Impact SEMI HERMETIC RECIPROCATING COMPRESSOR CATALOG INTRODUCTION This catalog is published by Hussmann Corporation to provide information required to select and service Ingersoll Rand Impact semi hermetic compressors. There are several major category tabs to enable quick access to required information.
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5. Electrical Data a. Electrical Description i. Rated Load Current ii. Component Sizing iii. Marking on Compressor Nameplate b. Tables – By Voltage, Application Range, and Refrigerant i. LRA ii. MCC iii. RLA iv. Circuit Breaker Size v. Contactor Size vi.
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8. Lubrication a. Polyolester Lubricants i. IR POE32 b. Mineral Oils i. IR MO32 9. Aftermarket a. Model Number Nomenclature b. Compressor Part Numbers c. Distribution Network Map d. Contact Information List e. Cross Reference for Replacement Compressors i. Copeland ii.
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Ingersoll Rand Impact Semi-hermetic Reciprocating Compressors Leading the way in Technology and Performance Low Pressure Drop Large Electrical Unloaders Service Valves Terminal Box Cast in Muffler Heads Electronic Motor Protection Chrome Plated Rings Dual Voltage, High Efficiency Motors Teflon Impregnated...
Ingersoll Rand Impact Semi-hermetic Reciprocating Compressors Features and Benefits Small physical size and weight for comparable displacement and capacity Universal o One compressor version for all temperature ranges using R404A, R507, and R22 Smooth and Quiet Operation can be Attributed to:...
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Teflon Impregnated Bearings o Bearing composition is metal and PTFE (Teflon) o Allows for safe operation during marginal lubrication periods Eccentric Rods o Aluminum alloy o High quality and low tolerances can be maintained due to one-piece construction o Low bearing loading & high velocities, increase the running capability of bearings under boundary lubrication conditions Crankshaft o High quality cast iron...
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Piston Rings o 4 & 6 cylinder models have two rings, a chrome plated compression ring and an oil ring o Chrome plated rings provide excellent running durability under boundary lubrication conditions o Piston rings are sealed by gas pressure balancing the ring tension to the proper value o Provides excellent sealing under various pressure and speed conditions Cylinder Design...
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INGERSOLL RAND Impact SEMI HERMETIC RECIPROCATING COMPRESSOR Model Number Nomenclature IR 4 C 0000 S B Voltage B – 208-230/460/3/60 K – 208/230/3/60 M – 460/3/60 P – 575/3/60 R – 208/230/1 /60 Oil System S – Enhanced Centrifugal P – Pump T –...
The application envelopes are marked to show when the I-COOL system applies. For further details refer to Mechanical Design - Section 6 of this manual. Liquid Injection For larger Ingersoll Rand Impact compressor models liquid injection is required for R22 low temperature applications.
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Unloaders All 4, 6, and 8 cylinder IR Impact compressors are available with capacity control. The method used is suction shut-off, whereby the suction-side gas flow is shut off from a bank of cylinders by means of a control piston (unloader). The following combinations are possible: 4-cylinder 50 %...
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R-404A/507 Compressors: IR2C0173S – IR4C1385S Additional cooling required Additional Cooling or Maximum 40°F RGT All Application Limit curves are based on 65°F return gas temperature, except where noted. Saturated Suction Temperature Saturated Condensing Temperature RGT Return Gas Temperature Suction Superheat Application Guidelines...
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R-404A/507 Compressors: IR4C1480S – IR6B6462P Additional cooling and SH < 35°F Additional cooling or maximum 40°F RGT All Application Limit curves are based on 65°F return gas temperature, except where noted. Saturated Suction Temperature Saturated Condensing Temperature RGT Return Gas Temperature Suction Superheat Application Guidelines...
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R-22 Compressors: IR2C0173S – IR4C1385S I-Cool Direct Suction and Head Fan Additional cooling Lower limit for IR4C1385S only, see Note All Application Limit curves are based on 65°F return gas temperature, except where noted. Saturated Suction Temperature Saturated Condensing Temperature RGT Return Gas Temperature Suction Superheat Note: I-Cool Direct Suction is not available for the IR4C1385S model.
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R-22 Compressors: IR4C1480S -- IR6B6462P IR8C7863P – IR8C9400P for High Temp Applications Only and Minimum of 32°F Saturated Suction Temp Added cooling and SH<35°F Additional cooling required Liquid Injection and head cooling fan All Application Limit curves are based on 65°F return gas temperature, except where noted.
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R-404A/507 Application limits for unloaded models 50 % IR4C0770S – IR4C1385S Additional cooling Additional cooling OR RGT < 40°F 50 % IR4C1480S – IR4B3604P Additional cooling and SH < 35°F Additional cooling OR RGT < 40°F All Application Limit curves are based on 65°F return gas temperature, except where noted.
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R-404A/507 Application limits for unloaded models 66 % IR6B4060P – IR6B6462P Additional cooling and SH < 35°F Additional cooling OR RGT < 40°F 33 % IR6B4060P – IR6B6462P Additional cooling and SH < 35°F Additional cooling OR RGT< 40°F All Application Limit curves are based on 65°F return gas temperature, except where noted.
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R-22 Application limits for unloaded models. 50 % IR4C0770S – IR4C1385S Additional cooling and SH < 18°F Additional cooling The application limits of the IR4C0770 – IR4C1145 are valid only for I-Cool suction gas cooling SL(A). 50 % IR4C1480S – IR4B3604P Additional cooling and SH <...
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R-22 Application limits for unloaded models. 66 % IR6B4060P – IR6B6462P Additional cooling and SH < 35°F Additional cooling 33 % IR6B4060P – IR6B6462P Additional cooling and SH < 35°F Additional cooling All Application Limit curves are based on 65°F return gas temperature, except where noted.
