Emerson Copeland ZR16, Manual

Page 1: ...ning System Suction Line Noise and Vibration 9 Mounting Parts 9 Single Phase Starting Characteristics 9 PTC Start Components 9 Electrical Connections 9 Deep Vacuum Operation 10 Shell Temperature 10 2013 Emerson Climate Technologies Inc 1 Printed in the U S A System Tubing Stress 10 Three Phase Scroll Electrical Phasing 10 Brief Power Interruptions 10 Application Tests Application Test Summary 11 C...

Page 2: ...to follow these safety instructions SafetyIconExplanation DANGER WARNING CAUTION NOTICE CAUTION 2013 Emerson Climate Technologies Inc Printed in the U S A DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION used with the safety alert symbol ind...

Page 3: ...tem Use only approved refrigerants and refrigeration oils Personal safety equipment must be used Failure to follow these warnings could result in serious personal injury BURN HAZARD Do not touch the compressor until it has cooled down Ensure that materials and wiring do not touch high temperature areas of the compressor Use caution when brazing system components Personal safety equipment must be u...

Page 4: ...ll depend on the type of refrigerant metering device Fixed orifice devices may flood the compressor with refrigerant and thermostatic expansion devices will attempt to control superheat and result in higher compressor top cap temperatures Fan failure testing or loss of air flow in both cooling and heating should be evaluated by the system designer to assure that the compressor and system are prote...

Page 5: ...A higher level of protection is achieved if the low pressure control is set to cut out around 55 psig 3 8 bar to prevent evaporator coil icing The cut in setting can be as high as 105 psig 7 2 bar to prevent rapid recycling in case of refrigerant loss If an 2013 Emerson Climate Technologies Inc Printed in the U S A electronic controller is used the system can be locked out after repeated low press...

Page 6: ... prevent liquid slugging and subsequent oil pump out at the beginning and end of the defrost cycle should be assessed during system development This will require special accumulators and compressors with 2013 Emerson Climate Technologies Inc Printed in the U S A sight tubes and or sight glasses for monitoring refrigerant and oil levels Charge Compensators Charge compensators are devices that store...

Page 7: ...siderations in the section on Brief Power 2013 Emerson Climate Technologies Inc Printed in the U S A Interruptions there is no minimum off time because Copeland Scroll compressors start unloaded even if the system has unbalanced pressures The most critical consideration is the minimum run time required to return oil to the compressor after startup To establish the minimum run time obtain a sample ...

Page 8: ...ystem manufacturing processes that leave solid or liquid contaminants in the evaporator coil condenser coil and interconnecting tubing plus any contaminants introduced during the field installation process Molecular sieve and activated alumina are two filter drier materials designed to remove moisture and mitigate acid formation A 100 molecular sieve filter can be used for maximum moisture capacit...

Page 9: ... sound phenomena described above are not usually associated with heat pump systems because of the isolation and attenuation provided by the reversing valve and tubing bends 2013 Emerson Climate Technologies Inc Printed in the U S A Mounting Parts Table 3 lists the mounting parts to be used with these compressors Many OEM customers buy the mounting parts directly from the supplier but Emerson s gro...

Page 10: ... other types of compressors will only compress in one rotational direction Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction except as described in the section Brief Power Interruptions Three phase compressors will rotate in either direction depending upon phasing of the power Since there is a 50 chance of connecting po...

Page 11: ...013 Emerson Climate Technologies Inc Printed in the U S A by 15 in this test to simulate overcharging often found in field installations The system should be operated at an indoor temperature of 70 F 21 C and outdoor temperature extremes of 10 F 12 C or lower in heating to produce flood back conditions The compressor suction and discharge pressures and temperatures as well as the sump temperature ...

Page 12: ...ge the compressor resulting in failure 2013 Emerson Climate Technologies Inc Printed in the U S A Pressure Testing WARNING Never pressurize the compressor to more than 350 psig 24 bar for leak checking purposes Never pressurize the compressor from a nitrogen cylinder or other pressure source without an appropriately sized pressure regulating and relief valve The pressure used on the line to meet t...

