Emerson Copeland Scroll ZR KC Series Bulletin
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Emerson Copeland Scroll ZR KC Series Bulletin

7 to 15 toncompressors
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AE4-1303 R15
7 to 15 Ton ZR*KC and ZP*KC Copeland Scroll
Section
Safety
Safety Instructions ......................................................2
Safety Icon Explanation ..............................................2
Shock, Fire, or Injury to Persons ..............................3
Safety Statements .......................................................3
Nomenclature ..............................................................4
Operating Envelope ....................................................4
Internal Pressure Relief (IPR) Valve ...........................4
Discharge Line Thermostat .........................................5
High Pressure Control .................................................5
Low Pressure Control .................................................5
Shut Down Device ......................................................5
Discharge Check Valve ...............................................5
Discharge Mufflers ......................................................5
Compressor Cycling ....................................................6
Suction & Discharge Fittings .......................................7
System Tubing Stress .................................................7
Accumulators ..............................................................7
Crankcase Heat ..........................................................7
Pump Down Cycle ......................................................8
Reversing Valves ........................................................8
System Screens & Strainers .......................................8
Contaminant Control ...................................................8
Oil Type & Removal ....................................................9
Three Phase Electrical Phasing ..................................9
Power Factor Correction ............................................10
Deep Vacuum Operation ............................................10
Manifolded Compressors ...........................................10
Manifolded Applications .............................................10
Motor Protection .........................................................11
Application Test Summary .........................................11
Continuous Floodback Test ........................................12
Field Application Test .................................................12
© 2016 Emerson Climate Technologies, Inc.

TABLE OF CONTENTS

Page
Section
Compressor Handling ............................................... 12
Mounting ................................................................... 13
Suction & Discharge Fittings ..................................... 13
Assembly Line Brazing Procedure ............................ 13
Unbrazing System Components ............................... 13
Pressure Testing ....................................................... 13
Electrical Connections .............................................. 14
Hipot Testing ............................................................. 14
Tandem Assembly ..................................................... 14
Field Replacement .................................................... 15
Mounting ................................................................. 15
Removing Oil .......................................................... 15
Electrical ................................................................. 15
Module .................................................................... 15
Manifolded Compressor Replacement ...................... 16
Communications Module ........................................ 17
Scroll Functional Check ............................................ 17
Refrigerant Retrofits .................................................. 18
How a Scroll Works.. ................................................. 19
Scroll Operating Envelopes ...................................... 20
Compressor Terminal Box Wiring ............................. 21
ASTP Label ............................................................... 22
Crankcase Heater Location ...................................... 23
Scroll Suction Tube Brazing ...................................... 24
Field Application Test ................................................ 25
Design Configurations ............................................... 25
Refrigerant Charge Limits... ...................................... 27
Torque Values ........................................................... 27
Protector Specifications ............................................ 28
Tandem Oil Balancing ............................................... 30
Tilted Tandem ............................................................ 30
1
AE4-1303 R15
June 2016
Compressors
™
Page

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  • Page 1: Table Of Contents

    Protector Specifications ..........28 Application Test Summary .........11 CoreSense LED Flash Code Information ....28-29 Continuous Floodback Test ........12 Tandem Oil Balancing ..........30 Field Application Test ..........12 Tilted Tandem ............30 APPENDIX Kriwan to CoreSense Retrofit Instructions ....31 © 2016 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. © 2016 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. © 2016 Emerson Climate Technologies, Inc.

  • Page 4: Introduction

    MP, TB ZP154-182KCE-TE/W* Module Last Character In Voltage Code (5 = 200/230-3-60, 200/220-3-50; D = 460-3-60, 380/420-3-50; E = 575-3-60; 7 = 380-3-60) MP = Molded Plug, TB = Terminal Block & Ring Terminals © 2016 Emerson Climate Technologies, Inc.

  • Page 5: Advanced Scroll Temperature Protection

    Prolonged operation in this manner could result © 2016 Emerson Climate Technologies, Inc.

  • Page 6: Compressor Cycling

    (available from Emerson) and install These compressors are also available to the OEM with it in a system with the longest connecting lines an oil Schrader fitting on the side of the compressor to that are approved for the system.

  • Page 7: Suction & Discharge Fittings

    Table 5. recommendations. This requirement is independent of system type and configuration. Table 5 lists Emerson crankcase heaters System Tubing Stress by part number and voltage. See Figure 6 for the proper System tubing should be designed to keep tubing heater location on the compressor shell.

  • Page 8: Pump Down Cycle

    The sound that the compressor adequately sized to accommodate the contaminants makes during this transition period is normal, and © 2016 Emerson Climate Technologies, Inc.

  • Page 9: Oil Type & Removal

    CAUTION POE must be handled carefully and is corrected. the proper protective equipment (gloves, eye © 2016 Emerson Climate Technologies, Inc.

  • Page 10: Power Factor Correction

    Manifolded Compressors Manifolded Applications Tandem compressor assemblies are available for NOTICE purchase from Emerson. In lieu of purchasing the assembled tandem, the OEM can choose to purchase Manifolded compressor designs employ a passive the manifold-ready compressor and perform the oil management system. All system designs must assembly in their factory.

  • Page 11: Motor Protection

    TW* electrical codes and TE* electrical codes respectively. Field Application Test: Models with a "W" or "E" in the electrical code (i.e. Required for any unit where both the design system © 2016 Emerson Climate Technologies, Inc.

  • Page 12: Continuous Floodback Test

    Field unit. If possible, the compressor should be kept vertical Application Test that is outlined in Table 2. Obtain a during handling. The discharge connection plug should © 2016 Emerson Climate Technologies, Inc.