Electrical Information ™ Ingersoll-Rand Impact Compressors comply with all applicable Underwriters Laboratories standards and the National Electrical Code, specifically, Article 440, Air-Conditioning and Refrigerating Equipment. The Scope of Article 440 includes: “electric motor driven air-conditioning and refrigeration equipment and to the branch circuits and controllers for that equipment. It provides for the special considerations necessary for circuits supplying hermetic refrigerant motor compressors and for any air-conditioning and refrigeration equipment that is supplied from a branch circuit that supplies a hermetic refrigerant motor compressor.”...
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Method Used to Determine Rated-Load Current Model Type Application LT only LT only Temperature R-22 R-22 R-22 R-22 Refrigerant R-404A R-404A R-404A R-404A R-22 R-22 R-507a R-507a R-507a R-507a NEC Method 440.52 440.52 440.52 440.52 440.52 440.52 Used (A)(2) (A)(3) (A)(2) (A)(3) (A)(2)
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Wire Size is based on specifications by Underwriters Laboratories and the National Electrical Code, and is set on the breaker size chosen. The minimum wire size is 12 AWG. See table below. Breaker Amperes Wire Size Breaker Amperes Wire Size 0 to 20 116 to 130 21 to 30...
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- Medium & High Temperature Application -10 to +53.5 °F-R-22, R-404A, R-507 208 VOLT Compressor Circuit NEMA Wire Model Number Breaker Size Contactor Contactor Size IR2C0173SK IR2C0222SK IR2C0278SK 14.8 IR2C0323SK 13.0 IR2C0407SK 16.5 10.6 IR2C0484SK 20.7 13.3 IR2C0572SK 23.8 15.3 IR2C0692SK 28.4 18.2...
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– Medium & High Temperature Application -10 to +53.5 °F – R-22, R-404A, R-507 575 VOLT Compressor Circuit NEMA Wire Model Number Breaker Size Contactor Contactor Size IR2C0173SP IR2C0222SP IR2C0278SP IR2C0323SP IR2C0407SP IR2C0484SP IR2C0572SP IR2C0692SP 10.2 IR4C0770SP 13.6 IR4C0969SP 12.9 IR4C1145SP 16.0 10.3...
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- Low Temperature Application -40 to +10 °F- R22, R-404A, R-507 208 VOLT Compressor Circuit NEMA Wire Model Number Breaker Size Contactor Contactor Size IR2C0173SK IR2C0222SK IR2C0278SK 14.8 IR2C0323SK 13.0 IR2C0407SK 16.5 IR2C0484SK 20.7 12.2 IR2C0572SK 23.8 16.0 IR2C0692SK 28.4 16.6 IR4C0770SK 34.3...
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- Low Temperature Application -40 to +10 °F- R22, R-404A, R-507 575 VOLT Compressor Circuit NEMA Wire Model Number Breaker Size Contactor Contactor Size IR2C0173SP IR2C0222SP IR2C0278SP IR2C0323SP IR2C0407SP IR2C0484SP IR2C0572SP IR2C0692SP 10.2 IR4C0770SP 13.6 IR4C0969SP 12.9 IR4C1145SP 16.0 10.0 IR4C1385SP 21.3 11.8...
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- Low Temperature Application -40 to +10 °F- R-22 (pre-existing models) 208 VOLT Compressor Circuit NEMA Wire Model Number Breaker Size Contactor Contactor Size IR2C0278TK 10.2 IR2C0323TK 13.0 IR2C0407TK 14.0 IR2C0484TK 16.8 10.8 IR2C0572TK 17.5 11.2 IR2C0692TK 20.5 13.1 IR4C0770TK 25.9 16.6 IR4C0969TK...
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- Low Temperature Application -40 to +10 °F- R-22 (pre-existing models) 575 VOLT Compressor Circuit NEMA Wire Model Number Breaker Size Contactor Contactor Size IR2C0278TP IR2C0323TP IR2C0407TP IR2C0484TP IR2C0572TP IR2C0692TP IR4C0770TP IR4C0969TP 10.6 IR4C1145TP 12.3 IR4C1480TP 14.6 IR4C1761TP 17.4 11.1 IR4C2067TP 21.6 13.8...
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Motor Protection Devices Protection Device Models SE-B1 is the typical motor protection module for IR compressor models up through IR4C2397. Compressors larger than the IR4C2397 use a module SE-B2. For compressor models IR4C0770 through IR4C2397 utilizing the PTC temperature sensor for oil control, the protection module used is the model INT69/70.
The integrity of the heater element can be verified by checking its resistance. Disconnect control circuit power. B) Remove the black & brown wires from INT 69/70 terminals #1 & #2. C) Use an ohmmeter to check the resistance across the black & brown wires. D) Heater resistance should be 320 Ω...
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Control Circuit Wiring Schematics Figure 1. Motor protector SE-B1 shown Electrical Data...
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Figure 2. Motor protector SE-B2 shown Electrical Data...
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Figure 3. Motor protector and oil failure control module INT69/70 shown. Electrical Data...
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Features Impact Semi-Hermetic Reciprocating Compressors cover the whole application range regardless of whether traditional or chlorine-free HFC refrigerants are used. The latest innovation is the "C Series" which offer very compact size, universal application, minimum energy consumption, and very low vibration levels. All IR Impact compressors have the same robust valve plate construction, high quality wear...
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Lubrication Impact compressors are supplied with two types of lubrication systems. C-Series compressors with the letters S or T in the model number have an Enhanced Centrifugal Lubrication system with no oil pump, while C-Series models with the letters P or Q in the model number, and all B-Series compressors have oil pumps.
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Oil Pump Figure 1: IR Impact compressor IR4C2397P with Positive Displacement Lubrication To avoid frequent tripping, the oil pressure switch includes a time delay (usually 90 to 120 seconds) since the compressor starts with refrigerant dissolved in the oil, for example, the pump’s operation may be temporarily interrupted by vapor bubbles in the suction port.
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Figure 2: IR Impact compressor IR4C2397S with Enhanced Centrifugal Lubrication Compared to commonly used splash lubrication, the new system has advantages with respect to its highly dynamic response characteristics: After starting, the oil flow is immediately present and maintained over the entire operating range. Oil carry over (% of mass flow) (Compressor IR4C0969, R404A, 40/120°F) Pump...
