“G” SERIES - Area Cooling Solutions
Contents
1. 17 18 Wiring a Two Speed for Single Speed 19 Parts and Accessories for Series 5 20 Rotalock Adapters and Valve Part Numbers and 21 Compressor Mounting 22 Explanation of the European Pressure Equipment Directive 22 Pressure Temperature Relation 23 WARNING Cannot use ICM parallel motor protection modules part numbers 241730 241731 with Kriwan sensors cold resistance of 30 100 ohms for parallel sensors because the modules have shorted sensor protection that does not allow operation below 500 ohms Page 2 COMPRESSOR MODEL NUMBER SYSTEM B UG A Mounting Feet Dimension Inches A 7 5x 7 5 Electrical Characteristics Motor Protector Generation Type of Refrigeration Application E 95x95 K 75 17 Y 7 5 7 75 48x80 10 5 10 5 Offset Mounting Rail 844x975 7 5 21 5 R Horizontal Vertical Mount D 6 12x8 0 J 7 5 22 5 X 8 8 6 1 A 115 1 602. 094 124 094 124 184 294 184 294 184 294 184 294 094 124 094 124 SERIES ROTALOCK ADAPTER INFORMATION SUCTION ADAPTERS SUCTION SEAL oF 250512 SUCTION VALVE 1 250529 250510 250533 250508 250525 DISCHARGE ADAPTERS 250526 pe DISCHARGE SEAL AS LAUR cu H D AN ye A ees EX DISCHARGE C 4H VALVE 250511 250509 250534 250530 Li A 250507 250527 Jerisrourarruo oescrenon a e e e SR apo e a e EL ER ucti ucti NOTE 344 part number includes Teflon seal COMPRESSORS WITH SWEAT FITTINGS CANNOT BE ADAPTED TO ROTALOCKS Page 21 MOUNTING HOLE DIMENSIONS 7 1 2 THRU 10 TON Q O 91 HOLD DOWN BOLT COMPRESSOR L PLAIN MOUNTING FOOT REF o 2 N Z 5 95 _ RUBBER MOUNT 12 THRU 24 TON Bn SLEEVE O O E pan ns MOUNTING PA 10 2 BASE REF P LOCK WASHER HEXNUT 10 M NOTE RUBBER MOUNT IS SHOWN IN NON COMPRES
3. TO CONTROL CIRCUIT M1 M2 CONTROL TO BE PLACED IN SERIES WITH CONTACTOR COIL 2 5 AMPS MAX IMPORTANT Bristol recommends a 4 m inute CAUTION delay on break anti short cycling time delay to ICM modules part numbers 241730 and prevent contactor chattering 241731 cannot be used with Kriwan sensors 30 100 ohms cold Control voltage thru M1 M2 on module can be different from module supply voltage L1 L2 Voltage to L1 L2 must be as marked on module HI LO CONNECTIONS APPLY ONLY TO AE OR 31AA and LO connections apply only on 120V and MODULE SUPPLY VOLTAGE 24V No additional wimg Crankcase heater must be connected to 120V Jumper terminal LO to L2 terminal continuous power source 230V Jumper terminal HI to L2 terminal Page 15 MODELS H NG094GP H NG104GP H NG124GP Voltages 230 208 3 PH 460 3 PH 575 3 PH G COMPRESSOR WIRING DIAGRAM TWO SPEED MODELS WITH AE 30AA 40AA OR 169R MODULE SERIES MODULE 2 SENSOR PINS POWER CIRCUIT CAUTION AE and 30AA module S1 sensor terminals are internally connected to line voltage can be hot to ground 2 POLE 4 POLE MOTOR FOUR POLE OPERATION 1750 RPM 2 POLE 4 POLE MOTOR TWO POLE OPERATION 3500 RPM L2 L3 S iX MECHANICAL INTERLOCK MECHANICAL INTERLOCK
4. Voltages 230 208 3 PH 460 3 PH G COMPRESSOR WIRING DIAGRAM DUAL POWER TERMINAL MODELS WITH AE 31AA 41AA OR 369R MODULE PARALLEL MODULE 4 SENSOR PINS POWER CIRCUIT WYE DELTA MODELS CAUTION AE and 31AA module common sensor terminal internally connected to line voltage can be hot to ground WARNING Compressor terminals must be wired in phase for proper operation Phase 1 T1 amp T6 Phase 2 T2 8 T4 Phase 3 T3 amp T5 Wye Delta Connection Run Delta 1 amp 6 2 amp 4 3 amp 5 Start Wye 1 2 3 4 5 6 together PROTECTION POWER TERMINAL POWER TERMINAL TERMINAL T2 T4 T N 5 BLACK 51 52 S3 HI LO L1L2M2M ORANGE TO T1 T3 T2 OF CONTACTOR TO T6 T5 T4 OF CONTACTOR MODULE SUPPLY VOLTAGE SEE MODULE SUMMARY ON PAGE 10 FOR APPLICABLE PART NUMBERS TO CONTROL CIRCUIT M1 M2 CONTROL TO BE PLACED IN SERIES WITH CONTACTOR COIL 2 5 AMPS MAX CAUTION ICM modules part numbers 241730 and 241731 cannot be used with Kriwan sensors 30 100 ohms cold HI LO CONNECTIONS APPLY ONLY TO AE OR 31AA MODULE SUPPLY VOLTAGE 24V No additional wiring 120V Jumper terminal LO to L2 terminal 230V Jumper terminal HI to L2 terminal Page 12 MOTOR PROTECTION SYSTEM Modules have a 4 minute delay upon interruption of L1 L2 supply or after any fault condition occurs To prevent
5. High Efficiency 4 Basic Standard Model Improved Sound M Alternate Pressure Relief Valve 5 Inertia Series Standard Model N 7 No Pressure Relief Valve Except G Series 6 7 Inertia Series High Efficiency Model Basic Standard Model 7 Inertia Series Second Generation High Efficiency Model P Basic Standard Model Upgrade Plus 8 Fifth Generation Basic Standard Model Upgrade 1 Second Generation Basic Standard Model 9 Sixth Generation Basic Standard Model Upgrade 1 R12 5 R502 or Alternate Replacement 7 R407C 2 R22 Refrigerant R402B 8 R410A 3 R134a 6 RA04A 9 R407C R22 High Temp R404A Medium Temp Compressors in this series may be applied with additional refrigerants Please contact your Bristol Compressors account representative for details High Temperature R Designed for Use with Multiple Refrigerants L Low Temperature T High Temperature 2 Capacities 2 or 4 Cylinders Twin Single M Medium Temperature V Variable Speed Page 3 WARNING The air conditioning unit is a pressurized system and hazards exist which could result in personal injury It is therefore required that the following steps for troubleshooting removal and installation of the hermetic compressor be performed by qualified personnel only BEFORE CONDEMNING A COMPRESSOR THAT FAILS TO START 1 Verify all the following components are OK A Contactor B Winding resistance within manufacturer s specification ass
