Charging Procedure; Refrigerant Charging Procedure - Emerson Copeland EazyCool ZX Series Application Manuallines

should be evacuated down to an absolute pressure of 0.3 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 on 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.
The highest demands are placed on the leak-proof design of the installation and on the leak testing
methods – please refer to EN 378.
4.4

Charging procedure

4.4.1 Refrigerant charging procedure

WARNING
Air/A2L refrigerant mixture in a potentially flammable atmosphere! Fire
hazard! Only use filling equipment designed and approved for use and
operation with A2L refrigerant. Make sure all connections are tight to avoid
leakage. Make sure to fill with pure A2L refrigerant.
Whenever starting up a system charged with A2L refrigerant, eg, after filling,
repair, or maintenance, make sure not to start and operate accidentally in a
flammable atmosphere.
IMPORTANT
Inadequate charge! Overheating! The scroll compressor design requires the
system to be charged as quickly as possible with liquid refrigerant into the
liquid line. This will avoid running the compressor under conditions whereby
insufficient suction gas is available to cool not only the motor but also the
scrolls. Temperature builds up very quickly in the scrolls if this is not done.
Service valve closed! Compressor damage! Do not charge the unit with
vapour (gas). The suction service valve must never be fully closed when the
compressor is running. This would cause damage to the compressor in the
same manner as explained above. This valve is provided for ease of
connection and for the fitting of service gauges without removing the unit
panel.
IMPORTANT
Refrigerant leakage! Contamination of surroundings! In case of leakage
the surrounding area can be contaminated with a mixture of oil and refrigerant.
Periodically check the system for leakage.
Before charging or re-charging, the system must be leak- and pressure-tested
with appropriate purging gas.
Ensure that the refrigerant system is grounded prior to charging with refrigerant.
Pre-charging must be carried out with liquid refrigerant through the service valve on the liquid line. It
is advisable to pre-fill the suction side with a partial charge to avoid vacuum operation. Further
charging can be done by carefully filling refrigerant through the suction line while simultaneously
checking the sight glass.
The system charge varies from system to system and therefore must always be adapted to the
required application. The refrigerant charge of the unit itself can be calculated approximately based
on the following:
▪ One-fan units: 0.1 L + 3.28 L + 0.1 L = 3.48 L (condenser 10 % + receiver 80 % + liquid line 10 %)
▪ Two-fan units: 0.29 L + 4.72 L + 0.2 L = 5.2 L (condenser 10 % + receiver 80 % + liquid line 10 %)
Extreme care shall be taken not to overfill the system with refrigerant.
The system manufacturer/installer must respect the charge limitations according to valid standards,
such as but not limited EN 378.
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