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Oil Monitoring with Enhanced Centrifugal Lubrication The more difficult task was to develop a suitable monitoring system for the oil circuit. An oil control sensor (4) has been developed, which is mounted directly into the pocket (2). It utilizes a heated PTC element, which is cooled by the circulating oil.
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If the differential oil pressure drops below the cutout pressure for more than 90 seconds, the output contact opens and stops the compressor. The control may be manually reset after approximately 3 minutes by pushing the reset button. The control’s internal microprocessor also integrates multiple time periods when low oil pressure is present, and may shut off the compressor even if 90 continuous seconds has not elapsed.
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Johnson Controls P545NCB-25C Oil Pressure Control Technical Data Supply Voltage 120 or 240 VAC + 10%, - 15%. 50/60 Hz Power Consumption 3 VA Time Delay with Low Oil Pressure 90 +/- 12 seconds Control Relay Pilot duty 375 VA at 120VAC, 750 VA at 240 VAC Switch P400BD-1...
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As an alternative to the Delta-P or the Johnson Controls P545, compressors with oil pumps may use an externally mounted oil differential pressure switch with tubing connections to compressor suction and the discharge of the oil pump. Applicable switches would include the Danfoss MP54 and the Johnson P128CA.
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I-Cool - Supplemental Cooling Impact C-Series compressors may be equipped with the optional I-COOL system that provides an optimized cooling method for low and medium temperature, but is only applicable for compressor models IR2C0173 - IR4C1145. The position of the suction strainer may be changed as shown in the figures below.
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Inject-Cool - Supplemental Cooling In addition to I-Cool, Inject-Cool is a further cooling method for larger single-stage low temperature R-22 compressors. Inject-Cool uses a liquid injection valve to inject liquid refrigerant directly into the compressor body whenever additional cooling is needed, as dictated by the discharge line temperature sensor.
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Note: Do not use unloaders with Inject-Cool compressors. The following table lists Inject-Cool liquid injection valve models and part numbers: Compressor Model Inject Cool Valve Part Inject Cool Valve Model Number Number Number IR4C1480 0707532 Y1037-FV-1-240 IR4C1761 0707533 Y1037-FV-1 ½-240 IR4C2067 0707533 Y1037-FV-1 ½-240...
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Discharge Mufflers Ingersoll-Rand Impact compressors are supplied with discharge mufflers cast into the cylinder heads (patent applied for), which significantly reduces discharge tubing vibration. Cylinder Head without Muffler Cylinder Head with Muffler Mechanical Design...
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Capacity Control Four and six cylinder compressors offer integrated capacity control that makes use of the principle of suction shut-off. The following combinations are possible: Compressor Type Possible Unloaded Capacity Number of Unloaders 4-Cylinder 6-Cylinder 66% and 33% 8-Cylinder 75% and 50% In full-load operation the solenoid coil is de-energized, and suction gas flows to all cylinders.
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Application limits with part-load operation With unloaders, compressor temperatures increase due to reduced refrigerant flow, reduced motor cooling, and electrical and mechanical losses. Therefore, the application ranges of compressors with unloaders are somewhat restricted. Please refer to the application envelopes when selecting compressors with unloaders.
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Crankcase heaters should be selected based on the following table: Compressor Model Voltage IR Part Wattage Securing Number Number Method 110 V 0704640 IR2C0173 – IR2C0407 60W * Clip 230 V 0704641 110 V 0704642 IR2C0484 – IR4C1385 120W * Clip 230 V 0704643...
Head Cooling Fans Head Cooling Fans: Fans are available for all compressor types upon request. The condenser air stream may be used in place of a head cooling fan if the air velocity over the compressor is at least 10 ft/sec at all operating conditions. The following table lists cooling fan parts: Compressor Model Mounting 120 Volt...
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Fan Mounting Bracket for IR4C0770 .. IR4C1385, Part. No. 0705467 Fan Mounting Bracket for IR4C1480 .. IR4C2397, Part. No. 0705466 Mechanical Design...
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Fan Mounting Bracket for IR4B2707 .. IR4B3604, Part. No. 0705465 Fan Mounting Bracket for IR6B4060 .. IR6B6462, Part. No. 0705464 Mechanical Design...
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Cylinder Heads Ingersoll-Rand Impact compressors use three types of cylinder heads. 1) Standard Head – no additional functions 2) Capacity Control cylinder heads are marked CR . 3) Start Unloader cylinder heads are marked SU . BE SURE TO APPLY THE CORRECT CYLINDER HEAD FOR THE INTENDED APPLICATION Minimum Space Requirements Ingersoll-Rand...
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INGERSOLL-RAND Impact SEMI-HERMETIC RECIPROCATING COMPRESSORS INSTALLATION AND START-UP INSTRUCTIONS Installation and Start-up...
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Operating Instructions. The following standards have procedures that should be followed when installing and operating Ingersoll Rand Impact semi-hermetic reciprocating compressors: Specific safety regulations and standards (UL 1995 and ANSI/ASHRAE 15), Generally acknowledged safety standards NFPA –...
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The following instructions are prepared to aid the installation and/or service in providing an adequate installation with optimum performance. These instructions are general in nature, and have been written primarily for field installation of Ingersoll Rand Impact compressors.
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Figure 1. Lifting the Compressor Installation – Mechanical Mounting The Ingersoll Rand Impact compressors may be rigidly mounted if no danger of breakage due to vibration exists in the associated piping system. For this purpose, place a washer between each compressor foot and frame. (Note: This washer is not required for compressor models IR4C1480 through IR4C2397.) Otherwise the compressor must be...
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Figure 2. Anti-vibration mounts Installation – Electrical The supply power, voltage, frequency, and phase must coincide with the compressor nameplate. Ingersoll Rand Impact compressor models IR4C1480 and larger have dual voltage motors, care should be taken to assure proper connection of wiring within the terminal box.
