Emerson Copeland Scroll K5 Series Application Bulletin Download

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Application Engineering

AE4-1383 R5

Application Engineering

Application Guidelines for ZF*K5E & ZB*K5E Copeland Scroll

™

K5 Compressors for Refrigeration 8-15 HP with CoreSense

™

Diagnostics

AE4-1383 R5

December 2012

TABLE OF CONTENTS

Section Page Section Page

Safety

Safety

Instructions

.............................................................2

Safety Icon Explanation .....................................................2

Instructions Pertaining to Risk of Electrical Shock,

Fire, or Injury to Persons ................................................3

Safety

Statements

.............................................................3

Introduction

Nomenclature

....................................................................4

Approved

Refrigerants.......................................................4

Operating

Envelope

...........................................................4

Extended ZF*K5E Operating Envelope .............................4

ZF*K5E Low Temperature K5 Compressors for

Refrigeration

......................................................................5

Liquid Injection for Discharge Temperature Protection ........4

DTC Valve Specifications ..................................................5

Installation of DTC Valve ...................................................5

Suggested Application Techniques for the DTC Valve ......5

Vapor

Injection

...................................................................5

Discharge Temperature Control with Vapor Injection ........6

System

Configuration

........................................................6

Downstream

Extraction

.....................................................6

Upstream

Extraction

..........................................................6

Heat Exchanger Piping Arrangements ..............................6

ZB*K5E Medium Temperature K5 Compressors for

Refrigeration

......................................................................6

Superheat

Requirements...................................................6

Crankcase

Heater..............................................................7

Pressure

Controls

..............................................................7

IPR Valve ..........................................................................7

Motor

Protection

................................................................7

PTC Motor Protection ........................................................7

Programmable Logic Controller Requirements .................7

Kriwan INT69 Module and Sensor Functional Check ........7

Module Voltage Supply Troubleshooting ...........................7

Sensor

Troubleshooting.....................................................7

Compressor Voltage Supply Troubleshooting ...................8

Oil Management for Rack Applications..............................8

Discharge

Mufflers

.............................................................8

Compressor

Mounting

.......................................................8

Connection Fittings, Service Valves and Adapters ............9

Deep Vacuum Operation ...................................................9

Unbrazing System Components ........................................9

HiPot

Testing

.....................................................................9

Three Phase Scroll Compressors – Directional

Dependence ....................................................................9

Copeland Scroll Compressor Functional Check ...............10

CoreSense

™

Diagnostics Module for K5 Compressors

....10

CoreSense Module LED Overview .....................................10

Product

Specifications

........................................................11

Compressor Lead Wiring ...................................................11

CoreSense Module Mounting .............................................11

110-220VAC CoreSense Module Power Wiring .................11

Demand

Wiring

...................................................................11

Protection/Contactor Control Wiring ...................................11

Discharge Temperature Protection with CoreSense

Diagnostics for K5 Compressors ......................................11

Communication Dipswitch Configuration ............................11

Cable Routing / Daisy Chain Configuration ........................12

Terminations

.......................................................................12

COMMISSIONING

..............................................................12

Stand

Alone

Mode

..............................................................12

MODBUS Communication to CoreSense Diagnostics

for K5 Compressors..........................................................12

CoreSense K5 Programming Instructions .......................13-17

Figures

Operating Maps ...............................................................18-21

