Emerson Copeland Scroll Digital ZBD114 Series, Application Manuallines

Page 1: ...Application Guidelines Digital Scroll Compressors for Refrigeration ZBD21K to ZBD114K ZFD13KVE to ZFD25KVE ZFD41K5E Digital ...

Page 2: ...BD57K and ZFD13KVE to ZFD25KVE 8 3 2 1 Securing the filter screen in position 8 3 2 2 Solenoid valve installation General recommendations 9 3 2 3 Solenoid valve installation Tubing recommendations 9 3 3 Copeland Scroll Digital compressors ZFD13KVE to ZFD25KVE with vapour injection wet vapour injection 9 3 3 1 Vapour injection EVI Economized Vapour Injection 10 3 3 2 Wet vapour injection vapour inj...

Page 3: ... 5 5 Initial start up 22 5 6 Rotation direction 22 5 7 Pressure fluctuations 22 5 8 Starting sound 22 5 9 Deep vacuum operation 23 5 10Shell temperature 23 5 11Minimum run time 23 5 12Sound characteristics 23 5 13Shut off sound 23 5 14Frequency 23 5 15Oil level 24 5 16Digital system control 24 5 17Power factor 24 6 Maintenance repair 25 6 1 Exchanging the refrigerant 25 6 2 Rotalock valves 25 6 3 ...

Page 4: ...ailable at www emersonclimate eu These instructions should be retained throughout the lifetime of the compressor You are strongly advised to follow these safety instructions 1 1 Icon explanation WARNING This icon indicates instructions to avoid personal injury and material damage CAUTION This icon indicates instructions to avoid property damage and possible personal injury High voltage This icon i...

Page 5: ...hat other materials in the area of the compressor do not get in touch with it Lock and mark accessible sections CAUTION Overheating Bearing damage Do not operate compressors without refrigerant charge or without being connected to the system CAUTION Contact with POE Material damage POE lubricant must be handled carefully and the proper protective equipment gloves eye protection etc must be used at...

Page 6: ...J TFD ZBD29KCE 2 20 2 14 2 09 2 07 TFD ZBD30KCE 2 22 2 16 2 22 2 15 2 21 2 24 2 12 TFD ZBD38KCE 2 23 2 20 2 22 2 15 2 23 2 25 2 14 TFD ZBD45KCE 2 24 2 17 2 23 2 22 2 20 2 27 2 14 TFD ZBD57KCE 2 26 2 17 2 17 2 36 1 99 TFD ZBD58KCE 2 12 2 02 2 08 TFD ZBD76KCE 2 16 2 08 2 16 2 18 2 08 TFD ZBD76K5E 2 14 2 11 2 19 TFD ZBD114K5E 2 07 2 08 2 08 TFD Table 2 Coefficient of performance COP for medium temper...

Page 7: ...ontains the following technical information about the compressor 2 3 Dimensions A B C D E ZBD21KCE 432 4 414 3 363 6 261 6 218 9 ZBD29KCE 463 2 445 2 394 3 291 3 249 7 Figure 1 Dimensions ZBD21KCE ZBD29KCE Figure 2 Dimensions ZBD30K to ZBD57K ZFD13KVE to ZFD25KVE ...

Page 8: ...d when adjusting pressure and superheat controls Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland brand products Select software at www emersonclimate eu Compressor ZBD21K to ZBD114K ZFD13K to ZFD41K Qualified refrigerants R404A R407A R407F R448A R449A R134a R450A R513A R507 R22 for ZBD30K ZBD45K only R404A R407A R407F R448A R449A R507 Copeland brand products...

Page 9: ...l evaporator expansion valve configuration a minimum stable superheat of at least 5K is required The application envelopes for Digital refrigeration Scroll compressors are for various refrigerants you can find them in the Copeland brand products Select software which can be downloaded for free on our website www emersonclimate eu Safety instructions Product description Installation Electrical conn...

Page 10: ...e compressor to escape Pulling the plugs in this sequence prevents oil mist from coating the suction tube making brazing difficult The copper coated steel suction tube should be cleaned before brazing No object eg a swaging tool should be inserted deeper than 51 mm into the suction tube or it might damage the suction screen and motor 3 1 3 Installation location Ensure the compressors are installed...

Page 11: ...fore brazing the tube connections as shown in Figure 10 below The solenoid valve has to be fitted in such a way that the sleeve with the stem inside which supports the solenoid coil is fixed and aligned in the upright position 3 2 1 Securing the filter screen in position The filter screen should be placed into the small tube running at 90 to the solenoid valve stem A narrow washer fixed on the fil...

Page 12: ...for running stresses and resonance in a single compressor lab environment However in some compressor applications such as racks and transport applications the OEM is strongly advised to re confirm the acceptability of the tube when the compressor is subject to additional vibration inputs The tube from the solenoid to the suction marked A see Figure 12 should be as short as possible less than 7 5 c...

Page 13: ...provide additional subcooling to the refrigerant before it enters the evaporator This subcooling process provides the increased capacity gain measured in the system The evaporated refrigerant through the heat exchanger economizer is injected into the compressors and provides additional cooling at higher compression ratios Figure 12 Vapour injection line diagram The application envelopes for the us...

Page 14: ...is fitted internally on the discharge port of the fixed scroll This discharge valve cannot be used with recycling pump down because it is not leak proof during the off period Models ZBD58K to ZBD114K work with an internal unloader mechanism and are equipped with a check valve in the discharge fitting that will prevent backward flow of gas through the scroll when the compressor shuts off 3 5 Brazin...