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For the electrical part of the installation, verify the following installed components match those listed in the Electrical section of this manual. 1. Wire sizes to handle the connected load 2. Circuit breaker size 3. Contactor size 4. Control circuit wiring, including high pressure safety controls, low pressure controls, and oil failure controls 5.
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Leak Testing Evaluate the refrigeration circuit assembly according to ANSI/ ASHRAE 15 or valid equivalent safety standards. The following procedure is recommended for leak checking the refrigeration system prior to starting any compressor. 1. Visually inspect all lines and joints for proper piping practices. 2.
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Evacuation Attention! Nitrogen and moisture will remain in the system unless proper evacuation procedures are followed. Nitrogen left in the system may cause excessive discharge pressure problems. Moisture causes TEV ice blockage, wax build up, acid oil, and sludge formation. Do not simply purge the system, this method is expensive, harmful to the environment, may leave moisture and nitrogen in the system, and may result in fines or penalties from the EPA.
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Pre-Check, Charging and Start-up After the installation, leak testing, and evacuation procedures are complete the following items should be checked before charging the system with refrigerant: 1. Check all electrical connections to make sure they are tight. 2. Observe compressor oil levels; oil should be visible in the compressor sight glass.
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9. Allow the full system to operate until it stabilizes. 10. Adjust all expansion valves, EPR valves, control valves, and other controls to their proper settings. 11. Re-check refrigerant charge and oil levels, adding refrigerant and oil as needed. Items to Watch and Check During Start-up Excessive Vibrations The whole system, especially the piping and capillary tubes must be designed to prevent abnormal vibrations.
After this initial change, it is recommended that the oil be replaced approximately every three years or 10,000 to 12,000 operating hours. Also replace the oil filter and clean the magnetic plug. Use only Ingersoll Rand approved lubricants as listed in the Lubricant – Section 8 of this manual. Attention! Ester oils are strongly hygroscopic.
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Troubleshooting - Procedures Warning! Before attempting any service work on the compressor, the following safety precautions should be strictly adhered to. Failure to follow these instructions could result in serious personal injury. Follow recognized safety practices and wear protective goggles. Do not operate compressor or provide any electric power to this unit unless the compressor terminal box cover is in place and secured.
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Troubleshooting - Chart Observation Possible Cause Remedy Power off Check main switch, fuses, and wiring Current overload open Reset manually 1. Compressor will Oil safety switch open Reset manually not start Loose electrical Tighten connections. Check wiring connections or faulty wiring and rewire if necessary.
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Observation Possible Cause Remedy Excessive water flow Adjust water regulating valve through condenser Suction service valve Open the valve partially closed 6. Low discharge pressure Leaky compressor suction Pump down, remove the valves cylinder head, examine valves and seats; replace if necessary Worn piston rings Replace compressor Improper system piping...
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Observation Possible Cause Remedy Inadequately supported Support pipes or check pipe piping or loose pipe connections 10. Pipe rattle connections Low oil charge Check oil level requirements Faulty oil pump drive Replace segment 11. Oil pressure lower segment than normal or no oil Worn oil pump Replace bearing head assembly pressure...
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Observation Possible Cause Remedy Check control box for Replace defective components. welded starter contacts, 14. Motor burnout welded overload contacts, or burned out heater elements. 15. On parallel Oil equalization line not Level oil equalization line compressor preventing gas equalization installations, oil level does not Excessive blow by into...
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Troubleshooting - Motor Burnout (Clean-up Procedure) When a hermetic motor burns out, the stator winding decomposes forming carbon, water, and acid, which contaminate refrigerant systems. These contaminants must be removed from the system to prevent repeat motor failures. Warning! Before attempting any service work on the compressor, see safety precautions listed on page 12 of this section.
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De-commissioning Standstill Keep the crankcase heater switched on until dismantling the compressor. This prevents increased refrigerant concentration in the compressor oil. Dismantling the compressor For repair work that makes compressor removal necessary, or when decommissioning: 1. Close the shut-off valves at the compressor. 2.
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Polyolester Lubricant (IRPOE32) for Reciprocating Compressors with an HFC Refrigerant General Ingersoll-Rand reciprocating compressors that are intended for use with chlorine free HFC refrigerants (R404A, R507, etc.) shall be charged with a high quality polyolester lubricant. IR POE 32 lubricant was formulated specifically for this purpose. IRPOE32 polyolester lubricant provides good miscibility with HFC refrigerants, contrary to conventional mineral oils, and is therefore the choice of polyolester lubricants when using an HFC refrigerant.
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Solubility Limits - IR POE 32 with R404A Immiscible Miscible % Oil by Weight Refrigerant Concentration in Lubricant IR POE32 and R-404A Oil Temperature F Lubricants...
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For air conditioning (H-range) and liquid injection cooling with single stage compressors, the use of a POE lubricant with a higher basic viscosity is needed. Contact Hussmann Global Engineering for proper application. Crankcase heaters with a high capacity and in certain cases pump down control are required.
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If the lubricant in the system is not listed, it is recommended that the lubricant be replaced with one on the list or contact Hussmann Global Engineering for further guidance. Consult the retrofit section of this catalog for proper retrofit procedures.
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Mineral Oil (IRMO32) for Compressors with an Reciprocating HCFC Refrigerant General Ingersoll Rand reciprocating piston compressors for HCFC refrigerants are fitted as standard with special refrigeration lubricant type Ingersoll Rand MO32. Its features include: Thermal stability Low tendency to foam...
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These lubricants are for use with HCFC refrigerants. Viscosity Supplier Oil Type Application Range Original Charge Ingersoll Rand RMO32 H M L Alternative Oils Energol LPTF 32 H M (L) Energol LPTF 46 Icematic 266...
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Lubrication Table, lost lubricant may be replaced with that lubricant. If the lubricant in the system is not listed, it is recommended that the lubricant be replaced with one on the list or contact Hussmann Global Engineering for further guidance. Consult the retrofit section of this manual for proper retrofit procedures.
