightness.
Repeat steps 7 through 9 for each of the compres-
5. Select one compressor on the rack to charge the sors on the rack. Please note that the suction service
system with refrigerant. valves on the rest of the compressors may be opened
up all the way.

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 Operating Specifications

Screw Compressor Oil System

R22 R404A/R507 R134a
Maximum oil temperature entering compressor
130°F 140°F 140°F
Minimum temperature exiting cooler 100°F
Maximum oil pressure differential across the oil filter* 25 psi (alarm only)
35 psi oil flow switch (cut-out)
Minimum differential across each compressor 90 psi oil flow switch cut-out
(suction to discharge pressure)

Motor Cooling Per Compressor

Maximum motor temperature* (read from thermistor) 212°F
Liquid injection None required

Discharge Temperature Per Compressor

Maximum discharge temperature* 212°F cut-out
Normal discharge temperature 180°F

Minumum discharge temperature < 35º above condensing temperature

Reverse Rotation Protection Per Compressor
Pressure switch low discharge pressure* 30 psi cut-in
20 psi cutout
Phase sequencing*
Proper sequence of phases to ESC 201
according to motor lead termination

Suction Gas Temperature

Open drive screw compressors Low temp. 40°F maximum superheat
Medium temp. 30°F maximum superheat
Semihermetic screw compressors Low temp. 30-40°F return gas temp.
Medium temp. 55-60°F return gas temp.

Subcooling Liquid Temperature Values

The subcooled liquid temperature is dependent upon TXV selection for cases or evaporators and insulation
quality of the liquid lines. Refer to the case or evaporator manufacturer for the allowable liquid temperature
to the equipment.
To correct the compressor capacity and power for the recommended liquid temperature; please refer to
he economizer system and capacity control section of the screw manual.

Economizer Superheat Temperature Values

ECO port superheat 12-15 superheat

*ESC 201 control function

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 Maintenance
Item Inspection Frequency of
Maintenance

Oil Filter Element Check Pressure Drop

Reference Section A. Trouble Shooting Guidelines Six Month Intervals

Oil Flow Switch Check for Proper Operation

Reference Section J. Trouble Shooting Guidelines Three Month Intervals

Compressor Power Connections Check for Tightness, Frayed Wires

Reference Section N. Trouble Shooting Guidelines Six Month Intervals

Compressor Contactor Connections Check for Tightness, Frayed Wires

Reference Section N. Trouble Shooting Guidelines Six Month Intervals

Compressor Breaker Connections Check for Tightness, Frayed Wires

Reference Section N. Trouble Shooting Guidelines Six Month Intervals

Control Circuit Terminations Check for Tightness, Frayed Wires

Reference Section N. Trouble Shooting Guidelines Six Month Intervals

High Pressure Bearings Check Bearings for Excessive Play 50,000 to 80,000
Lateral Movement Should be Less Than 0.001 in. Hours of Run Time

Oil Sampling Have Sample Tested by a Qualified Facility One Year Intervals

Trouble Shooting Guidelines

A. Oil Filter; The Filter Will Alarm Under The Fol- • Oil flow switch which will not close when the
lowing Conditions: compressor is started.

• When the pressure across the filter exceeds 25 • An obstruction within one of the screened
psi. This condition most likely will occur within orifices in the compressor.
weeks or months of the system start-up.
• An excessive amount of refrigerant contained
• A malfunctioning or miswired switch will also in the oil line of the compressor.
cause the ESC 201 to alarm. To verify that the
switch is malfunctioning or miswired, the filter C. Oil Level; The Oil Level Switch Will Alarm Under
element must be changed or the connections The Following Conditions:
must be verified that the switch is wired nor-
mally open. Reset the ESC 201 to see if the • An excessive amount of refrigerant in the oil
alarm can be cleared. separator causing the separator to foam up
during this situation. This can occur if too much
B. Oil Flow; The Flow Switch Will Alarm Under liquid is coming from a TXV that could be out
The Following Conditions: of adjustment or has malfunctioned.

• Loss of differential in the system which could • A large pressure drop on the discharge side
occur when the head pressure drops too low. of the separator occurs. This situation can
The differential cannot drop below 90 psi. take place with heat reclaim coils or split
condensers.
• An inoperative oil solenoid valve which will not
open.

