Bristol A Series Installation and maintenance instructions

REVISED: 5/03

SUPERSEDES: 2/98

A&BSERIES

INSTALLATION & SERVICE INSTRUCTIONS

REFRIGERATION/AIR CONDITIONING/HEAT PUMP COMPRESSORS

BRISTOL COMPRESSORS, INC.

BRISTOL, VIRGINIA 24202

(276) 466-4121

FAX (276) 645-2423

WARNING

ALWAYS MEASURE START WINDING CURRENT ON START-UP!

NORMALLY 2 to 10 AMPS (See Page 5 for Details)

AND

BEFORE A SUSPECT COMPRESSOR IS REMOVED, ALWAYS

CHECK LOCKED ROTOR PULL-DOWN VOLTAGE

(See Page 2 for Details)

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.

Page 2

WARNING: Read all procedures and warnings prior to performing maintenance! For your

safety, it is essential that you use properly sized and operating test equipment.

INSTALLATION PROCEDURES AFTER COMPRESSOR HAS BEEN VERIFIED AS FAULTY…

BEFORE CONDEMNING A SINGLE-PHASE COMPRESSOR THAT FAILS TO START…

1. Verify all following components are OK:

A. Run capacitor

B. Starting components (even if not originally installed, start assist should be tried before going to step 2)

C. Contactor

D. Winding resistance within manufacturer’s specification (assure compressor is cool to the touch)

E. Compressor not grounded via ohmmeter/Megger, etc.

F. Compressor power terminals are tight and secure

G. Check for hot spots in system wiring (wire insulation melted, connectors, insulators melted, etc.)

2. Verify locked 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 (single-phase 230/208 LRPDV is 197v), the power supply

must be corrected before removing the compressor.

Procedure to check for LRPDV: Warning! Make sure system is properly grounded before

proceeding!

A. Connect a voltmeter to the common terminal and run terminal of the compressor.

B. Remove the start wire from the compressor and insulate the connector lead wire.

C. Terminal cover and retainer MUST be installed before applying voltage. (See warning on page 4.)

D. Apply voltage to the compressor and measure the voltage as the compressor attempts to start (during

locked rotor). If internal overload trips, allow time for reset before continuing.

E. If the voltage at the compressor terminals does not pull down below the LRPDV, reconnect the start

wire and try to start again. If the compressor does not start, proceed to step 3 below.

3. Direct wiring. This wiring eliminates all other components and system wiring.

A. Hard-wire from a fused disconnect to the Cand Rterminals of the compressor

B. Wire in a new run capacitor from the Sterminal to the Rterminal at the compressor using new wire

leads (see page 9 permanent split capacitor-wiring diagram)

C. Turn on disconnect, verify LRPDV and measure start winding current (see item 10, page 5)

D. If compressor does not start, add a two-wire start assist kit in parallel with the run capacitor and repeat

step 3 (C). If the pressures are equalized and the LRPDV and start current are OK, and the

compressor still does not start, it is definitely faulty.

The following instructions are general in nature 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: Never use oxygen to pressurize a refrigeration or air conditioning system.

Oxygen can explode on contact with oil and could cause personal injury. When using high

pressure gas such as nitrogen or CO2for this purpose, be sure to use a regulator that can

control the pressure down to 1 or 2 psig.

WARNING: Air conditioning and refrigeration systems are pressurized; hazards could exist

resulting in personal injury. It is therefore recommended that the following steps for

troubleshooting, removal and installation of the hermetic compressor be performed by

qualified experienced personnel only.

Page 3

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

refrigerant reclaim programs.

B. Remove the electrical leads from the compressor. Note and label the terminal to which each wire is

connected.

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. Remove the faulty compressor.

E. 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 alternative below).

Good indicators of excess oil are: violent vibration and/or high variable sound as the extra oil moves

through the system.

Alternatives: If the excess oil cannot be flushed from the system, the last alternative is to reduce the

oil charge in the new compressor by the amount left in the system.

•This procedure should be used only if the following are true:

-The oil remaining in the system is dry (i.e., system had not leaked down)

-Oil type is same as in the replacement compressor

-Compressor failure was not a motor burnout

-The oil remaining in the system is less than 50% of the original oil charge

-Suction filter drier must be installed

•Procedure if failed compressor has lost more than 50% of the original oil charge

-Operate new compressor for 15 minutes in cooling mode (30 minutes if a suction line

accumulator is installed)

-Recover refrigerant and remove the compressor

-Remove oil from the compressor and recharge with fresh oil per the manufacturer’s

specifications

E. Remove the faulty compressor.

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 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.