6. L1 T1 amp T4 L2 T2 amp T5 L3 T3 amp T6 WARNING COMPRESSOR TERMINALS MUST BE WIRED IN PHASE TO PREVENT ROTATION CHANGE WHEN CHANGING SPEEDS PROTECTION TERMINAL POWER POWER TERMINAL TERMINAL je T2 5 T3 B LOW HIGH SPEED SPEED L1 L2 S1 S2 M1 M2 POWER POWER MODULE SUPPLY VOLTAGE SEE MODULE SUMMARY ON PAGE 10 FOR APPLICABLE PART NUMBERS TO CONTROL CIRCUIT M1 M2 CONTROL TO BE PLACED IN SERIES WITH CONTACTOR COIL 2 5 AMPS MAX Page 16 MOTOR PROTECTION SYSTEM Modules have a 4 minute delay upon interruption of L1 L2 supply or after any fault condition occurs To prevent short cycling of compressor wire high low pressure switch and other safety switches in series with L1 or L2 power terminal on module WARNING Turn power off before checking sensors Allow unit to cool for one hour minimum Disconnect module from terminals Check sensors resistance using ohmmeter with 6 volt maximum supply Cold resistance range From common pin top left to each of the other three pins Supplier 1 90 300 ohms Supplier 2 1500 7500 ohms L1 L2 MODULE SUPPLY VOLTAGE SAFETY HIGH LOW PROTECTION PRESSURE j A S MODULE CONTROL VOLTAGE MODULE COOLING RELAY CS AUX QGI 4H 2 T 9 zc CF AUX zc CT AUX 4 MINUTE DELAY 5 ON B
7. NOTE FOR REFRIGERANT BLENDS R404A R 407C To determine superheat use saturated vapor values small figures To determine subcooling use saturated liquid values BOLD figures Inches of Mercury 200023 EN Release 097X01 EN Revision U27003 Supersedes EN S08503 4 11 Page 23
8. Yes No 052 201126 651043 241774 INT 169 R 120 amp 240 Control Series 26K 34K Auto Yes Yes No 052 201126 651043 Series 7 1 2 8 1 2 10 ton Parallel 12 15 17 20 24 ton Page 10 MODELS H NG204FR H NG244FR H NG294FR Part Winding Start H 5G204DP Full Winding Start Voltages 230 208 3 PH G COMPRESSOR WIRING DIAGRAM DUAL POWER TERMINAL MODELS WITH AE 31AA 41AA OR 369R MODULE PARALLEL MODULE 4 SENSOR PINS POWER CIRCUIT Full and Part Winding Start Models CAUTION AE and 31AA module common C sensor terminal internally connected to line voltage can be hot to ground WARNING Compressor terminals must be wired in phase for proper operation PHASE 1 1 amp 7 2 2 amp 8 amp 9 PROTECTION TERMINAL POWER TERMINAL T T2 T POWER TERMINAL T O T8 T 9 BLACK 1 52 S3 LO 1112 2 1 TO T1 T3 T2 OF CONTACTOR TO T7 T9 T8 OF CONTACTOR MODULE SUPPLY VOLTAGE SEE MODULE SUMMARY ON PAGE 10 FOR APPLICABLE PART NUMBERS TO CONTROL CIRCUIT M1 M2 CONTROL TO BE PLACED IN SERIES WITH CONTACTOR COIL 2 5 AMPS MAX CAUTION ICM modules part numbers 241730 and 241731 cannot be used with Kriwan sensors 30 100 ohms cold HI LO CONNECTIONS APPLY ONLY TO AE OR 31AA MODULE SU
9. protection module when using Bristol replacement compressors WARNING Voltage should not be applied to the compressor with the terminal cover and retainer s removed as personal injury could result Check pages 11 thru 16 18 and 19 for correct wiring diagram WARNING Do not remove C sensor wire on AE or 31AA modules or S1 sensor wire on AE or 30AA modules These terminals are internally connected to line voltage can be hot to ground WARNING Cannot use ICM parallel motor protection modules part numbers 241730 or 241731 with Kriwan sensors cold resistance of 30 100 ohms for parallel sensors because the modules have shorted sensor protection that does not allow operation below 500 ohms VERY IMPORTANT Before applying power to the compressor be sure to perform a functional check of the motor protection system This can be done by wiring the provided module as shown with the appropriate schematic leaving the power supply wires from the main contactor open NO POWER TO COMPRESSOR Then apply control circuit power Main contactor should pull in or energize assuming all other safeties are closed Next carefully remove module sensor wires from compressor only one necessary unless block connector is used TAKE CARE NOT TO SHORT LEAD AGAINST HOUSING The main contactor should immediately open If this does not happen thoroughly check control wiring unit until this functional check is positive Then complete the system wi
10. 26 241353 241359 241731 or 241744 15AA1000A 24 Control Parallel 10K 18K Auto No No Yes obsolete 201126 241353 241373 241732 241742 15AA1106A 24 Control Series 26K 34K Auto Yes No Yes obsolete 201126 651043 241374 241733 or 241743 15AA1607B 120 Control Series 26K 34K Auto Yes Yes Yes obsolete 201126 651043 241375 241734 or 241743 15AA1607C 208 230 Control Series 26K 34K Auto Yes Yes Yes obsolete 201126 651043 241376 241732 or 241742 MP50 9401 24 Control Series 26K 34K Auto Yes No Yes obsolete 201126 651043 241377 241733 or 241743 MP50 8601 120 Control Series 26K 34K Auto Yes Yes Yes obsolete 201126 651043 241378 241734 or 241743 MP50 8801 208 230 Control Series 26K 34K Auto Yes Yes Yes obsolete 201126 651043 241379 241731 241744 15AA1105A 24 Control Parallel 10K 16K Auto Yes No Yes obsolete 201126 241353 241380 241745 15AA1606B 120 Control Parallel 10K 16K Auto Yes Yes Yes obsolete 201126 241353 241381 241745 15AA1606C 208 230 Control Parallel 10K 16K Auto Yes Yes Yes obsolete 201126 241353 241382 241731 or 241744 MP50 9201 24 Control Parallel 10K 16K Auto Yes No Yes obsolete 201126 241353 241383 241745 MP50 8001 120 Control Parallel 10K 16K Auto Yes Yes Yes obsolete 201126 241353 241384 241745 MP50 8201 208 230 Control Parallel 10K 16K Auto Yes Yes Yes obsolete 201126 241353 241559 241743 15AA1706C 208 230 Control Parallel 10K 16K Auto Yes Yes Yes obsolete 201126 241353 241560 241734 or 241743 15AA1707C 208 230 Control Se
