Emerson Copeland ZR16 Manual
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Emerson Copeland ZR16 Manual

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AE4-1374 R1
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
Shut Down Device .................................................... 5
Discharge Check Valve ............................................. 5
Motor Overload Protection ........................................ 5
Operating Envelope .................................................. 5
Power Supply ............................................................ 6
Accumulators ............................................................ 6
Charge Compensators .............................................. 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 ................................................ 8
Oil Type ..................................................................... 8
Contaminant Control ................................................. 8
Discharge Mufflers .................................................... 8
Vibration .................................................................... 9
Mounting Parts .......................................................... 9
Single Phase Starting Characteristics ....................... 9
PTC Start Components ............................................. 9
Electrical Connections ............................................... 9
Deep Vacuum Operation .......................................... 10
Shell Temperature .................................................... 10
© 2013 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Application Engineering
B U L L E T I N
ZR16 to ZR54K5E R-22 and R-407C
1.5 to 5 Ton Copeland Scroll

TABLE OF CONTENTS

Page
™
Compressors
Section
Suction & Discharge Fittings ....................................10
System Tubing Stress .............................................. 10
Three Phase Scroll Electrical Phasing ..................... 10
Brief Power Interruptions ......................................... 10
Application Test Summary ....................................... 11
Continuous Floodback Test ...................................... 11
Field Application Test ............................................... 11
Installing the Compressor ........................................ 12
Assembly Line Brazing Procedure ........................... 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
Oil Dilution Chart ...................................................... 15
Accumulator Piping .................................................. 16
Time Delay Wiring .................................................... 16
Compressor Electrical Connection ........................... 17
Discharge Thermostat .............................................. 17
Crankcase Heater .................................................... 17
Scroll Operating Envelope ....................................... 18
Scroll Suction Tube Brazing ..................................... 19
How a Scroll Works .................................................. 20
Field Application Test ............................................... 21
Design Configurations.............................................. 21
Mounting Parts......................................................... 21
Compressor Refrigerant Charge Limits .................... 22
Crankcase Heaters .................................................. 22
1
July 2013
Page

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Summary of Contents for Emerson Copeland ZR16

  • Page 1: Table Of Contents

    Crankcase Heaters ..........22 Mounting Parts ............9 Single Phase Starting Characteristics ....... 9 PTC Start Components ..........9 Electrical Connections ..........9 Deep Vacuum Operation .......... 10 Shell Temperature ............ 10 © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • 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 not CAUTION related to personal injury. © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • 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. © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 4: Introduction

    Quiet Discharge Motor Electrical Model Check Valve Protector Connections Frame Size* Shutdown ZR16-32K5 Molded Plug ZR38-54K5 Molded Plug * Approximate Shell Diameter (e.g. 53 = 5.5" and 63 = 6.5") © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 5: Heat Pump Protection

    The cut in setting can be as high as 105 psig (7.2 bar) to the return gas. Use of refrigerants other than R-22 or prevent rapid recycling in case of refrigerant loss. If an R-407C voids the UL listing of these compressor models © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 6: Power Supply

    This WARNING! Crankcase heaters must be properly will require special accumulators and compressors with grounded. To properly install the crankcase heater, the © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 7: Crankcase Heat-Three Phase

    Tighten the clamp screw carefully, ensuring equipped with a sight tube (available from Emerson) that the heater is uniformly tensioned along its entire and install it in a system with the longest connecting length and that the heating element is in complete lines that are approved for the system.

  • Page 8: Low Ambient Cut-Out

    Emerson Flow Controls APD-1 or APD-054 will work dielectric strength degradation, ice formation, and quite well. The mufflers should be located a minimum of oil hydrolysis, and metal corrosion. It is the system six inches (15 cm) to a maximum of 18 inches (46 cm) designer’s responsibility to make sure the filter-drier is...

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

    20:1 with a 30:1 ratio recommended. these compressors. Many OEM customers buy the The muffler should be from four to six inches (10 -15 mounting parts directly from the supplier, but Emerson’s cm) long. grommet design and durometer recommendation...

  • Page 10: Deep Vacuum Operation

    9.5 ksi (62 MPa), the endurance limit and run normally. of copper tubing. Start, stop and running (resonance) cases should be evaluated. © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 11: Application Tests Application Test Summary

    If the system allow refrigerant/oil to be ingested by the scrolls and is designed to be field charged, it should be overcharged pumped out of the compressor after start-up. © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 12: Assembly Line Procedures Installing The Compressor

    Emerson’s run charge to maintain at least 20 psig (1.4 bar) suction test. The inside of both fittings should be wiped with pressure.

  • Page 13: Final Run Test

    Three phase compressors - If suction the line voltage used to start the compressor, the lower pressure does not drop and discharge pressure the locked rotor amperage will be. © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 14: Compressor Replacement After Motor Burn

    Start-Up of a New or Replacement Compressor trouble-shooting sequence for compressors and It is good service practice, when charging a system systems can be found in Section H of the Emerson with a scroll compressor, to charge liquid refrigerant Climate...

  • Page 15: 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 1 Oil Dilution Chart © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 16: Accumulator Piping

    1 Electrical Cycle Timer Closes: Greater than 5 seconds later, whether (.016 Sec. With 60 HZ Operation) power is restored or not after power is removed Figure 3 Time Delay Wiring © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 17: Compressor Electrical Connection

    Connect the heater so that the connection point straddles the compressor seam weld Seam Weld Seam Weld ZR16-32K5 ZR38-54K5 WARNING Verify the correct crankcase heater voltage for the application and ensure heater is properly grounded. Figure 6 Crankcase Heater © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 18: Scroll Operating Envelope

    Application Engineering B U L L E T I N AE4-1374 R1 Evapora ng Temperature ( °C) Evapora ng Temperature ( °F) Figure 7 R-22 & R-407C Scroll Operating Envelope © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 19: 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. © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 20: How A Scroll Works

    Application Engineering B U L L E T I N AE4-1374 R1 Figure 9 © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 21: Field Application Test

    Mass / Suction muffler May be required (Acts as dampening mass) Table 3 Mounting Parts Model Frame Size Mounting Kit Grommet Sleeve ZR16-32K5 527-0044-15 027-0262-00 028-0188-15 ZR38-54K5 527-0116-00 027-0186-00 028-0188-16 © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 22: Compressor Refrigerant Charge Limits

    Crankcase Heaters Frame Emerson Part No. Model Volts Watts Leads Size (EHP Product) 21" 018-0094-00 ZR16-32K5 21" 018-0094-01 21" 018-0096-00 21" 018-0096-01 21" 018-0096-02 ZR38-54K5 21" 018-0096-03 48" 018-0096-04 48" 018-0096-05 © 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

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