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AE4-1365 R4

5 to 12 Ton ZP*K3, ZP*KC, and ZP*KW R-410A

Copeland Scroll

™

Compressors for Air Conditioning

AE4-1365 R4

September 2015

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

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

Nomenclature ...........................................................4

Application Considerations

Internal Pressure Relief Valve ..................................4

Discharge Temperature Protection ...........................4

Heat Pump Protection ..............................................5

Discharge Line Thermostat ......................................5

Air-Conditioning Unit Protection ...............................5

High Pressure Cut-Out Switch .................................5

Discharge Check Valve ............................................5

Motor Overload Protection .......................................5

Operating Envelope .................................................5

Power Supply ...........................................................6

Accumulators ...........................................................6

Screens ....................................................................6

Crankcase Heat-Single Phase .................................6

Crankcase Heat-Three Phase ..................................7

Pump Down Cycle ....................................................7

Minimum Run Time ..................................................7

Reversing Valves .....................................................7

Low Ambient Cut-Out ...............................................7

Oil Type ....................................................................7

Contaminant Control ................................................8

Long Line Sets/High Refrigerant Charge .................8

Discharge Mufflers

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

Air-Conditioning System Suction Line

Noise & Vibration .....................................................8

Mounting Parts .........................................................9

Electrical Connections ..............................................9

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

Shell Temperature ....................................................9

Suction & Discharge Fittings ....................................9

System Tubing Stress ..............................................9

Three Phase Scroll Electrical Phasing .....................9

Brief Power Interruptions .........................................10

Manifolding Tandem Compressors ..........................10

Tandem Applications ...............................................10

Application Tests

Application Summary ..............................................10

Continuous Floodback Test ..................................... 11

Field Application Test ............................................. 11

Assembly Line Procedures

Installing the Compressor ....................................... 11

Assembly Line Brazing Procedure ..........................12

Tandem Assembly ...................................................12

Pressure Testing .....................................................12

Assembly Line System Charging Procedure ...........12

High Potential (AC Hipot) Testing ............................12

Final Run Test .........................................................13

Unbrazing System Components .............................13

Service Procedures

Copeland Scroll Functional Check ..........................13

Compressor Replacement After Motor Burn ...........14

Start Up of a New or Replacement Compressor ...... 14

Figures & Tables

Operating Envelope ................................................15

Oil Dilution Chart .....................................................16

ASTP Label .............................................................17

Crankcase Heater ...................................................18

Typical ZPKC Tandem .............................................18

Tilted Tandem ..........................................................18

Scroll Suction Tube Brazing ....................................19

How a Scroll Works.. ...............................................20

Field Application Test ..............................................21

Design Configurations

.............................................21

Compressor Refrigerant Charge Limits... ................21

Compressor Accessories ..................................... 22-25

TABLE OF CONTENTS

Section Page Section Page

Содержание Copeland Scroll ZP K3 Series

Страница 1: ...ction Line Noise Vibration 8 Mounting Parts 9 Electrical Connections 9 Deep Vacuum Operation 9 Shell Temperature 9 Suction Discharge Fittings 9 System Tubing Stress 9 Three Phase Scroll Electrical Phasing 9 Brief Power Interruptions 10 Manifolding Tandem Compressors 10 Tandem Applications 10 Application Tests Application Summary 10 Continuous Floodback Test 11 Field Application Test 11 Assembly Li...

Страница 2: ...ssor 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 hazardous situation which if not avoided could result in...

Страница 3: ...ety 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 commponents Personal safety equipment must be used Failure to follow these warnings could result in serious personal...

Страница 4: ...fer to the on line product information at EmersonClimate com for details APPLICATION CONSIDERATIONS The following application guidelines should be considered in the design of a system using ZP K3 ZP KC and ZP KW scroll compressors Some of the guidelines are recommended in this bulletin for good practice or best in class other guidelines must be followed to ensure a safe and reliable application Th...

Страница 5: ...in oil pump out and eventual bearing failure A cut out setting no lower than 20 psig 1 4 bar is recommended Discharge Line Thermostat Some systems such as air to air heat pumps may not work with the above low pressure control arrangement A discharge line thermostat set to shut the compressor off before the discharge temperature exceeds 260 F 125 C may have to be used to achieve the same protection...

Страница 6: ...ring heating may not require an accumulator if testing assures the system designer that there will be no flood back throughout the operating range To test for flood back conditions and determine if the accumulator or TXV design is adequate please see the Application Tests section The accumulator oil return orifice should be from 040 to 055 inches 1 1 4mm in diameter depending on compressor size an...

Страница 7: ...h the minimum run time obtain a sample compressor equipped with a sight tube available from Emerson 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 startup to return to the compressor sump and restore a minimal oil level that will assure oil pick up through the crankshaft Cycl...

Страница 8: ...ing processes that leave solid or liquid contaminants in the evaporator coil condenser coil and interconnecting tubing plus any contaminants introduced during the field installation process Molecular sieve and activated alumina are two filter drier materials designed to remove moisture and mitigate acid formation A 100 molecular sieve filter can be used for maximum moisture capacity A more conserv...

Страница 9: ...internal suspension and can be easily avoided by using standard suction line isolation techniques as described in Table 2 The sound phenomena described above are not usually associated with heat pump systems because of the isolation and attenuation provided by the reversing valve and tubing bends Mounting Parts Table 4 lists the mounting parts to be used with these compressors Many OEM customers b...

Страница 10: ...reverse will sometimes make an abnormal sound 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 After several minutes of reverse operation the compressor s internal overload protector will trip shutting off the compressor If allowed to repeatedly restart and run in reverse withou...

