Emerson Copeland Scroll ZR24KRE Application Manuallines

Compressors for comfort, precision and process cooling
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Application Guidelines
Copeland Scroll
Compressors for
comfort, precision and process cooling


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  Summary of Contents for Emerson Copeland Scroll ZR24KRE

  • Page 1 Application Guidelines Copeland Scroll Compressors for ™ comfort, precision and process cooling ZR24KRE to ZR92KRE...
  • Page 2: Table Of Contents

    About these guidelines ....................1 Safety instructions ................... 1 1.1 Icon explanation ....................... 1 1.2 Safety statements ......................1 1.3 General instructions ......................2 Product description ..................3 2.1 Common information about Copeland Scroll™ compressors .......... 3 2.2 Nomenclature ........................3 2.3 BOM Variation ........................
  • Page 3 5.2 Tightness/pressure test ....................18 5.3 System evacuation ......................18 5.4 Preliminary checks – Pre-starting .................. 18 5.5 Charging procedure ....................... 19 5.6 Initial start-up ......................... 19 5.7 Rotation direction ......................19 5.8 Starting sound ........................ 20 5.9 Deep vacuum operation ....................20 5.10 Shell temperature ......................
  • Page 4: About These Guidelines

    Besides the support they provide, the instructions listed herein are also critical for the proper and safe functioning of the compressors. Emerson will not guarantee the performance and reliability of the product if it is misused in regard of these guidelines.
  • Page 5: General Instructions

    General instructions WARNING System breakdown! Personal injuries! Never install a system in the field and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system. System breakdown! Personal injuries! Only approved refrigerants and refrigeration oils must be used.
  • Page 6: Product Description

    Product description Common information about Copeland Scroll™ compressors The Scroll compressor has been under development at Emerson since 1979. It is the most efficient and durable compressor Emerson has ever developed. These application guidelines deal with all vertical single Copeland scroll compressors for air-conditioning applications from ZR24KRE to ZR92KRE.
  • Page 7: Dimensions

    Dimensions Compressor Ø G Ø H model [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] ZR24/28KRE 364.1 338.5 202.9 69.6 43.7 244.5 12.78-12.95 19.12-19.30 ZR36KRE 386.7 361.1 222.8 75.3 49.4 264.4 12.78-12.95 19.12-19.30 ZR42KRE 400.4 374.9 235.5 75.3 49.4 277.1 12.78-12.95 19.12-19.30 ZR48KRE...
  • Page 8 Figure 2: Dimensions for models ZR61KRE to ZR72KRE C6.2.41/0219/E...
  • Page 9 Figure 3: Dimensions for models ZR81KRE to ZR92KRE C6.2.41/0219/E...
  • Page 10: Application Range

    It is essential that the glide of refrigerant blends (primarily R450A) be carefully considered when adjusting pressure and superheat controls. Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland™ brand products Select software available at www.climate.emerson.com/en-gb. Compressor ZR*KRE...
  • Page 11: Installation

    Installation WARNING High pressure! Injury to skin and eyes possible! Be careful when opening connections on a pressurized item. Compressor handling 3.1.1 Transport and storage WARNING Risk of collapse! Personal injuries! Move compressors only with appropriate mechanical or handling equipment according to weight. Keep in the upright position.
  • Page 12: Brazing Procedure

    If the compressors are mounted in tandem or used in parallel, then the hard mountings (bolt M9 5/16") are recommended. The mounting torque should be 27 ± 1 Nm. It is possible to deliver these hard mounting parts as a kit. See Emerson spare parts software for reference. Mounting parts: ZR24K* to ZR92K* - Soft mountings...
  • Page 13: Shut-Off Valves And Adaptors

    Rotalock 2 ¼" – 12UNF 165-190 Table 4 NOTE: More information about adaptors and shut-off valves can be found in the spare parts software at www.climate.emerson.com/en-gb. Suction accumulators CAUTION Inadequate lubrication! Bearing destruction! Minimise liquid refrigerant returning to the compressor. Too much refrigerant dilutes the oil. Liquid refrigerant can wash the oil off the bearings leading to overheating and bearing failure.
  • Page 14: Screens

