Emerson Scroll ZB*KAU Application Manuallines
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Emerson Scroll ZB*KAU Application Manuallines

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AE4-1431 R1
Safety ........................................................................... 3
Safety Instructions.................................................... 3
Safety Icon Explanation ........................................... 3
Fire, or Injury to Persons ........................................ 4
Safety Statements .................................................... 5
1.
Introduction .......................................................... 6
1.1.
General instructions ..................................... 6
2.
Product Description .............................................. 7
2.1.
Nomenclature ............................................... 7
2.2.
Application .................................................... 7
2.2.1.
Qualified refrigerant and oil .................. 7
2.2.2.
Pressures ............................................. 7
2.2.3.
Application limits .................................. 7
2.2.4.
Oil level ................................................ 7
2.2.5.
Superheat Requirements ..................... 8
3.
Installation ............................................................ 9
3.1.
Transport and storage .................................. 9
3.2.
Positioning and securing .............................. 9
3.3.
Installation location ...................................... 9
3.4.
Compressor mounting parts ......................... 9
3.5.
Brazing procedure ...................................... 10
3.6.
Filter screens .............................................. 10
3.7.
Sound and vibration ................................... 11
4.
Electrical connection .......................................... 11
4.1.
Units Electrical connection per BOM 634. . 11
4.1.1.
4.1.2.
........................................................... 12
4.2.
Electrical installation .................................. 12
4.2.1.
US Units ............................................. 12
4.2.2.
European Units .................................. 12
4.2.3.
Protection devices .............................. 14
4.2.4.
Crankcase heaters ............................. 14
4.3.
Pressure protection devices ....................... 14
4.3.1.
High pressure protection .................... 14
4.3.2.
Low-pressure protection .................... 14
4.4.
© 2018 Emerson Climate Technologies, Inc.
Application Guidelines for ZB*KAU Copeland R-290
Scroll™ Compressors

TABLE OF CONTENTS

4.4.1.
............................................................ 15
4.4.2.
Discharge gas temperature protection ...
............................................................ 15
4.5.
Motor protection .......................................... 17
4.6.
High-potential testing .................................. 17
5.
Starting up & operation ....................................... 17
5.1.
Compressor tightness test .......................... 17
5.2.
System evacuation ..................................... 17
5.3.
Charging procedure .................................... 18
5.4.
5.5.
Rotation direction ........................................ 18
5.6.
Starting sound ............................................ 18
5.7.
Deep vacuum operation ............................. 18
5.8.
Shell temperature ....................................... 19
5.8.1.
Minimum Run Time ............................ 19
5.8.2.
Shut-off sound .................................... 19
6.
Maintenance & repair ......................................... 19
6.1.
6.2.
Exchanging the refrigerant ......................... 20
6.3.
Replacing a compressor ............................. 20
6.3.1.
Compressor replacement ................... 20
6.3.2.
compressor ......................................... 21
6.3.3.
6.4.
Lubrication and oil removal ........................ 22
6.5.
Oil additives ................................................ 22
7.
Troubleshooting .................................................. 22
8.
Dismantling & disposal ....................................... 23
9.
the field. ...................................................................... 25
1
August 2018

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Summary of Contents for Emerson Scroll ZB*KAU

  • Page 1: Table Of Contents

    4.2.3. Protection devices ......14 4.2.4. Crankcase heaters ......14 4.3. Pressure protection devices ....... 14 4.3.1. High pressure protection ....14 4.3.2. Low-pressure protection ....14 4.4. Discharge gas temperature protection ..15 © 2018 Emerson Climate Technologies, Inc.
  • Page 2 European Electrical ......... 14 TABLES Table 1 – ZB*KAU available compressors models ..6 Table 2 -Technical data of the discharge line thermostat ................... 16 Table 3 - Recommendations for assembling the discharge line thermostat ........... 16 © 2018 Emerson Climate Technologies, Inc.

