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Summary of Contents for Emerson Copeland ZH16KCU
- Page 1 Application Guidelines Copeland Scroll Compressors ™ for R290 Applications ZH04KCU to ZH16KCU...
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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 ......................2 1.3 General instructions ......................2 Product description ..................3 2.1 Compressor range ......................3 2.2 Nomenclature ........................3 2.3 BOM Variations ........................ 3 2.4 Application range ...................... - Page 3 Electrical connection ..................16 4.1 General recommendations..................... 16 4.2 Electrical installation ...................... 16 4.3 Terminal box ........................18 Terminal box – IP54 ................... 19 4.3.1 Terminal box – IP65 ................... 19 4.3.2 4.4 Motor insulation ......................20 4.5 Motor protection ......................20 4.6 High-potential testing .....................
- Page 4 Dismantling & disposal .................. 36 References ...................... 36 Appendix 1: Tightening torques ................37 DISCLAIMER ......................37 AGL_HP_ST_ZHKCU_E_Rev00...
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Page 6: About These Guidelines
NOTE: Only dedicated compressors are allowed to be used with flammable refrigerants. Emerson marks all compressors that are qualified for flammable refrigerants with a sticker indicating the usage of such refrigerants. Systems using flammable refrigerants must be executed correctly while observing safety rules, as specified in corresponding safety standards such as, but not limited to EN 378. -
Page 7: Safety Statements
Safety statements ▪ Refrigerant compressors must be employed only for their intended use. The system has to be labelled according to the applicable standards and legislation. ▪ Only qualified and authorized RACHP (refrigeration, air conditioning and heat pump) personnel are permitted to install, commission and maintain this equipment. Only competent personnel (as specified in EN 13313) qualified for flammable refrigerant handling is permitted to commission, initiate and maintain the compressor/refrigeration systems;... -
Page 8: Product Description
Tandem-ready Table 2: BOM designation Please refer to the Emerson price list for more details. Compressor versions BOM 524 and BOM 424 contain a terminal box IP65, which complies with the ATEX Directive 94/9/EC part II 3G. The compressor label conforms to the ATEX Directive 2014/34/EU specifications and to the harmonized standard series EN 60079. -
Page 9: Application Range
POE Hatcol 4467 (Ident Number 8410785) type Table 3: Qualified refrigerant and oil Oil recharge values can be taken from the compressor nameplate or from Copeland Select software available at www.climate.emerson.com/en-gb. 2.4.2 Application limits CAUTION Inadequate lubrication! Compressor breakdown! The superheat at the compressor suction inlet must always be sufficient to ensure that no refrigerant droplets enter the compressor. -
Page 10: Dimensions
Dimensions Figure 2: Compressor dimensions Model 534/434 168.85 247.5 252.6 ZH04KCU 364.4 69.6* 524/424 173.5 254.4 534/434 185.75 247.5 252.6 49˚ ZH06KCU 75.3* 165.8 115.5 96.9 58.2 524/424 193.4 254.4 534/434 198.43 247.5 252.6 ZH08KCU 400.8 75.3* 524/424 206.1 254.4 ZH09KCU 534/434 437.8... -
Page 11: Installation
Installation WARNING High pressure! Injury to skin and eyes possible! Be careful when opening connections on a pressurized item. Compressor handling 3.1.1 Transport and storage WARNING Risk of collapse! Personal injuries! Move compressors only with appropriate mechanical or handling equipment according to weight. Keep in the upright position. -
Page 12: Mounting Parts
If the compressors are mounted in tandem or used in parallel, then the hard mountings (bolt M9 5/16") are recommended. The mounting torque should be 27 ± 1 Nm. See Emerson spare parts software for references. Mounting parts ZH04KCU to ZH16KCU - Soft mountings... -
Page 13: Brazing Procedure For Zh*Kcu Compressors In Parallel Applications
When working on a refrigerant-filled system, make sure to follow the safety and working instructions given in the Chapter 6 "Maintenance & repair". Only compressor models officially approved by Emerson in the qualified configuration may be used for parallel applications. For ZH*KCU compressors in parallel applications with passive oil management, additional precautions shall be taken before brazing the oil and gas equalization ports. -
Page 14: Low-Pressure Protection
Emerson requires that ZH*KCU compressors be fitted with a low-pressure control, with no service valve between the low-pressure side and the pressure control. -
Page 15: Discharge Gas Temperature Protection
Crankcase heaters to be used in ATEX Zone 2 locations must comply with the ATEX Directive requirements. Non ATEX-certified crankcase heaters shall NOT be used in ATEX Zone 2 locations. NOTE: The crankcase heater presently available from Emerson is not ATEX-certified and can only be used in non-flammable environments. -
Page 16: Excessive Discharge Gas Temperatures
Emerson can supply an ATEX discharge line thermostat which can be used with A3 refrigerants. It can also be used in an ATEX zone 2 or non-ATEX environment. This thermostat is marked with a special ATEX label –... -
Page 17: Internal Pressure Relief Valve
Assembly of the discharge line thermostat ▪ Install the discharge line thermostat on the discharge tube 120 mm from top cap. ▪ Snap the retainer clip over the tube and onto the thermostat. ▪ The thermostat should be placed on the discharge tube so that its body is in upward position on a horizontal tube installation. -
Page 18: Mufflers
10 to 15 3.11 Sound shell At this time, no sound shell attenuation for ZH*KCU compressors is available from Emerson. If a sound shell is needed, particular attention shall be paid to its non-electrostatic properties – see EN 60079-0, clause 7.4. -
Page 19: Compressor Oil Return, Oil Balancing And Floodback Tests
(two, three, or more) require additional oil balancing qualification between the parallel compressors. A sample compressor equipped with an external oil sight tube can be ordered from Emerson for lab testing. Records of the evaporating temperature and the bottom shell temperature shall be taken with a high sampling rate during the entire oil return or oil balance testing and under all tested conditions. -
Page 20: Suction Line Accumulators
below. In case of operation in the (red) unsafe area, adjustments are required in order to modify the system design, refrigerant charge or superheat setting of the expansion device(s). The bottom shell temperature should be measured accurately. The thermo-probe must be positioned on the opposite side of the sight glass or at an angle of 90°... -
Page 21: Electrical Connection
For safety reasons, Emerson recommends that the electrical installation be executed in compliance with standard EN 60204-1 and/or other standards and regulations of application when dealing with A3 flammable refrigerants. - Page 22 Single-phase compressors (PF*) with internal motor protection: Power circuit Control circuit Motor terminal connections Single phase compressors are connected to the C, S and R connections Legend B1 ....System controller K1, K2 ..Contactors B3 ....Discharge gas thermostat Q1 ...
