Emerson Copeland Scroll ZR24KRE, Application Manuallines

Page 1: ...Copeland Scroll Compressors for comfort precision and process cooling ZR24KRE to ZR92KRE Application Guidelines ...

Page 2: ...ring 8 3 1 3 Installation location 8 3 1 4 Mounting parts 8 3 2 Brazing procedure 9 3 3 Shut off valves and adaptors 10 3 4 Suction accumulators 10 3 5 Screens 11 3 6 Mufflers 11 3 7 Suction line noise and vibration 11 4 Electrical connection 13 4 1 General recommendations 13 4 2 Electrical installation 13 4 2 1 Terminal box 15 4 2 2 Motor windings 15 4 2 3 Protection devices 15 4 2 4 Crankcase he...

Page 3: ...temperature 20 5 11 Pump down cycle 20 5 12 Minimum run time 20 5 13 Shut off sound 21 5 14 Frequency 21 5 15 Oil level 21 6 Maintenance repair 22 6 1 Exchanging the refrigerant 22 6 2 Rotalock valves 22 6 3 Replacing a compressor 22 6 3 1 Compressor replacement 22 6 3 2 Start up of a new or replacement compressor 22 6 4 Lubrication and oil removal 23 6 5 Oil additives 23 6 6 Unbrazing system comp...

Page 4: ...standards please refer to 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 propert...

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 al...

Page 6: ...62 6 59 TFD ZR92KRE 6 24 7 52 TFD Table 1 Cooling capacity for medium temperature compressors 10 C 45 C 10K 0K Copeland Scroll compressors have one Scroll compression set driven by a single or three phase induction motor The Scroll set is mounted at the upper end of the rotor shaft of the motor The rotor shaft axis is in the vertical plane 2 2 Nomenclature The model designation contains the follow...

Page 7: ... 12 78 12 95 19 12 19 30 ZR42KRE 400 4 374 9 235 5 75 3 49 4 277 1 12 78 12 95 19 12 19 30 ZR48KRE 417 4 391 9 252 5 75 3 49 4 294 1 12 78 12 95 22 30 22 48 ZR61 69 72KRE 434 9 440 8 409 6 230 2 236 2 79 6 47 6 296 7 12 78 12 95 22 30 22 48 ZR81 92KRE 434 9 440 8 409 6 230 2 236 2 79 6 47 6 296 7 19 12 19 30 22 30 22 48 Table 2 Dimensions Scroll ZR KRE Figure 1 Dimensions for models ZR24KRE to ZR4...

Page 8: ...C6 2 41 0219 E 5 Figure 2 Dimensions for models ZR61KRE to ZR72KRE ...

Page 9: ...6 C6 2 41 0219 E Figure 3 Dimensions for models ZR81KRE to ZR92KRE ...

Page 10: ...frigerants R450A R513A Copeland brand products standard oil Emkarate RL 32 3MAF Servicing oils Emkarate RL 32 3MAF Mobil EAL Arctic 22 CC Table 3 Qualified refrigerants and oils 2 5 2 Application limits CAUTION Inadequate lubrication Compressor breakdown The superheat at the compressor suction inlet must always be sufficient to ensure that no refrigerant droplets enter the compressor For a typical...

Page 11: ...ion 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 this sequence prevents oil mist from coating the suction tube making brazing difficult The copper coated steel suction tube should be cleaned before brazing The compressor plugs must be removed as late as possible before brazing so that the ...

Page 12: ...nt thermal properties of steel and copper brazing procedures may have to be changed from those commonly used Refer to Figure 6 and the procedure below for the brazing of the suction and discharge lines to a scroll compressor The copper coated steel tubes on Scroll compressors can be brazed in approximately the same manner as any copper tube Recommended brazing materials any silfos material is reco...

Page 13: ...e suction as well as discharge sides Using either straight or angled adaptors provides a way to convert a Rotalock into a brazing connection Refer to the following table for proper tightening torques Torque Nm Rotalock 16UNF 40 50 Rotalock 1 14UNS 70 80 Rotalock 1 12UNF 110 135 Rotalock 1 12UNF 135 160 Rotalock 2 12UNF 165 190 Table 4 NOTE More information about adaptors and shut off valves can be...

Page 14: ...more effective Choose a muffler with a length of 10 to 15 cm 3 7 Suction line noise and vibration Copeland Scroll compressors inherently have low sound and vibration characteristics However in some respects the sound and vibration characteristics differ from reciprocating compressors and in rare instances could result in unexpected sound generation One difference is that the vibration characterist...

Page 15: ...ll shock loop Service valve angled valve fastened to unit wall Suction muffler not required Alternative configuration Tubing configuration small shock loop Service valve straight through valve fastened to unit wall Suction muffler may be required acts as dampening mass ...

Page 16: ...ases and the frequency match the nameplate data 4 2 Electrical installation 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 thermostat R2 Crankcase heater C2 Run capacitor S1 Auxiliary switch F1 Fuse F3 HP switch F4 LP swi...

Page 17: ...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 10 ...

Page 18: ...gle phase version Compressor models from ZR61KRE to ZR92KRE are only available with three phase motors All three phase motors are connected in star single phase motors need a run capacitor The motor insulation material is class B TF for all compressor models covered in these guidelines 4 2 3 Protection devices Independently from the internal motor protection fuses must be installed before the comp...

Page 19: ...ll compressors which opens at a differential pressure of 28 bar 3 bar between high and low pressure sides A high pressure cut out may be required according to national regulations and is strongly recommended due to the capabilities of pumping to high pressures once the discharge is obstructed The IPR valve is a safety device not an HP switch It is not designed for repeated operation and there is n...

Page 20: ...t and secure it with plastic straps Wrap a second layer of insulation around the first one and around the thermostat and secure it with plastic straps 4 5 High potential testing WARNING Conductor cables Electrical shock Shut off power supply before high potential testing CAUTION Internal arcing Motor destruction Do not carry out high voltage or insulation tests if the compressor housing is under v...

Page 21: ...s at the furthest point from the compressor in the suction and 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 ...

Page 22: ...iquid abuse and high pressure run tests It is not 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 5 7 Rotation direction Scroll compressors like several other types of compressors will only com...

Page 23: ...eratures do not come in contact with the shell 5 11 Pump down cycle To control refrigerant migration a pump down system could 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 periods refrigerant could migrate into ...

Page 24: ...nverter 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 above 50...

Page 25: ...return orifice or screen may be plugged with debris 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 compre...

Page 26: ...em should be evacuated down to 0 3 mbar or lower If 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...

Page 27: ... and method of removal Dispose of oil and refrigerant 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 th...

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