11. 41AA OR 369R MODULE PARALLEL MODULE 4 SENSOR PINS POWER CIRCUIT CAUTION AE and 31AA module common C sensor terminal internally connected to line voltage can be hot to ground PROTECTION TERMINAL POWER TERMINAL 2 A BLACK EN 51 52 S3 1211 2 1 TO T1 T3 T2 OF CONTACTOR MODULE SUPPLY VOLTAGE SEE MODULE SUMMARY ON PAGE 10 FOR APPLICABLE PART NUMBERS TO CONTROL CIRCUIT M1 M2 CONTROL TO BE PLACED IN SERIES WITH CONTACTOR COIL 2 5 AMPS MAX CAUTION ICM modules part numbers 241730 and 241731 cannot be used with Kriwan sensors 30 100 ohms cold HI LO CONNECTIONS APPLY ONLY TO AE OR 31AA MODULE SUPPLY VOLTAGE 24V No additional wiring 120V Jumper terminal LO to L2 terminal 230V Jumper terminal HI to L2 terminal Page 13 MOTOR PROTECTION SYSTEM Modules have a 4 minute delay upon interruption of L1 L2 supply or after any fault condition occurs To prevent short cycling of compressor wire high low pressure switch and other safety switches in series with L1 or L2 power terminal on module WARNING Turn power off before checking sensors Allow unit to cool for 1 hour minimum Disconnect module from terminals Check sensors resistance using ohmmeter with 6 volt maximum supply Cold resistance range From common pin top left to each of the other three pins Supplier 1 30 100 ohms S
12. G 230 1 50 P 200 240 1 50 Y 230 208 3 60 B 230 1 60 H 265 1 60 220 240 1 50 T 208 1 60 Z 380 415 3 50 C 230 208 1 60 J 230 208 1 50 U 220 380 3 60 D 230 208 3 60 220 200 3 50 220 240 1 50 V 460 380 3 60 380 415 3 50 E 460 3 60 380 415 3 50 L 230 200 3 60 220 200 3 50 W 380 460 3 60 F 575 3 60 500 3 50 M 220 200 3 50 X 380 3 60 B Internal Line Break R Pilot Duty Solid State 2 Generation P Pilot Duty Solid State T Pilot Duty Internal Thermostat and External Sensing Elements PSC Permanent Split Capacitor F PWS 3 Phase Part Winding Start M 73 Phase Variable B CSR Capacitor Start Cap Run 3 Phase 2 4 Pole 2 Speed Speed Permanent Magnet C RSCR Resistance Start Cap Run J 71 Phase 2 4 Pole 2 Speed D AL 3 Phase Across the Line 3 Phase Dual Voltage E CSIR Cap Start Induction Run 3 Phase WYE DELTA 193 19 000 or 19 000 BTU Hr 244 24 0 000 or 240 000 BTU Hr 19B 19 000 Internal bleed applied for equalized start Note A letter E Q S T or U in the third position also indicates k 000 A Model A Reciprocating G Model Reciprocating B Model B Reciprocating J Benchmark Model Reciprocating C Scroll lt 42k R Scroll gt 42k D Dual Compressor Application B Second Generation No PRV Except G Series 2 Third Generation Basic Standard Model D Dual Compressor Application Single and Interconnected 3 Fourth Generation Basic Standard Model E
13. LING MODE HEAT PUMP STEP 1 Operate system in cooling mode with indoor fan disconnected and repeat steps 3 4 and 5 AIR CONDITIONING ONLY UNITS STEP 1 Operate system in the cooling mode with indoor fan disconnected and repeat steps 3 4 and 5 Page 8 E E FOR THE HARD TO GET it TO COMPRESSOR TAKE TEMPERATURES AND nn PRESSURES HERE AIR CONDITIONING UNIT ONLY HOW TO CHECK SUPERHEAT 58 F 14 C OO N TAKE SUCTION 2 6 12 FROM COMPRESSOR T 58 F 14 e 38F C 209 11 IS cdd CONVERT SUCTION 5 2 PRESSURE TO TEMPERATURE 65 PSIG 38 F 3 C SUPERHEAT CHECK FILTER DRIER FOR CONTAMINATION A Suction Line Filter If internal contamination is heavy the suction line filter drier may become clogged and ineffective Check the pressure drop across the filter drier after approximately 8 hours running time and if it exceeds 2 psig replace Liquid Line Filter Always replace the original equipment liquid line filter drier s If the OEM liquid line drier s is not removed from the system a restriction most likely will result Just a slight restriction in this filter will reduce the efficiency of the system A large restriction will cause the su
14. PPLY VOLTAGE 24V No additional wiring 120V Jumper terminal LO to L2 terminal 230V Jumper terminal HI to L2 terminal MOTOR PROTECTION SYSTEM Modules have a 4 minute delay upon interruption of L1 L2 supply or after any fault condition occurs To prevent short cycling of compressor wire high low pressure switch and other safety switches in series with L1 or L2 power terminal on module WARNING Turn power off before checking sensors Allow unit to cool for 1 hour minimum Disconnect module from terminals Check sensors resistance using ohmmeter with 6 volt maximum supply Cold resistance range From common pin top left to each of the other three pins Supplier 1 30 100 ohms Supplier 2 500 2500 ohms See caution below L1 L2 MODULE SUPPLY VOLTAGE HIGH LOW SAFETY L PRESSURE PROTECTION M yk 2 EE MY 2 A MODULE CONTROL VOLTAGE MODULE CONTACTS Ti 2 55 CONTACTOR COIL IMPORTANT Bristol recommends 4 minute delay on break anti short cycling time delay to prevent contactor chattering Control voltage thru M1 M2 on module can be different from module supply voltage L1 L2 Voltage to L1 L2 must be as marked on module Hl and LO connections apply only on 120V and 208 240V modules Crankcase heater must be connected to continuous power source Page 11 MODELS H 5G204LP H 5G244LP H 5G294LP
15. REAK TIME IMPORTANT Bristol recommends a 4 minute delay on break anti short cycling time delay to prevent contactor chattering Control voltage thru M1 M2 on module can be different from module supply voltage L1 L2 Voltage to L1 L2 must be as marked on module Crankcase heater must be connected to continuous power source SERIES INTERNAL LINE BREAK COMPARED TO MODULE PROTECTED H2NG SERIES PRODUCTS Housing Height in Inches Suction Tube Height in Inches Housing Diameter in Inches Models H2NG H2BG H25G H2NG H2BG H25G H2NG H2BG H25G 094 104 124 144 G COMPRESSOR HOUSING CONFIGURATION FIGURE 1 HSG DIA HSG DIA HSG DIA SUCTION HEIGHT 1 SUCTION SUCTION HEIGHT j HEIGHT MODULE PROTECTION INTERNAL LINE BREAK INTERNAL LINE BREAK NOTE 2nd digit defines refrigerant i e 2 R22 and 7 R407C The H BG and H 5G single speed compressors have internal line break protection and do not require a module They are available in the 094 104 and 124 models also 144 in H 5G The H BG models are physically identical to the old H NG solid state protector models except for a new smaller terminal box and a slight increase in height as shown in Figure 1 The only installation change needed when replacing an H NG with an H BG is a minor wiring modification The H 5G models are physically identical to the H BG except for suction tube location and an increase in housin
