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AE4-1331 R7

ZP16 to ZP44K3E and ZP14 to ZP61K5E R-410A

1.5 to 5 Ton Copeland Scroll

™

Compressors

AE4-1331 R7

July 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

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

Discharge Check Valve ........................................ 6

Motor Overload Protection ................................... 6

Operating Envelope .............................................6

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

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

Charge Compensators .........................................6

Screens ................................................................7

Crankcase Heat-Single Phase ............................. 7

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

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

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

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

Low Ambient Cut-Out ...........................................8

Oil Type ................................................................8

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

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

Discharge Mufflers

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

Air-Conditioning System Suction Line

Noise & Vibration .................................................9

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

Single Phase Starting Characteristics .................. 9

PTC Start Components .......................................10

Electrical Connections .........................................10

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

Shell Temperature ...............................................10

Suction & Discharge Fittings ............................... 10

System Tubing Stress .........................................10

Three Phase Scroll Electrical Phasing ................ 10

Brief Power Interruptions ..................................... 11

Manifolding Tandem Compressors ...................... 11

Tandem Applications ........................................... 11

Maximum Tilt Angles ........................................... 11

Application Tests

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

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

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

Assembly Line Procedures

Installing the Compressor ...................................12

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

Tandem Assembly ...............................................13

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

Assembly Line System Charging Procedure ....... 13

High Potential (AC Hipot) Testing ........................ 13

Final Run Test .....................................................14

Unbrazing System Components ......................... 14

Service Procedures

Copeland Scroll Functional Check ...................... 14

Compressor Replacement After Motor Burn ....... 15

Start Up of a New or Replacement Compressor .. 15

Tandem Service .....................................................15

Figures & Tables

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

Accumulator Piping .............................................17

Time Delay Wiring ...............................................17

Compressor Electrical Connection ...................... 18

Discharge Thermostat ........................................18

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

R410A Scroll Operating Envelope ....................... 19

Scroll Suction Tube Brazing ................................ 20

How a Scroll Works.. ...........................................21

Typical ZPK5 Tandem .........................................22

Tilted Tandem ......................................................22

Field Application Test ..........................................23

Design Configurations

.........................................23

Compressor Accessories ................................. 24-25

Compressor Refrigerant Charge Limits... ............ 25

TABLE OF CONTENTS

Section Page Section Page

Содержание ZP14

Страница 1: ...tart Components 10 Electrical Connections 10 Deep Vacuum Operation 10 Shell Temperature 10 Suction Discharge Fittings 10 System Tubing Stress 10 Three Phase Scroll Electrical Phasing 10 Brief Power Interruptions 11 Manifolding Tandem Compressors 11 Tandem Applications 11 Maximum Tilt Angles 11 Application Tests Application Summary 11 Continuous Floodback Test 12 Field Application Test 12 Assembly ...

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: ...ipment 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 injury...

Страница 4: ...ication guidelines should be considered in the design of a system using ZP K3 and ZP K5 scroll 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 Internal Pressure Relief IPR Valve The internal pressure relief valve is located between the...

Страница 5: ...tions can help keep the discharge temperature under control 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 Mount the discharge thermostat as close as poss...

Страница 6: ...rifice refrigerant control that allow large volumes of liquid refrigerant to flood back to the compressor during normal steady operation can dilute the oil to such an extent that bearings are inadequately lubricated and wear will occur In such a case an accumulator must be used to reduce flood back to a safe level that the compressor can handle Heat pumps designed with a TXV to control refrigerant...

Страница 7: ...ter is required for three phase compressors when the system charge exceeds the compressor charge limit listed in Table 5 and an accumulator cannot be piped to provide free liquid drainage during the off cycle See Figure 2 and Table 4 Pump Down Cycle A pump down cycle for control of refrigerant migration is not recommended for scroll compressors of this size If a pump down cycle is used a separate ...

Страница 8: ...ed in these compressors See the compressor nameplate for the original oil charge A complete recharge should be approximately four fluid ounces 118 ml less than the nameplate value If additional oil is needed in the field Copeland Ultra 32 3MAF Lubrizol Emkarate RL32 3MAF Parker Emkarate RL32 3MAF Virginia LE32 3MAF or Nu Calgon 4314 66 Emkarate RL32 3MAF should be used Copeland Ultra22 CC Hatcol E...

Страница 9: ...essors may result in a low level beat frequency that may be detected as noise coming along the suction line into a house under some conditions Elimination of the beat can be achieved by attenuating either of the contributing frequencies The most important frequencies to avoid are 50 and 60 Hz power supply line andtwice linefrequenciesforsingle phasecompressors and line frequency for three phase co...

Страница 10: ...ating of the scrolls and permanent damage to the scroll tips drive bearing and internal seal See AE24 1105 for proper system evacuation procedures Shell Temperature CAUTION Compressor top cap temperatures can be very hot Care must be taken to ensure that wiring or other materials which could be damaged by these temperatures do not come into contact with these potentially hot areas Certain types of...

