Emerson Copeland Scroll ZP23K Series, Application Manuallines

Page 1: ...Scroll compressors for air conditioning p A p i l ca i t o i u G n de n i l es ZR18K to ZR380K ZP23K to ZP385K ...

Page 2: ...ing parts 5 3 2 Brazing procedure 5 3 3 Shut off valves and adaptors 6 3 4 Accumulators 7 3 5 Mufflers 8 3 6 Reversing valves 8 3 7 Suction line noise and vibration 9 4 Electrical connection 10 4 1 General recommendations 10 4 2 Electrical installation 10 4 2 1 Terminal box 10 4 2 2 Motor winding 10 4 2 3 Protection devices 11 4 2 4 Crankcase heaters 11 4 3 Pressure safety controls 11 4 3 1 High p...

Page 3: ...wn cycle 17 5 10 Minimum run time 17 5 11 Shut off sound 17 5 12 Excessive liquid flood back tests 17 6 Maintenance repair 18 6 1 Exchanging the refrigerant 18 6 2 Rotalock valves 18 6 3 Replacing a compressor 18 6 3 1 Compressor replacement 18 6 3 2 Start up of a new or replacement compressor 19 6 4 Lubrication and oil removal 19 6 5 Unbrazing system components 20 7 Dismantling disposal 20 ...

Page 4: ...d possible personal injury High Voltage This icon indicates operations with a danger of electric shock IMPORTANT This icon indicates instructions to avoid malfunction of the compressor Danger of burning or frostbite This icon indicates operations with a danger of burning or frostbite NOTE This word indicates a recommendation for easier operation Explosion Hazard This icon indicates operations with...

Page 5: ...echnologies since 1979 It is the most efficient and durable compressor Emerson Climate Technologies has ever developed for air conditioning and refrigeration This application guideline deals with all vertical single Copeland Scroll compressors for air conditioning and heat pump applications from ZR18K to ZR380K and from ZP23K to ZP385K These compressors have one Scroll compression set driven by a ...

Page 6: ...0K 25 30 35 40 45 50 55 60 65 70 25 20 15 10 5 0 5 10 15 20 Evaporating Temperature to o C Condensing Temperature tc o C R407C Dew point 20 25 30 35 40 45 50 55 60 65 70 35 30 25 20 15 10 5 0 5 10 15 20 25 Evaporating Temperature to o C Condensing Temperature tc o C R407C Dew point ZR144 20 25 30 35 40 45 50 55 60 65 70 75 30 25 20 15 10 5 0 5 10 15 20 Evaporating Temperature to o C Condensing Tem...

Page 7: ...ropriate mechanical or handling equipment according to weight Keep in the upright position Stack pallets on top of each other when not exceeding 300 kg Do not stack single boxes on top of each other Keep the packaging dry at all times Figure 3 3 1 2 Positioning and securing IMPORTANT Handling damage Compressor malfunction Only use the lifting eyes whenever the compressor requires positioning Using...

Page 8: ... is recommended If the compressors are mounted in tandem or used in parallel then the hard mountings bolt M 9 5 16 are recommended The mounting torque should be 27 1 Nm It is possible to deliver these hard mounting parts as a kit or on request to deliver the compressor with these parts instead of the rubber grommets 3 2 Brazing procedure IMPORTANT Blockage Compressor breakdown Maintain a flow of o...

Page 9: ...l braze temperature is attained moving the torch up and down and rotating around the tube as necessary to heat the tube evenly Add braze material to the joint while moving the torch around the joint to flow braze material around the circumference After the braze material flows around the joint move the torch to heat area 3 This will draw the braze material down into the joint The time spent heatin...

Page 10: ...an extent that bearings are inadequately lubricated and wear will occur In such a case an accumulator must be used to reduce flood back to a safe level that the compressor can handle Heat pumps designed with a TXV to control refrigerant during heating may not require an accumulator if testing assures the developer that there will be no flood back throughout the operating range The accumulator oil ...

Page 11: ...sure Screens The use of screens finer than 30 x 30 mesh 0 6 mm openings anywhere in the system should be avoided with these compressors Field experience has shown that finer mesh screens used to protect thermal expansion valves capillary tubes or accumulators can become temporarily or permanently plugged with normal system debris and block the flow of either oil or refrigerant to the compressor Su...