3. 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 see steps 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 mounting bolts will bottom out when tight. Use care not to over-compress the

mounting grommets when the mounting sleeves cannot be used.

4. INSTALL FILTER DRIERS. Bristol Compressors recommends the use of new adequately sized liquid and

suction line driers anytime a compressor is replaced. If the new compressor is to be used to replace a

compressor with a burned motor, the use of a high acid neutralizing filter drier is recommended. For heat

pumps, a suction filter drier must be installed between the accumulator and the compressor suction

WARNING: To avoid electrical shock, power to the compressor sh

ould remain off during

performance of Steps 2 through 10.

Page 4

inlet. In addition, a bi-directional heat pump liquid line drier or factory recommended driers must be

installed. NOTE: ALWAYS REMOVE OLD FILTER DRIERS.

5.BRAZE ON SUCTION AND DISCHARGE LINES. Flow an inert gas, such as nitrogen or CO2, through the

system at approximately 2 psig. This will reduce the possibility of oxidation inside the tubing. Braze on the

suction and discharge lines and braze the process tube shut following the recommendation listed below (if

the process tube is to be used, it should be brazed shut after the system has been charged):

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 brazing 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 may

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.

6. 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.

7. 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.

8. CHECK THE ELECTRICAL SYSTEM. While the system is evacuating, connect the electrical leads to the

compressor terminals. Verify that the electrical system is wired according to the unit’s manufacturer and

Bristol’s wiring diagram on page 9. Verify that the electrical components match those specified on the

compressor electrical data sheet on pages 10 through 14. Start components (start capacitor and relay)

are required on all systems that incorporate a hard shut-off or non-bleed thermostatic expansion

valve. It is a normal practice to replace all starting components any time a compressor is changed. Check

all connections and terminals to be sure they are tight. Connect the crankcase heater (standard on all “A”

Series). Power to the crankcase heater must be energized continuously. Voltage to an insertion type

heater can be anything between 187 to 600 volts. Operational voltage for wrap-around type heaters must

be verified.

CAUTION: Do not use the Bristol replacement compressor as an evacuation assist and never

apply voltage to a compressor while it is in a vacuum as damage could result.

WARNING: Application of voltage to the compressor with the terminal cover and retainer removed

can result in serious personal injury or death.

Page 5

9. 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. Consult unit pressure/superheat chart on the unit door panel for the correct

superheat since pressures and superheat change with the ambient temperature.

WEIGHING in the system charge to the factory specification will help point out system faults that

may still exist.

10. START-UP. CLAMP-ON AMMETER MUST BE IN PLACE BEFORE POWER IS APPLIED TO MONITOR

START WINDING CURRENT ON START-UP!! See page 6

ASSURE THESE NORMAL START WINDING CURRENTS ON START-UP

CONFIGURATION APPROX. CURRENT

NORMAL START WITH RUN CAP ONLY 2 -10 AMPS

NORMAL START WITH RUN AND START CAP 20 AMPS AND DROP TO 2-10 AFTER START

NORMAL START WITH START CAP (INDUCTION RUN) 20 AMPS AND DROP TO 0 AFTER START

WARNING: If above currents are exceeded for more than 5 seconds, disconnect power and

correct the fault before restarting.

NOTE: Assure voltage to compressor does not drop below minimum allowable voltage (eg. 197

volts for 230/208-1-60) during the period the compressor is trying to start. Refer to page 2

for explanation of test to check LOCKED ROTOR PULL-DOWN VOLTAGE.

Page 6

FOR CAPACITOR START/CAPACITOR RUN (CSR) MODELS

FOR CAPACITOR START INDUCTION RUN (CSIR) MODELS

LINE

START

CAPACITOR

RUN

CAPACITOR POTENTIAL

RELAY

IDENTIFIED

TERMINAL

TO LINE SIDE

BLEED

RESISTOR

PUT YOUR CLAMP-ON AMMETER HERE

AMPS SHOULD DROP TO

"0" AFTER START

RUN

WINDING

START

WINDING

LINE

POTENTIAL

RELAY

BLEED

RESISTOR

START

CAPACITOR

PUT YOUR CLAMP-ON AMMETER HERE

AMPS SHOULD DROP TO "0"

AFTER START

START

WINDING

LINE

RUN

WINDING

Page 7

11. VERIFY SYSTEM WILL NOT ALLOW LIQUID FLOODBACK.

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 [6°K]).