Typical

Suction

Tubing........................................................22

Liquid Injection Scroll with DTC Valve ................................23

EVI Scroll with DTC and T-fitting Adapter ...........................23

Circuit Diagram and Cycle for EVI ......................................23

Downstream

Extraction

......................................................24

Upstream

Extraction

...........................................................24

H/X

Piping

Arrangement

.....................................................24

8 - 15 HP Copeland Scroll Compressor Rack Mounting ....24

8 - 15 HP Condensing Unit Mounting .................................24

CoreSense Module Wiring Schematics ..............................25

Discharge

Thermistor

Connector

........................................26

Top

Cap

Thermistor

............................................................26

Discharge

Line

Thermistor

.................................................26

CoreSense

Terminal

Box

....................................................27

K5 Communication Module DIP Switch Settings ................28

Wiring Relay Example ........................................................28

Jumpers

........................................................................28

RS485 Daisy Chain Connection .........................................29

Two Rack Daisy Chain Connection ....................................29

Tables

Injection

Accessories

..........................................................30

External Wrap-Around Crankcase Heaters ........................30

Kriwan INT69 Module Specifications ..................................30

K5 Compressor Additional Accessories ..............................31

K5 Compressor (8 to 15 HP) Fitting Sizes..........................31

High and Low Pressure Control Settings............................31

CoreSense

™

Diagnostics Fault Codes ...............................32

CoreSense

™

Diagnostics Module Troubleshooting .........33-34

Demand

Wiring

...................................................................35

K5 DIP Switch Settings .......................................................35

Summary of Contents for Copeland Scroll K5 Series

Page 1: ...Unbrazing System Components 9 HiPot Testing 9 Three Phase Scroll Compressors Directional Dependence 9 Copeland Scroll Compressor Functional Check 10 CoreSense Diagnostics Module for K5 Compressors 10 CoreSense Module LED Overview 10 Product Specifications 11 Compressor Lead Wiring 11 CoreSense Module Mounting 11 110 220VAC CoreSense Module Power Wiring 11 Demand Wiring 11 Protection Contactor Cont...

Page 2: ... be retained throughout the lifetime of the compressor You are strongly advised to follow these 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 hazard...

Page 3: ... 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 in...

Page 4: ...fitting can be capped using the rotalock to stub tube adaptor kit 998 0034 18 A copper line can be inserted into the stub end of the adaptor and sealed off The rotalock adaptor with the supplied Teflon seal will effectively seal the port and will not damage the fitting or the compressor Introduction The Copeland Scroll refrigeration compressor product offering has developed the K5 compressor for t...

Page 5: ...uld be applied to insulate and protect the valves remote bulb assembly This will reduce the total height requirement by 0 5 12 7mm Suggested Application Techniques for the DTC Valve For the most efficient thermal sensing spread a thin film of thermal grease around the DTC valve bulb before installing into the top cap well However for proper functioning of the valve this is not required For service...

Page 6: ...is method is that it is not as efficient as the upstream method however the difference is too small for practical purposes See Figure 4 Upstream Extraction In upstream extraction the TXV is placed between the condenser and the heat exchanger The TXV regulates the flow of subcooled refrigerant out of the condenser and into the heat exchanger With this type of configuration there is a potential for ...

Page 7: ... in the event of high temperatures The thermistors are used to sense motor temperatures The thermistor circuit is connected to the protector module terminals S1 and S2 When any thermistor reaches a limiting value the module interrupts the control circuit and shuts off the compressor After the thermistor has cooled sufficiently it will reset However the module has a 30 minute time delay before rese...

Page 8: ...supplied can accommodate the mounting of the oil control devices Unlike semi hermetic compressors scrolls do not have an oil pump with accompanying oil pressure safety controls Therefore an external oil level control is required The OMB Oil Level Management Control combines the functions of level control and timed compressor shut off should the level not come back to normal within a set period of ...

Page 9: ... and suction line tubing pressurized If a brazing torch is then applied to the low side the pressurized refrigerant and oil mixture could ignite as it escapes and contacts the brazing flame It is important to check both the high and low sides with manifold gauges before unbrazing or in the case of assembly line repair remove refrigerant from both the high and low sides Instructions should be provi...

Page 10: ...ule power discharge line thermistor and the current transducer referred to as CT in this document the CoreSense module can accurately detect the cause of electrical and system related issues A flashing LED indicator communicates the alert code and guides the service technician more quickly and accurately to the root cause of a problem The CoreSense module can provide both compressor protection and...

Page 11: ...hen the compressor cycles off or goes into a scheduled pump down Refer to the wiring diagram in Figure 8 for more detail Emerson recommends a general purpose industrial relay with mounting socket The relay contacts should be rated for 5A at 250VAC and the coil needs to match the system s control voltage typically 220 240 or 110 120 VAC For demand wiring kit see Table 9 For an example of wiring the...

Page 12: ...ing Passing the communications wire through the grommet in the plastic housing will help reduce abrasion to the wiring Appropriate strain relief is recommended Note The RS485 is polarity sensitive wires must connect to other terminals and wires must connect to other terminals The shield wire is connected to the center terminal or 0 volt position Terminations The last compressor in the daisy chain ...

Page 13: ...ration 2 From the System Configuration Menu Select 7 Network Setup 3 From the Network Setup Menu Select 2 Connected I O Boards and Controllers 4 From the Setup Screen Go To The C3 ECT Tab Press Ctrl 3 5 In Option 9 Enter The Number Of K5 Compressors Being Controlled By The E2 Press To Save Changes And Return To The Previous Screen CoreSense K5 Programming Instructions ...

Page 14: ...K5 module to Be Commissioned Press F4 Commission 8 Select the modbus that the CoreSense device is connected to If only 1 modbus network is connected this step will automatically complete itself skip to step 9 9 From the Modbus Device Menu Select an Unused Space That Matches the DIP Switch Address Of The CoreSense Device And Press Enter 10 Verify The Address Matches The Address Assigned By The Core...