16. REVISED 4 11 SUPERSEDES 3 08 SERIES BEFORE A SUSPECT COMPRESSOR IS REMOVED ALWAYS CHECK LOCKED ROTOR PULL DOWN VOLTAGE SEE PAGE 4 FOR DETAILS INSTALLATION amp SERVICE INSTRUCTIONS AIR CONDITIONING HEAT PUMP COMPRESSORS Bristol Compressors International Inc CAUTION Bristol compressors are completely interchangeable with other manufacturers However electrical specifications tubing configurations and wiring connections may vary Before installing and starting this compressor you must review the wiring diagrams and check for correct electrical components BRISTOL COMPRESSORS INTERNATIONAL INC BRISTOL VIRGINIA 24202 276 466 4121 FAX 276 645 2423 www bristolcompressors com Page o sd CM td 1 io M 2 Compressor Model Number System netten nete nnt hne LERRA IRR RR n MER TRA MR RR ER iR a 3 Before Condemning a Compressor that Fails to 4 Installation Procedures After Compressor has Been Verified as Faulty sss 4 9 Worst Case Condition Checks 1 6 1 nennen 8 How to Check S perheat ipsios 8 Check Filter Dr
17. SED FORM TIGHTEN HOLD DOWN BOLT UNTIL BOTTOMED OUT AGAINST SLEEVE PED LABEL INFORMATION Explanation of the European Pressure Equipment Directive PED label information if the compressor is PED approved first five digits of the 11 digit serial number give the manufacture and leak test date of the compressor The first three digits represent the day of the year for example 059 February 28 The next two digits represent the year for example 02 2002 e PS is the maximum allowable pressure e PT is the leak test pressure e TS max is the maximum design temperature e TS min is the minimum design temperature Page 22 PRESSURE TEMPERATURE RELATION CHART R404A R404A PSIG R 22 R 502 12 134a VapiLiq Vapor Liquid PSIG R 22 R 502 12 134 Vap Liq Vapor Liquid 5 48 57 56 31 23 58 59 20 34 9 26 62 62 23 27 64 25 3 37 8 26 3 64 65 65 26 67 66 27 32 68 29 68 33 70 69 30 34 71 71 32 36 73 72 33 37 74 73 34 38 76 75 35 77 81 40 37 43 40 46 84 42 49 87 85 45 90 88 48 51 54 93 90 50 57 96 93 52 59 99 96 55 62 102 98 57 64 104 100 59 67 69 62 64 71 66 73 68 75 70 77 72 80 74 76 78 80 82 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 NN NINNNN ON OTN 83 85 87 88 90 92 95 98 101 1 WIWN 0 MN Oo FB WIN
18. ction pressure and discharge pressure to be reduced This reduction in pressure will occur only with a properly charged system i e refrigerant weighed in to the OEM specifications An overcharged system will increase pressures when there is a restriction in the liquid line The service person tends to add more charge to the system to increase the suction pressure Normally any charge added above the OEM specifications will increase the suction pressure due to the discharge pressure increasing but in the case of a restriction charge can be added to a point the system shuts down on the high pressure switch The service person may not see the higher discharge pressure if the service port is in the liquid line which is normally downstream from the liquid line filter drier in split systems A pressure port installed in the hot gas discharge line just as it exits the compressor is required to see true discharge pressure IMPORTANT The compressor has an internal relief valve IPRV that is designed to open if the system is subjected to a high pressure situation Example causes are overcharged air in system restriction factory installed metering device screens not removed and cleaned old liquid line filter left in the system poor airflow across the condenser condenser fan failure poor airflow across the evaporator in the heating mode dirty return air filter s poor system design duct system undersized etc The IPRV will open when the discharge
19. ditioning system Oxygen can explode on contact with oil and could cause personal injury When using high pressure gas such as nitrogen or for this purpose be sure to use a regulator that can control the pressure down to 1 or 2 psig The following instructions are general but include major points of consideration that will ensure proper installation and protect you from possible personal injury Please use this as a checklist taking each item in its order before proceeding to the next If more information is required please call Bristol Compressors Service Department 1 VERIFY PROPER APPLICATION Verify that the compressor being replaced and the Bristol compressor have a like capacity for the refrigerant being used and that the voltage and frequency characteristics are the same Consult your wholesaler if you have any questions about proper compressor application WARNING To avoid electrical shock power to the compressor should remain off during performance of Steps 2 thru 14 2 DETERMINE CAUSE OF INITIAL FAILURE In order to prevent a second failure the cause of the original failure must be determined Identify the cause and make the necessary repairs A BEFORE REMOVING THE FAULTY COMPRESSOR Remove refrigerant charge using proper recovery procedures Call 1 800 441 9450 for the name of the nearest Dupont authorized distributor or 1 800 631 8138 for Genetron Representative or 1 800 ASK KLEA ICI for information on refri
