Emerson Copeland Scroll ZP K3 Series Bulletin
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Emerson Copeland Scroll ZP K3 Series Bulletin

R-410a 5 to 12 ton compressors for air conditioning
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AE4-1365 R4
Copeland Scroll
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
Discharge Check Valve ............................................ 5
Motor Overload Protection ....................................... 5
Operating Envelope ................................................. 5
Power Supply ........................................................... 6
Accumulators ........................................................... 6
Screens .................................................................... 6
Crankcase Heat-Single Phase ................................. 6
Crankcase Heat-Three Phase .................................. 7
Pump Down Cycle .................................................... 7
Minimum Run Time .................................................. 7
Reversing Valves ..................................................... 7
Low Ambient Cut-Out ............................................... 7
Oil Type .................................................................... 7
Contaminant Control ................................................ 8
Discharge Mufflers ................................................... 8
Noise & Vibration ..................................................... 8
Mounting Parts ......................................................... 9
Electrical Connections .............................................. 9
Deep Vacuum Operation .......................................... 9
Shell Temperature .................................................... 9
Suction & Discharge Fittings .................................... 9
System Tubing Stress .............................................. 9
© 2015 Emerson Climate Technologies, Inc.
5 to 12 Ton ZP*K3, ZP*KC, and ZP*KW R-410A
Compressors for Air Conditioning
™

TABLE OF CONTENTS

Page
Section
Brief Power Interruptions ......................................... 10
Manifolding Tandem Compressors .......................... 10
Tandem Applications ............................................... 10
Application Summary .............................................. 10
Continuous Floodback Test ..................................... 11
Field Application Test ............................................. 11
Installing the Compressor ....................................... 11
Assembly Line Brazing Procedure .......................... 12
Tandem Assembly ................................................... 12
Pressure Testing ..................................................... 12
High Potential (AC Hipot) Testing ............................ 12
Final Run Test ......................................................... 13
Unbrazing System Components ............................. 13
Copeland Scroll Functional Check .......................... 13
Figures & Tables
Operating Envelope ................................................ 15
Oil Dilution Chart ..................................................... 16
ASTP Label ............................................................. 17
Crankcase Heater ................................................... 18
Typical ZPKC Tandem ............................................. 18
Tilted Tandem .......................................................... 18
Scroll Suction Tube Brazing .................................... 19
How a Scroll Works.. ............................................... 20
Field Application Test .............................................. 21
Design Configurations ............................................. 21
Compressor Accessories ..................................... 22-25
1
AE4-1365 R4
September 2015
Page

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Summary of Contents for Emerson Copeland Scroll ZP K3 Series

  • Page 1: Table Of Contents

    Compressor Refrigerant Charge Limits....21 Electrical Connections ..........9 Compressor Accessories ........22-25 Deep Vacuum Operation .......... 9 Shell Temperature ............ 9 Suction & Discharge Fittings ........9 System Tubing Stress ..........9 © 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

    For additional information, please refer to the online product information accessible from the Emerson Internal Pressure Relief (IPR) Valve Climate Technologies website at EmersonClimate.com. NOTICE Operating principles of the Copeland Scroll compressor are described in Figure 8 of this bulletin.

  • Page 5: Discharge Temperature Protection

    (125°C) may have to be used to achieve the same temperatures do not come into contact with these protection. Mount the discharge thermostat as close potentially hot areas. as possible to the compressor discharge fitting and insulate well. See Table 4 for recommended Emerson Protection against abnormally high discharge Climate Technologies part numbers.

  • Page 6: Screens

    TXV to control refrigerant with liquid refrigerant under certain circumstances during heating may not require an accumulator if and system configurations, notably after long off testing assures the system designer that there will © 2015 Emerson Climate Technologies, Inc.

  • Page 7: Crankcase Heat-Three Phase

    AE4-1365 R4 cycles when the compressor has cooled. This may Emerson) and install it in a system with the longest cause excessive start-up clearing noise; or the connecting lines that are approved for the system. compressor may start and trip the internal overload The minimum on time becomes the time required protector several times before running.

  • Page 8: Low Ambient Cut-Out

    Ultra 32-3MAF, available from ™ not while the compressor is running. If the system Emerson Wholesalers, should be used if additional contains an accumulator the manufacturer of the oil is needed in the field. Mobil Arctic EAL22CC, accumulator should be consulted for a pre-charge Emkarate RL22, Emkarate 32CF and Emkarate 3MAF recommendation.

