3-D Scroll Compressors

Trane, the worlds leading producer of commercial and light commercial scroll compressors, sets the standard worldwide for scroll compressors larger than five tons.
Trane has manufactured scroll compressors since 1988. Scroll compressors are used in a variety of applications from less than 15 tons with a single compressor to more than 60 tons when used in tandem. Applications include air conditioning, airand water-cooled chillers and condensing units, process cooling, refrigeration, dehumidification, military, mobile, heat pumps, railroad cars and others. Tranes 3-D scroll technology and 3-D scroll compressors are recognized as state-of-the-art in the United States and around the world. Furthermore, Tranes 3-D scroll technology has been licensed to other manufacturers worldwide. Development of compressor technology is not new to Trane. Tranes expertise in compressor development started with the centrifugal compressor in the early 1930s. The early 1950s saw the
6.2 tons 7.5 tons 8.3 tons 9.3 tons 10 tons

Available 3-D Trane Scroll Compressors

Model CSHC Features:
Internal motor protection Standard: stub tube connections

Model CSHA
9.3 tons 10 tons 12.5 tons 14 tons 15 tons 20 to 60 ton tandems

Features:
Sight glass Oil charging valve Standard: stub tube connections Optional: rotalocks with access fittings

Standard Voltages
200-60-3 208/230-60-3 380-60-3 460-60-3/400-50-3 575-60-3 220-50-3 346-50-3

development and manufacturing of open reciprocating compressors. As technology and markets changed, the product line grew to include semihermetic and hermetic reciprocating compressors in size ranges from 1 to100 tons. Trane currently produces a variety of compressors including centrifugal, reciprocating, helical-rotary and scroll designs. As compressor technology evolves, Trane remains committed to improving existing products and developing new technology. Trane has been pursuing continuous improvement to the 3-D scroll compressor since its introduction in 1988. Improvements are the result of years of field experience and extensive laboratory testing. The 3-D scroll compressor is quiet, efficient, and has great application flexibility, yet has fewer parts and is lighter and more compact.

2005 American Standard All rights reserved 2005 American Standard All rights reserved

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Large discharge gas volume for lower pressure pulsation.

Improved check valve for quiet shutdown and less flow restriction.

Reverse vent to prevent scroll damage during reverse rotation caused by improper phase connection.

High strength cast iron fixed and orbiting scroll, resulting in less thermal distortion, less leakage and higher efficiency.

Optimized involute geometry for higher efficiency.

Fixed throw prevents scroll impact and resulting noise.

Journal bearings for low noise.

Motor tube for more accurate lower bearing alignment. Also, permits suction gas to enter shell prior to flowing through and cooling the motor. Dirt particles will then drop out and settle in the sump.

Internal motor temperature sensor is part of field-proven protection system.

High efficiency motor for lower energy consumption. EERs up to 11.5

High volume oil sump maintains lubrication during periods of high oil carry-over.

Oil charging valve for changing or adjusting oil level.

Dirt separator for maximum bearing life.

Sight glass to monitor oil level.

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High EERs
EER levels range to 11.5+ Btu/watt hour. This is due in part to the use of optimized involute geometry, improved porting and lower discharge flow losses with a check valve. In addition, accurate involute machining and a reduction in thermal expansion by using cast iron for both scrolls permits tight tolerances, resulting in reduced compression leakage. A specifically designed motor provides improved efficiency.

Compressor Protection
The protection system consists of an internal motor temperature sensor which is placed in series with an external current sensor (CSHA only), external high- and low-pressure switches, and the hold-in coil of the main contacts. This has proven to be a reliable, flexible and easy-to-service system.

Tandem Compressors - 18 to o
Model CSHA093 CSHA100 CSHA125 CSHA140 CSHA150

New Refrigerants
This compressor has the future in mind. The basic compressor platform with less rotating mass, all-cast-iron scrolls, journal bearings and a more responsive check valve, make this 3-D scroll compressor adaptable to the new highpressure refrigerants and POE oils as they replace existing HCFC refrigerants that use mineral oil. Properly designed journal bearings can operate successfully with POE oils that may contain a high concentration of refrigerant. In addition, the more responsive check valve is better suited to the various densities and operating pressures of the new HFC refrigerants. The 3-D scroll compressor is optimized for R-22 but is also available for use with R-134a, R-404a and R-407c. Future optimized designs for selected refrigerants will follow.

SIZES/COMPRESSOR COMBINAT T Nominal Tons 18.0 20.0 23.0 24.0 25.0 25.0 28.0 30.0 32 2 2 1 2 2 1 1 2 1 1 2 1 2 1

Quiet and Smooth Operation

Quiet operation is due in part to journal bearings which transmit less noise from the running gear to the shell. Additionally, the fixed throw eliminates the possibility of scroll impact and the resulting noise. The check valve closes fast and seals tight for quiet shutdown. Sound power levels of 80 dB have been achieved.

Durability/Extended Life
Many features contribute to durability and long life. A motor tube design is used. The motor and lower bearing head are both located in a steel tube bolted to the housing. This arrangement provides for a more precise motor and bearing alignment and permits the suction gas to enter the shell prior to flowing through the motor. The velocity of the suction gas decreases as it enters the shell, allowing the dirt particles to drop out and settle in the sump. The compressor has a built-in dirt separator/trap in the lower bearing head to prevent dirt from reaching the bearings. The high-volume oil sump helps prevent excessive oil loss that can occur in systems with large refrigerant charges. This high volume oil sump and large suction volume also help minimize the oil dilution and slugging that occur during periods of flooding. Also, the use of cast iron for both the orbiting and fixed scrolls provides greater strength and galling resistance.