20. e using the same mounting screws Two sensor lead wires should be Page 6 12 13 attached to the designated module terminals per the appropriate wiring diagram in this booklet The free ends should be fitted onto the two hermetic terminals Either wire on either terminal is OK 4 Follow appropriate wiring diagram in this booklet for connections to unit power and control circuit B H NG144 thru H NG294 and H 5G184 thru H 5G294 all 14 diameter housings 1 Before disconnecting the four sensor leads please note the top left pin of the four pin terminal is in the COMMON pin 2 Disconnect the four wire block connector from the four pin hermetic terminal in the compressor housing 3 Remove the module mounting screws and remove the module and connecting wires 4 Install the new module using the same mounting screws Make the sensor lead wire connections as follows depending on the particular module being installed a If the module includes one black wire and three orange wires connect the black wire to the common terminal as determined in Step 1 above Connect the other three orange wires to the three remaining pins in any order 5 Follow appropriate wiring diagram in this booklet for connections to unit power and control circuit All electrical components should be checked If faulty or signs of degradation are found they should be replaced Check all connections and terminals for tightness Use only a new Bristol
21. er 2 1500 7500 ohms MODELS H NG094DP H NG104DR H NG124DP L1 L2 MODULE SUPPLY VOLTAGE PROTECTION Voltages TERMINAL S POWER SAFETY 230 208 3 PH nle HIGH LOW PROTECTION 460 T3 PRESSURE WM L1 8 E 575 3 PH 1 MODULE CONTROL VOLTAGE L1 L2 31 82 1 2 MODULE TO T4 T2 T3 CONTACTS ZNS OF CONTACTOR M COMPRESSOR MODULE SUPPLY VOLTAGE CONTACTOR COIL SEE MODULE SUMMARY 1 PAGE 10 FOR APPLICABLE PART NUMBERS TO CONTROL CIRCUIT M1 M2 CONTROL TO WITA CONTACTOR Coll IMPORTANT Bristol recommends a 4 minute delay 2 5 AMPS MAX on break anti short cycling time delay to prevent contactor chattering Control voltage thru M1 M2 on module can be different from module supply voltage L1 L2 Voltage to L1 L2 must be as marked on module Crankcase heater must be connected to continuous power source Page 14 COMPRESSOR WIRING DIAGRAM TWO SPEED MODELS WITH AE 31AA 41AA OR 369R MODULE PARALLEL MODULE 4 SENSOR PINS POWER CIRCUIT MOTOR PROTECTION SYSTEM CAUTION AE or 31AA module common Modules have a 4 minute delay upon interruption of L1 C sensor terminal internally L2 supply or after any fault condition occurs connected to line voltage can be hot to To prevent short cycling of compressor wire high low ground pressure switch and other safety s
22. essor as an evacuation assist and never apply voltage to a compressor while it is in a vacuum as damage could result to the compressor EVACUATE THE SYSTEM Use a vacuum pump designed for this purpose Vacuum must be pulled on the discharge high side and suction low side of the system Evacuate to 200 microns or lower CHARGE THE SYSTEM When a vacuum of at least 200 microns is reached close gauge valve remove vacuum pump and break the vacuum using system refrigerant vapor Never dump liquid refrigerant into the compressor Liquid can be used to break the vacuum if it is connected to the liquid line not the discharge line Charge the system according to the manufacturer s specifications Be sure to compensate the charge for the addition of the filter drier The preferred superheat should be 18 20 F 10 11 at the compressor on a system with a TXV see Step 16 WEIGHING in the system charge to the factory specification will help point out system faults that may still exist INSTRUCTIONS FOR CHANGING MOTOR PROTECTION MODULES IN BRISTOL G SERIES COMPRESSORS Refer to page 10 for module summary chart WARNING Assure power is turned off sensor terminals can be hot to ground A H NG094 H NG104 and H NG124 12 diameter housing 1 Disconnect the two wires from the two pin hermetic terminal in the compressor housing 2 Remove the module mounting screws and remove the module and connecting wires 3 Install the new modul
23. for correct contactor sizes Model H BG094 H BG104 H BG124 Minimum Contactor Size INTERNAL LINE BREAK 2 COMPRESSOR INTERNAL WIRING H BG T2 TO T1 T3 T2 OF CONTACTOR Minimum Contactor Size 230 Volt 30 Amp 35 Amp 40 Amp 460 Volt 20 Amp 20 Amp 20 Amp Model H 5G094 H 5G104 H 5G124 H 5G144 Page 18 230 Volt 35 Amp 40 Amp 50 Amp 50 Amp 460 Volt 20 Amp 25 Amp 30 Amp 30 Amp WIRING A TWO SPEED FOR SINGLE SPEED OPERATION LOW SPEED L1 d L2 L3 cs NO CONNECTION ON LOW SPEED 19 L1 L3 T1 HIGH SPEED tom S Sits T3 T6 PART NUMBER 250507 344029 250508 344030 250509 344031 250510 344032 250511 250512 250527 344035 250525 344033 250526 344034 250530 344037 250533 344038 250534 344039 250529 344036 309008 309009 241711 241712 241713 241714 241703 241705 241708 241707 241706 241710 241730 241731 241732 241733 241734 241744 241745 241770 241771 241772 241774 PARTS AND ACCESSORIES FOR G SERIES COMPRESSORS DESCRIPTION Discharge Service Valve 7 8 Suction Service Valve 1 1 8 Discharge Sweat Adapter 7 8 Suction Sweat Adapter 1 1 8 Discharge Seal Suction Seal Discharge Serv
24. g height NOTE The H 5G has higher efficiency than the H NG or H BG and offers the 12 ton H 5G144 with internal line break protection Procedure for replacement of H NG single speed with H BG or H 5G single speed models when module is used as motor protection only and is not controlled by thermostat see page 18 if module is controlled by the thermostat 1 Remove the wires originally run from the line or transformer to terminals L1 and L2 on the solid state module 2 Connect the two wires together that were originally run to terminals M1 and M2 on the solid state module 3 The only wires connected to the H BG compressor will be the three power terminal leads and the crankcase heater leads Page 17 REPLACING H NG WITH H BG OR H 5G WHERE THE SYSTEM THERMOSTAT IS USED TO CONTROL THE MODULE H NG 24 VOLT POWER COMPRESSOR CONTACTOR COIL THERMOSTAT HIGH LOW SAFETY PROTECTION PRESSURE 1 PR 11 12 3 5 M1 MODULE FR H BG and H 5G 24 VOLT POWER 2 THERMOSTAT HIGH LOW SROTECTION 5 PRESSURE a d COMPRESSOR CONTACTOR COIL COMPRESSOR WIRING DIAGRAM Single Power Terminal Models H NG PROTECTION FUSITE TERMINAL 5 y 73 AE Mi L AU 1 C ORS S1 MODULE TO CONTROL CIRCUIT TO T1 T3 T2 OF CONTACTOR MODULE SUPPLY VOLTAGE 4 Check