Page 15: ...the U S A 11 Press To Return To The Network Summary Screen The Device Should Now Be Online Repeat Steps 8 10 To Address The Remaining CoreSense K5 Modules 12 Once All The Devices Are Addressed Press To Save Changes And Exit The Network Summary 13 Press to Enter the Main Menu Select 7 System Configuration ...

Page 16: ...he U S A 14 From the System Configuration Menu Select 7 Network Setup 15 From the Network Setup Menu Select 4 Controller Associations Then Select 4 Compressor Press Enter 16 Highlight The Suction Group2 Field Select F4 Look Up Press F4 And Select The Appropriate Suction Group For The Device And Press Enter ...

Page 17: ...mation On Setting Up Suction Groups In The E2 Consult Your Emerson Retail Solutions Representative 17 Scroll Over To The Comp Stage And Type In The Compressor Stage CoreSense Protection Provides Proofing Only On The Compressor Note The Compressor Stage Number Should Correspond To The Stage Numbers in the Suction Group Setup Step 7 ...

Page 18: ...ting Temperature F ZF K5E Low Temperature Vapor Injection Operating Map 65 F Return Gas R 404A R 507 Figure 1A 0 20 40 60 80 100 120 140 160 50 40 30 20 10 0 10 Condensing Temperature F Evaporating Temperature F ZF K5E Low Temperature Vapor Injection Operating Map 65 F Return Gas DTC Liquid Injection Required with EVI for R 407A R 407C R 407F Maximum 40F Superheat R 407A R 407C R 407F Figure 1B ...

Page 19: ... Evaporating Temperature F ZF K5E Low Temperature Liquid Injection Operating Map 65 F Return Gas DTC Liquid Injection Required R 22 Figure 1D 0 20 40 60 80 100 120 140 160 50 40 30 20 10 0 10 Condensing Temperature F Evaporating Temperature F ZF K5E Low Temperature Liquid Injection Operating Map 65 F Return Gas DTC Liquid Injection Required R 404A R 507 R 407A R 407C R 407F Figure 1C ...

Page 20: ... F ZB K5E Medium High Temperature Operating Map 65 F Return Gas R 22 Figure 1F Note For operating maps at different return gas conditions contact your Application Engineer 0 20 40 60 80 100 120 140 160 20 10 0 10 20 30 40 50 Condensing Temperature F Evaporating Temperature F ZB K5E Medium Temperature Operating Map 65 F Return Gas R 404A R 507 R 407A R 407C R 407F 65 F Maximum Return Gas R 407C F L...

Page 21: ...aporating Temperature F ZB K5E High Temperature Operating Map 20F Superheat R 134a Figure 1G 0 20 40 60 80 100 120 140 15 10 5 0 5 10 15 20 25 30 Condensing Temperature F Evaporating Temperature F ZF K5E Excluding ZF49K5E Medium Temperature Operating Map with and without Vapor Injection R 404A R 507 R 407A R 407C R 22 65 F Maximum Return Gas R 22 Not Approved for Vapor Injection Figure 1H ...

Page 22: ...ines to minimize tube stress 2 Follow similar guidelines for discharge tubing and oil return tubing as needed 3 If a run over 30 is required intermediate clamps may be necessary 4 Do not hang weights on tubing e g filter drier on suction tubing except after clamps or close to the header 5 This dimension should be made as short as possible but still insuring a proper braze joint 6 The above tubing ...

Page 23: ... U L L E T I N AE4 1383 R5 2012 Emerson Climate Technologies Inc Printed in the U S A Figure 3 Circuit Diagram and Cycle for EVI Figure 2B Liquid Injection Scroll with DTC Valve Figure 2C EVI Scroll with DTC and T fitting Adapter ...

Page 24: ...VO Vapor temperature leaving H X VI Vapor temperature entering H X LI Liquid temperature entering H X LO Subcooled liquid leaving H X Figure 5 Upstream Extraction Vapor Out Cond Out Liq In TXV SIT Liq Out Vapor In Figure 7A 8 15 HP Copeland Scroll Compressor Rack Mounting 102 0283 00 WASHER 027 0115 00 RUBBER PAD KIT 998 0178 00 027 0383 00 STEEL SPACER Figure 7B 8 15 HP Condensing Unit Mounting 0...