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™ INGERSOLL RAND Impact SEMI HERMETIC RECIPROCATING COMPRESSOR Model Number Nomenclature IR 4 C 0000 S B Voltage B – 208-230/460/3/60 K – 208/230/3/60 M – 460/3/60 P – 575/3/60 R – 208/230/1 /60 Oil System S – Enhanced Centrifugal P –...
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Aftermarket Compressor Part Numbers IR Impact Hussmann Service Part Service Core Part Compressor Aftermarket Part Voltage Number Number Model Number Number IR2C0173SK CU.8420421 8420421 208-230/3 CU.C420421 IR2C0173SM CU.8420422 8420422 460/3 CU.C420422 IR2C0173SP CU.8420423 8420423 575/3 CU.C420423 IR2C0173SR CU.8420367 8420367 208-230/1 CU.C420367...
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IR Impact Hussmann Service Part Service Core Part Voltage Compressor Aftermarket Part Number Number Model Number Number IR4C0969SM CU.8420386 8420386 460/3 CU.C420386 IR4C0969SP CU.8420387 8420387 575/3 CU.C420387 IR4C0969TK CU.8420473 8420473 208-230/3 CU.C420473 IR4C0969TM CU.8420474 8420474 460/3 CU.C420474 IR4C0969TP CU.8420475 8420475 575/3 CU.C420475...
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IR Impact Hussmann Service Part Service Core Part Voltage Compressor Aftermarket Part Number Number Model Number Number IR4B3604QP CU.8420500 8420500 575/3 CU.C420500 IR6B4060PB CU.8420413 8420413 208-230/460-3 CU.C420413 IR6B4060PP CU.8420414 8420414 575/3 CU.C420414 IR6B4060QB CU.8420501 8420501 208-230/460-3 CU.C420501 IR6B4060QP CU.8420502 8420502 575/3 CU.C420502...
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Responsible for the Quality of Manufactured (770) 291-2390 Service Manager Products (IR IMPACT compressor and the Refrigeration System Solution Package RSS) produced at The Hussmann Suwanee Facility Ken Hughes Customer Service / Provides Factory support for (IR IMPACT (770) 291-2984...
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Alfred Gutierrez Field Service Engineer, Provides field support for the IR IMPACT (817) 819-1498 compressor installed in Hussmann OEM equipment Dave Hampton Field Service Engineer, Provides field support for the IR IMPACT (636) 236-2538 compressor installed in Hussmann OEM equipment...
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Compressor Model Cross Reference Table ™ Copeland Model Carlyle Model Impact Compressor CFH Unld Model Number Number Number IR2C0173SK KAGA-010A-TAC-800 IR2C0173SK KAGA-010E-TAC-800 IR2C0173SK KAGA-015A-TAC-800 IR2C0173SK KAMA-007A-TAC-800 IR2C0173SK KAMA-007E-TAC-800 IR2C0173SK KAMA-010A-TAC-800 IR2C0173SK KARA-010E-TAC-800 IR2C0173SM KAGA-015A-TAD-800 IR2C0173SM KAM1-010A-TAD-800 IR2C0173SM KARA-011E-TAD-800 IR2C0222SK KAJA-010A-TAC-800 IR2C0222SK KAJA-011A-TAC-800 IR2C0222SK...
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™ Impact Compressor Copeland Model Carlyle Model CFH Unld Number Number Model Number IR2C0692SM NRB2-040E-TFD-800 IR2C0692SP LAHA-032A-TAE-800 IR2C0692SP LAHA-032E-TAE-800 IR4C0770SK 2DC3-0500-TFC-800 06DM3130CA3200 IR4C0770SK 2DC3-050E-TFC-800 06DM3130CA3200 IR4C0770SK LACA-032E-TAC-800 06DR0130CA3200 IR4C0770SK LALA-032E-TAC-800 06DR0130CA3200 IR4C0770SK NRA2-050A-TFC-800 06DM3130CA3200 IR4C0770SK NRD1-032E-TFC-800 06DR0130CA3200 IR4C0770SM 2DC3-0500-TFD-800 06DM3130CA3600 IR4C0770SM 2DC3-050E-TFD-800 06DM3130CA3600...
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™ Impact Compressor Copeland Model Carlyle Model CFH Unld Number Number Model Number IR4C1480SB 1480 3DE3A0750-TFC-800 1371 06DA824DA3270 1435 IR4C1480SB 1480 3DE3A0750-TFD-800 1371 06DA824DA3670 1435 IR4C1480SB 1480 3DE3A0750-TFD-800 1371 06DA824DA3670 1435 IR4C1480SB 1480 3DE3A075E-TFC-800 1371 06DA824DA3200 1435 IR4C1480SB 1480 3DE3A075E-TFC-800 1371 06DA824DA3200 1435...
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™ Impact Compressor Copeland Model Carlyle Model CFH Unld Number Number Model Number IR4C1761SB 1761 3DPHA100E-TFD-800 1615 06DA328DA3670 1680 IR4C1761SB 1761 9RC1-101A-TFC-800 1615 06DA328DA3200 1680 IR4C1761SB 1761 9RC1-101A-TFC-800 1615 06DA328DA3200 1680 IR4C1761SB 1761 9RC1-101A-TFD-800 1615 06DA328DA3600 1680 IR4C1761SB 1761 9RC1-101A-TFD-800 1615 06DA328DA3600 1680...
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™ Impact Compressor Copeland Model Carlyle Model CFH Unld Number Number Model Number IR4C2397SB 2397 3DS3A150E-TFC-800 2127 06DM337DA3200 2225 IR4C2397SB 2397 3DS3A150E-TFD-800 2127 06DM337DA3600 2225 IR4C2397SB 2397 3DS3A150E-TFD-800 2127 06DM337DA3600 2225 IR4C2397SB 2397 3DT3A1500-TFC-800 2127 06DM337DA3270 2225 IR4C2397SB 2397 3DT3A1500-TFC-800 2127 06DM337DA3270 2225...
