Emerson COPELAND ZH04K1P, Application Manuallines

Page 1: ...Copeland ScrollCompressors for Heat Pump Applications with R410A ZH04K1P to ZH19K1P ZHI05K1P to ZHI46K1P Application Guidelines ...

Page 2: ...1 4 Mounting parts 9 3 2 Brazing procedure 9 3 3 Pressure safety controls 10 3 3 1 High pressure protection 10 3 3 2 Low pressure protection 10 3 4 Crankcase heaters 11 3 5 Soft starters 12 3 6 Discharge gas temperatureprotection 12 3 6 1 Excessive discharge gas temperatures 14 3 7 Screens 14 3 8 Mufflers 14 3 9 Reversing valves 14 3 10Sound and vibration 15 3 11Compressor oil return oil balancing...

Page 3: ...inary checks Pre starting 25 5 4 Charging procedure 25 5 5 Initial start up 25 5 6 Rotationdirection 26 5 7 Starting sound 26 5 8 Deep vacuum operation 26 5 9 Shell temperature 26 5 10Pumpdowncycle 26 5 11Pump out cycle 27 5 12Minimum run time 27 5 13Shut off sound 27 5 14Supply frequency and voltage 27 5 15Oil level 28 5 16Oil stub 28 6 Maintenance repair 29 6 1 Exchanging the refrigerant 29 6 2 ...

Page 4: ...elevant standards please refer to the Manufacturer s Declaration available on request 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 ...

Page 5: ...g out the system Only approved refrigerants and refrigerationoils must be used Remove refrigerant from both high and low pressure sides with a suitable recovery unit before removing compressor WARNING High shell temperature Burning Do not touch the compressor until it has cooled down Ensure that other materials in the area of thecompressor do not come into contact with it Lock and mark accessible ...

Page 6: ...H12K1P 11 45 PFZ TFM ZHI18K1P 19 00 TFM ZH15K1P 15 05 TFM ZHI23K1P 23 40 TFM ZH19K1P 18 70 TFM ZHI27K1P 26 56 TFD ZHI32K1P 31 88 TFD ZHI35K1P 35 80 TFD ZHI40K1P 39 98 TFD ZHI46K1P 46 57 TWD Evaporating temperature 7 C Condensingtemperature 50 C Suction gas superheat 5 K Liquid sub cooling 4 K Injection superheat 5 K Table 1 Compressor models overview These compressors have one scroll compression s...

Page 7: ...mpressor suction inlet must always be sufficient to ensure that no refrigerant droplets enter the compressor For a typical evaporator expansion valveconfiguration a minimum stable superheat of at least 5K is required In the same way the superheat at the compressor suction must always stay below a maximum limit specified by Emerson depending on the model and for which the operating envelope is defi...

Page 8: ...e refer to Technical Information C7 4 3 Vapour injection scroll compressors for heat pumps 10 15 20 25 30 35 40 45 50 55 60 65 70 75 35 30 25 20 15 10 5 0 5 10 15 20 25 30 Condensing Temperature o C Evaporating Temperature oC R410A 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 35 30 25 20 15 10 5 0 5 10 15 20 25 30 Condensing Temperature o C Evaporating Temperature oC R410A Vapour injection 5K super...

Page 9: ...6 AGL_HP_ST_ZHK1P_EN_Rev00 2 4 Dimensions ZH04K1P ZH05K1P ZH06K1P to ZH12K1P ZHI18K1P for tandem ZHI05K1P ZHI08K1P to ZHI23K1P ZHI23K1P for tandem ZH15K1P ZH19K1P ZHI27K1P to ZHI32K1P ZHI35K1P ZHI40K1P ...

Page 10: ...AGL_HP_ST_ZHK1P_EN_Rev00 7 ZHI46K1P ...

Page 11: ...even when tilting at 30 3 1 2 Positioning and securing IMPORTANT Handling damage Compressor 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 p...