Страница 11: ... rotation Astart kit specified start capacitor and relay is another effective means of mitigating a powered reverse condition that is caused by a brief power interruption Manifolding Tandem Compressors All of the ZPK5 compressors are available for manifolding with another ZPK5 compressor of equal capacity These compressors are designated with a 4XX bill of material number at the end of the model n...

Страница 12: ... 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 tubeisatalowerpressurethanthebottomcausing a higher apparent oil level Set the system up in a configuration with the indoor unit elevated several feet above the outdoor unit with a minimum of 25 feet 8 m...

Страница 13: ... The oil equalization stubs of both compressors should be wiped clean with a lint free towel to remove any oil residue before brazing Pressure Testing WARNING Never pressurize the compressor to more than 475 psig 32 8 bar for leak checking purposes Never pressurize the compressor from a nitrogen cylinder or other pressure source without an appropriately sized pressure regulating and relief valve T...

Страница 14: ...the minimum guaranteed starting voltage the variable transformer must be reset to a higher voltage When discussing this starting amperage it should be noted that inrush current and locked rotor amps LRA are one and the same The nameplate LRA is determined by physically locking a compressor and applying the highest nameplate voltage to the motor The amperage that the motor draws after four seconds ...

Страница 15: ...t and attached to the failed compressor to be returned The information on this tag is captured in our warranty data base Compressor Replacement After a Motor Burn In the case of a motor burn the majority of contaminated oil will be removed with the compressor The rest of the oil is cleaned with the use of suction and liquid line filter driers A 100 activated alumina suction filter drier is recomme...

Страница 16: ...ise superheat A cold sump may result in high refrigerant migration after shut down Figure 1 Oil Dilution Chart 30 25 20 15 10 5 0 5 10 24 14 4 6 16 26 36 10 0 10 20 30 40 50 60 70 80 90 100 110 20 10 0 10 20 30 40 50 Evaporating Temperature C Compressor Sump Temperature C Compressor Sump Temperature F Evaporating Temperature F 200 F 93 3 C Max Oil Temp Acceptable Unacceptable Too Much Refrigerant ...

Страница 17: ...es Greater than 5 seconds later whether 016 Sec With 60 HZ Operation power is restored or not after power is removed To prevent flooded start damage due to off cycle migration the accumulator may be configured on some systems to allow free drainage from the compressor to the accumulator during the off cycle When the above configuration is not possible and the unit charge is over the charge limit s...

Страница 18: ...uit use Figure 5 Discharge Thermostat Figure 4 Compressor Electrical Connection T1 C T2 S T3 R ZR16 32K5 ZR38 54K5 Connect the heater so that the connection point straddles the compressor seam weld Seam Weld Seam Weld Figure 6 Crankcase Heater ZP14 31K5 ZP34 61K5 ZP16 44K3 WARNING Verify the correct crankcase heater voltage for the application and ensure heater is properly grounded ...

Страница 19: ...14 9 4 1 6 11 21 26 31 36 41 46 51 56 61 66 70 80 90 100 110 120 130 140 150 160 20 10 0 10 20 30 40 50 60 Evaporating Temperature C Condensing Temperature C Condensing Temperature F Evaporating Temperature F Note ZP51 61K5E PFV Compressors Are Limited To 145 F Condensing For 5 Voltage Tolerance See Note ...

Страница 20: ... 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 charge...

Страница 21: ...21 2015 Emerson Climate Technologies Inc AE4 1331 R7 Figure 9 ...

Страница 22: ...12 for Installation of the Oil Equalization Line Oil Equalization Line Figure 11 Tilted Tandem Suction Gas Equalization Line Discharge Manifold Assembly Suction Manifold Assembly Mounting Rail 2 Required Compressor to Rail Mounting Kit Tandem to Unit Mounting Kit Figure 10 Typical ZPT K5 Tandem ...

Страница 23: ...Field Application Test Recommended Configuration Component Description Tubing Configuration Shock loop Service Valve Angled valve fastened to unit Suction muffler 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 3 Design Configuration...

Страница 24: ...3 Grounding Screw 100 0605 00 All Models 10 32 x 8mm Long Taptite Screw Molded Plug 529 0370 00 All Models Universal Plug 10 Gauge 42 Leads Molded Plug Retainer Clip 032 0717 00 All Models Optional Part Locks the Molded Plug to Fence Flexible Metal Conduit Retainer 032 7051 01 All Models Optional Part Use with 032 0717 00 Run Capacitor Refer To Online Product Information At www EmersonClimate com ...

Страница 25: ...ZPT32 62K5 Not Available For Purchase From Emerson Contact System OEM Discharge Manifold 528 1571 00 Oil Equalization Tube 028 1162 00 Gas Equalization Manifold 028 1770 00 Suction Manifold 528 1572 00 ZPT88 122K5 Discharge Manifold 528 1978 00 Oil Equalization Tube 028 1162 00 Gas Equalization Manifold 028 1770 00 Tandem Mounting Kit Compressor To Rails 527 0212 00 ZPT32 108K5 60 70 Duromter 2 Ki...

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