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™ Impact Compressor Copeland Model Carlyle Model CFH Unld Number Number Model Number IR4B3604PB 3604 4DT3-220E-FSD-800 3603 IR4B3604PB 3604 4DT3-220E-TSK-800 3603 IR4B3604PB 3604 4RJ1-300A-FSD-800 3603 IR4B3604PB 3604 6RN2-300A-TSK-800 3580 IR4B3604PP 3604 4DR3-3000-TSE-800 3603 IR6B4060PB 4060 06EM265300 4096 IR6B4060PB 4060 06EM765300 4096 IR6B4060PB 4060...
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™ Impact Compressor Copeland Model Carlyle Model CFH Unld Number Number Model Number IR6B5406PB 5406 6DS3-4000-FSD-800 5407 IR6B5406PB 5406 6DS3-4000-FSU-800 5407 IR6B5406PB 5406 6DS3-4000-TSN-800 5407 IR6B5406PB 5406 6DS3-400E-TSN-800 5407 IR6B5406PB 5406 6DT3-300E-FSD-800 5407 IR6B5406PB 5406 6DT3-300E-TSK-800 5407 IR6B5406PB 5406 6RS2-400A-FSD-800 5404 IR6B5406PB 5406...
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™ Impact Compressor Parts List Sight Glass Head Gasket Valve Plate Gasket Valve Plate Complete Gasket Compressor Part # Part # Item # Part # Item # Part # Item # Item # IR2C0173S GA.4330120 GA.4330148 CU.4220142 GA.4330126 IR2C0222S GA.4330120 GA.4330149 CU.4220143 GA.4330126...
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Sight Glass Compressor Gasket Kit Suction Service Valve Discharge Service Valve IR Compressor Part # Item # Part # Item # Part # Item # Part # Item # IR2C0173S SG.4220131 GA.4330162 CU.4220166 CU.4220160 IR2C0222S SG.4220131 GA.4330163 CU.4220166 CU.4220160 IR2C0278T SG.4220131 GA.4330112 CU.4220166...
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Suction Valve Discharge Valve Suction Valve Discharge Valve Gasket to Body Gasket to Body Gasket to Collar Gasket to Collar Compressor Part # Item # Part # Item # Part # Item # Part # Item # IR2C0173S GA.4330131 GA.4330114 #N/A #N/A IR2C0222S...
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™ Impact Compressor Accessory Parts List Crankcase Heater Crankcase Heater Capacity Control Capacity Control 230V 115V Head Stem Compressor Part # Item # Part # Item # Part # Item # Part # Item # IR2C0173S HE.4850332 HE.4950325 #N/A #N/A #N/A #N/A IR2C0222S...
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Capacity Control Coil Capacity Control Coil Oil Protection Oil Protection Sensor 115-1-60 208-220-1-60 Module Compressor Item # Item # Part # Item # Part # Item # Part # Part # IR2C0173S #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A IR2C0222S #N/A #N/A...
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Refrigeration Lubricant Kits Service Part Hussmann Aftermarket Description Number Part Number CL.4610786 4610786 OIL MINERAL 3GS 1 GALLON 4610787 CL.4610787 OIL MINERAL 3GS 5 GALLON 4610788 CL.4610788 OIL MINERAL 4GS 1 GALLON 4610789 CL.4610789 OIL MINERAL 4GS 5 GALLON 4610790 CL.4610790...
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HUSSMANN AFTERMARKET ™ IR IMPACT COMPRESSOR RETROFIT PARTS LIST IR4C to 3D ADAPTER KITS (Required when using existing piping, based on model type) Service Part # Description CU.4220171 Kit Adapter 3D 2 bolt to 2 bolt CU.4220172 Kit Adapter 3D 2 bolt to 4 bolt CU.4220173...
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Compressor Exploded View IR2C0173 to IR4C1385 Aftermarket...
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Compressor Exploded View IR8C7863 to IR8C9400 Aftermarket...
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Compressor CR Head Exploded View IR8C7863 to IR8C9400 Aftermarket...
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Retrofit Check Lists On the following pages are two forms that were developed to help ensure a successful retrofit with an IR Impact compressor. IR Impact Retrofit Survey Check List This form is intended for use in the planning stages of the retrofit process. It is to be used to gather information about the existing compressor and rack installation to ensure that the proper parts will be ordered and important piping and clearance issues are addressed prior to ordering a replacement compressor.
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RETROFIT TO IMPACT IMPACT COMPRESSOR EXISTING SYSTEM CHECK SHEET Location Name: _____________________________ City : _______________________ State:_____ System Manufacture: _________________________ Rack / Unit ID _____ MFG. DATE: ___/___/__ UNIT MODEL NUMBER:________________________ UNIT SERIAL NUMBER: __________________ REFRIGERANT TYPE: _____ RACK VOLTAGE: ______________ CONTROL VOLTAGE: _________ TYPE RETROFIT: Copeland 3D To IR4C _______...
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EXISTING SYSTEM CHECK SHEET p.2 Suction Valve Type 2 Bolt 4 Bolt Discharge Service Valve Valve On Compressor Flange & Roto-Lock Top Mounted Front Mounted Head Cooling Fan Clearance: ___________ inch. How Much Clearance Is There ? Top Of Head Cooling Fans To Bottom Of Control Panel REASON FOR EXISTING COMPRESSOR FAILURE Mechanical: ________ Electrical:...
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RETROFIT TO IMPACT IMPACT COMPRESSOR REPLACEMENT COMPRESSOR CHECK SHEET Location Name: _____________________________ City : _______________________ State:_____ System Manufacture: _________________________ Rack / Unit ID _____ MFG. DATE: ___/___/__ UNIT MODEL NUMBER:________________________ UNIT SERIAL NUMBER: __________________ REFRIGERANT TYPE: _____ OIL TYPE: ______________ CONTROL VOLTAGE: _________ NEW COMPRESSOR INFORMATION MODEL NUMBER:...
