Emerson Copeland Scroll ZP KC Series Bulletin Download

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AE4-1303 R15

7 to 15 Ton ZR*KC and ZP*KC Copeland Scroll

™

Compressors

AE4-1303 R15

June 2016

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

Application Considerations

Operating Envelope ....................................................4

Internal Pressure Relief (IPR) Valve ...........................4

Advanced Scroll Temperature Protection ....................5

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

High Pressure Control .................................................5

Low Pressure Control .................................................5

Shut Down Device ......................................................5

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

Discharge Mufflers

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

Compressor Cycling ....................................................6

Piping Length & High Refrigerant Charge ...................6

Suction & Discharge Line Noise & Vibration ...............6

Suction & Discharge Fittings .......................................7

System Tubing Stress .................................................7

Accumulators ..............................................................7

Crankcase Heat ..........................................................7

Pump Down Cycle ......................................................8

Reversing Valves ........................................................8

System Screens & Strainers .......................................8

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

Oil Type & Removal ....................................................9

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

Power Factor Correction ............................................10

Deep Vacuum Operation ............................................10

Manifolded Compressors ...........................................10

Manifolded Applications .............................................10

Motor Protection .........................................................11

Application Tests

Application Test Summary .........................................11

Continuous Floodback Test ........................................12

Field Application Test .................................................12

Assembly Line Procedures

Compressor Handling ............................................... 12

Mounting ................................................................... 13

Suction & Discharge Fittings ..................................... 13

Assembly Line Brazing Procedure ............................ 13

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

Pressure Testing ....................................................... 13

Assembly Line System Charging Procedures ........... 14

Electrical Connections .............................................. 14

Hipot Testing ............................................................. 14

Tandem Assembly ..................................................... 14

Service Procedures

Field Replacement .................................................... 15

Mounting ................................................................. 15

Removing Oil .......................................................... 15

Electrical ................................................................. 15

Module .................................................................... 15

Compressor Replacement after a Motor Burn .......... 16

Manifolded Compressor Replacement ...................... 16

Start-Up of a New or Replacement Compressor ...... 16

Field Troubleshooting the Kriwan Module ................. 16

Field Troubleshooting the CoreSense

Communications Module ........................................ 17

Scroll Functional Check ............................................ 17

Refrigerant Retrofits

.................................................. 18

Figures & Tables

How a Scroll Works.. ................................................. 19

Scroll Operating Envelopes ...................................... 20

Compressor Terminal Box Wiring ............................. 21

ASTP Label ............................................................... 22

Crankcase Heater Location ...................................... 23

Scroll Suction Tube Brazing ...................................... 24

Field Application Test ................................................ 25

Design Configurations

............................................... 25

Compressor Accessories & Service Parts ................ 26

Refrigerant Charge Limits... ...................................... 27

Torque Values ........................................................... 27

Protector Specifications

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

CoreSense LED Flash Code Information ................28-29

Tandem Oil Balancing ............................................... 30

Tilted Tandem ............................................................ 30

APPENDIX

Kriwan to CoreSense Retrofit Instructions

................ 31

TABLE OF CONTENTS

Section Page Section Page

Summary of Contents for Copeland Scroll ZP KC Series

Page 1: ...tion Test Summary 11 Continuous Floodback Test 12 Field Application Test 12 Assembly Line Procedures Compressor Handling 12 Mounting 13 Suction Discharge Fittings 13 Assembly Line Brazing Procedure 13 Unbrazing System Components 13 Pressure Testing 13 Assembly Line System Charging Procedures 14 Electrical Connections 14 Hipot Testing 14 Tandem Assembly 14 Service Procedures Field Replacement 15 Mo...

Page 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...

Page 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...

Page 4: ... compressors Some of this information is recommended whereas other guidelines must be followed The Application Engineering department will always welcome suggestions that will help improve these types of documents Operating Envelope NOTICE It is essential that the glide of R 407C is carefully considered when adjusting pressure and superheat controls Figure 2 illustrates the operating envelopes for...

Page 5: ...nded for loss of charge protection and other system fault conditions that may result in very low evaporating temperatures Even though these compressors have internal discharge temperature protection loss of system charge will result in overheating and recycling of the motor overload protector Prolonged operation in this manner could result in oil pump out and eventual bearing failure The low press...

Page 6: ...refrigerant over initial 20 pounds Other system components such as shell and tube evaporators can trap significant quantities of oil and should be considered in overall oil requirements Reheat coils and circuits that are inactive during part of the normal cycle can trap significant quantities of oil if system piping allows the oil to fall out of the refrigerant flow into the inactive circuit The o...