18 to 30 TONS
(30 TON SET SHOWN)

Tandem Capability
The tandem capability of the scroll allows, with suitable piping, up to four compressors on a single circuit. The outstanding reliability of the 3-D scroll compressor, with properly designed piping, makes this a practical alternative to single large compressors. High part-load efficiency and capacity control are a few of the benefits.

50 to 60 TONS
(60 TON SET SHOWN)

Testing and Evaluation

Trane has an impressive background in scroll compressor technology and has accumulated over 25 years of experience, testing hundreds of compressors for hundreds of thousands of hours.
A B C

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o 60 Tons

T TIONS

These compressors have ranged in size from one to more than 15 tons, including single and tandem compressors. Trane has approximately 30 U.S. and international patents. Confidence in the durability of this design is based on both mathematical and rigorous laboratory testing conducted by compressor and system engineers who apply the 3-D scroll compressors.

pressure ratios, high pressure differentials, flooded starts, rapid on-off cycling and pump down. Qualifications included a battery of tests in the (SEET) Systems Extreme Environmental Test chamber in Tyler, Texas, where the compressor and unit are subjected to extreme conditions outside the operating range. The SEET facility is designed to put compressors through five years of wear and tear in 16 grueling weeks. Other tests include evaluation of the tandem system for proper oil management and line vibration. Additionally, over 250,000 hours of field and other laboratory testing was accumulated utilizing over 180 development and qualification compressors.

2 2.0 35.0 40.0 45.0 50.0 60.0 2 2 1 2

Qualification 32 to 45 TONS
(45 TON SET SHOWN) Qualification of the compressor included long-term endurance testing to determine wear and five-mode durability testing exposing the compressor to severe stress levels outside the operating limits. Five-mode tests are designed to fail compressors. Various forms of debris are added to the system, subjecting the compressor to high levels of stress and wear. This ten-week test included high
A B C

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Six Sigma and Quality

Six Sigma is the tool used by Trane to improve all facets of a product encompassing design, engineering, manufacturing, and business systems. In a Six Sigma environment, processes are scrutinized by teams using data and statistical analysis in a constant relentless pursuit to reduce variation and improve customer satisfaction. The result is a reduction in defects that focuses on developing and delivering near-perfect products. Six Sigma strives to directly link the customers needs to the product. Our simultaneous engineering efforts culminate in a method of production known as Demand Flow Manufacturing. Demand Flow Manufacturing is a pull type, just-in-time manufacturing method that requires quality to be designed in and that all manufacturing processes produce a quality part every time. A concept known as Total Quality Control (TQC) is built into every process. In this concept, whenever possible, parts are designed to fit only one way and production operators inspect each other's work. In a demand flow environment, the design must meet all the requirements and the manufacturing process must provide a quality product every time. With this extensive background of scroll knowledge, experience and the exhaustive battery of tests and evaluations, Trane confidently offers the 3-D scroll compressor.

ISO 9000
The Trane 3-D scroll compressor is manufactured under a quality management system that is in compliance with, and registered to, ISO Standard 9000.

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Reverse Vent Valve

Discharge E

Trane 3-D Scroll Compressor

Check Valve Discharge Port Stationary Scroll D Orbiting Scroll

The principles of operation: The suction gas is drawn into the compressor at A. The gas then passes through the gap between the rotor and stator, B, cooling the motor, C. The gas then enters the intake chamber, D, that encircles the scrolls. The oil in the suction gas is separated by changing directions and impinging on surfaces within the compressor and then draining back to the oil sump. Finally, the suction gas is drawn into the scroll assembly where it is compressed and discharged into the dome of the compressor. The dome of this compressor acts as a hot gas muffler which dampens the pulsations before the gas enters the discharge line, E.

Motor Shaft C

Motor

Suction A

How the Scroll Compressor Works

General
A 3-D compressor has two scrolls. The top scroll is fixed and the bottom scroll orbits. Each scroll has walls in a spiral shape that intermesh. Oil Pump Oil Sump

Inlet - First Orbit

As the bottom scroll orbits, two refrigerant gas pockets are formed and enclosed.

Compression - Second Orbit

The refrigerant gas is compressed as the volume is reduced closer to the center of the scroll.

Discharge - Third Orbit

The gas is compressed further and discharged through a small port in the center of the fixed scroll.

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History of Trane 3-D Scroll

1978 First sample built 1983 Initial field trial 1987 Qualification and endurance testing completed 1988 First production 1989 Full production sizes 9.3, 10, 14, 15 tons
3-D Compliance EERs to 10.9 Low noise and vibration Tandems in sizes from 18 to 30 tons

1996 Phase I Redesign sizes 9.3, 10, 14, 15 tons

EER improved: 11.5 Quieter: 80 dba 23 percent fewer parts versus previous design Swinglink removed Tandem to 60 tons

1999 Phase II Redesign sizes 6.2, 7.5, 8.3, 9.3, 10 tons

EER to 11.5 Internal motor protection

2004 Phase I 12.5 ton size introduced

Future
Optimize the design for the new HFC refrigerants and POE oils Various methods of capacity control are being evaluated Larger scroll compressors in sizes 20, 25 and 30 tons are being designed

COM-S-9 October 2005 0899 La Crosse