Emerson Scroll ZB*KAU, Application Manuallines

Page 1: ...its 12 4 2 3 Protection devices 14 4 2 4 Crankcase heaters 14 4 3 Pressure protection devices 14 4 3 1 High pressure protection 14 4 3 2 Low pressure protection 14 4 4 Discharge gas temperature protection 15 4 4 1 Excessive discharge gas temperatures 15 4 4 2 Discharge gas temperature protection 15 4 5 Motor protection 17 4 6 High potential testing 17 5 Starting up operation 17 5 1 Compressor tigh...

Page 2: ...tion USA 13 Figure 11 Terminal dome cover and correct electrical installation European Electrical 14 Figure 12 European Electrical connections 14 Figure 13 Cover European 14 Figure 14 ATEX discharge line thermostat and ATEX label 16 Figure 15 Suction tube connecting areas 20 Figure 16 Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 77 F and 50 relative humidity...

Page 3: ...ese safety instructions Safety Icon Explanation 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 indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE is used t...

Page 4: ...on 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 used Failure to follow these warnings could result ...

Page 5: ...f a system never leave it unattended when it has no charge A servicing tag must be used for advising to other technician about servicing procedure running This will prevent unauthorized personnel from accidentally starting the equipment and potentially ruining the compressor by operating with no refrigerant In case of explosive atmosphere do not energize any electrical component in the system no u...

Page 6: ...r electrical component equipment no unshielded flame is allowed Furthermore before opening the refrigeration system or working on it with an unshielded flame continuously check if the ambient atmosphere is non explosive and ensure proper ventilation of the room before creating any naked flame no naked flame is allowed in an explosive atmosphere if the atmosphere reaches a dangerous concentration o...

Page 7: ...he relevant standards applicable to the given product Compressor Maximum Allowable Operation Pressure High pressure side Low pressure side ZB07KAU to ZB11KAU 406 PSIG 28 bar 247 PSIG 17 bar 2 2 3 Application limits 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 typ...

Page 8: ...essor shell place a thermocouple on the bottom center not the side of the compressor shell and insulate from the ambient During rapid system changes such as defrost or ice harvest cycles this temperature difference may drop rapidly for a short period of time When the crankcase temperature difference falls below the recommended 50 F 27 K our recommendation is the duration should not exceed a maximu...

Page 9: ...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 plugs must be removed as late as possible before brazing so that the air humidity does not affect the oil characteristics As oil might spill out of the suction connection located low on the shell the suction con...

Page 10: ...ame manner as any copper tube Recommended brazing material Any SIL FOS 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 t...

Page 11: ...el capacity and the condition pressure ratio 4 Electrical connection 4 1 Units Electrical connection per BOM 634 ZB KAU compressors for applications in US market are delivered with electrical pin connections ready for molded plug connection Its protection class is IP65 R290 qualified and dedicated molded plug cables must be used The R290 dedicated kit includes a special o ring a grounding connecti...

Page 12: ...electric current surge of the compressor motor at start up For more information please contact Application Engineering Figure 10 shows electrical connections schematic NOTE Emerson recommends the use of a Residual Current Device RCD as an additional safety measure NOTE Emerson recommends the use of a second contactor K2 for the safety chain of the compressor This protection must be considered it i...

Page 13: ...s they could damage the glass and or ceramic This might result in hermetic failure or loss of terminal performance Precautions are required to prevent striking or bending of pins Bent or damaged pins may result in loss of hermeticity and or terminal performance Power Circuit Control circuit Motor terminal connections Three phase compressors are connected to the TI T2 and T3 connections Legend B1 S...

Page 14: ...EC 60335 2 89 UL 60335 2 89 and EN 60335 2 89 no high pressure switch is required 4 3 2 Low pressure protection Operation under ambient pressure During operation under ambient pressure an explosive mixture can form inside the system Make sure that the pressure never falls below atmospheric pressure Operation outside the application envelope A low pressure protection shall be fitted in the suction ...

Page 15: ... ATEX directive consists of two EU directives describing what equipment and work space is allowed in an environment with an explosive atmosphere for 250 F 121 C for all ZB KAU models These compressors have no internal discharge gas temperature protection Therefore an external protector is required See Section 4 4 2 for more details 4 4 1 Excessive discharge gas temperatures A few of the possible c...