STEP 5: Sump temperature should always be 50°F (28°C) or higher above saturated suction temperature.

EXAMPLE: “R-22”

38 psig = 16°F (-9°C) = SATURATED SUCTION

+ 50°F (28°K) = MINIMUM TEMP. DIFFERENCE

66°F (19°C) = MINIMUM SUMP TEMPERATURE

COOLING MODE (HEAT PUMP)

STEP 1: Operate system in cooling mode with indoor fan disconnected and repeat steps 3, 4 and 5.

AIR-CONDITIONING/REFRIGERATION UNITS

STEP 1: Operate system in the cooling mode with indoor fan disconnected and repeat steps 3, 4 and 5.

TAKE SUCTION

TEMPERATURE

6" TO 12"

FROM COMPRESSOR

NOTE:

58° F (14°C)

38° F (

3°C)

20° F (11°K)

FOR THE “HARD TO GET

TO” COMPRESSOR

TAKE TEMPERATURES

AND PRESSURES HERE,

AIR CONDITIONING

MODE ONLY

CONVERT SUCTION

PRESSURE TO

TEMPERATURE

65 PSIG = 38°F (3°C)

SUPERHEAT

HOW TO CHECK SUPERHEAT

58°F

DIGITAL

THERMOMETER

(14°C)

12. CHECK FILTER DRIERS 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.

Page 8

B. 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. A slight restriction in

this filter will reduce the efficiency of the system. A large restriction will cause the suction 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 over-charged 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

limit switch. The service person may not see the higher discharge pressure due to his service port

being in the liquid line which is normally downstream from the liquid line filter drier in residential 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.

C. Discharge Line Filter: Some OEM equipment may have a filter in the hot gas line (6” –12” from

compressor). Checks outlined in (B) above apply.

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 pressure exceeds the suction pressure by

more than 450 psi (“B” products) or 400 psi (“A” products). If the relief valve opens, a high velocity

gas flow may be heard inside the compressor housing. In some cases, the relief valve 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 exits 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 at least 5 minutes,

allowing pressures to equalize.

RREVIEW ALL TWELVE STEPS TO MAKE SURE NOTHING WAS OVERLOOKED.

Page 9

LINE

START

CAPACITOR

RUN

CAPACITOR

POTENTIAL

RELAY

IDENTIFIED

TERMINAL TO

LINE SIDE

BLEED

RESISTOR

LINE

IDENTIFIED

TERMINAL TO

LINE SIDE

RUN

CAPACITOR

LINE

IDENTIFIE

TERMINAL

TO LINE SIDE

RUN

CAPACITOR

LINE

RUN

WINDING

START

WINDING

LINE

RUN

WINDING

START

WINDING

LINE

RUN

WINDING

START

WINDING

START ASSIST WIRING DIAGRAM (START AND RUN CAPACITORS):

Use this diagram on systems with expansion valve and systems that do not allow pressure equalization

prior to compressor start.

NOTE

: WHEN CRANKCASE HEATER IS USED, CONNECT TO INCOMING POWER LINE SO THAT

HEATER IS ENERGIZED CONTINUOUSLY.

PERMANENT SPLIT CAPACITOR (PSC) WIRING DIAGRAM:

Use this diagram on systems that allow pressure equalization prior to compressor start.

NOTE: WHEN CRANKCASE HEATER IS USED, CONNECT TO INCOMING POWER LINE SO

THAT HEATER IS ENERGIZED CONTINUOUSLY.

START ASSIST WIRING DIAGRAM (PTCR AND RUN CAPACITOR):

PTCR

Use this light start assist in case of a slight low voltage condition with equalized pressures prior to

compressor start.

NOTE: SOFT START ASSIST (PTCR) IS REQUIRED ON SOME HIGH EFFICIENCY COMPRESSORS

(SEE PAGE 12) EVEN WHEN THE SYSTEM EQUALIZES. “C” IN THE 8TH-DIGIT OF MODEL NUMBER

IDENTIFIES COMPESSORS THAT REQUIRE PTCR START ASSIST. NOT REQUIRED WHEN A

START ASSIST KIT IS USED (RELAY, START CAPACITOR).