  • Page 3: Safety

    NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices not related to CAUTION personal injury. FLAMMABLE, Fire hazard! Sparking in a potentially explosive atmosphere! Explosion hazard! © 2018 Emerson Climate Technologies, Inc.

  • Page 4: Instructions Pertaining To Risk Of Electrical Shock, Fire, Or Injury To Persons

    Continuously check if the ambient atmosphere is non explosive. • Vibrations! Creation of an explosive atmosphere! Carefully check the system for vibrations. • Check for conductor cables in a potentially explosive atmosphere! Fire hazard! © 2018 Emerson Climate Technologies, Inc.

  • Page 5: Safety Statements

    • The national legislation and regulations must be observed. • These compressors shall be used only in non-explosive environments. Emerson recommends to carefully observe relevant information from standard IEC60335-2-89, UL60335-2-34. • During installation or maintenance procedure of a system never leave it unattended when it has no charge.

  • Page 6: Introduction

    Besides the support they provide, the instructions listed room before creating any naked flame; no naked herein are also critical for the proper and safe flame is allowed in an explosive atmosphere; functioning of the compressors. Emerson will not • atmosphere reaches...

  • Page 7: Product Description

    POE68B (Hatcol 4467) below 150 grams. This reduced oil filling is close to the minimum oil required, Oil Filling Test of Appendix B is Refer to Emerson Accepted Refrigerant List 93-11 required for application approval. See Figure 2 for for more options or details.

  • Page 8: Superheat Requirements

    (not the requirements. side) of the compressor shell and insulate from the Figure 1 - Extended Medium Temp operating envelope for ZB*KAU compressors Figure 2 - Oil filling and minimum acceptable oil level © 2018 Emerson Climate Technologies, Inc.

  • Page 9: Installation

    0.335 inches (8.5 mm) positioning. Using discharge or suction connections for to fit, e.g., an M8 screw. The mounting torque should be lifting may cause damage or leaks © 2018 Emerson Climate Technologies, Inc.

  • Page 10: Brazing Procedure

    This minimizes any entry of contaminants expansion valves, capillary tubes or accumulators can and moisture become temporarily or permanently plugged with © 2018 Emerson Climate Technologies, Inc.

  • Page 11: Sound And Vibration

    The R290 dedicated kit includes a special o- ring, a grounding connection and a retainer, see figures below. Emerson recommends that the electrical installation be executed considering the recommendations of NEC- Figure 7 - Circle fence with motor...

  • Page 12: Removing The Molded Plug Power Cable

    Figure 8 - Principle of connecting the molded Figure 10 shows electrical connections schematic. plug power cable to the connection pins NOTE: Emerson recommends the use of a Residual Current Device (RCD) as an additional safety measure. 4.1.2. Removing the molded plug power cable NOTE: Emerson recommends the use of a second •...

  • Page 13: Figure 9 - Connection Dimensions In Inches

    Three-phase compressors are connected to the TI, T2 and T3 connections. Legend System controller Main switch Discharge gas thermostat Auxiliary switch F1, F6, F7, F8 Fuses LP limiter Contactors Figure 10 - Three-phase compressors (TF*) with internal motor protection, USA © 2018 Emerson Climate Technologies, Inc.

  • Page 14: Protection Devices

    In some instances, systems must operate at low evaporating pressure because of the low ambient temperatures, sometimes combined with a high level of relative humidity. Proper evaporator sizing Figure 13 – Cover, European adequate defrost strategy control will prevent the © 2018 Emerson Climate Technologies, Inc.

  • Page 15: Discharge Gas Temperature Protection

    AE4-1431 R1 system from operating outside the operating envelope for 250°F (121°C) for all ZB*KAU models. These published by Emerson, whatever the climatic conditions compressors have internal discharge and the capacity demand. temperature protection. Therefore, an external protector is required. See Section 4.4.2 for more details.

