Related Manuals for Emerson Copeland Scroll ZH04K1P
Summary of Contents for Emerson Copeland Scroll ZH04K1P
- Page 1 Copeland Scroll Compressors for Heat Pumps with R410A ZH04K1P to ZH19K1P, ZHI05K1P to ZHI46K1P...
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Page 2: Table Of Contents
About these guidelines ....................1 Safety instructions .................... 1 1.1 Icon explanation ......................... 1 1.2 Safety statements ......................1 1.3 General instructions ......................2 Product description ..................3 2.1 Common information about Copeland Scroll™ compressors ..........3 2.2 Nomenclature ........................3 2.3 Application range ....................... - Page 3 4.6 Kriwan protector functional check and failure detection ..........20 4.6.1 Checking the connection ..................21 4.6.2 Checking the compressor thermistor chain ............21 4.6.3 Checking the protection module ................21 4.7 High-potential testing ....................... 21 Starting up & operation................... 22 5.1 Strength pressure test ......................
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Page 4: About These Guidelines
Besides the support they provide, the instructions listed herein are also critical for the proper and safe functioning of the compressors. Emerson cannot guarantee the performance and reliability of the product if it is misused in regard of these guidelines. -
Page 5: General Instructions
General instructions WARNING System breakdown! Personal injuries! Never install a system in the field and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system. System breakdown! Personal injuries! Only approved refrigerants and refrigeration oils must be used. -
Page 6: Product Description
Common information about Copeland Scroll™ compressors The Scroll compressor has been under development at Emerson Climate Technologies since 1979. It is the most efficient and durable compressor Emerson Climate Technologies has ever developed for air-conditioning, refrigeration and heating applications. These application guidelines deal with all vertical single Copeland Scroll compressors for dedicated heat pump applications from ZH04K1P to ZH19K1P. -
Page 7: Application Range
Copeland Scroll compressors are qualified for operation inside the envelope published by Emerson Climate Technologies. The envelope is defined according to Emerson Climate Technologies testing and experience. Operating a compressor outside the envelope might lead to compressor failure which would be the heat pump manufacturer’s responsibility. The superheat at the compressor suction inlet must always be sufficient to ensure that no refrigerant droplets enter the compressor. - Page 8 This can be achieved by the use of wet vapour injection. For further information about wet vapour injection, contact Application Engineering at Emerson Climate Technologies. NOTE: For information and design recommendations regarding vapour injection, please refer to Technical Information C7.4.3 "Vapour injection Scroll compressors for heat...
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Page 9: Dimensions
Dimensions ZH04K1P, ZH05K1P ZH06K1P to ZH12K1P ZHI18K1P for tandem ZHI05K1P ZHI08K1P to ZHI23K1P ZHI23K1P for tandem ZH15K1P, ZH19K1P ZHI27K1P to ZHI32K1P ZHI35K1P, ZHI40K1P C6.2.26/1013-1116/E... - Page 10 ZHI46K1P C6.2.26/1013-1116/E...
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Page 11: Installation
The suction stub on compressor models ZHI27K1P to ZHI46K1P is located at low level. Oil might flow through the suction stub and get trapped in the system. To avoid this, Emerson Climate Technologies strongly recommends mounting the suction piping turning vertically upward from the compressor connection. -
Page 12: Mounting Parts
lubrication. For multiple compressor parallel configurations, the compressors must be positioned completely vertically on a totally horizontal surface or rail. 3.1.4 Mounting parts The compressors are designed to be mounted on vibration absorber grommets (part of the standard delivery). The grommets dampen the start-up surge of the compressor and minimise sound and vibration transmission to the compressor base during operation. -
Page 13: Accumulators
Copeland Scroll compressors have copper-plated steel suction, injection and discharge tubes. These tubes are far more robust and less prone to leaks than copper tubes. Due to the different thermal properties of steel and copper, brazing procedures may have to be changed from those commonly used. Refer to Figure 5 and procedure below for the brazing of the suction and discharge lines to a Scroll Figure 5: Suction tube connecting areas... -
Page 14: Screens
Reversing valves Since Copeland Scroll compressors have a very high volumetric efficiency their displacements are lower than those of equivalent capacity reciprocating compressors. As a result, Emerson Climate Technologies recommends that the capacity rating on reversing valves be no more than 1.5 to 2 times the nominal capacity of the compressor in order to ensure proper operation of the... -
Page 15: Suction Line Noise And Vibration
compressor. This results in a condition of system pressures equalising through the compressor which can cause the compressor to slowly rotate until the pressures equalise. This condition does not affect compressor durability but can cause unexpected sound after the compressor is turned off. -
Page 16: Electrical Connection
Electrical installation 4.2.1 Wiring diagrams The recommended wiring diagrams are shown in figures hereunder. NOTE: Emerson Climate Technologies recommends using a contactor K2 for the safety chain in order to comply with EN 60335. Single-phase (PF*) compressors For the ZH04K1P to ZH12K1P and ZHI05K1P & ZHI11K1P ranges of compressors the following... - Page 17 Three-phase compressors (TF*) with internal motor protection For the ZH04K1P to ZH19K1P and ZHI05K1P to ZHI40K1P ranges of compressors the following circuit diagrams can be used: Power circuit Control circuit P> P< Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend B1 ....