25. g to ensure proper alignment B Tighten the nuts on the suction and discharge line until you detect metal to metal contact between the fittings At this point the Teflon fiber seal has been totally compressed Tighten the nuts an additional 1 4 turn to ensure good contact and a proper seal CAUTION A Teflon seal is factory installed on the face of the suction and discharge line rotalock fitting of the compressor Use care not to damage this seal while removing the shipping plug or attaching the suction line Also be sure to check the shipping plug once it has been removed to ensure that part of the plug did not remain in the compressor BRAZE ON SUCTION AND DISCHARGE LINES Carefully remove the rubber plugs from the suction and discharge line fittings Flow an inert gas such as nitrogen or through the system at approximately 2 psig to reduce the possibility of oxidation inside the tubing Braze on the suction and discharge lines following the recommendation listed below if a process tube is provided it should be brazed shut after the system has been charged Page 5 10 11 COPPER TUBING If additional copper tubing is required use only clean dehydrated refrigeration grade tubing with sealed ends BRAZING ALLOYS CAUTION Do not use 95 5 50 50 or 40 60 soft solder for brazing Use Sil Fos or Phos Copper or similar brazing alloys with high tensile strength on copper welds only Weld steel to copper only with silver b
26. gerant reclaim program B Remove the electrical leads from the compressor Note the terminal to which each wire is connected Page 4 C During the next operation the access ports should be open so that pressure does not build up in the System Use a high temperature torch to sweat the suction line and the discharge line loose from the compressor D Assure excessive oil does not remain in the system measure oil in the failed compressor and if oil is low flush excess from system or see step 15 as an alternative Good indicators of excess oil are violent vibration and or high variable sound as the extra oil moves through the system CAUTION The compressor may contain harmful acids be sure to handle with extreme care using proper protection equipment After confirming oil charge level return oil to the compressor and install suction and discharge rotalock caps Copper tube fittings should be brazed closed This is needed to prevent further contamination of the compressor and to prevent spillage from the compressor MOUNT THE NEW COMPRESSOR Do not remove dust cover or rubber shipping plugs until all other connections have been completed i e filters installed and all tubing changes made per Steps 3 4 5 and 6 Compressor should not be open to the atmosphere for more than 15 minutes Be sure to use the new mounting grommets that were shipped with the compressor If the mounting sleeves shipped with the compressor are used the m
27. ice Valve 1 1 8 Suction Service Valve 1 3 8 Suction Service Valve 1 5 8 Discharge Sweat Adapter 3 4 90 Suction Sweat Adapter 1 3 8 90 Discharge Adapter 1 1 8 Suction Adapter 1 3 8 Mounting Parts Set 236203 Grommet Sleeve 236400 Mounting Parts Set 236205 Grommet Sleeve 226260 Crankcase Heater 115V Crankcase Heater 230V Crankcase Heater 460V Crankcase Heater 575V Crankcase Heater 115V Crankcase Heater 460V Crankcase Heater 115V Crankcase Heater 230V Crankcase Heater 460V Crankcase Heater 575V Module 115 230V Replaces 241380 241381 and 241680 Module 24V Replaces 241379 and 241679 Module 24V Replaces 241373 and 241696 Module 115V Replaces 241374 and 241697 Module 230V Replaces 241375 and 241698 Module 24V Replaces 241379 241679 and 241731 Module 115 230V Replaces 241380 241381 241680 and 241730 Module 24V Replaces 241379 241679 241731 and 241744 Module 120 240V Replaces 241380 241381 241680 241730 and 241745 Module 24V Replaces 241373 241696 and 241732 Module 120 240V Replaces 241374 241375 241697 241698 241733 and 241734 344 _ part number includes Teflon seal Page 20 MODEL 094 144 094 124 094 144 094 124 094 294 094 294 184 294 144 184 294 094 144 144 184 294 144 094 124 144 294 094 124 094 124 094 124 094 124 144 144 184 294 184 294 184 294 184 294 184 294 184 294 094 124
28. iers for 9 Module Electrical Schematics and Other Information Summary of Electronic Modules sse ene 10 AE 31AA 41AA or INT 369R Protection Modules Parallel Sensors Dual Power Terminal Full and Part Winding Start Models 11 AE 31AA 41AA or INT 369R Protection Modules Parallel Sensors Dual Power Terminal WYE Delta 2 12 AE 31AA 41AA or INT 369R Protection Modules Parallel Sensors Single Power Terminal 0 4000000 000 atte neta a nrbes e nna 13 AE 30AA 40AA or INT 169R Protection Modules Series Sensors Single Power Terminal Models 22 ccccceccccesecccceedseceeeedenceceeseeceeeedecceeeessaceeesduaceceedsaceeesdeceeeeedsnseeenteaeeeentiaes 14 AE 31AA 41AA or INT 369R Modules Parallel Sensors Twozopeed 16 tint e 15 AE 30AA 40 or INT 169R Modules Series Sensors tete att edd tutte e toe 16 Series Internal Line Break 5 17 H NG H BG and H 5G Housing Configuration esses ene eene ennemis 17 Replacing Module Protected Compressor with Line Break
