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Emerson Copeland Scroll ZBH30K Series Application Manuallines Download Page 7

 

4 

 

C6.2.7/1007-0619/E 

2.3.2  Application limits 

 

CAUTION 
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  typical  evaporator-expansion  valve 
configuration a minimum stable superheat of at least 5K is required. 

 

NOTE:  The  application  envelopes  for  all  horizontal  compressor  models  covered  in  these 
guidelines 

are 

available 

in 

Copeland 

brand 

products 

Select 

software 

at 

www.climate.emerson.com/en-gb

. 

2.3.3  Comparison between ZRH* and ZBH* compressors 

ZRH* and ZBH* horizontal compressor models are basically available in two BOM variations: 

▪

 

BOM 650

  Compressor with brazing stub tubes, electrical box ready for molded plug IP65 

▪

 

BOM 651

  Compressor with Rotalock connections, electrical box ready for molded plug IP65 

Table 2

 below describes the differences and similarities between ZRH* and ZBH* models: 

Compressor 

version 

BOM 650 

BOM 651 

ZRH* 

Brazing stub tubes 

Electrical connection ready for 

molded plug IP65 

Without oil sight glass 

Without oil service Schraeder valve 

Rotalock connections 

Electrical connection ready for molded 

plug IP65 

Without oil sight glass 

Without oil service Schraeder valve 

ZRHV* 

Brazing stub tubes 

Electrical connection ready for 

molded plug IP65 

Without oil sight glass 

Without oil service Schraeder valve 

Variable speed 

Rotalock connections 

Electrical connection ready for molded 

plug IP65 

Without oil sight glass 

Without oil service Schraeder valve 

Variable speed 

ZBH* 

Brazing stub tubes 

Electrical connection ready for 

molded plug IP65 

Oil sight glass 

Oil service Schraeder valve 

Rotalock connections 

Electrical connection ready for molded 

plug IP65 

Oil sight glass 

Oil service Schraeder valve 

ZBHV* 

Brazing stub tubes 

Electrical connection ready for 

molded plug IP65 

Oil sight glass 

Oil service Schraeder valve 

Variable speed 

Rotalock connections 

Electrical connection ready for molded 

plug IP65 

Oil sight glass 

Oil service Schraeder valve 

Variable speed 

Table 3: Differences and similarities between ZRH* and ZBH* horizontal scroll compressors 

2.4  Special requirements for transport applications 

Transport  air-conditioning  or  refrigeration  applications  can  be  particularly  sensitive  and  require 
experience  and  thorough  case-by-case  analysis.  Compared  to  static  applications,  additional 
demands in terms of applicability to specific norm and standard requirements can arise. The system 
designer must pay particular attention to higher demands with regard to shock stress, high vibration 
levels, power supply and other installation characteristics. 

The qualification for the parts and individual requirements,  like system components, piping, piping 
layout, fixation, as well as a study about shock, vibration and load requirements must be carried out 
by  the  unit  designer  for  the  whole  system.  Emerson  can  provide  support  and  assistance  with 
individual projects. 

 

 

Summary of Contents for Copeland Scroll ZBH30K Series

Page 1: ...Copeland Scroll Horizontal Compressors for Air Conditioning Applications ZRH49K to ZRH72K ZBH30K to ZBH45K ZRHV45K ZRHV72K Application Guidelines ...

Page 2: ...g 7 3 1 1 Transport and storage 7 3 1 2 Positioning and securing 7 3 1 3 Installation location 7 3 1 4 Mounting parts 8 3 2 Brazing procedure 8 3 3 Shut off valves and adaptors 9 3 4 Accumulators 10 3 5 Screens 10 3 6 Mufflers 10 4 Electrical connection 11 4 1 General recommendations 11 4 2 Electrical installation 11 4 2 1 Molded plug connection 11 4 2 2 Assembly of the molded plug cable 11 4 2 3 ...