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Page 18: Terminal Box
Three-phase compressors (TWD) with external motor protection INT69SU2 For ZHI46K1P compressors the following circuit diagrams can be used: Power circuit Control circuit T1/L S1 S2 T2/N P> P< Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend A1 .... -
Page 19: Motor Winding
Emerson Climate Technologies advises installers/service providers to pay attention to this aspect every time they install or replace a Copeland Scroll compressor and to use cable glands according to EN 50262 or any other relevant standard of application in their country/region. -
Page 20: Protection Devices
The motor insulation material is class "B" (PF* and TF*) or "H" (TW*) for compressor models covered in these guidelines. 4.2.4 Protection devices Independently from the internal motor protection, fuses must be installed before the compressor. The selection of fuses has to be carried out according to VDE 0635, DIN 57635, IEC 269-1 or EN 60-269-1. -
Page 21: Pressure Safety Controls
(expansion valve, screens...) – the evaporating conditions may be such that the compressor will tend to operate outside the Emerson operating envelope limits. All those conditions may starve the compressor in refrigerant and oil, and may result in compressor failure. -
Page 22: Motor Protection
Temperature Resistance Temperature Resistance in °C in KΩ in °C in KΩ 2889.60 10.79 1522.20 7.87 834.72 5.85 475.74 4.45 280.82 3.35 171.17 2.58 107.44 2.02 86.00 1.59 69.28 1.25 45.81 1.01 Spring coil 30.99 0.83 21.40 0.68 15.07 Figure 17: NTC-sensor in top cap and resistance values for compressors ZHI18K1P and ZHI23K1P tandem ready BOM 477 and ZHI27K1P to ZHI46K1P In case the NTC top cap sensor shown in Figure 17 has to be replaced please refer to the Spare parts catalogue available at... -
Page 23: Kriwan Protector Functional Check And Failure Detection
a winding head at the lower end of the motor. The entire chain is internally led to the fusite from where it is connected to the module connections S1 and S2. When any resistance of the thermistor chain reaches the tripping value, the module interrupts the control line and causes the compressor to switch off. -
Page 24: Checking The Connection
Emerson Climate Technologies subjects all Scroll compressors to a high-voltage test after final assembly. Each motor phase winding is tested, according to EN 0530 or VDE 0530 part 1, at a differential voltage of 1000V plus twice the nominal voltage. -
Page 25: Starting Up & Operation
Starting up & operation WARNING Diesel effect! Compressor destruction! The mixture of air and oil at high temperature can lead to an explosion. Avoid operating with air. Strength pressure test The compressor has been strength-tested in the factory. It is not necessary for the customer to strength- or leak-test the compressor again although the compressor will normally be exposed to the testing made as part of system testing. -
Page 26: Initial Start-Up
Initial start-up CAUTION Oil dilution! Bearing malfunction! It is important to ensure that new compressors are not subjected to liquid abuse. Turn the crankcase heater on 12 hours before starting the compressor. CAUTION High discharge pressure operation! Compressor damage! Do not use compressor to test opening set point of high-pressure cut-out. -
Page 27: Pump-Down Cycle
5.12 Minimum run time Emerson Climate Technologies recommends a maximum of 10 starts per hour. There is no minimum off time because scroll compressors start unloaded, even if the system has unbalanced pressures. -
Page 28: Oil Level
During the system development, adequate oil return in any operation should be checked whatever the compressor model. For this purpose, sample compressors equipped with sight tubes can be ordered from Emerson Climate Technologies. Oil return check test recommendations are also available on demand from Application Engineering. -
Page 29: Maintenance & Repair
Maintenance & repair Exchanging the refrigerant Qualified refrigerants and oils are given in section 2.3.1. It is not necessary to replace the refrigerant with new unless contamination due to an error such as topping up the system with an incorrect refrigerant is suspected. To verify correct refrigerant composition, a sample can be taken for chemical analysis. -
Page 30: Oil Additives
Compressors supplied by Emerson Climate Technologies contain oil with low moisture content, and it may rise during the system assembling process. Therefore it is recommended that a properly sized filter-drier is installed in all POE systems. -
Page 31: Troubleshooting
Troubleshooting Most in-warranty electrical failures are a result of mechanical problems (particles in the oil, liquid refrigerant in the oil, etc.) and most mechanical problems are a result of system problems. Unless the reason for the failure is found, replacing the compressor will probably lead to another compressor failure. - Page 32 Condition Cause Corrective action Defective Check if the pressure control or thermostat works system control properly or if the controls are open. components Power circuit Check the fuse for a tripped circuit breaker or for an open open disconnected switch. ...
- Page 33 Too high Make sure the compressor operates within the compressor acceptable superheat range published by Emerson. superheat Excessive cooling/heating Check the load design; make sure that proper load or insulation is applied.
- Page 34 Condition Cause Corrective action System design If the compressor is running in a tandem or in parallel, load too small modulate the running process. Lower normal discharge pressure values can lead to Low suction Inadequate insufficient refrigerant flow to the system. pressure refrigerant This can also be verified by checking the evaporator...
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Page 35: Dismantling & Disposal
The latest version of Emerson Climate Technologies Select software with performance data and technical data is available from our home page. Spare parts and accessories: The latest version of Emerson Climate Technologies spare parts tool with spare parts and accessories is available from our home page. DISCLAIMER 1. - Page 36 Tel. +49 (0) 2408 929 0 - Fax: +49 (0) 2408 929 570 - Internet: www.emersonclimate.eu The Emerson Climate Technologies logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co.