Emerson Copeland Scroll ZH19K1P, Manual

Page 1: ...Copeland Scroll Compressors for Heat Pumps with R410A ZH04K1P to ZH19K1P ZHI05K1P to ZHI46K1P TM ...

Page 2: ...llation location 8 3 1 4 Mounting parts 9 3 2 Brazing procedure 9 3 3 Accumulators 10 3 4 Screens 11 3 5 Mufflers 11 3 6 Reversing valves 11 3 7 Suction line noise and vibration 12 4 Electrical connection 13 4 1 General recommendations 13 4 2 Electrical installation 13 4 2 1 Wiring diagrams 13 4 2 2 Terminal box 15 4 2 3 Motor winding 16 4 2 4 Protection devices 17 4 2 5 Crankcase heaters 17 4 2 6...

Page 3: ...ion direction 23 5 7 Starting sound 23 5 8 Deep vacuum operation 23 5 9 Shell temperature 23 5 10 Pump down cycle 24 5 11 Pump out cycle 24 5 12 Minimum run time 24 5 13 Shut off sound 24 5 14 Supply frequency and voltage 24 5 15 Oil level 25 5 16 Oil stub 25 6 Maintenance repair 26 6 1 Exchanging the refrigerant 26 6 2 Rotalock valves 26 6 3 Replacing a compressor 26 6 3 1 Compressor replacement ...

Page 4: ...ese 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 and possible personal injury High voltage This icon indicates operations with a danger o...

Page 5: ...cking out the system Only approved refrigerants and refrigeration oils 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 the compressor do not get in touch with it Lock and mark accessible...

Page 6: ... 62 PFZ TFM ZHI11K1P 10 87 PFZ TFM ZH09K1P 8 96 PFZ TFM ZHI14K1P 14 03 TFM ZH12K1P 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 Condensing temperature 50 C Suction gas superheat 5K Liquid sub cooling 4K Injection superheat 5K These co...

Page 7: ...t at the compressor suction inlet must always be sufficient to ensure that no refrigerant droplets enter the compressor For a typical evaporator expansion valve configuration 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 Climate Technologies depending on the model and for whi...

Page 8: ...s 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 Safety instructions Product description Installation Electrical connection Starting up operation Ma...

Page 9: ...6 C6 2 26 1013 1116 E 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: ...C6 2 26 1013 1116 E 7 ZHI46K1P Safety instructions Product description Installation Electrical connection Starting up operation Maintenance repair Trouble shooting Dismantling disposal References ...

Page 11: ...he oil sump 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 ...

Page 12: ...kit or on request to deliver the compressor with these parts instead of the rubber grommets NOTE For more information please refer to Technical Information C7 11 2 Scroll Mounting Parts Mounting 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 t...

Page 13: ...k valve care 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 3 Accumulators CAUTION Inadequate lubrication Bearing and moving parts destruction Minimise liqui...

Page 14: ... External mufflers normally applied to piston compressors in the past may not be required for Copeland Scroll compressors Individual system tests should be performed to verify acceptability of sound performance If adequate attenuation is not achieved use a muffler with a larger cross sectional area to inlet area ratio A ratio of 20 1 to 30 1 is recommended A hollow shell muffler will work quite we...

Page 15: ...unning of the compressor without transmitting excessive stress into any line attached to the unit In a split system the most important goal is to ensure minimal vibration in all directions to avoid transmitting vibrations to the structure to which the lines are fastened Under some conditions the Copeland Scroll has a normal starting rotational motion that can transmit a transient noise along the l...

Page 16: ...I05K1P 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 Contactors B3 Discharge gas thermostat Q1 Main switch C2 Run capacitor R2 Crankca...

Page 17: ...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 9 Wiring diagrams f...

Page 18: ...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 connections at the terminals according to Table 2 hereunder Compressor model Grounding sc...

Page 19: ...mpressor 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 12 13 below Figure 12 Correct electrical installation with cable glands for IP21 T box eg model ZH04K1P Figure 13 Correct electrical installation with cable glands for IP54 T box model ZHI46K1P 4 2 3 Motor win...

Page 20: ...ZH04K1P to ZH19K1P and ZHI05K1P to ZHI23K1P the crankcase heater must be mounted 10 to 40 mm above compressor legs see Figure 14 Figure 14 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 15 Figure 15 Cran...