Page 3: ...p 18 5 8 Rotation direction 18 5 9 Starting sound 19 5 10 Deep vacuum operation 19 5 11 Refrigerant migration 19 5 12 Pumpdown cycle 19 5 13 Shell temperature 20 5 14 Minimum run time 20 5 15 Shut off sound 20 5 16 Oil level 20 6 Maintenance repair 21 6 1 Exchanging the refrigerant 21 6 2 Replacing a compressor 21 6 2 1 Compressor replacement 21 6 2 2 Start up of a new or replacement compressor 21...

Page 4: ...ervice only if they have been installed in these systems according to instructions and conform to the corresponding provisions of legislation For relevant standards please refer to the Manufacturers Declaration available at www climate emerson com en gb These instructions should be retained throughout the lifetime of the compressor You are strongly advised to follow these safety instructions 1 1 I...

Page 5: ... other materials in the area of the compressor do not come into contact with it Lock and mark accessible sections CAUTION Overheating Bearing damage Do not operate compressors without refrigerant charge or without being connected to the system CAUTION Contact with POE Material damage POE lubricant must be handled carefully and the proper protective equipment gloves eye protection etc must be used ...

Page 6: ...2KJE 15 0 10 5 17 1 TFD TF5 Table 1 Cooling capacity at 5 C 50 C 10K 0K 2 2 Nomenclature The model designation contains the following technical information about the compressor ARI conditions Evaporating temperature 7 2 C Liquid sub cooling 8 3K Condensing temperature 54 4 C Ambient temperature 35 C Suction gas superheat 11K 2 3 Application range 2 3 1 Qualified refrigerants and oils IMPORTANT It ...

Page 7: ...lve Variable speed Rotalock connections Electrical connection ready for molded plug IP65 Without oil sight glass Without oil service Schraeder valve Variable speed ZBH Brazing stub tubes Electrical connection ready for molded plug IP65 Oil sight glass Oil service Schraeder valve Rotalock connections Electrical connection ready for molded plug IP65 Oil sight glass Oil service Schraeder valve ZBHV B...

Page 8: ...C6 2 7 1007 0619 E 5 2 5 Dimensions Figure 1 Dimensions of models ZBH30KJE to ZBH45KJE and ZBHV45KJE ...

Page 9: ...6 C6 2 7 1007 0619 E Figure 2 Dimensions of models ZRH42KJE to ZRH72KJE and ZRHV72KJE ...

Page 10: ...ing tabs are located on the side of the compressor shell end caps Figure 4 Handling of a horizontal scroll compressor NOTE It is essential to use the lifting tabs to maintain the compressor in the horizontal position during handling installation or removal in order to avoid damage to the compressor Horizontal scroll compressors have a holding charge and are factory filled with dry air It is recomm...

Page 11: ...d rubber mounting parts kit contains two metal washers which have to be positioned above the rubber grommet and the metal sleeve The bolt must be tightened until positive contact occurs between the bolt head and the washer ensuring that both are securely clamped together The recommended mounting torque is 18 1 Nm The metal sleeve inside helps to hold the grommet in place Figure 5 Installation of s...

Page 12: ...aterial 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 To disconnect Heat joint areas 2 and 3 slowly and uniformly until the braze material softens and the tube can be pulled out of the fitting To reconnect Recommended brazing materials Silfos with minimum 5 silver or silver braze used on other compres...

Page 13: ...ad operation may be acceptable in the yellow marked area For further information please contact the Application Engineering department 3 5 Screens CAUTION Screen blocking Compressor breakdown Use screens with at least 0 6 mm openings 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 ...

Page 14: ...ibited WARNING Electrical shock hazard Serious personal injuries and or system breakdown Use qualified molded plug cables with grounding connection only Make sure to connect the grounding first before attaching the molded plug cable to the connection pins of the compressor When removing the molded plug cable from the connection pins disconnect the grounding last ZRH and ZBH horizontal Scroll compr...

Page 15: ...ppropriate molded plug power cables please refer to the Emerson spare parts software available at www climate emerson com en gb 4 2 4 Wiring diagram Three phase compressors TF with internal motor protection Power circuit Control circuit L1 K1 K2 S1 P P F3 F4 B3 K2 R2 N 1 2 3 B1 K1 B1 F1 Motor terminal connections Three phase compressors are connected to the T1 T2 and T3 connections Legend B1 Room ...

