1. Introduction
This manual provides essential information for the safe and efficient installation, operation, and maintenance of your Copeland Hermetic Compressor, Model CR35K6E-TF5-875. This compressor is designed for use in various refrigeration and air conditioning applications, including packaged systems, geothermal, and heat pump applications. Please read this manual thoroughly before attempting any procedures to ensure proper handling and to prevent potential hazards.
The Copeland CR series compressors are known for their efficiency, durability, and reliability in systems requiring a wide range of evaporative capacity.
2. Safety Information
WARNING: Installation, service, and maintenance of this compressor must be performed by qualified and experienced personnel only. Failure to comply with safety instructions can result in serious injury, death, or property damage.
- Always disconnect power before servicing the unit.
- Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
- Handle refrigerants with care. Refer to local regulations for proper handling and disposal.
- Ensure proper ventilation when working with refrigerants.
- Do not operate the compressor if any components are damaged.
- This compressor operates at high voltage (208/230V, 3 Phase). Exercise extreme caution.
Figure 1: Front view of the Copeland Hermetic Compressor CR35K6E-TF5-875. This image shows the main body of the compressor, electrical connection box, and refrigerant line connections.
3. Specifications
| Feature | Detail |
|---|---|
| Model Number | CR35K6E-TF5-875 |
| Brand | Copeland |
| Refrigerant | R22 |
| Capacity | 35,000 BtuH at 45°F |
| Voltage | 208/230V |
| Phase | 3 (Three) |
| Connection Size (Suction) | 3/4" Sweat |
| Connection Size (Liquid) | 1/2" Sweat |
| Mounting Base | 7-1/2" x 7-1/2" |
| Special Feature | Hermetic Design |
| Power Source | Electric, Corded Electric |
| Recommended Uses | Industrial systems, geothermal, heat pump applications |
| Manufacturer | Copeland |
| Color | Black |
Figure 2: Side view of the Copeland Hermetic Compressor CR35K6E-TF5-875, showing the lower refrigerant line connections and mounting feet.
4. Setup and Installation
Installation of the Copeland Hermetic Compressor requires specialized knowledge and tools. It is strongly recommended that installation be performed by a certified HVAC technician.
4.1 Pre-Installation Checks
- Verify that the compressor model matches the system requirements (refrigerant type, voltage, capacity).
- Inspect the compressor for any shipping damage. Do not install if damage is present.
- Ensure the mounting surface is level and capable of supporting the compressor's weight.
- Confirm that the electrical supply matches the compressor's voltage and phase requirements (208/230V, 3 Phase).
4.2 Mounting
- Position the compressor on the designated mounting base (7-1/2" x 7-1/2").
- Secure the compressor using appropriate vibration isolation mounts to minimize noise and stress on refrigerant lines.
4.3 Refrigerant Line Connections
- Connect the 3/4" suction line and 1/2" liquid line using proper brazing techniques.
- Ensure all connections are leak-free. Use nitrogen purge during brazing to prevent oxidation.
- Evacuate the system to a deep vacuum (typically 500 microns or less) to remove non-condensable gases and moisture.
- Charge the system with the correct type and amount of R22 refrigerant as specified by the system manufacturer.
4.4 Electrical Wiring
- Connect the 208/230V, 3-phase power supply to the compressor's electrical terminals according to the wiring diagram provided with the system.
- Ensure all electrical connections are tight and secure.
- Install appropriate overcurrent protection devices.
- Verify correct phase rotation for 3-phase compressors to ensure proper motor operation.
5. Operating Instructions
Once properly installed and charged, the compressor will operate as part of the overall refrigeration or air conditioning system. The following are general operating principles:
- The compressor is designed to cycle on and off based on the system's thermostat or control signals to maintain desired temperature.
- Ensure the system is adequately charged with R22 refrigerant. Low or high refrigerant levels can lead to inefficient operation or damage.
- Monitor system pressures and temperatures to ensure operation within design limits.
- Avoid frequent short cycling, which can reduce compressor lifespan.
6. Maintenance
Regular maintenance is crucial for the longevity and efficient operation of your Copeland compressor. All maintenance should be performed by qualified personnel.
6.1 Routine Checks (Monthly/Quarterly)
- Inspect for any unusual noises or vibrations during operation.
- Check for refrigerant leaks using an electronic leak detector.
- Monitor system pressures and temperatures.
- Inspect electrical connections for tightness and signs of overheating.
6.2 Annual Maintenance
- Perform a comprehensive system check, including refrigerant charge verification.
- Clean the condenser and evaporator coils to ensure optimal heat transfer.
- Check the compressor oil level and condition if accessible and recommended by the system manufacturer.
7. Troubleshooting
This section provides general guidance for common issues. For complex problems, consult a qualified technician.
7.1 Compressor Not Starting
- No Power: Check circuit breakers, fuses, and electrical connections.
- Control Issue: Verify thermostat settings and control board signals.
- Overload Protection: Compressor may be tripped on internal overload. Allow time to cool and reset. Investigate cause of overload (e.g., high head pressure, low voltage).
- Incorrect Wiring: Ensure correct 3-phase wiring and phase rotation.
7.2 Insufficient Cooling/Heating
- Low Refrigerant Charge: Check for leaks and recharge system.
- Dirty Coils: Clean condenser and evaporator coils.
- Airflow Restrictions: Check filters and ductwork.
- Compressor Malfunction: If compressor runs but does not pump effectively, it may indicate internal damage.
7.3 Excessive Noise or Vibration
- Loose Mounting: Check and tighten mounting bolts.
- Refrigerant Slugging: Ensure proper superheat and subcooling.
- Internal Compressor Issue: If noise persists, the compressor may require replacement.
8. Disposal
When the compressor reaches the end of its service life, it must be disposed of in accordance with all local, state, and federal regulations. Refrigerants must be recovered by certified technicians before disposal. Do not vent refrigerants into the atmosphere.
9. Warranty and Support
Information regarding the specific warranty terms for the Copeland Hermetic Compressor CR35K6E-TF5-875 was not available in the provided product data. For warranty details and technical support, please contact your authorized Copeland distributor or the point of purchase. Ensure you have your model number (CR35K6E-TF5-875) and serial number ready when seeking support.
Figure 3: Seal indicating a genuine Copeland Compressor. Always ensure you are using authentic Copeland parts for optimal performance and reliability.