29. ounting bolts will bottom out when tight Use care not to over compress the mounting grommets when the mounting sleeves cannot be used INSTALL FILTER DRIERS Bristol Compressors recommends the use of adequately sized liquid and suction line driers anytime a compressor is replaced If the new compressor is used to replace a compressor with a burned motor the use of high acid neutralizing filter drier is recommended For heat pumps a suction filter drier must be installed between the accumulator and the compressor suction inlet In addition a bi directional heat pump liquid line drier or factory recommended driers must be installed NOTE ALWAYS REMOVE OLD FILTER DRIERS ATTACH SUCTION AND DISCHARGE LINES FOR UNITS WITH ROTALOCKS WARNING Do not remove the rotalock caps without first relieving the dry air charge in the compressor by carefully loosening the 1 4 flare suction access port cap to allow slow release of all pressure After all housing pressure is relieved remove the rotalock caps from the suction and discharge line fittings on the compressor On rotalock fittings be sure the Teflon fiber seal located on the face of the fittings are seated properly and are not damaged Attach the suction and discharge line to the compressor as follows A Align the suction and discharge line with the fitting on the compressor to ensure a good seal when the lines are tightened In some cases it may be necessary to modify the system tubin
30. pressure exceeds the suction pressure by more than 450 psi smaller than 15 ton products or 400 psi larger than 15 ton products If the relief valve opens a high velocity gas flow may be heard inside the compressor housing In some cases the relief may open so quickly due to a restriction in the system the high pressure will be difficult to observe on standard gauges In most instances if the service person installs a discharge service gauge on the discharge line just as it exists the compressor the development of high pressure can be observed before the relief valve opens Installing the discharge service gauge on the liquid line outside the system may not detect a restriction To reset the relief valve shut the compressor off for a couple of minutes allowing pressures to equalize REVIEW ALL SEVENTEEN STEPS TO MAKE SURE NOTHING WAS OVERLOOKED Page 9 Summary of Electronic Modules 248XXX Bristol Replace with Supply Delay After Short Schematic Connector P N Bristol P N Vendor P N Voltage Output Sensors Rtrip Q Reset Break LVCO Sensor Decals Screw Wires 241073 None 10AA307 24 Voltage Series 25K 35K Auto No No Yes obsolete 201125 obsolete 241283 None 10AA309 24 Voltage Series 25K 35K Manual Yes lock out No Yes obsolete 201125 obsolete 241317 None 15AA1500A 24 Control Parallel 10K 18K Manual Yes lock out No Yes obsolete 2011
31. razing alloys BRAZING PROCEDURE To ensure properly brazed joints Bristol Compressors recommends that the following steps be used a Exercise extreme care when cutting and forming tubes to keep dirt filings and other contaminants from entering the system b Do not use excessive amounts of brazing alloy as some of the excess penetrate the joint and enter the system c If flux must be used take necessary precautions to ensure that the flux does not enter the system d Use damp cloths or other heat absorbent material to ensure that the factory brazed joints on the compressor do not become damaged If damp cloths are used take care not to allow moisture to enter the system e Do not overheat brazed joints as excess heat will cause formation of copper oxide on the inside wall of the tubing Flow an inert gas through the system as explained above If the Bristol compressor is being used as a replacement for a semi hermetic using an oil pressure switch remove the switch from the unit The Bristol compressor requires no such switch CHECK SYSTEM FOR LEAKS After installation is complete pressurize the system to 75 psig using nitrogen and a few ounces of system refrigerant Check for leaks using a halide torch soap bubbles or an electronic halogen leak detector When all connections test satisfactorily release pressure using proper recovery procedures then proceed to next step CAUTION Do not use the Bristol replacement compr
32. ries 26K 34K Auto Yes Yes Yes obsolete 201126 651043 241679 241731 31AA1105A 24 Control Parallel 10K 16K Auto Yes Yes No 053 508 509 510 201126 241353 241680 241745 31AA1606E 120 amp 208 230 Control Parallel 10K 16K Auto Yes Yes No 051 052 201126 241353 241696 241732 30AA200A 24 Control Series 26K 34K Auto Yes Yes No 053 508 509 510 201126 651043 241697 241733 or 241743 30AA300B 120 Control Series 26K 34K Auto Yes Yes No 051 052 201126 651043 241698 241734 or 241743 30AA300C 208 230 Control Series 26K 34K Auto Yes Yes No 051 052 201126 651043 241730 241745 AE7114 120 amp 208 230 Control Parallel 10K 16K Auto Yes Yes Yes obsolete 201126 241353 241731 241770 7113 24 Control Parallel 10K 16K Auto Yes Yes Yes 053 508 509 510 201126 241353 241732 241772 AE7110 24 Control Series 26K 34K Auto Yes Yes No 051 052 201126 651043 241733 241774 AE7111 120 Control Series 26K 34K Auto Yes Yes No 051 052 201126 651043 241734 241774 AE7112 208 230 Control Series 26K 34K Auto Yes Yes No 051 052 201126 651043 241744 241770 41AA1105A 24 Control Parallel 10K 16K Auto Yes Yes No obsolete 201126 241353 241745 241771 41AA1606E 120 amp 208 240 Control Parallel 10K 16K Auto Yes Yes No 511 512 513 514 201126 241353 241770 INT 369 24 Control Parallel 10K 16K Auto Yes Yes No 511 512 513 201126 241353 241771 INT 369 R 120 amp 240 Control Parallel 10K 16K Auto Yes Yes No 511 512 513 201126 241353 241772 INT 169 R 24 Control Series 26K 34K Auto Yes
33. ring WARNING Replacement compressor failure may result if you fail to check the total electrical system against the equipment manufacturer s service manual and the Bristol compressor wiring diagram before start up Make sure the electrical characteristics of the Bristol replacement compressor are the same as the original compressor Page 7 14 15 16 Bristol recommends a four minute time delay on break in series with the contactor to prevent short cycling of the compressor from possible defective or improper operation of controls Confirm oil is in compressor sight glass by depressing Schrader After approximately two hours running time check the sight glass to be sure there is adequate oil in the compressor If oil level is not visible add Shrieve Zerol 150T oil until the level reaches the approximate mid point of sight glass If oil level is above sight glass remove oil until level is approximately mid point of sight glass WORST CASE CONDITION CHECKS HEAT PUMP STEP 1 Operate system in the heating mode with outdoor fan disconnected STEP 2 Run system until the designed winter condition in your area is reached may need to cover coil for this test STEP 3 Check suction superheat 6 from compressor inlet STEP 4 Superheat should not drop below 5 F 3 K prefer no lower than 10 F G K STEP 5 Sump temperature should always be 50 F 28 C or higher above saturated suction temperature EXAMPLE R 22 COO
