Emerson Copeland Scroll ZB114K5E, Application Manuallines

Page 1: ...Copeland Scroll Compressors for Refrigeration ZB50KCE to ZB114KCE ZB66K5E to ZB114K5E ZF25K5E to ZF54K5E Application Guidelines ...

Page 2: ...ocation 5 3 1 4 Mounting parts 5 3 2 Brazing procedure 6 3 3 Shut off valves and adaptors 7 3 4 Suction accumulators 7 3 5 Screens 8 3 6 Mufflers 8 3 7 Suction line noise and vibration 8 4 ZF K5E compressors for low temperature applications 9 4 1 ZF K5E compressors with liquid injection 9 4 1 1 DTC valve specifications 9 4 1 2 Valve installation 9 4 1 3 Compressor or valve service 10 4 2 ZF K5E co...

Page 3: ...n 18 6 4 Preliminary checks Pre starting 18 6 5 Charging procedure 19 6 6 Initial start up 19 6 7 Rotation direction 19 6 8 Starting sound 20 6 9 Deep vacuum operation 20 6 10 Shell temperature 20 6 11 Pump down cycle 20 6 12 Minimum run time 20 6 13 Shut off sound 21 6 14 Frequency 21 6 15 Oil level 21 7 Maintenance repair 22 7 1 Exchanging the refrigerant 22 7 2 Rotalock valves 22 7 3 Replacing ...

Page 4: ... the Manufacturers Declaration available at www climate emerson com en gb 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...

Page 5: ...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 all...

Page 6: ...the standard and vapour injection compressors ARI Conditions high medium temperature Evaporating temperature 6 67 C Liquid sub cooling 0K Condensing temperature 48 90 C Ambient temperature 35 C Suction gas return 18 33K ARI Conditions low temperature Evaporating temperature 31 67 C Liquid sub cooling 0K Condensing temperature 40 56 C Ambient temperature 35 C Suction gas return 18 33K 2 3 BOM Varia...

Page 7: ...e 2 hereunder explains the differences and similarities between ZB KCE and ZB K5E models Equipment ZB KCE compressors ZB K5E compressors Suction and discharge connections Rotalock Rotalock raised suction fitting Oil connections Oil sight glass and Schraeder oil valve Electrical connection Traditional 3 screws Option Molded plug Traditional 3 screws Terminal box protection class IP21 standard IP66 ...

Page 8: ...be making brazing difficult For all models the suction connection plug must be left in place until the compressor is set into the unit otherwise oil might spill out of the suction connection located low on the shell The compressor plugs must be removed as late as possible before brazing so that the air humidity does not affect the oil characteristics The copper coated steel suction tube should be ...

Page 9: ...pper tube Recommended brazing materials any Silfos material is recommended preferably with a minimum of 5 silver However 0 silver is acceptable Be sure tube fitting inner diameter and tube outer diameter are clean prior to assembly Using a double tipped torch apply heat in area 1 As the tube approaches brazing temperature move the torch flame to area 2 Heat area 2 until braze temperature is attain...

Page 10: ...shut off valves can be found in the Spare parts list available at www climate emerson com en gb 3 4 Suction accumulators CAUTION Inadequate lubrication Bearing destruction Minimise liquid refrigerant returning to the compressor Too much refrigerant dilutes the oil Liquid refrigerant can wash the oil off the bearings leading to overheating and bearing failure Irrespective of system charge oil dilut...

Page 11: ...he scroll compressor although low includes two very close frequencies one of which is normally isolated from the shell by the suspension of an internally suspended compressor These frequencies which are present in all compressors may result in a low level beat frequency that can be detected as noise coming along the suction line into the building under some conditions Elimination of the beat can b...

Page 12: ...eded and in the required quantity The DTC valve connections are 1 Rotalock for the compressor injection port and 3 8 braze for the connection to the liquid line To prevent a partial or full blockage at the injection port caused by shavings foreign bodies etc a filter should be installed in the liquid line prior to the DTC valve inlet Figure 6 DTC valve assembly 4 1 1 DTC valve specifications Openi...

Page 13: ...nt evaporated through the heat exchanger is injected into the compressor and provides additional cooling at higher compression ratios Figure 7 Vapour injection line diagram During the sub cooling process a small amount of refrigerant is evaporated and superheated This superheated refrigerant is then injected into the mid compression cycle of the scroll compressor and compressed to discharge pressu...