  • Page 9: Air-Conditioning System Suction Line Noise & Vibration

    When no testing compressors. Many OEM customers buy the mounting is performed, mufflers are recommended in heat parts directly from the supplier, but Emerson’s pumps. The mufflers should be located a minimum of grommet design and durometer recommendation six inches (15 cm) to a maximum of 18 inches (46 should be followed for best vibration reduction through cm) from the compressor for most effective operation.

  • Page 10: Suction & Discharge Fittings

    Verification of proper Tandem compressor assemblies are available for rotation direction is made by observing that suction purchase from Emerson. In lieu of purchasing the pressure drops and discharge pressure rises when the assembled tandem, the OEM can choose to purchase compressor is energized.

  • Page 11: Tandem Applications

    Drawings of tandem tubing assemblies are available Continuous Floodback Test from Emerson Climate Technologies by contacting It is expected that the design would not flood during your Application Engineer. standard air conditioning operation. Running a partially...

  • Page 12: Assembly Line Procedures

    Emerson’s run test. The inside a minimum of 25 feet (8 meters) of connecting tubing of both fittings should be wiped with a lint free cloth with no traps between the indoor and outdoor units.

  • Page 13: Pressure Testing

    Pre-charging on the high side and adding © 2015 Emerson Climate Technologies, Inc.

  • Page 14: Unbrazing System Components

    If a brazing torch is then used equipped) or the compressor is faulty. Reconnect to disconnect tubing, the pressurized refrigerant and the compressor leads as originally configured oil mixture could ignite when it escapes and contacts © 2015 Emerson Climate Technologies, Inc.

  • Page 15: Compressor Replacement After Motor Burn

    Do not operate with the low pressure for compressors and systems can be found in cut-out disabled. Allowing suction pressure to drop Section H of the Emerson Climate Technologies below 55 psig (3.8 bar) for more than a few seconds Electrical Handbook, Form No. 6400.

  • Page 16: Operating Envelope

    AE4-1365 R4 Evaporating Temperature (°C) ZP*KW Pool Envelope ZP*K3 & ZP*KC Envelope Evaporating Temperature (°F) Figure 1a – Operating Envelope ZP104KC/ZP122KC/ZP143KC ONLY Evapora ng Temperature (°C) Evapora ng Temperature (°F) Figure 1b – Operating Envelope © 2015 Emerson Climate Technologies, Inc.

  • Page 17: 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 2 – Oil Dilution Chart © 2015 Emerson Climate Technologies, Inc.

  • Page 18: Crankcase Heater

    Seam Weld for the application and ensure heater is properly grounded. ZP50-57K3 ZP61-143KC ZP70-83KW Figure 4 – Crankcase Heater Connect the heater so that the connection point straddles the compressor seam weld. © 2015 Emerson Climate Technologies, Inc.
  • Page 19 Tandem to Unit Mounting Kit Figure 5 – Typical ZP*KC Tandem Oil Equalization Line Tilt the Compressor a Minimum of 12° for Installation of the Oil Equalization Line ° Figure 6 – Tilted Tandem © 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 AE4-1365 R4 Figure 8 © 2015 Emerson Climate Technologies, Inc.

  • Page 22: Field Application Test

    Frame Size* Pounds Pounds Pounds ZP50 - 57K3 ZP70 - 83KW 10.0 12.0 12.0 ZP61 - 91KC ZP104-122KC 11.0 13.0 13.0 ZP143KC *Approximate Shell Diameter (e.g. 70 - 7.3 Inches) **Charge Allowance For System © 2015 Emerson Climate Technologies, Inc.

  • Page 23: Compressor Accessories

    ZP70-83KW Grounding Screw 100-0605-00 All Models 10-32 x 8mm Long, Taptite Screw ZP50-57K3 Universal Plug, 10 Gauge Wire, Molded Plug 529-0370-00 ZP61-91KC 42" Leads ZP70-83KW Molded plug 529-0099-00 ZP104-143KC 8 Gauge Wire, 42" Leads © 2015 Emerson Climate Technologies, Inc.
  • Page 24 Discharge Rotalock Adapter to ZP50-57K3 998-0034-18 1/2" Sweat ZP61-83KC Discharge Rotalock Adapter to 998-0034-08 ZP91-143KC 7/8" Sweat Suction Rotalock Adapter to 7/8" ZP50-57K3 998-0034-08 Sweat ZP61-91KC Suction Rotalock Adapter to 998-0034-13 ZP104-143KC 1-3/8" Sweat © 2015 Emerson Climate Technologies, Inc.
  • Page 25 The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. 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. Emersondoes 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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