Page 15: ...braze material flows around the joint move the torch to heat area 3 This will draw the braze material down into the joint The time spent heating area 3 should be minimal As with any brazed joint overheating may be detrimental to the final result To disconnect Heat joint areas 2 and 3 slowly and uniformly until the braze material softens and the tube can be pulled out of the fitting To reconnect Re...

Page 16: ... overheating and bearing failure Irrespective of system charge oil dilution may occur if large amounts of liquid refrigerant repeatedly flood back to the compressor during normal off cycles defrost varying loads In such a case an accumulator must be used to reduce flood back to a safe level that the compressor can handle The use of accumulators is dependent on the application If an accumulator mus...

Page 17: ... the building under some conditions Elimination of the beat can be achieved by attenuating either of the contributing frequencies This is easily done by using one of the common combinations of recommended design configurations The scroll compressor makes both a rocking and twisting motion and enough flexibility must be provided in the line to prevent vibration transmission into any lines attached ...

Page 18: ...tallation Single phase PF compressors Power circuit Control circuit Motor terminal connections Single phase compressors are connected to the Common C Start S and Run R connections Legend B1 Room thermostat F4 LP switch B3 Discharge gas thermostat K1 Contactor C2 Run capacitor R2 Crankcase heater F1 Fuse S1 Auxiliary switch F3 HP switch Figure 17 Safety instructions Product description Installation...

Page 19: ...ol circuit Motor terminal connections Three phase compressors are connected to the T1 T2 and T3 connections Legend B1 Room thermostat K1 Contactor B3 Discharge gas thermostat R2 Crankcase heater F1 Fuse S1 Auxiliary switch F3 HP switch Y5 Solenoid valve for refrigerant injection F4 LP switch Figure 18 ...

Page 20: ... electrical installations are shown in Figures 22 23 below Figure 19 Correct electrical installation with cable glands for IP21 T box compressors ZBD21K ZBD29K Figure 20 Correct electrical installation with cable glands for IP21 T box compressors ZBD30K to ZBD114K ZFD13KVE to ZFD25KVE ZFD41K5E 4 2 2 Motor winding Compressor model ZBD21K is available in single phase PF ZBD and ZFD compressors are o...

Page 21: ...ised during compressor off cycles The crankcase heater must be mounted below the oil Schraeder valve located on the bottom shell see Figure 24 The crankcase heater should be wired in such a way that it is turned on whenever the compressor is switched off 4 3 Pressure safety controls 4 3 1 IPR valve Internal Pressure Relief valve The internal pressure relief valves for models ZBD21K to ZBD57K and Z...

Page 22: ...land brand compressors in order to guarantee positive compressor protection This protection must not be used as an operating envelope controller but as a safety device Compressors ZBD21K ZBD29K These compressors have no internal temperature protection Therefore they are supplied with a discharge temperature thermostat Compressors ZBD30K to ZBD57K and ZFD13KVE to ZFD25KVE These compressors are equi...

Page 23: ...arge temperature protection since its rating is not suitable for R407A R407F R448A and R449A The R404A R407A R407F R448A and R449A dedicated discharge thermostat has a cut out setting of 130 C 4K with closing at 101 C 8K The thermostat should be installed approximately 120 mm from the discharge valve outlet see Figure 25 It must be insulated in order to avoid improper functioning due to false read...

Page 24: ...k list but always check the following Visual check of the electrics wiring fuses etc Visual check of the plant for leaks loose fittings such as TXV bulbs etc Compressor oil level Calibration of HP LP switches and any pressure actuated valves Setting and operation of all safety features and protection devices All valves in the correct running position Pressure and compound gauges fitted Correctly c...

Page 25: ...cation of proper rotation direction There is no negative impact on durability caused by operating three phase Copeland Scroll compressors in the reversed direction for a short period of time under one hour but oil may be lost Oil loss can be prevented during reverse rotation if the tubing is routed at least 15 cm above the compressor After several minutes of operation in reverse the compressor s p...

Page 26: ...gies and install it in a system with the longest connecting lines that are approved for the system The minimum on time becomes the time required for oil lost during compressor start up to return to the compressor sump and restore a minimal oil level that will ensure oil pick up through the crankshaft Cycling the compressor for a shorter period than this for instance to maintain very tight temperat...

Page 27: ...erheat control needs to be performed by qualified solutions in order to assure the stability reliability and good performance of the system NOTE For further information about these solutions see Technical Information C7 8 3 Refrigeration Controlling Digital Scroll 5 17 Power factor During the loaded state when the Copeland Scroll Digital compressor operates at full capacity the power factor is alm...

Page 28: ... failure This will result in starvation of oil to the replacement compressor and a second failure When a singlecompressor or tandem is exchanged in the field it is possible that a major portion of the oil may still be in the system While this may not affect the reliability of the replacement compressor the extra oil will add to rotor drag and increase power usage 6 3 2 Start up of a new or replace...

Page 29: ...ppm Figure 23 Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 25 C and 50 relative humidity h hours If the moisture content of the oil in a refrigeration system reaches unacceptably high levels corrosion and copper plating may occur The system should be evacuated down to 0 3 mbar or lower If there is uncertainty as to the moisture content in the system an oil s...

Page 30: ...embly line repair areas If compressor removal is required the compressor should be cut out of system rather than unbrazed 7 Dismantling disposal Removing oil and refrigerant Do not disperse in the environment Use the correct equipment and method of removal Dispose of oil and refrigerant properly Dispose of compressor properly DISCLAIMER 1 The contents of this publication are presented for informat...

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