Page 21: ...mage Compressors ZH04K1P to ZH19K1P and ZHI05K1P to ZHI46K1P must be equipped with a discharge gas temperature protection A good control should prevent the system from operating outside the published operating envelope and acceptable superheat range whatever the climatic conditions and the heating demand However under some extreme operating conditions such as loss of charge or improper control ope...

Page 22: ...r the ZH04K1P to ZH19K1P and ZHI05K1P to ZHI40K1P range of compressors conventional inherent internal line break motor protection is provided 4 5 2 External protection with Kriwan 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 ...

Page 23: ...y voltage Dual voltage 115 230V AC 50 Hz 15 10 3VA 120 240V AC 60 Hz 15 10 3VA Supply voltage 24V AC 50 60 Hz 15 10 3VA 24V DC 20 2W Ambient temperature range 30 70 C R25 total 1 8k Trip resistance 4 50kΩ 20 Reset time delay type 1 type 2 30 min 5 min 60 min 5 min Reset of running time Power interruption mains failure for approx 5 sec Short circuit monitoring system Typically 30 Protection class a...

Page 24: ...mistor terminals S1 and S2 and switch on the voltage supply the relay must switch on then off again after a short period connection established then interrupted between terminals M1 and M2 Simulation of an open thermistor chain Ω Remove the jumper used for the short circuit simulation and switch on the voltage supply the relay remains switched off no connection between terminals M1 and M2 If one o...

Page 25: ...c Visual check of the plant for leaks loose fittings such as TXV bulbs etc Compressor oil level Calibration of HP LP switches and any pressure actuated valves Check setting and operation of all safety features and protection devices All valves in the correct running position Pressure and compound gauges fitted Correctly charged with refrigerant Compressor electrical isolator location position 5 4 ...

Page 26: ...t Oil loss can be prevented during reverse rotation if the tubing is routed at least 15 cm above the compressor After several minutes of operation in reverse the compressor s protection system will trip due to high motor temperature The operator will notice a lack of cooling However if allowed to repeatedly restart and run in reverse without correcting the situation the compressor will be permanen...

Page 27: ... time because 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 start up To establish the minimum run time obtain a sample compressor equipped with a sight tube available from Emerson Climate Technologies and install it in a system with the longest connecting lines tha...

Page 28: ...red from Emerson Climate Technologies 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 9 to 6 8 Nm For tandemization remove the insert with the Schraeder valve and braze the oil equilization line into the stub F...

Page 29: ... 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 compressor the extra oil will add to rotor drag and increase power usage 6 3 2 Start up of a new or replacement compressor Rapid charg...

Page 30: ... POE oil To determine the actual moisture content of the lubricant samples have to be taken from the system and analysed 6 5 Oil additives Although Emerson Climate Technologies 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 st...

Page 31: ... 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 are elec...

Page 32: ... 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 high suction pressure check the evaporator superheat first to diagnose th...

Page 33: ... applied Correct it as necessary Control circuit inoperative Check the thermostat measure the temperature of the room and compare with the thermostat replace or re calibrate the thermostat Check the LP control switch and replace it if it is found defective Compressor lubrication problem Oil trap due to incorrect piping layout sizing Check the piping layout design Installations of pipe being routed...

Page 34: ...fficient refrigerant flow to the system This can also be verified by checking the evaporator outlet superheat if it is found unusually high Check the selection of the expansion valve likely undersized Noise during shut off Anti reverse device This does not have any effect on the durability of the compressor no action is necessary Safety instructions Product description Installation Electrical conn...

Page 35: ...rtificates The latest updates of the drawings and certificates are available from our home page Performance and technical data The latest version of Emerson Climate Technologies Select software with performance data and technical data is available from our home page Spare parts and accessories The latest version of Emerson Climate Technologies spare parts tool with spare parts and accessories is a...

Page 36: ... 971 4 811 81 00 Fax 971 4 886 54 65 mea sales emerson com ASIA PACIFIC Suite 2503 8 25 F Exchange Tower 33 Wang Chiu Road Kowloon Bay Kowloon Hong Kong SPAIN PORTUGAL C Pujades 51 55 Box 53 ES 08005Barcelona Tel 34 93 412 37 52 Fax 34 93 412 42 15 iberica sales emerson com RUSSIA CIS Emerson LLC Dubininskaya str 53 build 5 4th floor 115054 Moscow Russia Phone 7 495 995 95 59 Fax 7 495 424 88 50 R...