Page 13: ...ing a compressor and applying the highest nameplate voltage to the motor The amperage that the motor draws after four seconds is the value that is used on the nameplate Since there is a direct ratio between voltage and locked rotor amperage the lower the line voltage used to start the compressor the lower the locked rotor amperage will be 2013 Emerson Climate Technologies Inc Printed in the U S A ...

Page 14: ...base 2013 Emerson Climate Technologies Inc Printed in the U S A Compressor Replacement After a Motor Burn In the case of a motor burn the majority of contaminated oil will be removed with the compressor The rest of the oil is cleaned with the use of suction and liquid line filter driers A 100 activated alumina suction filter drier is recommended but must be removed after 72 hours See AE24 1105 for...

Page 15: ...30 Unacceptable 4 20 Too Much Refrigerant Dilu on 10 14 0 10 24 20 10 0 10 20 30 40 50 Evapora ng Temperature F Note 1 Operation in this refrigerant dilution area is safe in air to air heat pump heating mode For other applications such as AC only review expansion device to raise superheat A cold sump may result in high refrigerant migration after shut down Figure 1 Oil Dilution Chart 2013 Emerson ...

Page 16: ...harge is over the charge limit shown in Table 5 a crankcase heater is required Figure 2 Accumulator Piping Line Voltage Fuse A B Typical Solid State Timer if used Discharge Line System Operating Thermostat Time Delay Relay Specifications Timer Opens 1 Electrical Cycle Thermostat if used Compressor Contactor C Other Protective Devices if used Timer Closes Greater than 5 seconds later whether 016 Se...

Page 17: ...Figure 5 Compressor Electrical Connection Discharge Thermostat Connect the heater so that the connection point straddles the compressor seam weld Seam Weld Seam Weld ZR16 32K5 ZR38 54K5 WARNING Verify the correct crankcase heater voltage for the application and ensure heater is properly grounded Figure 6 Crankcase Heater 2013 Emerson Climate Technologies Inc 17 Printed in the U S A ...

Page 18: ... N AE4 1374 R1 Evapora ng Temperature C 29 24 19 14 9 4 1 6 11 160 150 66 61 140 56 130 51 120 46 110 41 100 36 90 31 80 26 70 21 20 10 0 10 20 30 40 50 60 Evapora ng Temperature F Figure 7 R 22 R 407C Scroll Operating Envelope 2013 Emerson Climate Technologies Inc 18 Printed in the U S A ...

Page 19: ...e as necessary to heat tube evenly Add braze material to the joint while moving torch around joint to flow braze material around circumference After braze material flows around joint move 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 2013 Emerson ...

Page 20: ...Application Engineering B U L L E T I N AE4 1374 R1 Figure 9 2013 Emerson Climate Technologies Inc 20 Printed in the U S A ...

Page 21: ...uration Shock loop Service Valve Angled valve fastened to unit Suction muffler Not required Alternate Configuration Component Description Tubing Configuration Shock loop Service Valve Straight through valve not fastened to unit Mass Suction muffler May be required Acts as dampening mass Table 3 Mounting Parts Model Frame Size Mounting Kit Grommet Sleeve ZR16 32K5 53 527 0044 15 027 0262 00 028 018...

Page 22: ... Shell Diameter e g 53 5 5 Inches 63 6 5 Inches Charge Allowance For System Table 5 Crankcase Heaters Model Frame Size Emerson Part No Volts Watts Leads EHP Product ZR16 32K5 53 240 40 21 018 0094 00 120 40 21 018 0094 01 240 40 21 018 0096 00 120 40 21 018 0096 01 ZR38 54K5 63 480 40 21 018 0096 02 575 40 21 018 0096 03 240 40 48 018 0096 04 480 40 48 018 0096 05 2013 Emerson Climate Technologies...