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CORE ACCOUNT # 3RCORECPN FORM # 4150191 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST-CLASS PERMIT NO.4203 MINNEAPOLIS, MN 55420 POATAGE WILL BE PAID BY ADDRESSEE HUSSMANN AFTERMARKET CUSTOMER SERVICE 314 WEST 90 STREET MINNEAPOLIS, MN 55420-9859 Aftermarket...
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Reliability and Performance IR Impact Compressors are designed for years of trouble free service. An advanced slinger oil system reduces oil carry over and increases efficiency. The compressor uses a single casting with no bottom cover, eliminating bottom bolts that may leak.
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With two standard base rails and a simple adapter kit, your new IR Impact Compressors can be easily and quickly installed to get your systems back up and running smoothly with the latest compressor technology. Contact your local Hussmann Service Branch for purchase information.
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IR Ingersoll-Rand 12999 St. Charles Rock Rd. Bridgeton, MO 63044-2483 (314) 291-2000 Printed in U.S.A. Cat. IR Impact Compressor 0604...
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COPELAND to IR IMPACT™ COMPRESSOR 3D Adapter Kits Service Hussmann Copeland Model # CFH IR Model # Part # AM # Description 3DA3A0500-TFC-800 1371 IR4C1480PB 1480 CU.4220171 4220171 Kit Adapter 3D 2 bolt to 2 bolt 3DA3A0500-TFC-800 1371 IR4C1480SB 1480 CU.4220171...
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Service Hussmann Copeland Model # CFH Model # CFH Part # AM # Description 3DE3A0750-TFC-800 1371 IR4C1480SB 1480 CU.4220171 4220171 Kit Adapter 3D 2 bolt to 2 bolt 3DE3A0750-TFD-800 1371 IR4C1480PB 1480 CU.4220171 4220171 Kit Adapter 3D 2 bolt to 2 bolt 3DE3A0750-TFD-800 1371 IR4C1480SB 1480 CU.4220171...
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Service Hussmann Copeland Model # CFH Model # Part # AM # Description 3DH3A060E-TFC-800 1371 IR4C1480SB 1480 CU.4220171 4220171 Kit Adapter 3D 2 bolt to 2 bolt 3DH3A060E-TFD-800 1371 IR4C1480PB 1480 CU.4220171 4220171 Kit Adapter 3D 2 bolt to 2 bolt...
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Service Hussmann Copeland Model # CFH Model # Part # AM # Description 3DP3A1000-TFD-800 1615 IR4C1761SB 1761 CU.4220171 4220171 Kit Adapter 3D 2 bolt to 2 bolt 3DP3A100E-TFC-800 1615 IR4C1761PB 1761 CU.4220171 4220171 Kit Adapter 3D 2 bolt to 2 bolt...
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Service Hussmann Copeland Model # CFH Model # Part # AM # Description 3DT3A0750-TFD-800 2127 IR4C2397SB 2397 CU.4220172 4220172 Kit Adapter 3D 2 bolt to 4 bolt 3DT3A1000-TFC-800 2127 IR4C2397PB 2397 CU.4220172 4220172 Kit Adapter 3D 2 bolt to 4 bolt...
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Remove oil float by tilting the compressor away from the oil sight glass. Unbolt IR4C the oil float assembly, leaving the compressor tilted until the sight glass from the be installed on the 3D compressor. Figure 2 Hussmann Aftermarket 1/13/06 Page 3 of 19...
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3. Compressor may be dry of oil, if not, tilt compressor away from sight glass. Remove sight glass and Install oil float using the sight glass bolts and new o-ring (H). Figure 5 Figure 6 Hussmann Aftermarket 1/13/06 Page 4 of 19...
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4. Install all the required fittings removed from the old compressor. See Figure 7 compressor fitting locations Figure 7 Hussmann Aftermarket 1/13/06 Page 5 of 19...
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(S ) Install suction adapter to the C4 compressor with the 4 cap screws (V) provided in the kit. Figure 8c Position the adapter with the throat angle down. Tighten the 4 cap screws evenly. Hussmann Aftermarket 1/13/06 Page 6 of 19...
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Rail (B)- marked (Right Front) mounts to right side with the relief facing down 8. Place compressor on rails and secure with the 1/2”-13 x 1 1/2” bolt (C) and1/2” washers (G). Figure 11 Hussmann Aftermarket 1/13/06 Page 7 of 19...
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Rota-lock nut with the other channel lock pliers. Figure 13 11. Connect oil line to oil float using hose provided in kit. 12. Connect all remaining lines and controls to the compressor. Figure 14 Hussmann Aftermarket 1/13/06 Page 8 of 19...
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If the hole is oversized for the connector, use the reduction washers (E) with the 1” connector. Figure 17 Hussmann Aftermarket 1/13/06 Page 9 of 19...
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Jumpers for 208/230 V (3 needed for 460 V) Flat Washers Hex nuts Lugs NOTE: For Direct-Start all parts received may not be needed. Please disregard any extra parts. To start remove nuts and washers holding the cap. Figure 20. Hussmann Aftermarket 1/13/06 Page 10 of 19...
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. Add lugs to 1, 2, and 3. Mount one . Add cover and center Figure 23 Figure 24 washer on each lug. Place nuts on all terminals washers and nuts. tighten to 4.4 ft-lb. Hussmann Aftermarket 1/13/06 Page 11 of 19...
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6-9. Mount lugs on terminals 1, 2, and 3. Add one flat washer on each lug and install nuts on all terminals. Torque to 4.4 ft-lb. . Add cover, center washers and nuts. Figure 27 Hussmann Aftermarket 1/13/06 Page 12 of 19...
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F ie ld In s ta lle d W ire T h e rm isto r J u m p er T e rm in a ls Figure 29 Wiring SE-B1 Motor Overload Module Hussmann Aftermarket 1/13/06 Page 13 of 19...
