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© 2018 Emerson Climate Technologies, Inc.

 

AE4-1431 R1 

3.  Installation 

 

High  pressure!  Injury  to  skin  and  eyes  possible!

 

Compressors 

are 

delivered 

pre-charged 

with 

pressurized  dry  air.  Be  careful  when  opening 
connections. 

3.1.  Transport and storage 

 

Risk 

of 

collapse! 

Personal 

injuries!

 

Move 

compressors  only  with  appropriate  mechanical  or 
handling  equipment  according  to  weight.  Keep  in  the 
upright  position.  Respect  stacking  loads  according  to 
Figure  3.  Check  the  tilting  stability  and  if  needed  take 
action to ensure the stability of the stacked loads. Do not 
stack  single  boxes  on  top  of  each  other.  Keep  the 
packaging dry at all times 

Respect  the  maximum  number  of  identical 
packages  which  may  be  stacked  on  one 
another, where “n” is the limiting number: 

 

Transport: n = 1 

 

Storage: n = 2 

 

Figure 3 - Maximum stacking loads for transport and 
storage 

The compressor tilt angle should not be more than 30° 
during transport and handling. This will prevent oil from 
exiting through the suction stub. A tilt angle of maximum 
45°  is  allowed  for  a  very  short  time.  Tilting  the 
compressor more than 45° might affect its lubrication at 
start-up. 

NOTE: The compressor is pre-charged with dry air 
to avoid any moisture contamination. 

3.2.  Positioning and securing 

 

Handling  damage!  Compressor  malfunction!

  Only 

use the lifting eyes whenever the compressor requires 
positioning. Using discharge or suction connections for 
lifting may cause damage or leaks 

The compressor should be kept vertical during handling. 

The discharge connection plug should be removed first 
before  pulling  the  suction  connection  plug  to  allow  the 
dry  air  pressure  inside  the  compressor  to  escape. 
Pulling the plugs in this sequence prevents oil mist from 
coating  the  suction  tube  making  brazing  difficult.  The 
copper-coated  steel  suction  tube  should  be  cleaned 
before brazing. 

The plugs must be removed as late as possible before 
brazing  so  that  the  air  humidity  does  not  affect  the  oil 

characteristics. 

As oil might spill  out of the suction connection located 
low on the shell, the suction connection plug must be left 
in place until the compressor is set into the unit. 

No object, e.g.,  a swaging  tool should be inserted  into 
the suction tube or it might damage the suction screen 
and motor. 

3.3.   Installation location 

These  compressors  shall  be  installed  only  in  a  non-
explosive atmosphere. 

Scroll compressors are capable of operating correctly in 
ambient humidity from 30% to 95% and at altitudes up 
to  6562  feet  (2000  meters).  For  correct  operation,  the 
ambient air temperature must range from -31°F to 122°F 
(-35°C  to  50°C)  and  the  compressor  Maximum 
Allowable Operation Pressure shall be respected at all 
times during operation and at standstill. 

Ensure  the  compressors  are  installed  on  a  solid  level 
base.  For  multiple-compressor  parallel  configurations, 
the  compressors  must  be  positioned  completely 
vertically on a totally horizontal surface or rail. 

3.4.  Compressor mounting parts 

The  compressors  are  designed  to  be  mounted  on 
vibration  absorber  grommets.  The  grommets  dampen 
the  start-up  surge  of  the  compressor  and  minimize 
sound  and  vibration  transmission  to  the  compressor 
base  during  operation.  The  metal  sleeve  inside  is  a 
guide  designed  to  hold  the  grommet  in  place.  It  is  not 
designed as a load-bearing member, and application of 
excessive torque to the bolts can crush the sleeve. Its 
inner diameter is approximately 0.335 inches (8.5 mm) 
to fit, e.g., an M8 screw. The mounting torque should be 

CAUTION

 

CAUTION

 

CAUTION

 

Содержание Scroll ZB*KAU

Страница 1: ...its 12 4 2 3 Protection devices 14 4 2 4 Crankcase heaters 14 4 3 Pressure protection devices 14 4 3 1 High pressure protection 14 4 3 2 Low pressure protection 14 4 4 Discharge gas temperature protection 15 4 4 1 Excessive discharge gas temperatures 15 4 4 2 Discharge gas temperature protection 15 4 5 Motor protection 17 4 6 High potential testing 17 5 Starting up operation 17 5 1 Compressor tigh...