Page 12: ...ounting parts for single compressor applications ZH04K1P ZH05K1P 3 pieces per compressor ZH06K1P to ZH19K1P ZHI05K1P to ZHI23K1P 4 pieces per compressor Mounting parts for single compressor applications ZHI27K1P to ZHI46K1P 4 pieces per compressor Figure 4 Rubber mounting parts with sleeve and washer NOTE For more information please refer to Technical Information C7 11 2 Scroll Mounting Parts 3 3 ...

Page 13: ...must be taken not to overheat it to prevent brazing material from flowing into it NOTE Since the injection tubing design of the ZHI K1P compressors includes some O rings a wet rag or any other suitable heat protection device must be used when brazing the injection line to the compressor 3 4 Pressure safety controls 3 4 1 High pressure protection Applicable regulations and standards for example EN ...

Page 14: ...e Figure 6 Figure 6 Crankcase heater location models ZH04K1P to ZH19K1P and ZHI05K1P to ZHI23K1P For compressor models ZHI27K1P to ZHI46K1P the crankcase heater must be mounted below the oil removal valve located on the bottom shell for tandem versions see Figure 7 Figure 7 Crankcase heater location models ZHI27K1P to ZHI46K1P The initial start up in the field is a very critical period for any com...

Page 15: ...herent design of the Copeland scroll the internal compression components start unloaded evenif system pressures are not balanced Since the compressor internal pressures are balanced at start up low voltage starting characteristics are excellent and starting components are normally not required However for extremeelectrical conditions such as weak power supplies single phase soft starters can be su...

Page 16: ... the thermal well Dispense 0 75 1 cm3 of thermally conductive compound into the bottom of the thermal well Clean any debris grease or dirt from the upper cap surface outside the thermistor tubeopening along with the inside tube surface If the areas shown are not clean the silicone sealant will not adhere to the compressor Apply a 5 mm bead of silicone sealant Copeland ident nr 8413046 on the therm...

Page 17: ...e in the system should be avoided withthese compressors Field experience has shown that finer mesh screens used to protect thermal expansion valves capillary tubes or accumulators can becom e temporarily or permanently plugged with normal system debris and block the flow of either oil or refrigerant to the compressor Such blockage can result in compressor failure 3 9 Mufflers External mufflers nor...

Page 18: ...fully designed to ensure sufficient refrigerant gas velocity so that oil returns to the compressor at all times and conditions Individual piping diameter calculation depends on the refrigerant properties pressure level mass flow and density Once a new system design is set and assembled a functional test is required The functional test includes a qualification for the general system oil return and ...

Page 19: ...orating temperature and oil temperature 3 13 Suction line accumulator Due to Copeland scroll s inherent ability to handleliquid refrigerant for example in flooded start and defrost cycleoperation an accumulator is not required in most systems To determine if a suction line accumulator is required the system designer must check this with an appropriate test scenario See section 3 11 Compressor oil ...

Page 20: ...ith EN 60335 Single phase PF compressors For the ZH04K1P to ZH12K1P and ZHI05K1P ZHI11K1P ranges of compressors the following circuit diagrams can be used Power circuit Control circuit L1 K1 K2 K1 K2 S1 P P F3 F4 B3 K2 R2 N 1 2 3 4 Y5 B1 K1 B1 F1 Motor terminal connections Single phase compressors are connected to the Common C Start S and Run R connections Legend B1 System controller K1 K2 Contact...

Page 21: ...4 B3 K2 R2 N 1 2 3 4 Y5 B1 K1 B1 F1 Motor terminal connections Three phase compressors are connected to the T1 T2 and T3 connections Legend B1 System controller Q1 Main switch B3 Discharge gas thermostat R2 Crankcase heater F1 F6 F8 Fuses S1 Auxiliary switch F3 HP limiter Y5 Solenoid valve for injection if available F4 LP switch RCD Residual current device K1 K2 Contactors Figure 18 Wiring diagram...