Page 16: ...ZRH72K and ZBH30K to ZBH45K are limited to fixed speed operation at either 50 or 60 Hz Compressor models ZRHV72K and ZBHV45K can be operated on inverter derived power over the range of 35 to 75 Hz The inverter drives used to power these compressors must comply with the provisions of technical specification IEC 600034 17 In particular the motor input voltage must be limited to 1 35 kV microsecond l...

Page 17: ...velope for variable speed ZRHV72KJE and ZBHV45KJE with R134a 25 30 35 40 45 50 55 60 65 70 25 20 15 10 5 0 5 10 15 Condensing Temperature o C Evaporating Temperature oC R407C 45 75Hz 35 75Hz 15 20 25 30 35 40 45 50 55 60 65 70 75 20 15 10 5 0 5 10 15 20 Condensing Temperature o C Evaporating Temperature oC R134a 35 75Hz 45 75Hz ...

Page 18: ... NOT have any internal pressure relief valve To ensure safe operation a high pressure control must be used in all applications 4 5 Discharge gas temperature protection IMPORTANT Inadequate lubrication Scroll set damage All ZRH and ZBH horizontal Scroll compressors must be equipped with an external discharge gas temperature protection Internal discharge temperatures can reach unacceptable values un...

Page 19: ...nt and motor winding temperature The internal protector protects against single phasing Time must be allowed for the motor to cool down before the protector will reset 4 7 High potential testing WARNING Conductor cables Electrical shock 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 h...

Page 20: ... vacuum pressure Torr gauge on the access valves and not on the vacuum pump this serves to avoid incorrect measurements resulting from the pressure gradient along the connecting lines to the pump Evacuating the system only on the suction side of a Scroll compressor can occasionally result in a temporary no start condition for the compressor The reason for this is that the floating seal could axial...

Page 21: ...igh pressure loads could be detrimental to new bearings It is therefore important to ensure that new compressors are not subjected to liquid abuse and high pressure run tests It is not good practice to use the compressor to test the high pressure switch function on the production line Switch function can be tested with nitrogen prior to installation and wiring can be checked by disconnecting the h...

Page 22: ...neering department at Emerson or your local Emerson representative 5 12 Pumpdown cycle A pumpdown cycle may be used in conjunction with the crankcase heater to control refrigerant migration at standstill ZRH and ZBH horizontal scroll compressors are equipped with an internal check valve inside the discharge connection of the compressor housing The internal check valve is mainly designed to stop ex...

Page 23: ...tem 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 restore a minimal oil level that will ensure oil pick up through the crankshaft Cycling the compressor for a shorter period than this for instance to maintain very tight temperature control will result in p...

Page 24: ...d but must be removed after 72 hours It is highly recommended that the suction accumulator be replaced if the system contains one This is because the accumulator oil return orifice or screen may be plugged with debris or may become plugged shortly after a compressor failure This will result in starvation of oil to the replacement compressor and a second failure When a single compressor or tandem i...

Page 25: ...lower If there is uncertainty as to the moisture content in the system an oil sample should be taken and tested for moisture Sight glass moisture indicators currently available can be used with the HFC refrigerants and lubricants The moisture indicator will just show the moisture content of the refrigerant The actual moisture level of POE would be higher than the sight glass indicates This is due ...

Page 26: ...ving oil and refrigerant Do not disperse in the environment Use the correct equipment and method of removal Dispose of oil and refrigerant properly Dispose of compressor properly 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...

Page 27: ...outh Dubai UAE Tel 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 Tel 852 2866 3108 Fax 852 2520 6227 CZECH REPUBLIC Hajkova 22 CZ 133 00 Prague Tel 420 733 161 651 Fax 420 271 035 655 Pavel Sudek emerson com SPAIN PORTUGAL C Pujades 51 55 Box 53 ES 08005 Barcelona Tel 34 93 412 37 52 iberica s...

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