Страница 11: ... for any unit where both the design system charge is higher than the compressor refrigerant charge limit listed in Table 3 and a capillary tube fixed orifice or bleed type TXV is used on either the indoor or the outdoor coil of the unit Continuous Floodback Test It is expected that the design would not flood during standard air conditioning operation Running a partially blocked indoor air filter o...

Страница 12: ...lined above for the appropriate application tests ASSEMBLY LINE PROCEDURES Installing the Compressor WARNING Use care and the appropriate material handling equipment when lifting and moving compressors Personal safety equipment must be used Copeland Scroll compressors leave the factory dehydrated withadryairholdingcharge Ifcompressors are stored in a cold ambient i e outside during the winter the ...

Страница 13: ...onal charge is needed it should be added as liquid to the low side of the system with the compressor operating Pre charging on the high side and adding liquid on the low side of the system are both meant to protect the compressor from operating with abnormally low suction pressures during charging NOTICE Do not operate the compressor without enough system charge to maintain at least 55 psig 3 8 ba...

Страница 14: ...ng one side only it is very possible that either the high or low side of the system remains pressurized If a brazing torch is then used to disconnect tubing the pressurized refrigerant and oil mixture could ignite when it escapes and contacts the brazing flame Instructions should be provided in appropriate product literature and assembly line repair areas If compressor removal is required the comp...

Страница 15: ...ecommendations NOTICE 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 The system contactor should be inspected for pitted...

Страница 16: ... ng Temperature C Condensing Temperature C Condensing Temperature F Evapora ng Temperature F 29 19 9 1 11 21 31 4 14 24 34 44 54 64 40 50 60 70 80 90 100 110 120 130 140 150 160 20 10 0 10 20 30 40 50 60 70 80 90 Evaporating Temperature C Condensing Temperature C Condensing Temperature F Evaporating Temperature F ZP KW Pool Envelope ZP K3 ZP KC Envelope Figure 1a Operating Envelope Figure 1b Opera...

Страница 17: ...mpressor Sump Temperature F Evaporating Temperature F 200 F 93 3 C Max Oil Temp Acceptable Unacceptable Too Much Refrigerant Dilu on See Note 1 Note 1 Operation in this refrigerant dilution area is safe in air to air heat pump heating mode For other applications such as AC only review expansion device to raise superheat A cold sump may result in high refrigerant migration after shut down Figure 2 ...

Страница 18: ... Label Figure 4 Crankcase Heater Connect the heater so that the connection point straddles the compressor seam weld ZP50 57K3 ZP61 143KC ZP70 83KW Seam Weld WARNING Verify the correct crankcase heater voltage for the application and ensure heater is properly grounded ...

Страница 19: ...e Discharge Manifold Assembly Suction Manifold Assembly Mounting Rail 2 Required Compressor to Rail Mounting Kit Tandem to Unit Mounting Kit Figure 5 Typical ZP KC Tandem 12 Min Tilt the Compressor a Minimum of 12 for Installation of the Oil Equalization Line Oil Equalization Line Figure 6 Tilted Tandem ...

Страница 20: ...evenly Add braze material to the joint while moving torch around joint to flow braze material around circumference After braze material flows around joint move torch to heat Area 3 This will draw the braze material 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 Field Service WARNING Remove refrigerant ...

Страница 21: ...21 2015 Emerson Climate Technologies Inc AE4 1365 R4 Figure 8 ...

Страница 22: ...fler Not required Alternate Configuration Component Description Tubing Configuration Shock loop Service Valve Straight through valve not fastened to unit Mass Suction muffler May be required Acts as dampening mass Table 2 Design Configurations Table 3 Compressor Refrigerant Charge Limits Model Frame Size Charge Limit 120 x Limit Tandem Charge Limit Pounds kg Pounds kg Pounds kg ZP50 57K3 ZP70 83KW...

Страница 23: ...case Heater 277V 70W 018 0095 09 21 Leads Crankcase Heater Junction Box 998 7024 00 All Models Terminal Cover 005 1213 00 ZP50 57K3 ZP61 91KC ZP70 83KW Terminal Cover Gasket 020 0964 00 Terminal Cover 005 1494 00 ZP104 143KC Terminal Cover Gasket 020 1390 00 Terminal Block 021 0227 03 ZP104 143KC All Voltages Terminal Block 021 0234 00 ZP50 57K3 ZP61 91KC ZP70 83KW 230 Volt Only Terminal Block 021...

Страница 24: ...1 1 Phase Only Comfort Alert Module 543 0038 02 All Models 3 Phase Only Discharge Line Thermostat 998 7022 02 ZP50 57K3 ZP61 83KC Fits 1 2 Tube Discharge Line Thermostat not available ZP91KC Fits 3 4 Tube Discharge Line Thermostat 998 0071 02 ZP104 143KC Fits 7 8 Tube Discharge Rotalock Pipe Plug 036 0008 16 ZP104 143KC 1 8 27 NPTF Discharge Rotalock O Ring Seal 028 0028 00 ZP50 57K3 ZP61 83KC Dis...

Страница 25: ...required per tandem Includes bolts washers and steel spacers Tandem Mounting Kit Rails To Unit 527 0150 00 ZPT100 114K3 ZPT122 182KC Includes sleeves washers and grommets 35 45 durometer Tandem Mounting Kit Rails To Unit 527 0177 00 ZPT208 286KC Includes sleeves washers and grommets 65 75 durometer Tandem Rail 074 1235 00 ZPT100 114K3 ZPT122 182KC 2 rails required per tandem Tandem Rail 574 0053 0...

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