Страница 2: ...tion USA 13 Figure 11 Terminal dome cover and correct electrical installation European Electrical 14 Figure 12 European Electrical connections 14 Figure 13 Cover European 14 Figure 14 ATEX discharge line thermostat and ATEX label 16 Figure 15 Suction tube connecting areas 20 Figure 16 Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 77 F and 50 relative humidity...

Страница 3: ...ese 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 minor or moderate injury NOTICE is used t...

Страница 4: ...on 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 ...

Страница 5: ...f a system never leave it unattended when it has no charge A servicing tag must be used for advising to other technician about servicing procedure running This will prevent unauthorized personnel from accidentally starting the equipment and potentially ruining the compressor by operating with no refrigerant In case of explosive atmosphere do not energize any electrical component in the system no u...

Страница 6: ...r electrical component equipment no unshielded flame is allowed Furthermore before opening the refrigeration system or working on it with an unshielded flame continuously check if the ambient atmosphere is non explosive and ensure proper ventilation of the room before creating any naked flame no naked flame is allowed in an explosive atmosphere if the atmosphere reaches a dangerous concentration o...

Страница 7: ...he relevant standards applicable to the given product Compressor Maximum Allowable Operation Pressure High pressure side Low pressure side ZB07KAU to ZB11KAU 406 PSIG 28 bar 247 PSIG 17 bar 2 2 3 Application limits 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 typ...

Страница 8: ...essor shell place a thermocouple on the bottom center not the side of the compressor shell and insulate from the ambient During rapid system changes such as defrost or ice harvest cycles this temperature difference may drop rapidly for a short period of time When the crankcase temperature difference falls below the recommended 50 F 27 K our recommendation is the duration should not exceed a maximu...

Страница 9: ...escape Pulling the plugs in this sequence prevents oil mist from coating the suction tube making brazing difficult The copper coated steel suction tube should be cleaned before brazing The plugs must be removed as late as possible before brazing so that the air humidity does not affect the oil characteristics As oil might spill out of the suction connection located low on the shell the suction con...

Страница 10: ...ame manner as any copper tube Recommended brazing material Any SIL FOS material is recommended preferably with a minimum of 5 silver However 0 silver is acceptable Be sure tube fitting inner diameter and tube outer diameter are clean prior to assembly Using a double tipped torch apply heat in area 1 As the tube approaches brazing temperature move the torch flame to area 2 Heat area 2 until braze t...

Страница 11: ...el capacity and the condition pressure ratio 4 Electrical connection 4 1 Units Electrical connection per BOM 634 ZB KAU compressors for applications in US market are delivered with electrical pin connections ready for molded plug connection Its protection class is IP65 R290 qualified and dedicated molded plug cables must be used The R290 dedicated kit includes a special o ring a grounding connecti...

Страница 12: ...electric current surge of the compressor motor at start up For more information please contact Application Engineering Figure 10 shows electrical connections schematic NOTE Emerson recommends the use of a Residual Current Device RCD as an additional safety measure NOTE Emerson recommends the use of a second contactor K2 for the safety chain of the compressor This protection must be considered it i...

Страница 13: ...s they could damage the glass and or ceramic This might result in hermetic failure or loss of terminal performance Precautions are required to prevent striking or bending of pins Bent or damaged pins may result in loss of hermeticity and or terminal performance Power Circuit Control circuit Motor terminal connections Three phase compressors are connected to the TI T2 and T3 connections Legend B1 S...

Страница 14: ...EC 60335 2 89 UL 60335 2 89 and EN 60335 2 89 no high pressure switch is required 4 3 2 Low pressure protection Operation under ambient pressure During operation under ambient pressure an explosive mixture can form inside the system Make sure that the pressure never falls below atmospheric pressure Operation outside the application envelope A low pressure protection shall be fitted in the suction ...

Страница 15: ... ATEX directive consists of two EU directives describing what equipment and work space is allowed in an environment with an explosive atmosphere for 250 F 121 C for all ZB KAU models These compressors have no internal discharge gas temperature protection Therefore an external protector is required See Section 4 4 2 for more details 4 4 1 Excessive discharge gas temperatures A few of the possible c...

Страница 16: ...the thermostat body against mechanical damage according to UL471 SB5 IEC 60079 0 clause 26 4 2 table 13 There is no need for an additional housing around the thermostat body Protection against mechanical damage to the thermostat can be achieved with an overall cover or box placed around the compressor or refrigerant system See Table 2 for Technical data of the discharge line thermostat For install...