  • Page 16: Table 2 -Technical Data Of The Discharge Line Thermostat

    Protection against NOTE: For correct discharge line thermostat (DLT) mechanical damage to the thermostat can be achieved selection, please refer to the Emerson.com/OPI. with an overall cover or box placed around the compressor or refrigerant system.

  • Page 17: Motor Protection

    The compressor has been leak-pressure tested in the housing is under vacuum. Emerson factory according to standards EN 14276-1, Emerson subjects all Scroll compressors to a high- EN 60335-2-34, IEC 60335-2-34 and UL60335-2-34. voltage test after final assembly. Each motor phase...

  • Page 18: Charging Procedure

    Vacuum operation! Compressor damage! Copeland Scroll compressors should never be used to evacuate 5.5. Rotation direction refrigeration or air-conditioning systems. Scroll compressors are directional dependent; i.e. they will compress in one rotational direction only. Three © 2018 Emerson Climate Technologies, Inc.

  • Page 19: Shell Temperature

    • if the atmosphere reaches a dangerous concentration of flammable gas, avoid any Emerson recommends a maximum of 10 starts per hour. ignition source and ventilate the room further; Recommend stating minimum 2-3 minutes run time is required for adequate oil return. There is no minimum •...

  • Page 20: Exchanging The Refrigerant

    Use a suitable cylinder for oil disposal as R290 may still In any case avoid air/R290 mixture in the refrigeration be solved in the oil. system. Make sure that the system is filled with pure © 2018 Emerson Climate Technologies, Inc.

  • Page 21: Start-Up Of A New Or Replacement Compressor

    Mention the following message on the box: 6.3.3. Compressor return procedure "Warning! Hydrocarbon compressor To return a compressor to Emerson for analysis, the analysis". procedure below shall be followed: • The compressor shipment must be kept in the •...

  • Page 22: Lubrication And Oil Removal

    Compressors Most in-warranty electrical failures are a result of supplied by Emerson contain oil with low moisture mechanical problems (particles in the oil, liquid content, and it may rise during the system assembling refrigerant in the oil, etc.) and most mechanical...

  • Page 23: Dismantling & Disposal

    9. General Guidelines and More Information For general Copeland Scroll™ compressor please log in Diesel effect! The mixture of air and oil at high to Online Product Information at Emerson.com/OPI, temperature can lead to an explosion. Avoid operating refer to the Application Engineering bulletins listed with air.

  • Page 24: Figure 18 Dimensions Of Zb*Kau Compressors

    Emerson Climate Technologies, Inc. and/or its affiliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifications of such products at any time without notice. Emerson does not assume responsibility for the selection, use or maintenance of any product.

  • Page 25: Appendix A: Common Scroll Problems Encountered In The Field

    For sizing information please consult with winding Contactor manufacturer data sheet. If the application of the compressor is changed the contactor sizing should be rechecked. Check for unbalanced voltage. © 2018 Emerson Climate Technologies, Inc.
  • Page 26 Check the thermostat, measure the temperature of the room and Control circuit compare with the thermostat; replace or re-calibrate the thermostat. inoperative Check the LP control switch and replace it if it is found defective. © 2018 Emerson Climate Technologies, Inc.
  • Page 27 Check the selection of the evaporator expansion valve (likely undersized). Noise during Anti-reverse This does not have any effect on the durability of the compressor, shut-off device no action is necessary. © 2018 Emerson Climate Technologies, Inc.

  • Page 28: Appendix B: Oil Filling Test For New Applications

    Test different operating points in the corners of the operating Figure 19 - ZB*KAU with external oil sight tube envelope as well. Refer to Figure 21 for main operating point, high load HL, maximum differential © 2018 Emerson Climate Technologies, Inc.

  • Page 29: Figure 21 - Testing Points For Oil Return Behavior Investigation

    Figure 21 - Testing points for oil return drop rapidly for a short period of time. When the behavior investigation crankcase temperature difference falls below the recommended 50°F (27°C), our recommendation is © 2018 Emerson Climate Technologies, Inc.

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