Page 22: ...al motor protection 4 2 2 Terminal box The terminal box is IP21 for ZH04K1P to ZH19K1P and ZHI08K1P to ZHI14K1P models ie TF PF For compressor ZHI18K1P single BOM 526 the terminal box is IP21 and for compressor ZHI18K1P tandem ready BOM 476 the terminal box is IP54 For ZHI27K1P to ZHI40K1P models the terminal box is IP54 enclosure class according to IEC 60034 5 Respect the torques for the screw co...

Page 23: ...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 21 22 below Figure 21 Correct electrical installation with cable glands for IP21 T box eg model ZH04K1P ...

Page 24: ... the same potential for power supply and the switch contact of the control loop M1 M2 The electronic motor protection system used in ZHI46K1P is identified by a W as the centre letter in the motor code This system utilizes the temperature dependent resistance of the thermistors also called PTC resistance to read the winding temperature A chain of four thermistors connected in series is embedded in...

Page 25: ...g steps should be followed 4 5 1 Checking the connection Check the connection of the thermistor leads in the terminal box and at the protection module for possible loose connections or cable breakage If there is neither loose connection nor cable breakage the resistance of the thermistor chain must be checked 4 5 2 Checking the compressor thermistor chain Caution Use maximum measuring voltage of 3...

Page 26: ...Electrical shock hazard 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 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 10...

Page 27: ...ucted with the compressor connected but in that case the two pressure zones of the scroll compressor need to be respected System high pressure section o Define the system high side PS compressor high side PS o Isolate the high and low pressure sections of the system by closing valves solenoid valves expansion valves or by other means o Use the internal check valve of the compressor on the discharg...

Page 28: ... envelope Allowing the suction pressure to drop below the envelope limit for more than a few seconds may overheat scrolls and cause early drive bearing and moving parts damage Prior to charging or re charging the refrigerant system must be leak and pressure tested with appropriate purging gas Ensure that the system is grounded prior to charging with refrigerant The system shall be liquid charged t...

Page 29: ...rt 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 8 Deep vacuum operation CAUTION Vacuum operation Compressor damage Copeland scroll compressors should never be used to evacuate refrigeration or air conditioning systems Operating s...

Page 30: ...estore a minimal oil level that will ensure oil pick up through the crankshaft Cycling the compressor for a shorter periodthan this for instance to maintain very tight temperature control will result in progressive loss of oil and damage to the compressor 5 13 Shut off sound Scroll compressors incorporate a device that minimizes reverse rotation The residual momentary reversal of the scrolls at sh...

Page 31: ...e ordered from Emerson Oil return check test recommendations are also available on demand from Application Engineering 5 16 Oil stub Compressors ZHI27K1P to ZHI46K1P are equipped with an oil Schraeder valve The torque for the insert of the Schraeder valve is 5 9to 6 8 Nm For tandemisation remove the insert with the Schraeder valve and braze the oil equalisation line into the stub Figure 24 Val ve ...

Page 32: ...perature and pressure using precision measurements at a location in the system where liquid and vapour phases are present and when the temperatures have stabilised 6 2 Rotalock valves Rotalock valves should be periodically re torqued to ensure that leak tightness is maintained 6 3 Disassembling system components When disassembling system components please follow the main steps described hereunder ...

Page 33: ...prevent unauthorised personnel from accidentally operating the system and 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 d...

Page 34: ...tives 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 complex and difficult to evaluate without rigorously controlled chemical laboratory testing The use of additives without adequate testing may result in malfun...

Page 35: ... 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 Defective capacitor or relay For a single phase motor a defective capacitor or relay may prevent the compressor from starting Check these components by substituting a known to be good component if available Make sure that the capacitors a...

Page 36: ...scharge 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 temperature surrounding the condenser For hig...

Page 37: ...nadvertently create unwanted traps for the oil return As much as possible the refrigerant line should travel a direct and straight course between the evaporator and compressor It should also be remembered that the entire system will be coated in oil to some extent Oil viscosity changes with temperature More oil stays in the system than was originally expected Makesure the line is correctly sized O...

Page 38: ... Emerson spare parts and accessories software is available from the webpage www climate emerson com en gb tools resources 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 Technologie...

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