Page 12: ...frequencies This is easily done by using one of the common combinations of recommended design configurations The scroll compressor makes both a rocking and twisting motion and enough flexibility must be provided in the line to prevent vibration transmission into any lines attached to the unit In a split system the most important goal is to ensure minimal vibration in all directions at the service ...

Page 13: ... phase Figure 11 Power circuit three phase Control Circuit A1 motor protection module B1 room thermostat F1 fuse F3 high pressure switch F4 low pressure switch K1 contactor R2 crankcase heater S1 auxiliary switch Y1 liquid line solenoid valve Motor Terminal Connections Figure 12 4 2 1 Terminal box The terminal box is IP21 for all models without electronic motor protection eg TF PF and IP54 for all...

Page 14: ...ll no longer have to clear out liquid during start Crankcase heater Three phase A crankcase heater is required for three phase compressors when the system charge exceeds the compressor charge limit listed in Table 3 hereunder Model Refrigerant Charge Limit ZR18K 2 7 kg ZR22K to ZR80K ZP23K to ZP83K 4 5 kg ZR94K to ZR190K ZP90K to ZP182K 7 0 kg ZR250K ZP235K 11 3 kg ZR310K to ZR380K ZP295K to ZP385...

Page 15: ...fice or TXV All of these conditions may starve the compressor for refrigerant and may result in compressor failure The low pressure cut out should have a manual reset feature for the highest level of system protection 4 4 Discharge temperature protection The ZR18K to ZR81K and ZP23K to ZP83K compressors have an internal thermo disc discharge gas temperature protection This thermo disc opens a gas ...

Page 16: ...60 Hz Control Rating 60 VA 25 A Inrush 300 375 VA 25 15 A Inrush Normal PTC resistance 250 to 1000 Ohms Trip resistance 4500 20 Ohms Reset resistance 2750 20 Ohms Module time out 30 minutes 5 minutes Low Voltage Sensing None Phase Monitor No Recommended set time delay 0 5 seconds for module built from 06 05 Module For protection in case of blocked rotor one thermistor for each phase is embedded in...

Page 17: ...tage supply first and the switching conditions must be checked by an ohmmeter or signal buzzer Bridge the already disconnected thermistor contactors S1 and S2 and switch on the voltage supply the relay must switch connection established between contactors M1 and M2 remove the jumper between S1 and S2 the relay must switch off no connection between contactors M1 and M2 Bridge the contactors S1 and ...

Page 18: ...sonal injuries DO NOT USE other industrial gases If using dry air do not include the compressor in the pressure test isolate it first Never add refrigerant to the test gas as leak indicator 5 3 Preliminary checks Pre starting WARNING Vacuum operation Compressor damage Discuss details of the installation with the installer If possible obtain drawings wiring diagrams etc It is ideal to use a check l...

Page 19: ...essure drops and discharge pressure rises when the compressor is energized allows verification of proper rotation direction There is no negative impact on durability caused by operating three phase Copeland Scroll compressors in the reversed direction for a short period of time under one hour but oil may be lost Oil loss can be prevented during reverse rotation if the tubing is routed at least 15 ...

Page 20: ...d 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 that are approved for the system The minimum on time becomes the time required for oil lost during compressor start up to return to the compressor sump and re...

Page 21: ... 7 14 54 System off time minutes 13 8 6 Number of on off cycles 5 5 4 Table 4 6 Maintenance repair 6 1 Exchanging the refrigerant Qualified refrigerants and oils are given in section 2 4 1 It is not necessary to replace the refrigerant with new unless contamination due to an error such as topping up the system with an incorrect refrigerant is suspected To verify correct refrigerant composition a s...

Page 22: ...ally ruining the compressor by operating with no refrigerant flow 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 4 Lubrication and oil removal WARNING Chemical reaction Compressor destruction Do not mix up ester oils with mineral oil and or alkyl benzene wh...

Page 23: ... unshielded flame in a refrigerant charged system Before opening up a system it is important to remove all refrigerant from both the high and low sides of the system If the refrigerant charge is removed from a scroll equipped unit from the high side only it is possible for the scrolls to seal preventing pressure equalization through the compressor This may leave the low side shell and suction line...

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