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SE-B1 Motor Protector Module SE-B2 Motor Protector Module Also shown are the included connectors for the M1 and M2 posts in the terminal box Figure 30 INT69/70 Motor protector and Oil Monitoring Module Figure 31 Hussmann Aftermarket 1/13/06 Page 14 of 19...
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4. Mount the INT 69/70 sensor in the compressor housing as shown in Figure 37. Wire the INT 69/70 and sensor into the compressor control circuit according to the wiring diagram in Figure 36. Figure 34 Hussmann Aftermarket 1/13/06 Page 15 of 19...
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2 4 V o lt T ra n sfo rm er 5 0 V A Tem p S ensor Field Installed W ire Figure 36. Retrofit With INT 69/70 Overload Module With Oil Control Hussmann Aftermarket 1/13/06 Page 16 of 19...
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17. To reset the INT 69/70 after an oil failure trip, the 24V power to the control must be interrupted. A pushbutton momentary switch is shown on the line side of the transformer as an option for this purpose. Figure 37 Hussmann Aftermarket 1/13/06 Page 17 of 19...
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40. Requires Bracket # BR.4220261. 4. The complete head cooling fan kits which include the fan, motor and brackets are: CU. 4220215 for 120 volt CU.4220220 for 208/230 volt CU.4220225 for 460 volt Hussmann Aftermarket 1/13/06 Page 18 of 19...
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19 mm socket Philips Head Screwdriver 24mm socket Large Channel Lock Pliers 10 mm Wrench Straight Slot Screwdriver 7/16” Wrench 10” Adjustable Wrench 9/16” Wrench Wire Cutters & Strippers 3/4“ socket Hammer 10. 15/16” socket Hussmann Aftermarket page 1 of 18 4/7/2006...
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Unbolt the oil float assembly, leaving the compressor tilted until the sight glass from the IR ™ Impact can be installed on the 4D compressor. (3D compressor shown for demonstration purposes only.) Figure 1 Hussmann Aftermarket page 2 of 18 4/7/2006...
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Leave terminal box cover in place. Refer to electrical connection section of manual Install all the required fittings removed from the old compressor to ™ IR Impact fitting locations (See Figure 4). Figure 4 Hussmann Aftermarket page 3 of 18 4/7/2006...
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IMPORTANT DO NOT TIGHTEN THE MOUNTING BOLTS UNTIL BOTH SUCTION AND DISCHARGE VALVES ARE ALIGNED AND TIGHT Spacer Washers Figure 6 Figure 7 Figure 8 Oil Float Adapter Oil Float Hussmann Aftermarket page 4 of 18 4/7/2006...
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Bolts (E) provided in the kit. Remove the service valve and place the blank off plate in the position of the service valve using the existing bolts. Figure 10 Hussmann Aftermarket page 5 of 18 4/7/2006...
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Screw them into the flange about 1 -2 turns. Center the gasket between the suction spacer and the suction valve with a screwdriver while lifting up on the valve. Tighten the suction valve bolts evenly. Figure 12 Hussmann Aftermarket page 6 of 18 4/7/2006...
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Attach the two thermistor wires to the sensor connectors using a 7mm nut driver or socket. Refer to the wiring diagram in Figure 27 for connections for the motor protector. Figure 14. Hussmann Aftermarket page 7 of 18 4/7/2006...
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Figure 15 PLEASE NOTE: The compressor may have additional parts that are used for part winding start. Disregard the extra parts if you receive them. Figure 16 IR4B Compressor Terminals Prior to Starting Hussmann Aftermarket page 8 of 18 4/7/2006...
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Fig.20 Nuts on 4, 5, and 6. Lugs on 1,2, and 3. Fig.21 Nuts on 7, 8, and 9 and on top of lugs on 1, 2, and 3. Torque all nuts to 7.4 ft-lb. Hussmann Aftermarket page 9 of 18 4/7/2006...
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460-Volt Connection Instructions Fig.22 Three smaller jumpers on 4-7, 5-8, and 6-9. Fig.23 Insulator on 1-2-3. Fig.24 Lugs on 1, 2, and 3. Fig.25 Nuts on all terminals and torque to 7.4 ft-lb. Hussmann Aftermarket page 10 of 18 4/7/2006...
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CU.4220233 INT69/70 SE-B1 Motor Protector Module SE-B2 Motor Protector Module Also shown are the included connectors For the M1 and M2 posts in the terminal box INT69/70 Motor protector and Oil Monitoring Module Hussmann Aftermarket page 11 of 18 4/7/2006...
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Low Pressure Control Control 240V P545 Switch SE-B Protection Device Alarm Out Reference to line number in text Field Installed Wire Thermistor jumper Terminals Figure 27. SE-B Overload Module and Johnson P545 Oil Control Hussmann Aftermarket page 12 of 18 4/7/2006...
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It is possible to use the switch from the P545 (the P400BD-1C) with the Sentronic module, although the timeout will approach 120 seconds instead of the 90 seconds in the P545 specifications. Figure 28. P545 Oil Control Figure 29. P545 Switch Installed Hussmann Aftermarket page 13 of 18 4/7/2006...
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P ro te ctio n D e vice A larm O u t F ie ld In sta lle d W ire T h erm istor J um p er T erm in a ls Figure 30 Hussmann Aftermarket page 14 of 18 4/7/2006...
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Retain the metal gasket to be Figure 31. used with the sensor. If the gasket is not metal it will leak. Figure 19 Figure 20 Oil Sensor Plug Figure 32 Figure 33 Hussmann Aftermarket page 15 of 18 4/7/2006...
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Connect the black wire from the Delta-P oil failure control to line (L2). Connect the thermistor wires (1,2) to the compressor thermistor terminals. Once all the connections have been transferred to the new control device, the old controls can be removed. Hussmann Aftermarket page 16 of 18 4/7/2006...
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3 screws provided with the existing fan. Wiring the fan will be the same as the previous compressor. Complete Fan Assembly Kits CU.4220216 120 volt Figure 35 CU.4220221 208-230- volt CU.4220226 460 volt Hussmann Aftermarket page 17 of 18 4/7/2006...