Page 14: ...out vapour injection please refer to Technical Information C7 19 1 Vapour Injection Scroll Compressors for Refrigeration 4 3 ZF K5E compressors with wet vapour injection When using scroll compressors in low temperature applications with R407A R407F R448A or R449A and an extended envelope see Chapter 2 4 3 Application limits additional liquid injection with a DTC valve is required in conjunction wi...

Page 15: ...e phases and the frequency match the nameplate data 5 2 Electrical installation Three phase compressors TF with internal motor protection Power circuit Control 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 F4 LP s...

Page 16: ... cable glands in order to reach the rated protection class We advise installers service providers to pay attention to this aspect every time they install or replace a Copeland Scroll compressor and to use cable glands according to EN 50262 or any other relevant standard of application in their country region Examples of correct electrical installations are shown in Figures 10 11 Figure 10 Correct ...

Page 17: ...the Copeland Scroll s inherent ability to handle liquid refrigerant in flooded conditions a crankcase heater is not required as long as the system charge does not exceed 7 5kg If a crankcase heater is fitted it is recommended that the heater be turned on for a minimum of 12 hours prior to starting the compressor This will prevent oil dilution and bearing stress on initial start up The crankcase he...

Page 18: ...ch applications it is strongly advised to install an additional external discharge thermostat To identify compressors with Advanced Scroll Temperature Protection a label has been added above the terminal box NOTE Depending upon the heat build up in the compressor it may take up to two hours for the ASTP and motor protector to reset 5 5 2 Discharge line thermostat The use of an external discharge t...

Page 19: ...ody is in upward position on a horizontal tube installation Ensure that the thermostat is not tilted The wire must not be in contact with the top cap of the compressor or the discharge tube Care should be taken to route wires so that they do not come into contact with sharp objects To avoid any impact on tripping temperature by the ambient the discharge line thermostat must be insulated Wrap therm...

Page 20: ...ion tests if the compressor housing is under vacuum Emerson subjects all Scroll compressors to a high voltage test after final assembly Each motor phase winding is tested according to EN 0530 or VDE 0530 part 1 at a differential voltage of 1000V plus twice the nominal voltage Since high voltage tests lead to premature ageing of the winding insulation further additional tests of that nature are not...

Page 21: ...nd liquid lines is advisable Pressure must be measured using a vacuum pressure gauge on the access valves and not on the vacuum pump this serves to avoid incorrect measurements resulting from the pressure gradient along the connecting lines to the pump Evacuating the system only on the suction side of a Scroll compressor can occasionally result in a temporary no start condition for the compressor ...

Page 22: ...ot good practice to use the compressor to test the high pressure switch function on the production line Switch function can be tested with nitrogen prior to installation and wiring can be checked by disconnecting the high pressure switch during the run test 6 7 Rotation direction Scroll compressors like several other types of compressors will only compress in one rotational direction Direction of ...

Page 23: ...that could be damaged by these temperatures do not come in contact with the shell 6 11 Pump down cycle To control refrigerant migration a pump down system should be used The discharge check valve with a refrigeration scroll compressor is designed for low leak back and will allow the use of a pump down without the addition of an external check valve If the compressor is stationary for prolonged per...

Page 24: ...ign inverter selection and operating envelopes at various conditions Only frequencies from 50 Hz to 60 Hz are acceptable Operation outside this frequency range is possible but should not be done without specific Application Engineering review The voltage must vary proportionally to the frequency If the inverter can only deliver a maximum voltage of 400V the amps will increase when the speed is abo...

Page 25: ...ris or may become plugged shortly after a compressor failure This will result in starvation of oil to the replacement compressor and a second failure When a single compressor 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 in...

Page 26: ... there is uncertainty as to the moisture content in the system an oil sample should be taken and tested for moisture Sight glass moisture indicators currently available can be used with the HFC refrigerants and lubricants however the moisture indicator will just show the moisture content of the refrigerant The actual moisture level of POE would be higher than the sight glass indicates This is due ...

Page 27: ...frigerant according to national legislation and regulations Dispose of compressor according to national legislation and regulations DISCLAIMER 1 The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability 2 Emerson Climate T...

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