  • Page 13: Mounting

    Many OEM customers buy the mounting parts directly the low side shell and suction line contain pressure, the from the supplier, but Emerson's grommet design and pressurized refrigerant and oil mixture could ignite when durometer recommendations should be followed for it escapes and contacts the brazing flame. CAUTION!

  • Page 14: Assembly Line System Charging Procedures

    See Figure 9 for a picture of conduits, poor conduit connections to the terminal box, a typical tandem assembly. Special consideration an incorrectly installed terminal box cover or a missing © 2016 Emerson Climate Technologies, Inc.

  • Page 15: Service Procedures

    3. The only wiring connections to the new replaced by this scroll compressor family. The mounting compressor will be the three high-power leads. dimensions of the older scroll and the reciprocating compressor are 8.65" X 8.65" (220mm X 220mm) to the © 2016 Emerson Climate Technologies, Inc.

  • Page 16: Compressor Replacement After A Motor Burn

    12 degrees from horizontal If the compressor will not operate with the jumper to move the oil away from the fitting (see Figure 10). installed, then the problem is external to the solid state protection system. © 2016 Emerson Climate Technologies, Inc.

  • Page 17: Field Troubleshooting The Coresense Communications Module

    4. With service gauges connected to suction run when connected properly, the solid state and discharge pressure fittings, turn on the module is defective and should be replaced. The compressor. If suction pressure falls below normal © 2016 Emerson Climate Technologies, Inc.

  • Page 18: Refrigerant Retrofits

    Technologies, Inc. and the OEM should be considered. any two of the compressor power leads and For a list of Emerson approved refrigerants please reapply power to make sure compressor was not refer to Form 93-11, Refrigerants and Lubricants wired to run in reverse direction.

  • Page 19: Figures & Tables How A Scroll Works

    AE4-1303 R15 Figure 1 © 2016 Emerson Climate Technologies, Inc.

  • Page 20: Scroll Operating Envelopes

    AE4-1303 R15 R-407C, R-22, & R-134a 50/60 Hertz Operation Evapora ng Temperature (°C) Evapora ng Temperature (°F) R-410A 50/60 Hertz Operation Evapora ng Temperature (°C) Evapora ng Temperature (°F) Figure 2 – Scroll Operating Envelopes © 2016 Emerson Climate Technologies, Inc.

  • Page 21: Compressor Terminal Box Wiring

    DEBEN REPSETAR LAS ESPECIFICACIONES DE LAS AGENCIAS DE CERTIFICACION DEL EQUIPO ENABLE / SHORT CYCLE PROTECTION / DISABLE / – VER PLACA DE IDENTIFICACION 09-13 052-2841-00 PROTECCION CONTRA CICLADO FRECUENTE ACTIVADO DESACTIVADO Figure 3 Compressor Terminal Box Wiring with CoreSense Protection © 2016 Emerson Climate Technologies, Inc.

  • Page 22: Astp Label

    AE4-1303 R15 Figure 4 ASTP Label © 2016 Emerson Climate Technologies, Inc.

  • Page 23: Crankcase Heater Location

    AE4-1303 R15 ZR84-144KC ZR160-190KC ZP90-137KC ZP154-182KC Figure 5 Crankcase Heater Location © 2016 Emerson Climate Technologies, Inc.

  • Page 24: 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. © 2016 Emerson Climate Technologies, Inc.

  • Page 25: 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) © 2016 Emerson Climate Technologies, Inc.

  • Page 26: Compressor Accessories & Service Parts

    Suction Rotalock Adapter to 1-3/8" Sweat 998-0034-13 998-0034-13 998-0034-13 998-0034-13 Terminal boxes are rarely replaced; please contact Application Engineering if replacement part numbers are required All Voltages 200/230 Volts Only 380, 460, 575 Volts © 2016 Emerson Climate Technologies, Inc.

  • Page 27: Refrigerant Charge Limits

    100-110 Discharge Rotalock Valve 95-103 1150-1240 130-140 Suction Rotalock Valve 125-132 1505-1593 170-180 Schrader Valve 3.3-5.0 40-60 4.5-6.8 Terminal Block Screws 10-32 Green Ground Screw M6 Terminal Box Mounting Stud Nuts 2.6-3.2 31.9-38.9 3.6-4.4 © 2016 Emerson Climate Technologies, Inc.

  • Page 28: Protector Specifications

    Flash Code 3 cycles exceeds 48 in 24 24 hours temperature controller hours 3) Install anti-short cycling control Green Not used with this Flash Code 4 compressor family Green Future Use Flash Code 5 © 2016 Emerson Climate Technologies, Inc.
  • Page 29 Low voltage on T2-T1 the voltage is back in transformer Flash Code 9 Voltage terminals the normal range 3) Check for blown fuse in transformer secondary This Alert does not result in a Lockout © 2016 Emerson Climate Technologies, Inc.

  • Page 30: Tandem Oil Balancing

    AE4-1303 R15 Figure 9 Tandem Oil Balancing Oil Equalization Line Two-Phase Tandem Line Two -Phase Tube Line Figure 10 Tilted Tandem Oil Equalization Line Tilting the Compressor For Installation of the Oil Equalization Line ° © 2016 Emerson Climate Technologies, Inc.

  • Page 31: Appendix 1

    Kriwan modules that are non-operational and out of warranty should be field scrapped in the appropriate manner. If you have any questions, please contact your Emerson Climate Application Engineer or visit Emerson’s Online Product Information (OPI) located at www.emersonclimate.com Holding Replacing Kriwan Module with CoreSense ™...
  • Page 32 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...

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