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D. Rotation; The Rotation Switch Will Alarm Under H. Phase Protection; The Phase Protection Alarm
The Following Situation: Will Occur Under The Following Circumstanc-
es:

• Pressure in the dishcharge area of the rotor • Power conductors that are improperly
chamber does not reach at least 70 PSI. sequenced to the compressor. This normally
occurs at start-up when the electrical contrac-
• A 5 VAC signal is not being sent back to termi- tor improperly sequences the phases from the
nal A7 from terminal A3. Check for proper wir- distribution equipment. The Power Company
ing and for a 5 VAC signal across the switch. changes the phase arrangement at their trans-
former.
E. Run Proof; The Run Proof Will Alarm Under
The following Conditions: • Phase leads from the load side of the
compressor contactor, which are improperly
• The run proof will not close during the starting sequenced to the phase connections of the
of the compressor. ESC 201.

• The run proof is lost during the operation of • The ESC 201 will detect single-phase condi-
the compressor. tions. If one or more phase is lost the ESC
201 will drop the compressor offline while
F. Motor Overload Temperature; The Motor Over- running.
load Will Alarm Under The Following Condi-
tions: • The ESC 201 will detect welded contact situ-
ations as well. This will occur if the system
• Locked rotor conditions:This condition could controller has stopped calling for a compres-
occur if the rotors are locked due to excessive sor to run. If the ESC 201 has two or more
oil in the compressor or debris has lodged in phase attached and a run proof the ESC 201
the rotors. will alarm the phase light. The ESC 201 will
turn the oil back on to prevent damage to the
• Over or under voltage condition within the compressor should the compressor continue
electrical system. to run. This also will prevent damage to the
compressor in the event that a mechanic
• Malfunctioning temperature sensor. To check closes the contactor manually (This should
the sensor measure the DC voltage on the not be done under any circumstances).
ESC 201 (points B1 and B7). The voltage
across these points will read .4 to .6 VDC for I. ESC 201 In General; If the ESC 201 Is Not Oper-
a good sensor if the voltage reads 2.3 VDC or ating Properly Please Check The Following:
above the sensor is open.
• Check the power supply to make sure that the
G. Discharge Temperature Sensor; This Alarm Will ESC 201 is receiving 24 VAC control power to
Occur Under The Following Conditions: terminals marked A/C.

• When the discharge temperature exceeds • Check fuses F1 and F2 to see if any of these
212°Fahrenheit. The cause for high discharge are blown.
temperature is generally due to high oil
temperatures entering the compressor. • Make sure that the ESC 201 is solidly grounded
via the ground strap that is provided on the
• Malfunctioning sensor: To check the sensor lower right hand corner of the ESC 201 when
measure discharge gas temperature at the mounted horizontally.
outlet of the compressor. If the temperature is
below 212°, the sensor is bad. • Make sure that all of the commons for the
compressor safeties are connected to points
A7 and B7 and it is solidly grounded.

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J. Oil Flow Switch Check; The Oil Flow Switch • The Copeland screw compressor contains an
Must Be Checked On A Regular Basis. Below internal check valve. The symptom of a bad
You Will Find The Procedure For Checking check valve is when the compressor cycles
This Item: off you will hear the rotors turning and close
the suction service valve. Turn the compres-
• Close the oil ball valve and wait for 15 seconds. sor back on and allow the compressor to pull
If the ESC 201 does not take the compressor into a vacuum (verify with your gauges). If the
off-line the flow switch must be replaced. The compressor will not hold a vacuum then the
switch could have possibly gotten debris in check valve is bad. The compressor may be
it and piston will not drop down to open the locked on manually until a new check valve
switch. can be installed.