    In such a case an accumulator must be used to reduce flood-back to a safe level that the compressor can handle. The use of accumulators is dependent on the application. If an accumulator must be used, the oil-return orifice should be from 1 to 1.4 mm in diameter for all ZR*KRE models, depending on compressor size and compressor flood-back results.
  • Page 15 Recommended configuration ▪ Tubing configuration: ...small shock loop ▪ Service valve: ....."angled” valve fastened to unit / wall ▪ Suction muffler: ....not required Alternative configuration ▪ Tubing configuration: ...small shock loop ▪ Service valve: ......."straight through" valve fastened to unit / wall ▪...
  • Page 16: Electrical Connection

    Electrical connection General recommendations The compressor terminal box has a wiring diagram on the inside of its cover. Before connecting the compressor, ensure the supply voltage, the phases and the frequency match the nameplate data. Electrical installation Single-phase (PF*) compressors: Power circuit Control circuit Motor terminal connections...
  • Page 17 Three-phase compressors (TF*) with internal motor protection: Power circuit Control circuit Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend B1 ..Room thermostat K1 ..Contactor B3 ..Discharge gas thermostat R2 ..Crankcase heater F1 ..
  • Page 18: Terminal Box

    4.2.1 Terminal box The standard terminal box is IP21 for all ZR*KRE compressors. Cable glands have an influence on the protection class of the terminal box. Emerson strongly recommends to use appropriate cable glands in order to reach the rated protection class.
  • Page 19: Pressure Safety Controls

    The minimum cut-out setting shall be determined according to the refrigerant and to the allowed operation envelope – see technical data in Select software at www.climate.emerson.com/en-gb. For example, a minimum cut-out setting of 0.5 bar(g) is required for ZR compressors using R513A.
  • Page 20: High-Potential Testing

    Emerson subjects all Scroll compressors to a high-voltage test after final assembly. Each motor phase winding is tested, according to EN 0530 or VDE 0530 part 1, at a differential voltage of 1000V plus twice the nominal voltage.
  • Page 21: Starting Up & Operation

    Starting up & operation WARNING Diesel effect! Compressor destruction! The mixture of air and oil at high temperature can lead to an explosion. Avoid operating with air. IMPORTANT Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours before starting the compressor. Strength pressure test The compressor has been strength-tested in the factory.
  • Page 22: Charging Procedure

    ▪ Check setting and operation of all safety features and protection devices ▪ All valves in the correct running position ▪ Pressure and compound gauges fitted ▪ Correctly charged with refrigerant ▪ Compressor electrical isolator location & position Charging procedure CAUTION Low suction pressure operation! Compressor Damage! Do not operate with a restricted suction.
  • Page 23: Starting Sound

    (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 start- up to return to the compressor sump and restore a minimal oil level that will ensure oil pick-up through the crankshaft.
  • Page 24: Shut-Off Sound

    Shut-off sound 5.13 Scroll compressors incorporate a device that minimizes reverse rotation. The residual momentary reversal of the scrolls at shut off will cause a clicking sound, but it is entirely normal and has no effect on compressor durability. Frequency 5.14 There is no general release of standard Copeland Scroll compressors for use with variable speed AC drives.
  • Page 25: Maintenance & Repair

    Maintenance & repair Exchanging the refrigerant Qualified refrigerants and oils are given in section 2.5.1. It is not necessary to replace the refrigerant with new unless contamination due to an error such as topping up the system with an incorrect refrigerant is suspected. To verify correct refrigerant composition, a sample can be taken for chemical analysis.
  • Page 26: Lubrication And Oil Removal

    Compressors supplied by Emerson contain oil with low moisture content, and it may rise during the system assembling process. Therefore it is recommended that a properly sized filter-drier is installed in all POE systems.
  • Page 27: Dismantling & Disposal

    3. 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.
  • Page 28 The Emerson logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners.

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