Emerson Copeland Scroll ZR108KRE, Application Manuallines

Page 1: ...Copeland Scroll Compressors for Comfort Precision and Process Cooling ZR24KRE to ZR190KRE Application Guidelines ...

Page 2: ...unting parts 8 3 3 Brazing procedure 8 3 3 1 General brazing procedure 8 3 3 2 Brazing procedures for ZR KRE compressors in parallel applications 9 3 4 Shut off valves and adaptors 9 3 5 Pressure safety controls 10 3 5 1 High pressure protection 10 3 5 2 Low pressure protection 10 3 6 Crankcase heater 10 3 7 Soft starter and single phase compressor start assists 11 3 8 Discharge gas temperature pr...

Page 3: ...n in time 23 5 7 Initial start up 23 5 8 Rotation direction 24 5 9 Starting sound 24 5 10 Deep vacuum operation 24 5 11 Shell temperature 24 5 12 Pump down cycle 24 5 13 Minimum run time 25 5 14 Shut off sound 25 5 15 Supply frequency and voltage 25 5 16 Oil level 25 6 Maintenance repair 26 6 1 Disassembling system components 26 6 2 Provisions of legislation leak check requirements 26 6 3 Exchangi...

Page 4: ...AGL_AC_ST_ZRKRE_E_Rev01 DISCLAIMER 34 ...

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Page 6: ...he individual refrigerant shall be considered when working with this type of refrigerant please check this document provided by the gas supplier These instructions shall 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 ...

Page 7: ...e Burning Do not touch the compressor until it has cooled down Ensure that 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 th...

Page 8: ...D ZR42KRE 5 24 6 20 PFJ TFD ZR48KRE 6 01 6 91 TFD ZR61KRE 7 62 9 01 TFD ZR69KRE 8 59 10 15 PFJ ZR72KRE 9 08 10 55 TFD ZR81KRE 10 0 11 60 TFD ZR92KRE 11 3 13 50 TFD ZR108KRE 15 80 TFD ZR125KRE 18 40 TFD ZR144KRE 20 80 TFD ZR160KRE 22 90 TFD ZR190KRE 27 40 TFD Refrigerant dew temperature evaporating temperature 5 C condensing temperature 50 C suction gas superheat 10 K liquid sub cooling 0 K frequen...

Page 9: ...ants R450A R513A R513A Copeland brand products standard oil Emkarate RL 32 3MAF Emkarate RL 32 3MAF Servicing oils Emkarate RL 32 3MAF Mobil EAL Arctic 22 CC Emkarate RL 32 3MAF Mobil EAL Arctic 22 CC Table 2 Qualified refrigerants and oils Oil recharge values can be taken from Copeland brand products Select software available at www climate emerson com en gb 2 4 2 Application limits CAUTION Inade...

Page 10: ...pplicable to the given product 2 5 Dimensions Compressor model A mm B mm C mm D mm E mm F mm Ø G Ø H ZR24KRE ZR28KRE 364 1 338 5 202 9 69 6 43 7 244 5 1 2 3 4 ZR36KRE 386 7 361 1 222 8 75 3 49 4 264 4 1 2 3 4 ZR42KRE 400 4 374 9 235 5 75 3 49 4 277 1 1 2 3 4 ZR48KRE 417 4 391 9 252 5 75 3 49 4 294 1 1 2 7 8 Figure 1 Dimensions for models ZR24KRE to ZR48KRE Compressor model A mm B mm Ø C ZR61KRE to...

Page 11: ...1 122 1 252 7 ZR160KRE ZR190KRE 551 5 519 5 140 4 271 Figure 3 Dimensions for models ZR108KRE to ZR190KRE BOM411 Compressor model A mm B mm C mm D mm ZR108KRE to ZR144KRE 533 2 501 1 122 1 242 8 ZR160KRE ZR190KRE 551 5 519 5 140 4 261 2 Figure 4 Dimensions for models ZR108KRE to ZR190KRE BOM455 ...

Page 12: ...essor malfunction Only use the lifting eyes whenever the compressor requires positioning Using discharge or suction connections for lifting may cause damage or leaks The compressor should be kept vertical during handling The discharge connection plug should be removed first before pulling the suction connection plug to allow the dry air pressure inside the compressor to escape Pulling the plugs in...