Page 7: ...o control refrigerant during 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 to determine if the accumulator or TXV design is adequate please see the section entitled Application Tests A large area protective screen no finer than 30x30 mesh 0 6mm openings is required ...

Page 8: ...charge pressures will go outside of the normal operating envelope The sound that the compressor makes during this transition period is normal and the duration of the sound will depend on the coil volume outdoor ambient and system charge level The preferred method of mitigating defrost sound is to shut down the compressor for 20 to 30 seconds when the reversing valve changes position going into and...

Page 9: ...s been achieved CAUTION POE must be handled carefully and the proper protective equipment gloves eye protection etc must be used when handling POE lubricant POE must not come into contact with any surface or material that might be harmed by POE including without limitation certain polymers e g PVC CPVC and polycarbonate Three Phase Scroll Compressor Electrical Phasing NOTICE Compressors that emplo...

Page 10: ...and reliability are its critical design characteristics Two different oil balancing techniques are used with tandems in this family of compressors two phase tandem line TPTL and oil equalization line OEL For trio assemblies only the TPTL design has been qualified The TPTL design is a larger diameter pipe connecting the oil sumps of the individual compressors allowing both gas and oil to flow betwe...

Page 11: ...l compressors that have TW electrical codes and TE electrical codes respectively Models with a W or E in the electrical code i e ZP182KCE TWD have a motor overload system that consists of an external electronic control module connected to a chain of four thermistors embedded in the motor windings The module will trip and remain off for a minimum of 30 minutes if the motor temperature exceeds a pre...

Page 12: ...ack Field Application Test To test for repeated excessive liquid flood back during normal system off cycles perform the Field Application Test that is outlined in Table 2 Obtain a sample compressor with a sight tube to measure the liquid level in the compressor when it is off Note The sight tube is not a good liquid level indicator when the compressor is running because the top of the sight tube i...

Page 13: ...nearby temperature sensitive parts Fire extinguishing equipment should be accessible in the event of a fire Figure 6 discusses the proper procedures for brazing the suction and discharge lines to a scroll compressor NOTICE It is important to flow nitrogen through the system while brazing all joints during the system assembly process Nitrogen displaces the air and prevents the formation of copper o...

Page 14: ... to keep the terminal box completely sealed Oversized conduits poor conduit connections to the terminal box an incorrectly installed terminal box cover or a missing terminal box cover gasket are a few possible air leakage paths CAUTION Moisture from warm moist air that is permitted to freely enter the terminal box can condense into droplets of water inside the cooler terminal box of the compressor...

Page 15: ...compressor family BR that can be replaced by this scroll compressor family The mounting dimensions of the older scroll and the reciprocating compressor are 8 65 X 8 65 220mm X 220mm to the center of the mounting holes The newer scroll has a mounting dimension of 7 5 X 7 5 190mm X 190mm To help adapt to this new dimension use mounting kit 922 0001 00 that contains an adaptor plate and mounting bolt...

Page 16: ...of 12 degrees from horizontal to move the oil away from the fitting see Figure 10 Start up of a New or Replacement Compressor It is good service practice when charging a system with a scroll compressor to charge liquid refrigerant into the high side only It is not good practice to dump liquid refrigerant from a refrigerant cylinder into the crankcase of a stationary compressor If additional charge...

Page 17: ...cement module must have the same supply voltage rating as the original module NOTE The Kriwan INT69 SU2 has been phased out of production by Kriwan Kriwan modules that require replacement in the field should be replaced with the CoreSense Communications module listed in Table 4 Kriwan to CoreSense retrofit instructions are listed at the end of this bulletin Field Troubleshooting CoreSense Communic...

Page 18: ...ne third of compressors returned to Emerson Climate Technologies Inc for warranty analysis are determined to have nothing found wrong They were misdiagnosed in the field as being inoperable Replacing working compressors unnecessarily costs everyone Refrigerant Retrofits NOTICE ZR compressors are UL recognized for use with R 22 R 407C or R 134a only Use of any other refrigerants will void the compr...

Page 19: ...19 2016 Emerson Climate Technologies Inc AE4 1303 R15 Figure 1 ...

Page 20: ... 60 70 80 Evapora ng Temperature C Condensing Temperature C Condensing Temperature F Evapora ng Temperature F R 407C R 22 R 134a 50 60 Hertz Operation 34 24 14 4 6 16 26 4 14 24 34 44 54 64 40 50 60 70 80 90 100 110 120 130 140 150 160 30 20 10 0 10 20 30 40 50 60 70 80 90 Evapora ng Temperature C Condensing Temperature C Condensing Temperature F Evapora ng Temperature F R 410A 50 60 Hertz Operati...