K. AMOT Valve; If You Are Having Problems With M. Compressor Logged With Oil; This Condition
The AMOT Valve(s) Not Functioning Properly Could Occur Under The Following Condi-
The Compressors Will Trip On High Discharge tions:
Temperature
• The oil solenoid could stick open and fill the
• The AMOT valve may be examined in the compressor with oil. To verify the problem of
following manner. The valve can be disas- the oil solenoid observe the oil line sight glass.
sembled for servicing. If this is done care must If there is movement of oil in the sight glass
be taken not to damage the oil rings located after the compressor has been cycled off. The
inside the valve. compressor will not start and should trip the
branch breaker due to lock rotor condition.
• Copper shavings could have caused the valve
to jam and not mix properly. Examine the valve • To resolve the problem the oil line ball valve
for shavings and remove them. Reassemble must be closed and the oil line should be
the valve. pumped out. The solenoid must be taken
apart and inspected. If there is debris in the
• The internal element has gone bad; to check valve clear it. If the internal components of the
the element one of two methods is acceptable. valve are bad a rebuild kit can be purchased
Run hot water over the temperature-sensing to repair it. After the valve has been repaired
element to make sure that the valve will op- the compressor must be cleared of oil.
erate. If hot water is not available then use a
lighter. Hold the lighter under the temperature- • There is a drain plug on the bottom of the
sensing element for just a moment. compressor midway between suction and
discharge. Place pan underneath the com-
L. Compressor Checks; The Following Will Allow pressor and remove the plug. Be sure there
For Compressors Checks For The Following is no pressure in the compressor.
Conditions:
N. General Electrical Checks; Electrical Checks
• Checking a compressor that does not appear Should Be Performed As Part Of the “P.M.” Of
to be pumping. Shut the compressor off and The System:
close the suction service valve. Restart the
compressor and see if the compressor will • All terminals that supply power to the com-
pull into a short vacuum. Use a gauge on pressor should be checked for tightness.
the suction valve’s access fitting to check. If These include the compressor terminals in
the compressor does not then it should be the terminal box, contactor lugs, breaker lugs
replaced. and distribution block terminals.

• Control points should also be checked for

termination tightness to avoid false alarming
of ESC 200 alarms.

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O. Sub-Cooler Adjustments; The Expansion • Should the Sporlan valve malfunction the
Valves Used For The Sub Cooler Must Be screw compressor will draw very high am-
Adjusted To Obtain The Proper Superheat At perage due to the volume of the liquid be-
The Economizer Inlet To The Screw Compres- ing delivered to the screw compressor. The
sors: discharge temperature will drop too low. To
possible keep the compressor on line, adjust
• If the superheat is too high the sub-cooler liq- the rotolock valve to let just enough liquid in
uid temperature will be higher than the system to the screw to provide some oil cooling. The
design value. This will cause the system’s indication that enough is being provided will
capacity to be lower than the design. be the discharge temperature. Check the
discharge temperature to insure that 180
• Should the superheat at the economizer inlet degrees is not exceeded.
be below 5 degrees the vapor entering the
compressor would be too wet, when this oc- • In the future, Copeland will be providing a
curs the compressor’s capacity will be less proportional valve, which will be operated
than design. Additionally the compressor’s from a discharge temperature sensor that will
amperage draw will be much higher than the be able to read real temperature values and
running condition indicates. operate the valve accordingly. The propor-
tional valve will regulate the liquid feed to the
• The superheat adjustment for the sub-cooler compressor’s economizer port.
expansion valve must be 12 to 15 degrees at
the inlet of the economizer port on the com- Q. “Jet Kool” Oil Cooling; This Is A New Devel-
pressor. opment For Screw Compressor Oil Cooling
Which Will Eliminate Air Cooled Oil Coolers
• Most low temperature systems have an EPR In All Applications:
on the economizer header to adjust the back-
pressure on the sub-cooler. This must be done • The main item that can malfunction in this
to obtain the proper liquid temperature that is system is a multi position soleniod valve. The
indicated in the manufacturer’s legends. The valve is controlled by discharge temperature.
EPR pressure must be set to the pressure The valve will open or close, as the discharge
indicated in the economizer charts, which cor- temperature requires.
responds to the liquid temperature selected
by the manufacturer. The economizer chart • The multi position solenoid valve is provided
can be found in the training manual, section with a manual adjustment. The manual adjust-
labeled “Economizer System & Capacity Con- ment will allow for manual positioning of the
trol”. valve. If the operator fails the mechanic can
manually position the valve about ¾ of the
P. Liquid Injection Used For Oil Cooling way open. This will keep the system on-line
until a new operator can be obtained.
• Medium temperature screw compressors used
with R404A refrigerant can be supplied with a
liquid injection system to provide oil cooling on
these screw compressors. The valve, which is
used for this application, is a Sporlan Y1037
valve. The valve is selected to operate when
the compressor’s discharge temperature
reaches a range of 180 to 190 degrees. At
this point the valve will open and supply liquid
to the compressor via the economizer port.

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Sidney, Ohio 45365-0669
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Form No. 99-14 R2 Issued (11/05)

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