Страница 17: ... any remaining refrigerant from the compressor prior to high potential testing and Megohm resistance reading 5 Starting up operation 5 1 Compressor tightness test High pressure Personal injuries Consider personal safety requirements and refer to test pressures prior to test System explosion Personal injuries Use only dry nitrogen for leak testing DO NOT USE other industrial gases System contaminat...

Страница 18: ...ill rotate in either direction depending on power phasing Since there is a 50 50 chance of connected power being backwards contractors should be warned of this Appropriate instructions or notices should be provided by the OEM Verification of proper rotation can be made by observing that the suction pressure drops and the discharge pressure rises when the compressor is energized There is no negativ...

Страница 19: ...y case To maximize efficiency in controlling leaks when opening the refrigeration equipment or working on it it is recommended to use a leak detector designed for use with R290 refrigerant Continuously check if the ambient atmosphere is non explosive In case of explosive atmosphere do not energize any electrical component in the system fire and smoking are strictly forbidden no unshielded flame is...

Страница 20: ...overy unit and dedicated cylinders Low suction pressure operation Compressor damage Do not operate with a restricted suction Do not operate with the low pressure limiter bridged Do not operate compressor at pressures that are not allowed by the operating envelope Allowing the suction pressure to drop below the envelope limit for more than a few seconds may overheat scrolls and cause early drive be...

Страница 21: ... below shall be followed During the entire working procedure continuously check if the ambient atmosphere is explosive If explosive atmosphere is detected ensure proper ventilation of the working space and immediately cut off the power supply Resume working after the atmosphere is no longer dangerous Recover the refrigerant from the system using a suitable recovery unit Do not allow the recovery u...

Страница 22: ...he actual moisture content of the lubricant samples must be taken from the system and analyzed 6 5 Oil additives Although Emerson cannot comment on any specific product from our own testing and experience we do not recommend the use of any additives to reduce compressor bearing losses or for any other purpose Furthermore the long term chemical stability of any additive in the presence of refrigera...

Страница 23: ...val Dispose of oil and refrigerant according to national legislation and regulations Dispose of compressor according to national legislation and regulations 9 General Guidelines and More Information For general Copeland Scroll compressor please log in to Online Product Information at Emerson com OPI refer to the Application Engineering bulletins listed below or contact your Application Engineer 93...

Страница 24: ...limate Technologies Inc and or its affiliates collectively Emerson as applicable reserve the right to modify the design or specifications of such products at any time without notice Emerson does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any Emerson product remains solely with the purchaser or end user Th...

Страница 25: ...isture oxygen metal salts metal oxides and or high discharge temperatures The chemical reactions are accelerated at higher temperatures Oil and acid react with each other Acid formation leads to damage of the moving parts and in extreme cases to motor burnout Several different test methods can be used to test for acid formation If acid is present a complete oil change including the oil in the oil ...

Страница 26: ...porator outlet is usually the consequence of oversized selection of the expansion valve or incorrect bulb sensor mounting The valve may freeze up in the open position due to accumulation of debris in the system For a system with very short refrigeration lines an accumulator is recommended Compressor operating outside the design limits Check the compressor suction and discharge pressures while it i...

Страница 27: ... Try to limit the number of cycles to maximum 10 per hour Low gas velocity System gas velocity changes depending on temperature and load capacity control In low load conditions gas velocity may not be high enough to return oil to the compressor Low discharge pressure Low ambient temperature Fit a fan cycling control system Refrigerant undercharge Check the system for leaks Observe sight glass for ...

Страница 28: ... can be measured from the top of the compressor footplate Figure 19 ZB KAU with external oil sight tube Figure 20 Markings on the external oil sight tube Start and run the system until it reaches stable conditions then run at stable conditions for a minimum of 15 minutes Stop the compressor and read the oil level during standstill Any oil level between 12oz 355 mL and 16oz 473 mL is in the nominal...

Страница 29: ...of 50 F 27 C This crankcase differential temperature requirement supersedes the minimum suction superheat requirement detailed in section Applications limits To measure oil temperature through the compressor shell place a thermocouple on the bottom center not the side of the compressor shell and insulate from the ambient During rapid system changes such as defrost or ice harvest cycles this temper...

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