34. short cycling of compressor wire high low pressure switch and other safety switches in series with L1 or L2 power terminal on module WARNING Turn power off before checking sensors Allow unit to cool for 1 hour minimum Disconnect module from terminals Check sensors resistance using ohmmeter with 6 volt maximum supply Cold resistance range From common pin top left to each of the other three pins Supplier 1 30 100 ohms Supplier 2 500 2500 ohms See caution below L1 L2 MODULE SUPPLY VOLTAGE HIGH LOW SAFETY PRESSURE PROTECTION VLA 1 L2 Yr MODULE CONTROL VOLTAGE MODULE CONTACTS 52 4 Mj M2 520 55 CONTACTOR COIL IMPORTANT Bristol recommends a 4 minute delay on break anti short cycling time delay to prevent contactor chattering Control voltage thru M1 M2 on module can be different from module supply voltage L1 L2 Voltage to L1 L2 must be as marked on module Hl and LO connections apply only on 120V and 208 240V modules Crankcase heater must be connected to continuous power source MODELS H NG144DP H NG184DP H 5G184DP Voltages 230 208 3 PH H NG144DP H NG184DP H NG204DR H NG244DR H NG294DP H 5G184DP H 5G204DP H 5G244DP H 5G294DP Voltages 460 3 PH 575 3 PH H NG204DR H NG244DR Voltages 380 3 PH G COMPRESSOR WIRING DIAGRAM SINGLE POWER TERMINAL MODELS WITH AE 31AA
35. upplier 2 500 2500 ohms See caution below L1 L2 MODULE SUPPLY VOLTAGE HIGH LOW SAFETY PRESSURE PROTECTION 4 VA C MODULE Yr CONTROL VOLTAGE MODULE CONTACTS p M COMPRESSOR CONTACTOR COIL IMPORTANT Bristol recommends a 4 minute delay on break anti short cycling time delay to prevent contactor chattering Control voltage thru M1 M2 on module can be different from module supply voltage L1 L2 Voltage to L1 L2 must be as marked on module Hl and LO connections apply only on 120V and 208 240V modules Crankcase heater must be connected to continuous power source G COMPRESSOR WIRING DIAGRAM SINGLE POWER TERMINAL MODELS WITH AE 30AA 40AA OR 169R MODULE SERIES MODULE 2 SENSOR PINS MOTOR PROTECTION SYSTEM POWER CIRCUIT Modules have a 4 minute delay upon interruption of L1 L2 supply or after any fault condition occurs To prevent short cycling of compressor wire high low pressure switch and other safety switches CAUTION and 30AA module 51 in series with L1 or L2 power terminal on module sensor terminals are internally connected to line voltage can be hot to ground WARNING Turn power off before checking sensors Allow unit to cool for 1 hour minimum Disconnect module from terminals Check sensors resistance using ohmmeter with 6 volt maximum supply Cold resistance range Supplier 1 90 300 ohms Suppli
36. ure compressor is cool to the touch C Compressor not grounded via ohmmeter Megger etc D Compressor power terminals are tight and secure E Check for hot spots in system wiring wire insulation melted connectors insulators melted etc 2 Verify lock rotor pull down voltage LRPDV Always check LRPDV before removing the old or new replacement compressor If the LRPDV reduces the supply voltage to the compressor below the guaranteed to start voltage of the compressor three phase 230 208 LRPDV is 187V the power supply must be corrected before removing the compressor Always check all three legs T1 to T2 T1 to T3 and T2to T3 To perform this test on two speed compressors you should wire for single speed operation as illustrated on page 19 Procedure to check for LRPDV Warning Make sure unit is properly grounded before proceeding A Connect a voltmeter to the T1 terminal and T2 terminal of the compressor B Make sure the terminal cover and retainer is in place see warning page 7 then apply power to the compressor If motor protector trips allow time for reset before continuing C Ifthe voltage at the compressor terminals does not pull down below the LRPDV and the compressor still does not start it is electrically or mechanically faulty D Repeat A through C for voltage at T1 T3 and T2 T3 INSTALLATION PROCEDURES AFTER COMPRESSOR HAS BEEN VERIFIED AS FAULTY WARNING Never use oxygen to pressurize a refrigeration or air con
37. witches in series with 2 POLE 4 POLE MOTOR 2 POLE 4 POLE MOTOR L1 or L2 power terminal on module TWO POLE OPERATION 3500 RPM FOUR POLE OPERATION 1750 RPM WARNING Turn power off before checking sensors Allow unit to cool for 1 hour minimum Disconnect EZZ zii module from terminals Check sensors resistance using INTERLOCK NTERLOCK ohmmeter with 6 volt maximum supply Cold resistance range From common pin top left to each of the other three pins Supplier 1 30 100 ohms Supplier 2 500 2500 ohms See caution below WARNING COMPRESSOR TERMINALS MUST BE WIRED IN PHASE TO PREVENT ROTATION CHANGE WHEN CHANGING SPEEDS L1 L2 MODULE SUPPLY VOLTAGE H2NG184GP HIGH LOW SAFETY PRESSURE PROTECTION 11 12 H2NG204GP 1 PROTECTIO H2NG244GP POWER TERMINAL POWER MODULE TERMINAL TERMINAL Voltages T 9 CONTROL VOLTAGE _ BLACK ONTACT Ta 7 575 3 Phase 1 M2 e 8 lt CF AUX S3 S281 C 4MINUTE DELAY HI L E ON BREAK 7 CT AUX LOW SPEED HIGH SPEED POWER POWER MODULE SUPPLY VOLTAGE SEE MODULE SUMMARY ON PAGE 10 FOR APPLICABLE PART NUMBERS
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