Page 21: ...RA CICLADO FRECUENTE 1 1 0 9 600 19 200 EVEN PAR STANDALONE DESCONECTADODELARED ENABLE ACTIVADO DISABLE DESACTIVADO 0 NONE NINGUNA LOCKOUT PERDIDA DE FUNCION WARNING PRECAUCION WARNING PRECAUCION NETWORK CONECTADOALARED LOCKOUT TRIP PERDIDA DE FUNCION INTERRUPCION DE FUNCION 4 N A N A 5 WARNING PRECAUCION FUTURE USE USO FUTURO SHORT CYCLING CICLO FRECUENTE 8 N A FUTURE USE USO FUTURO SYMBOLS SIMBO...

Page 22: ...22 2016 Emerson Climate Technologies Inc AE4 1303 R15 Figure 4 ASTP Label ...

Page 23: ...23 2016 Emerson Climate Technologies Inc AE4 1303 R15 ZR84 144KC ZP90 137KC ZR160 190KC ZP154 182KC Figure 5 Crankcase Heater Location ...

Page 24: ...be Recommended brazing materials Any silfos material is recommended preferably with a minimum of 5 silver However 0 silver is acceptable Be sure suction tube fitting I D and suction tube O D are clean prior to assembly If oil film is present wipe with denatured alcohol Dichloro Trifluoroethane or other suitable solvent Using a double tipped torch apply heat inArea 1 As tube approaches brazing temp...

Page 25: ...quired 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 3 Design Configurations Outdoor Ambient 85 F 29 C 95 F 35 C 105 F 40 C System On Time Minutes 7 14 54 System Off Time Minutes 13 8 6 Number of On Off Cycles 5 5 4 Table 2 Field Application Te...

Page 26: ...1 100 0550 01 100 0550 01 Molded Plug TF Electricals Only 529 0099 00 529 0099 00 Protection Kriwan Module 120 240V not required replace with CoreSense not required replace with CoreSense Kriwan Module 24 V not required not required Kriwan Diagnose Module 120 240V not required 971 0641 00 not required 971 0641 00 Kriwan Diagnose Module 24 V not required 971 0641 01 not required 971 0641 01 CoreSen...

Page 27: ...93 257KC 24 10 9 ZPT308 364KC 27 12 2 ZPU274 336KC 27 12 2 Even Tandem Assembly Uneven Tandem Assembly Note Refer to AE4 1365 for ZP104 and ZP122 Table 6 Torque Values Part Torque ft lb in lb N m Sight Glass TPTL Rotalock Fitting 74 81 885 975 100 110 Discharge Rotalock Valve 95 103 1150 1240 130 140 Suction Rotalock Valve 125 132 1505 1593 170 180 Schrader Valve 3 3 5 0 40 60 4 5 6 8 Terminal Blo...

Page 28: ...de 3 Short Cycling Run time of less than 1 minute number of short cycles exceeds 48 in 24 hours 48 short cycles in 24 hours 1 Check system charge and pressure control setting 2 Adjust set point of temperature controller 3 Install anti short cycling control Green Flash Code 4 Not used with this compressor family N A N A N A Green Flash Code 5 Future Use N A N A N A Table 7 Protector Specifications ...

Page 29: ...mand 1 Check system charge and pressure control setting 2 Adjust set point of temperature controller 3 Install anti short cycling control Red Flash Code 4 Not used with this family of compressors N A N A N A Red Flash Code 5 Future Use N A N A N A Red Flash Code 6 Missing Phase Missing phase Lockout after 10 consecutive Alerts After 5 minutes and missing phase condition is not present 1 Check inco...

Page 30: ...gies Inc AE4 1303 R15 Figure 10 Tilted Tandem 12 Tilting the Compressor For Installation of the Oil Equalization Line Oil Equalization Line Oil Equalization Line Two Phase Tube Line Figure 9 Tandem Oil Balancing Two Phase Tandem Line ...

Page 31: ...ommunications 1 Disconnect and lock out the power to the unit 2 Using a straight blade screwdriver carefully depress the tabs holding the terminal cover to the terminal box to remove the terminal cover Before proceeding use a volt meter to verify that the power has been disconnected from the unit 3 Verify the Kriwan module part number matches one of those shown in the table below APPENDIX 1 Kriwan...

Page 32: ...12 Connect the L1 L2 and L3 phase sensing wires to the L1 L2 and L3 compressor terminal block connections See the compressor terminal cover wiring diagram for identification of the L1 L2 and L3 connections on the compressor terminal block 13 Double check the installation and make sure all connections are secure Install the compressor terminal cover 14 The module change is complete and the system c...

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