Page 16: ...the thermostat body against mechanical damage according to UL471 SB5 IEC 60079 0 clause 26 4 2 table 13 There is no need for an additional housing around the thermostat body Protection against mechanical damage to the thermostat can be achieved with an overall cover or box placed around the compressor or refrigerant system See Table 2 for Technical data of the discharge line thermostat For install...

Page 17: ... any remaining refrigerant from the compressor prior to high potential testing and Megohm resistance reading 5 Starting up operation 5 1 Compressor tightness test High pressure Personal injuries Consider personal safety requirements and refer to test pressures prior to test System explosion Personal injuries Use only dry nitrogen for leak testing DO NOT USE other industrial gases System contaminat...

Page 18: ...ill rotate in either direction depending on power phasing Since there is a 50 50 chance of connected power being backwards contractors should be warned of this Appropriate instructions or notices should be provided by the OEM Verification of proper rotation can be made by observing that the suction pressure drops and the discharge pressure rises when the compressor is energized There is no negativ...

Page 19: ...y case To maximize efficiency in controlling leaks when opening the refrigeration equipment or working on it it is recommended to use a leak detector designed for use with R290 refrigerant Continuously check if the ambient atmosphere is non explosive In case of explosive atmosphere do not energize any electrical component in the system fire and smoking are strictly forbidden no unshielded flame is...

Page 20: ...overy unit and dedicated cylinders Low suction pressure operation Compressor damage Do not operate with a restricted suction Do not operate with the low pressure limiter bridged Do not operate compressor at pressures that are not allowed by the operating envelope Allowing the suction pressure to drop below the envelope limit for more than a few seconds may overheat scrolls and cause early drive be...

Page 21: ... below shall be followed During the entire working procedure continuously check if the ambient atmosphere is explosive If explosive atmosphere is detected ensure proper ventilation of the working space and immediately cut off the power supply Resume working after the atmosphere is no longer dangerous Recover the refrigerant from the system using a suitable recovery unit Do not allow the recovery u...

Page 22: ...he actual moisture content of the lubricant samples must be taken from the system and analyzed 6 5 Oil additives Although Emerson cannot comment on any specific product from our own testing and 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 refrigera...

Page 23: ...val Dispose of oil and refrigerant according to national legislation and regulations Dispose of compressor according to national legislation and regulations 9 General Guidelines and More Information For general Copeland Scroll compressor please log in to Online Product Information at Emerson com OPI refer to the Application Engineering bulletins listed below or contact your Application Engineer 93...

Page 24: ...limate Technologies Inc and or its affiliates collectively Emerson as applicable reserve the right to modify the design or specifications of such products at any time without notice Emerson does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any Emerson product remains solely with the purchaser or end user Th...

Page 25: ...isture oxygen metal salts metal oxides and or high discharge temperatures The chemical reactions are accelerated at higher temperatures Oil and acid react with each other Acid formation leads to damage of the moving parts and in extreme cases to motor burnout Several different test methods can be used to test for acid formation If acid is present a complete oil change including the oil in the oil ...

Page 26: ...porator outlet is usually the consequence of oversized selection of the expansion valve or incorrect bulb sensor mounting The valve may freeze up in the open position due to accumulation of debris in the system For a system with very short refrigeration lines an accumulator is recommended Compressor operating outside the design limits Check the compressor suction and discharge pressures while it i...

Page 27: ... Try to limit the number of cycles to maximum 10 per hour Low gas velocity System gas velocity changes depending on temperature and load capacity control In low load conditions gas velocity may not be high enough to return oil to the compressor Low discharge pressure Low ambient temperature Fit a fan cycling control system Refrigerant undercharge Check the system for leaks Observe sight glass for ...

Page 28: ... can be measured from the top of the compressor footplate Figure 19 ZB KAU with external oil sight tube Figure 20 Markings on the external oil sight tube Start and run the system until it reaches stable conditions then run at stable conditions for a minimum of 15 minutes Stop the compressor and read the oil level during standstill Any oil level between 12oz 355 mL and 16oz 473 mL is in the nominal...

Page 29: ...of 50 F 27 C This crankcase differential temperature requirement supersedes the minimum suction superheat requirement detailed in section Applications limits To measure oil temperature through the compressor shell place a thermocouple on the bottom center not the side of the compressor shell and insulate from the ambient During rapid system changes such as defrost or ice harvest cycles this temper...