Page 25: ...nse Module Wiring Schematic with Pressure Safety Control 9 5 13 14 K1 Relay INJ Sol CC System Control LPCO HPCO L2 L1 Alarm K1 Relay OMB CoreSense Module Kriwan Module M1 D M2 L2 L1 T2 T1 M1 M2 CoreSense Module Wiring Schematic with System Control 9 5 13 14 Note If Kriwan is used wire in series with CoreSense Module If not used directly connect M1 to M1 M2 to M2 T1 to L1 T2 to L2 Note If Kriwan is...

Page 26: ... probe to the compressor but to also prevent any moisture from entering the thermal well Figure 11 Discharge Line Thermistor The discharge line thermistor should be attached to the discharge about 6 inches from the discharge of the compressor Note Although not depicted in this figure the thermistor should be well insulated to ensure accurate temperature sensing Figure 9 Discharge Thermistor Connec...

Page 27: ...nted in the U S A Control Voltage L1 Control Voltage L2 Communication Cable CT DLT Thermistor L1 L2 D M2 M1 M1 M2 T1 T2 S1 S2 Relay Back to M2 Motor Protection Module if needed C T Module CoreSense Diagnostics Module Wire from Pressure Controls Figure 12 CoreSense Terminal Box Photo of Actual Box ...

Page 28: ... 4 5 1 2 3 4 5 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 9600 Even Network Terminated Baud Rate Control Mode Parity Network Termination 19200 Not Terminated No Parity Stand Alone 1 2 3 4 5 On UP Off Down Figure 13 K5 Communication Module DIP Switch Settings Terminal 5 Demand Wire Terminal 9 Jumper To Terminal 13 Terminal 13 L1 and Jumpered to Terminal 9 Terminal 14 L2 Figure 14 Wiring Relay Example F...

Page 29: ... N AE4 1383 R5 2012 Emerson Climate Technologies Inc Printed in the U S A Terminated Terminated Terminated Terminated Figure 16 RS485 Daisy Chain Connection Terminated Terminated Terminated Terminated Figure 17 Two Rack Daisy Chain Connection ...

Page 30: ...120 240V Frequency 50 60 Hz M1 M2 Module Output Contacts Maximum Voltage 264 VAC Maximum Current 2 5 Amps Minimum Current 100 milliamps S1 S2 Thermal Protection Trip Out Resistance 4500 20 Reset Resistance 2750 20 Reset Time 30 min 5 min Manual Reset T1 T2 interrupt for minimum of 5 sec Application Injection Refrigerants Required Kits Reference Figure ZB Medium Temp N A All Top Cap Thermistor is F...

Page 31: ...8 Suction Rotalock to Stub 1 3 4 12 Thread to 1 3 8 Sweat 998 0034 13 1 14 Thread to 1 2 Sweat 998 0034 18 Stub Tube to Rotalock Connection Adapter Discharge Stub Tube to Rotalock 7 8 Sweat to 1 1 4 12 Thread 998 0034 02 Suction Stub Tube to Rotalock 1 3 8 Sweat to 1 3 4 12 Thread 998 0034 04 Motor Protection External Motor Protection Module for ZB95K5E TWC ZB114K5E TWC 971 0641 00 Oil Monitoring ...

Page 32: ...5 Min No Lockout 3 Excessive Demand Cycling Default is 240 Cycles Per 24 Hr Period No 4 Locked Rotor Compressor Did Not Start Within Alloted Time Yes 20 Min 4 5 Demand Present No Current Detected Over 4 Hr Period No 6 Phase Loss Detected Yes 20 Min 10 7 Reversed Phase Detected Yes Until Module Is Reset 1 8 Welded Contactor Current Detected Without Demand No1 9 Low Module Voltage Yes 5 Min No Locko...

Page 33: ...to module 4 Verify Wiring Green Alert LED 10 Flashes Loss of Communication Communication lost between rack controller and module for 10 minutes or more 1 Check communications wiring 2 Verify wiring follows application guidelines Green Alert LED 11 Flashes Discharge Temperature Sensor Error Short or Open Circuit Detected 1 Check discharge temperature sensor wiring and mounting 2 Verify sensor is no...

Page 34: ...e Line Temperature Trip See inside label to determine cut out temp 1 Possible loss of refrigerant charge 2 Blocked condenser 3 Verify that discharge valve is open 4 On low temperature scroll compressors check liquid injection Red Alert LED 4 Flashes LOCKED OUT ON 4 Consecutive Locked Rotors Detected Compressor is drawing current without rotating or four consecutive compressor trips after run time ...

Page 35: ...itch Settings 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 their use or applicability Emerson Climate Technologies Inc and or its affiliates collectively Emerson as applicable reserve the right to modify the design or specifications of ...

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