Emerson ZPK3E Series User Manual
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Emerson ZPK3E Series User Manual

R-410a 1.5 to 5 ton copeland scroll compressors
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AE4-1331 R7
Section
Safety
Safety Instructions ................................................ 2
Safety Icon Explanation ....................................... 2
Fire, or Injury to Persons ...................................... 3
Safety Statements ................................................ 3
Introduction ............................................................. 4
Nomenclature ....................................................... 4
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
Discharge Mufflers ............................................... 9
Noise & Vibration ................................................. 9
Mounting Parts ..................................................... 9
PTC Start Components ....................................... 10
Electrical Connections ......................................... 10
Deep Vacuum Operation ..................................... 10
Shell Temperature ............................................... 10
Suction & Discharge Fittings ............................... 10
© 2015 Emerson Climate Technologies, Inc.
ZP16 to ZP44K3E and ZP14 to ZP61K5E R-410A
1.5 to 5 Ton Copeland Scroll

TABLE OF CONTENTS

Compressors
™
Page
Section
System Tubing Stress ......................................... 10
Brief Power Interruptions ..................................... 11
Manifolding Tandem Compressors ...................... 11
Tandem Applications ........................................... 11
Maximum Tilt Angles ........................................... 11
Application Summary........................................... 11
Continuous Floodback Test ................................. 12
Field Application Test .......................................... 12
Installing the Compressor ................................... 12
Assembly Line Brazing Procedure ...................... 13
Tandem Assembly ............................................... 13
Pressure Testing ................................................. 13
High Potential (AC Hipot) Testing ........................ 13
Final Run Test ..................................................... 14
Unbrazing System Components ......................... 14
Copeland Scroll Functional Check ...................... 14
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
1
AE4-1331 R7
July 2015
Page

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Summary of Contents for Emerson ZPK3E Series

  • Page 1: Table Of Contents

    PTC Start Components ........10 Design Configurations ......... 23 Electrical Connections ......... 10 Compressor Accessories ......... 24-25 Deep Vacuum Operation ........10 Shell Temperature ..........10 Compressor Refrigerant Charge Limits....25 Suction & Discharge Fittings ....... 10 © 2015 Emerson Climate Technologies, Inc.

  • Page 2: Safety Instructions

    NOTICE NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices CAUTION not related to personal injury. © 2015 Emerson Climate Technologies, Inc.

  • Page 3: Instructions Pertaining To Risk Of Electrical Shock, Fire, Or Injury To Persons

    • Refrigerant compressors must be employed only for their intended use. • install, commission and maintain this equipment. • • All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed. © 2015 Emerson Climate Technologies, Inc.

  • Page 4: Introduction

    Internal Pressure Relief (IPR) Valve Online Product Information, accessible from the The internal pressure relief valve is located between Emerson Climate Technologies website at www. the high and low side of the compressor. It is designed emersonclimate.com. Operating principles of the to open when the discharge-to-suction pressure Copeland Scroll compressor are described in Figure 9.

  • Page 5: Heat Pump Protection

    Please refer to the section on Brief Power Some systems, such as air-to-air heat pumps, may not Interruption. work with the above low pressure control arrangement. © 2015 Emerson Climate Technologies, Inc.

  • Page 6: Discharge Check Valve

    The size is dependent on how application. The Copeland Scroll compressor’s inherent much refrigerant has to be removed from the system ability to handle liquid refrigerant during occasional throughout the system operating map. © 2015 Emerson Climate Technologies, Inc.

  • Page 7: Screens

    (available from Emerson) length and that the circumference of the heater element and install it in a system with the longest connecting is in complete contact with the compressor shell.

  • Page 8: Reversing Valves

    See the compressor nameplate for the original oil refrigerant, it is our recommendation to add one fluid charge. A complete recharge should be approximately ounce of oil for every 5 pounds (15 ml/kg) of refrigerant © 2015 Emerson Climate Technologies, Inc.

  • Page 9: Discharge Mufflers

    The sound phenomena described above are not usually are recommended in heat pumps. A hollow shell muffler associated with heat pump systems because of the such as the Emerson Flow Controls APD-1 or APD-054 isolation and attenuation provided by the reversing will work quite well. The mufflers should be located a valve and tubing bends. minimum of six inches (15 cm) to a maximum of 18...

