Application Engineering Application Engineering

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AE22-1230 R5

U U L LL E L T E I B

N T

I AE22-1230 N R5
October 1984

Reformatted October 2010

Off Cycle Motor Heat for Liquid Refrigerant Migration Control

The use of off cycle motor heat in lieu of a crankcase heater is being considered more frequently by users of single phase welded compressors, since it does offer some economies and advantages. Off cycle heat essentially performs the same function as a crankcase heater. Either can offer some signicant advantages in system design. It is almost impossible to entirely avoid some start up buzz on any unit where liquid can migrate to the compressor during a long off cycle. Maintaining a warm compressor can eliminate noise problems of this type. Undoubtedly the life expectancy of any compressor is affected by the number of times it is exposed to large amounts of liquid refrigerant on start up. The compressor may be able to clear the crankcase without damage under repeated test conditions, but certainly repeated stress of this nature can eventually reach the critical stage. Although it is difcult to obtain detailed long term experiences data, eld experience strongly indicates that over an extended life, some type of crankcase heat can be a major factor in compressor survival on all split systems. Basically, off cycle heating is accomplished by connecting the run capacitor used for the motor heat cycle directly to the line beyond the unit disconnect rather than to the run terminal. Thus when the unit is cycled off by the thermostat, the start winding remains connected across the line through the run capacitor. A schematic diagram of an off cycle heat connection is shown in Figure 1. Note that the run capacitor has been split. Assume that the standard run capacitor is 35 MFD. A 15 MFD capacitor is connected in the normal fashion while a 20 MFD run capacitor is connected for off cycle heat. Since the capacitors are in parallel in a normal operating condition, the compressor then sees the normal 35 MFD. The control may be contactor or any other device that breaks the line current when the compressor is not operating. The same sort of electrical connection may be accomplished by means of a split run capacitor, which in effect is actually two capacitors in a single casing.

220,000 ohm bleed resister

Figure 1 Typical Schematic Connection for Off Cycle Heat Standard run capacitor 35 MFD Heating run capacitor 20 MFD

Off cycle heat has a number of advantages and some disadvantages. 1. It is not as susceptible to damage as an external crankcase heater and there is no heater element to burn out. the life expectancy of external crankcase heaters is very probably not as good as we would like to see. 2. Since it is economical and compact, off cycle heat may be attractive on small package units. 3. One of the side benets of off cycle heat may be better low voltage starting characteristics. A warm stator and rotor develops more starting torque than a cold motor, and this can materially improve the compressors ability to start under marginal conditions. 4. Since the off cycle heat circuit is mad through the motor protector, in the event of a protector trip, no

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Application Engineering B U L L E T
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AE22-1230 R5

heat is added until the protector resets. External crankcase heaters are frequently connected across the line so that they are energized continuously. On split systems where the compressor is located in an insulated compartment to reduce noise to a minimum, the reset time after a protector trip may be excessive unless the motor temperature is reduced fairly quickly. Off cycle heat would have a denite advantage over a crankcase heater in this type of situation. A major disadvantage is that the compressor is electrically energized at all times, even when the unit is off. Maintenance personnel or users may run the risk of a shock if attempting repairs without being aware of the hazard. There are at least three limiting factors that must be considered in the application of off cycle heat. 1. Start winding temperatures during the off cycle heating phase must be held within safe limitations. 2. Since there is no refrigerant vapor owing to cool the motor or protector during the off cycle, the protector is sensing a different condition than that encountered during either an operating cycle or a locked rotor condition. Unless the capacitance is limited, it is possible that the protector may trip on start up due to temperature, even though the motor windings are still within safe limits. 3. If start components are used, or if there is any possibility that supplementary start components may be applied in the eld, the capacitance used for off cycle heat must be limited to avoid impressing excessive voltage on the start capacitor. Most manufacturers limit continuous voltage on the start capacitor to 10% of its nominal rating, with the exception of General Electric who has approved a continuous voltage of 20% of their nominal rating. In order to avoid the possibility of a dangerous electrical shock to maintenance personnel even when disconnected from power, a 220,000 ohm bleed resister must be mounted across the run capacitor used for off cycle heat. In the event of a short in the heating run capacitor, the motor protector could not prevent a start winding burn in the motor, and a fuse of the proper size must be mounted in the run capacitor for motor protection, or a fused run capacitor must be used. The necessary fuse size may be calculated as follows:

C(E 1.2) divided by 2650 Fuse size in amps (use next larger standard size)

C = Capacitance in MFD E = Rated voltage of capacitor In the case of the example in Figure 1, assume the standard capacitor voltage rating was 370 volts. l = 20 (370 x 1.2) = 3.35 amps Use 4 amp fuse 2650 Emerson Climate Technologies has approved the use of off cycle heat by several manufacturers on an individual basis. Laboratory test have indicated that off cycle heat properly applied can effectively raise the oil temperature without creating dangerous temperatures in the motor windings, and we have not encountered any eld problems traceable to this type of application. Obviously, electrical connections are simpler if the standard run capacitor can be used for off cycle heat, without the necessity for splitting the capacitor. Extensive tests have been run in the Emerson Climate Technologies Application Engineering Laboratory to establish acceptable limits for the application of heating run capacitors. A minimum temperature difference of 15F between ambient temperature and oil temperature was established as the criteria as to whether off cycle heat could be effectively applied. On some smaller compressors operating on 115 volt power, insufcient heat was generated to make off cycle heating practical. In order to prevent the possibility of nuisances trips on start up in high ambient conditions, tests were run at high ambient conditions to determine stabilized compressor temperatures with various sized run capacitors. Capacitor selection has been limited to provide a maximum of 50F temperature difference between the compressor shell temperature and ambient temperature. In general it was found that power input should be limited depending on the size of the compressor, with acceptable values varying from 25 to 75 watts. For those customers applications where tightly enclosed compressor compartments can result in temperatures surrounding the compressor remaining above 110F for extended periods, it is essential that the manufacturer

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Application Engineering B U L L E T I N
AE22-1230 R5
run adequate development tests to insure that a nuisance protector trip does not occur on start-up after long off periods if a maximum size run capacitor is used for off cycle heat. If the fan motor is wired across the line and controlled by the same single pole contactor that controls current ow to the compressor motor, a trip of the motor protector can create an unexpected circuit that may allow sufcient current to ow to keep the fan motor operating. The current path is shown by the dotted line in Figure 2, through the fan motor, through both motor windings, through the off cycle heat run capacitor, and back to the line beyond the contactor contacts. It is doubtful if the current ow under such conditions is sufcient to harm the compressor motor windings, but it is possible the fan motor windings might be adversely affected, and the current owing through the compressor motor could delay the reset of the motor protector. The only solution to this problem that has been found is the use of a two pole contactor to break the fan motor circuit as well as the compressor motor circuit. The following table is a listing of Copelaweld compressors with recommendation for capacitor sizing for off cycle heat. The compressors indicated have been listed with U.L. for off cycle heat application, the U.L. listing covering the standard run capacitor as a maximum.

Figure 2 Sneak Fan Motor Circuit in Event of Motor Protector Trip

Model CRA1-0150-PFV CRB1-0175-PFV CRC1-0175-PFV CRD1-0200-PFV CRE1-0225-PFV CRG1-0250-PFJ CRH1-0275-PFV CRJ1-0300-PFV CRK1-0325-PFV CRL1-0350-PFV CRN1-0500-PFV

Std. Run Capacitor MFD 25 25 30 35 35 35 40 35 40 40 55

Maximum Run Capacitor for Off Cycle Motor Heat 25 25 30 35 20 25 25 35 25 25 40

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