Page 13: ...essor until it has cooled down Ensure that other materials in the area of the compressor do not come into contact with it IMPORTANT Blockage Compressor breakdown Maintain a flow of oxygen free nitrogen through the system at very low pressure during brazing Nitrogen displaces the air and prevents the formation of copper oxides in the system If allowed to form the copper oxide material can later be ...

Page 14: ... plug from the discharge port of the compressor has to be removed first then the rubber plugs from the oil port Most probably the oil port will be coated with some oil It is mandatory to clean out the oil before brazing If the inner surface is contaminated with oil the brazing material will not adhere to the surface and the joint will fail generating leakage The oil should be carefully wiped out w...

Page 15: ...dards shall be followed to apply appropriate control to ensure that the pressure is always above the required minimum limit Low pressure protection is required to stop the compressor operating outside the published envelope limits The low pressure control must be installed correctly into the suction line meaning no service valve between the compressor and the pressure protection is allowed The min...

Page 16: ...y inclined Fig 12 Close the lock and tighten the screw torque 2 3 Nm The excess clamp bracket may be trimmed Sharp edges must not come into contact with wires The presence of the heater shall be made evident by the posting of caution signs or markings at appropriate locations Figure 9 Figure 10 Figure 11 Figure 12 Electrical connection Connect the crankcase heater according to the compressor appli...

Page 17: ...ls oil filters etc The oil lubricity will be reduced and a progressive wear process will occur which will prematurely damage the compressor The stability of the refrigerant can also be affected particularly if traces of contaminant are present The problems listed under the first 2 points frequently occur simultaneously particularly since the chemical reaction speed approximately doubles with every...

Page 18: ...line thermostat with clamp Technical data of the discharge line thermostat Voltage 120 240 VAC Maximum amperage 5 A 240 V Operating temperatures Open 130 C 4 K Close 101 C 8 K Wire insulation maximum temperature 150 C Clips for tube Ø 15 8 19 1 mm 5 8 3 4 Table 5 Discharge line thermostat technical data To ensure proper functioning and to avoid false readings the discharge line thermostat must be ...

Page 19: ...sure switch It is not designed for repeated operation and there is no guarantee that it will reset correctly if it does have repeated operation 3 10 Discharge check valve All ZR KRE compressors contain an internal check valve on the discharge connection The discharge check valve prevents the high side high pressure discharge gas from flowing rapidly back through the compressor after shutdown This ...

Page 20: ...dequate oil return from the system into the compressor at any time No liquid refrigerant return to the compressor Liquid refrigerant dilutes the oil could wash the oil off the bearings and moving parts and could lead to overheating and compressor failure System piping must be carefully designed to ensure sufficient refrigerant gas velocity so that oil returns to the compressor at all times and con...

Page 21: ...on the opposite side of the sight glass or at an angle of 90 clockwise from the suction inlet with view on the top Figure 16 Oil dilution chart tb bottom shell temp te evaporating temp and oil temperature 3 15 Suction line accumulator Due to Copeland Scrolls inherent ability to handle liquid refrigerant for example in flooded start and defrost cycle operation an accumulator is not required in most...

Page 22: ...onductor cables Electrical shock Shut off power supply before undertaking any task on electrical equipment The recommended wiring diagrams are shown in figures hereunder 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 K1 Contactor B3 Discharge gas ther...

Page 23: ...tion 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 switch Figure 18 ...

Page 24: ...te to avoid local overheating Cable glands have an influence on the protection class of the terminal box Emerson strongly recommends to use appropriate cable glands according to EN 50262 in order to reach the rated protection class Examples of correct electrical installations are shown in Figures 19 21 below 4 3 1 Terminal box IP21 The standard terminal box is IP21 for all ZR24KRE to ZR190KRE BOM4...

Page 25: ... assembled 4 4 Motor insulation The motor insulation material is class B TF for all ZR KRE models within maximum allowable operating temperatures according to IEC 34 1 or DIN 57530 4 5 Motor protection Independently from the internal motor protection fuses must be installed before the compressor The selection of fuses has to be made according to EN 60269 1 or EN 60204 1 and compressor maximum oper...