  • Page 10: Ptc Start Components

    Due to the different thermal properties of steel and copper, Molded electrical plug (Emerson p/n 529-0060-04 brazing procedures may have to be changed from or OEM equivalent) must be used with all -1XX and those commonly used.

  • Page 11: Brief Power Interruptions

    There is no negative impact on durability caused by and parts required for assembly. Drawings of tandem operating three phase Copeland Scroll compressors in tubing assemblies are available from Emerson Climate the reversed direction for a short period of time (under Technologies by contacting your Applications Engineer.

  • Page 12: Continuous Floodback Test

    Emerson’s run test. The inside Note: The sight-tube is not a good liquid level indicator of both fittings should be wiped with a lint free cloth when the compressor is running because the top of the ©...

  • Page 13: Assembly Line Brazing Procedure

    In this respect, the scroll is more of both compressors should be wiped clean with a lint like semi-hermetic compressors that have horizontal free towel to remove any oil residue before brazing. © 2015 Emerson Climate Technologies, Inc.

  • Page 14: Final Run Test

    LRA is determined by physically locking system is either low on charge or there is a flow a compressor and applying the highest nameplate blockage in the system. voltage to the motor. The amperage that the motor © 2015 Emerson Climate Technologies, Inc.

  • Page 15: Compressor Replacement After Motor Burn

    If additional systems can be found in Section H of the Emerson charge is required, charge liquid into the low side of Climate Technologies Electrical Handbook, the system with the compressor operating.

  • Page 16: Oil Dilution Chart

    Note 1: Operation in this refrigerant dilution area is safe in air-to-air heat pump heating mode. For other applications, such as AC only, review expansion device to raise superheat. A cold sump may result in high refrigerant migration after shut down. Figure 1 Oil Dilution Chart © 2015 Emerson Climate Technologies, Inc.

  • Page 17: Accumulator Piping

    Time Delay Relay Specifications Timer Opens: 1 Electrical Cycle Timer Closes: Greater than 5 seconds later, whether (.016 Sec. With 60 HZ Operation) power is restored or not after power is removed Figure 3 Time Delay Wiring © 2015 Emerson Climate Technologies, Inc.

  • Page 18: Compressor Electrical Connection

    Connect the heater so that the connection point straddles the compressor seam weld Seam Weld Seam Weld ZP34-61K5 ZR16-32K5 ZR38-54K5 ZP14-31K5 ZP16-44K3 WARNING Verify the correct crankcase heater voltage for the application and ensure heater is properly grounded. Figure 6 Crankcase Heater © 2015 Emerson Climate Technologies, Inc.

  • Page 19: R410A Scroll Operating Envelope

    AE4-1331 R7 Evaporating Temperature (°C) Note: ZP51-61K5E-PFV Compressors Are Limited To 145°F Condensing For -5% Voltage Tolerance See Note Evaporating Temperature (°F) Figure 7 – R-410A Scroll Operating Envelope © 2015 Emerson Climate Technologies, Inc.

  • Page 20: Scroll Suction Tube Brazing

    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. © 2015 Emerson Climate Technologies, Inc.

  • Page 21: How A Scroll Works

    AE4-1331 R7 Figure 9 © 2015 Emerson Climate Technologies, Inc.

  • Page 22: Typical Zpk5 Tandem

    Tandem to Unit Mounting Kit Figure 10 Typical ZPT*K5 Tandem Oil Equalization Line Tilt the Compressor a Minimum of 12 ° for Installation of the Oil Equalization Line 12° Min Figure 11 Tilted Tandem © 2015 Emerson Climate Technologies, Inc.

  • Page 23: Field Application Test

    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) © 2015 Emerson Climate Technologies, Inc.

  • Page 24: Compressor Accessories

    Comfort Alert™ Module 543-0032-00 All Models 1-Phase Only, Has "L" Terminal Comfort Alert™ Module 543-0038-02 All Models 3-Phase Only Comfort Alert™ Module 543-0067-00 All Models 1-Phase Only, Geothermal Discharge Line Thermostat 998-7022-02 All Models Conduit Ready, fits 1/2" tube © 2015 Emerson Climate Technologies, Inc.

  • Page 25: Compressor Refrigerant Charge Limits

    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. © 2015 Emerson Climate Technologies, Inc.

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Zpk5e seriesZp32k3e-pfvZp51k5e-pfvZp16Zp44k3eZp14 ... Show all

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