Page 10

AIR CONDITIONING & HEAT PUMP ELECTRICAL

COMPONENTS PARTS FOR SINGLE PHASE

COMPRESSORS

H24B SERIES 60 HZ

Capacitors Potential Relays

Mars

Compressor

Model Number

Voltage

Phase

Hz Run

µfd/Volts

Start

µfd/Volts GE

3ARR3 6-Pak

OEM PTCR

Starter

H24B13QABCA

230/208-1-60

15/370 88-108/250

3U 66 16049

Optional

H24B13QABCB

230/208-1-60

15/370 88-108/250

3U 66 16049

Optional

H23B SERIES 60 HZ

Capacitors Potential Relays

Mars

Compessor

Model Number

Voltage

Phase

Hz Run

µfd/Volts Start

µfd/Volts GE

3ARR3 6-Pak

OEM PTCR

Starter

H23B15QABC 230/208-1-60 25/370 88-108/250 3T 69 16068 Optional

H23B15QABH 265-1-60 20/440 88-108/330 10T 69 16073 Optional

H23B17QABC 230/208-1-60 25/370 88-108/250 3P 65 16050 Optional

H23B17QABH 265-1-60 25/370 88-108/330 10U NA NA Optional

H23B19QABC 230/208-1-60 25/370 88-108/250 10S 69 16067 Optional

H23B20QABC 230/208-1-60 25/370 88-108/250 10S 69 16067 Optional

H23B22QABC 230/208-1-60 30/370 88-108/250 10S 69 16067 Optional

H23B22QABH 265-1-60 25/440 88-108/250 25U 66 NA Optional

H23B24QABC 230/208-1-60 35/370 88-108/250 24P 69 16072 Optional

H23B26QABC 230/208-1-60 35/370 88-108/250 3P 65 16050 Optional

H23B28QABC 230/208-1-60 35/370 88-108/250 10S 69 16067 Optional

H23B28QABH 265-1-60 30/440 88-108/330 10S 69 16067 Optional

H23B30QABC 230/208-1-60 40/370 88-108/250 24P 69 16072 Optional

H23B32QABC 230/208-1-60 45/370 88-108/250 3L NA 16083 Optional

H29B SERIES 60 HZ

Capacitors Potential Relays

Mars

Compressor

Model Number

Voltage

Phase

Hz Run

µfd/Volts Start

µfd/Volts GE

3ARR3 6-Pak

OEM PTCR

Starter

H29B14UABC 230/208-1-60 30/370 161-193/250

3V 66 16048 Optional

H29B15UABC 230/208-1-60 30/370 161-193/250

3V 66 16048 Optional

H29B16UABC 230/208-1-60 30/370 161-193/250

3V 66 16048 Optional

H29B17UABC 230/208-1-60 30/370 161-193/250

3V 66 16048 Optional

H29B17UABH 265-1-60 25/440 88-108/330 10U NA NA Optional

H29B18UABC 230/208-1-60 30/370 161-193/250

3V 66 16048 Optional

H29B18UABH 265-1-60 25/440 88-108/330 10U NA NA Optional

H29B20UABC 230/208-1-60 30/370 145-175/250

3U 66 16048 Optional

H29B20UABH 265-1-60 30/440 88-108/330 10S 69 16067 Optional

H29B22UABC 230/208-1-60 30/370 145-175/250

3U 66 16049 Optional

H29B22UABH 265-1-60 30/440 88-108/330 10S 69 16067 Optional

H29B24UABC 230/208-1-60 35/370 145-175/250

3T 69 16068 Optional

H29B24UABH 265-1-60 30/440 88-108/330 10S 69 NA Optional

H29B26UABC 230/208-1-60 35/370 145-175/250

3T 69 16068 Optional

H29B26UABH 265-1-60 30/440 88-108/330 10S 69 NA Optional

H29B28UABC 230/208-1-60 35/370 145-175/250

3T 69 16068 Optional

H29B28UABH 265-1-60 30/440 88-108/330 10S 69 NA Optional

H29B30UABC 230/208-1-60 40/370 145-175/250

3P 65 16050 Optional

H29B30UABH 265-1-60 30/440 88-108/330 10S 69 NA Optional

NOTE: Eleventh character of the model number represents the foot configuration

–could be A or B.

PROCESS

DISCHARGE

CRANKCASE HEATER

RECEPTACLE (THIS END)

SUCTION

H24B, H29B

SUCTION

PROCESS

DISCHARGE

CRANKCASE HEATER

RECEPTACLE (THIS END)

H23B

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