Start-Up & Operation; Strength Pressure Test; Compressor Tightness Test; System Evacuation - Emerson Copeland Scroll ZR24KRE Application Manuallines

5 Start-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! It is important to ensure that new
compressors are not subjected to liquid abuse. It is mandatory to have a
crankcase heater installed if the refrigerant charge exceeds 3.6 kg for
compressors ZR24KRE to ZR48KRE, 4.5 kg for compressors ZR61KRE to
ZR92KRE, 7.3 kg for compressors ZR108KRE to ZR144KRE and 8.2 kg for
compressors ZR160KRE & ZR190KRE. Turn the crankcase heater on
12 hours before starting the compressor.

Strength pressure test

5.1
WARNING
High pressure! Personal injuries! Consider personal safety requirements
and refer to test pressures prior to test.
CAUTION
System contamination! Bearing malfunction! Use only dry nitrogen for
pressure testing. DO NOT USE other industrial gases.
The compressor has been strength-pressure tested in the Emerson factory according to EN 14276-
1 and EN 60335-2-34 standards. Therefore, it is not necessary for the manufacturer/installer to
strength-pressure test the compressor again on the assembly/system.

Compressor tightness test

5.2
WARNING
High pressure! Personal injuries! Consider personal safety requirements
and refer to test pressures prior to test.
CAUTION
System contamination! Bearing malfunction! Use only dry inert gases (for
example nitrogen) for leak testing. DO NOT USE other industrial gases.
The compressor has been leak-pressure tested in the Emerson factory. Therefore, it is not necessary
for the system manufacturer/installer to leak-pressure test the compressor again on the
assembly/system.
All compressors get a factory holding charge of dry air (about 1 to 2.5 bar, relative pressure). An
intact holding charge serves as a proof of quality against penetrating moisture.
When removing plugs from the compressor, the plugs may pop out due to pressure and oil can spurt.
Any later modification to compressor connections can have an impact on the compressor tightness.
Always leak-pressure test the compressor after opening or modifying the connections.
Never add refrigerant to the test gas (as leak indicator).

System evacuation

5.3
Before the installation is put into commission, it has to be evacuated with a vacuum pump. The
installation should be evacuated down to an absolute pressure of 3 mbar. Proper evacuation reduces
residual moisture to 50 ppm. During the initial procedure, suction and discharge shut-off valves on
the compressor remain closed. The installation of adequately sized access valves at the furthest
point from the compressor in the suction and liquid lines is advisable. The pressure must be
measured using a vacuum pressure gauge on the access valves and not on the vacuum pump; this
serves to avoid incorrect measurements resulting from the pressure gradient along the connecting
lines to the pump.
Evacuating the system only on the suction side of a scroll compressor can occasionally result in a
temporary no-start condition for the compressor. The reason for this is that the floating seal could
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