Page 26: ..._Rev01 21 made with the compressor charged with refrigerant Carry out the test with a lower voltage as described above Disconnect all electronic devices eg motor protection module fan speed control etc prior to testing ...

Page 27: ...USE other industrial gases The compressor has been leak pressure tested in the Emerson factory Therefore it is not necessary for the system manufacturer installer to leak pressure test the compressor again on the assembly system All compressors get a factory holding charge of dry air about 1 to 2 5 bar relative pressure An intact holding charge serves as a proof of quality against penetrating mois...

Page 28: ...d prior to charging with refrigerant The system shall be liquid charged through the liquid receiver shut off valve or through a valve in the liquid line The use of a filter drier in the charging line is highly recommended Systems shall be liquid charged on both the high and low sides simultaneously to ensure a positive refrigerant pressure is present in the compressor before it runs The majority o...

Page 29: ...on components always start unloaded even if system pressures are not balanced In addition since internal compressor pressures are always balanced at start up low voltage starting characteristics are excellent for Copeland Scroll compressors 5 10 Deep vacuum operation CAUTION Vacuum operation Compressor damage Copeland Scroll compressors should never be used to evacuate refrigeration or air conditi...

Page 30: ...here is no general release of standard Copeland Scroll compressors for use with variable speed AC drives A number of considerations must be taken into account when applying Scroll compressors with variable speed including system design inverter selection and operating envelopes at various conditions Only frequencies from 50 to 60 Hz are acceptable Operation outside this frequency range is possible...

Page 31: ...and uniformly until the braze material softens and the tube end can be pulled out from the fitting To reconnect Recommended brazing material Silfos with minimum 5 silver or silver braze used on other compressors Due to the different thermal properties of steel and copper brazing procedures may have to be changed from those commonly used NOTE Since the discharge stub contains a check valve care mus...

Page 32: ...ional requirements depending on the system and stipulates training requirements for alternative refrigerants HFO refrigerants are covered by the F gas Regulation as far as reporting of placing on the market is concerned 6 3 Exchanging the refrigerant CAUTION Low suction pressure operation Compressor damage Do not operate with a restricted suction Do not operate with the low pressure limiter bridge...

Page 33: ...nd potentially ruining the compressor by operating with no refrigerant Do not start the compressor while the system is in a deep vacuum Internal arcing may occur when a scroll compressor is started in a vacuum causing burnout of the internal lead connections 6 5 Lubrication and oil removal CAUTION Chemical reaction Compressor destruction Do not mix up ester oils with mineral oil and or alkyl benze...

Page 34: ...6 6 Oil additives Although Emerson cannot comment on any specific product from our own testing and past experience we do not recommend the use of any additives to reduce compressor bearing losses or for any other purpose Furthermore the long term chemical stability of any additive in the presence of refrigerant low and high temperatures and materials commonly found in refrigeration systems is comp...

Page 35: ... compressor terminals if there is voltage measured Trace the wiring diagram to see where the circuit is interrupted Low supply voltage If the voltage falls below 90 of the nameplate voltage the motor may develop insufficient torque Make sure the compressor is supplied with rated nominal voltage Shorted or grounded motor windings Check the motor for ground by means of a continuity check between the...

Page 36: ...ed undersized discharge line can increase discharge pressure This is also true for an undersized condenser Correct the component selection as needed Check the fan motor make sure it is running properly in the right direction Check the condenser if dirt has been accumulated it will clog the airflow clean as necessary High discharge pressure is also caused by an overcharged system and high ambient t...

Page 37: ...ectly sized Oil pump out due to high cycling rate A high cycling rate will pump oil into the system and lead to lubrication failure Oil leaves the compressor at start up and the short running time is insufficient to return the oil to the compressor via the suction side Try to limit the number of cycles to maximum 10 per hour Low gas velocity System gas velocity changes depending on temperature and...

Page 38: ...and regulations 9 References Please visit www climate emerson com en gb for free download of Application Guidelines and Technical Information Performance and technical data The latest version of Copeland brand products Select software with performance data and technical data is available from the webpage www climate emerson com en gb Spare parts and accessories Visit the webpage www climate emerso...

Page 39: ...1 8 2 Table 8 Tightening torques 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 Technologies GmbH and or its affiliates collectively Emerson as applicable reserve the right to modi...

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