Application Engineering
B U L L E T I N
AE4-1374 R1
July 2013
ZR16 to ZR54K5E R-22 and R-407C
1.5 to 5 Ton Copeland Scroll
™
Compressors
TABLE OF CONTENTS
Section
Page Section
Page
Safety
Suction & Discharge Fittings ....................................10
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
Shut Down Device .................................................... 5
Discharge Check Valve ............................................. 5
Motor Overload Protection ........................................ 5
Operating Envelope .................................................. 5
Power Supply ............................................................ 6
Accumulators ............................................................ 6
Charge Compensators .............................................. 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 ................................................ 8
Oil Type ..................................................................... 8
Contaminant Control ................................................. 8
Long Line Sets/High Refrigerant Charge................... 8
Discharge Mufflers .................................................... 8
Air-Conditioning System Suction Line Noise and
Vibration .................................................................... 9
Mounting Parts .......................................................... 9
Single Phase Starting Characteristics ....................... 9
PTC Start Components ............................................. 9
Electrical Connections ............................................... 9
Deep Vacuum Operation .......................................... 10
Shell Temperature .................................................... 10
© 2013 Emerson Climate Technologies, Inc.
1
Printed in the U.S.A.
System Tubing Stress .............................................. 10
Three Phase Scroll Electrical Phasing ..................... 10
Brief Power Interruptions ......................................... 10
Application Tests
Application Test Summary ....................................... 11
Continuous Floodback Test ...................................... 11
Field Application Test ............................................... 11
Assembly Line Procedures
Installing the Compressor ........................................ 12
Assembly Line Brazing Procedure ........................... 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
Oil Dilution Chart ...................................................... 15
Accumulator Piping .................................................. 16
Time Delay Wiring .................................................... 16
Compressor Electrical Connection ........................... 17
Discharge Thermostat .............................................. 17
Crankcase Heater .................................................... 17
Scroll Operating Envelope ....................................... 18
Scroll Suction Tube Brazing ..................................... 19
How a Scroll Works .................................................. 20
Field Application Test ............................................... 21
Design Configurations.............................................. 21
Mounting Parts......................................................... 21
Compressor Refrigerant Charge Limits .................... 22
Crankcase Heaters .................................................. 22