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Page 23: Terminal Box
Fusite pins which might lead to refrigerant leaks. Cable glands have an influence on the protection class of the terminal box. Emerson strongly recommends using appropriate cable glands according to EN 50262 in order to reach the rated protection class. -
Page 24: Terminal Box - Ip54
4.3.1 Terminal box – IP54 ZH*KCU compressor versions with BOM 534 (single compressor) and BOM 434 (tandem-ready compressor) are available in a version with terminal box IP54. These terminal box variations cannot be applied in an ATEX environment. Figure 16: IP54 T-Box and correct electrical installation with cable gland Compressor model Grounding screw Terminals screw... -
Page 25: Motor Insulation
Figure 18: IP65 T-Box and correct electrical installation Make sure to assemble the cable gland M25 with a torque of 9.8 - 10 Nm. The cable gland is designed for cable diameters of 10 to 17 mm – see Figure 19 & Table 10. The degree of protection (IP) will be safeguarded only if sealing and cable glands are properly assembled. -
Page 26: High-Potential Testing
Emerson subjects all scroll compressors to a high-voltage test after final assembly. Each motor phase winding is tested according to EN 60034-1 at a differential voltage of 1000 V plus twice the nominal voltage. -
Page 27: Starting Up & Operation
DO NOT USE other industrial gases. 5.1.1 Compressor strength-pressure test The compressor has been strength-pressure tested in the Emerson factory. Therefore, it is not necessary for the system manufacturer/installer to strength-pressure test the compressor again. Scroll compressors are divided into two pressure zones. The compressor high-side and low-side maximum allowable pressures PS have to be respected at all times. -
Page 28: Compressor Tightness Test
System contamination! Bearing malfunction! Use only dry inert gases (for example nitrogen) for leak testing. DO NOT USE other industrial gases. The compressor has been leak-pressure tested in the Emerson factory. All compressors get a factory holding charge of dry air (about 1 to 2.5 bar, relative pressure). An intact holding charge serves as a proof of quality against penetrating moisture. -
Page 29: Charging Procedure
Charging procedure WARNING Air/R290 refrigerant mixture in a potentially flammable or explosive atmosphere! Fire and explosion hazard! Only use filling equipment designed and approved for use and operation with R290 refrigerant. Make sure all connections are tight to avoid leakage. Make sure to fill with pure R290 refrigerant. -
Page 30: Starting Sound
Observing that suction pressure drops and discharge pressure rises when the compressor is energized allows verification of proper rotation direction. There is no negative impact on durability caused by operating three-phase Copeland scroll compressors in the reverse direction for a short period of time (under one hour) but oil may be lost. -
Page 31: Minimum Run Time
5.13 Minimum run time Emerson 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. The most critical consideration is the minimum run time required to return oil to the compressor after start-up. - Page 32 Figure 20: Sample compressor equipped with an oil level glass Height Total Interior Exterior Width level glass height ± 65 mm ± 145 mm ± 250 mm ± 270 mm ± 70 mm Table 12: Dimensions of level glass The sample compressors can be used for oil return check in single or tandem applications. Oil return check test recommendations for paralleling are available on request.
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Page 33: Maintenance & Repair
Maintenance & repair WARNING Conductor cables! Electrical shock! Follow the lockout/tag out procedure and the national regulations before carrying out any maintenance or service work on the system. Use compressor with grounded system only. Screwed electrical connections must be used in all applications. Refer to original equipment wiring diagrams. Electrical connections must be made by qualified electrical personnel. -
Page 34: Preparation And Work Procedure
Preparation and work procedure A work procedure shall be provided in the preparation stage. All maintenance staff and others working at the site shall be instructed on the nature of the work being carried out. If any work is to be conducted on the refrigeration systems or any associated parts, appropriate fire extinguishing equipment shall be provided. -
Page 35: Replacing A Compressor
CAUTION Low suction pressure operation! Compressor damage! Do not operate with a restricted suction. Do not operate with the low-pressure limiter bridged. Do not operate compressor at pressures that are not allowed by the operating envelope. Allowing the suction pressure to drop below the envelope limit for more than a few seconds may overheat scrolls and cause early drive bearing and moving parts damage. -
Page 36: Lubrication And Oil Removal
Since POE holds moisture more readily than mineral oil it is more difficult to remove it through the use of vacuum. The compressors supplied by Emerson contain oil with low moisture content, which may rise during the system assembling process. Therefore, it is recommended that a properly sized filter-drier be installed in all POE systems. -
Page 37: Oil Additives
Oil additives Although Emerson cannot comment on any specific product, from our own testing and past experience, we do not recommend the use of any additives to reduce compressor bearing losses or for any other purpose. -
Page 38: Troubleshooting
Troubleshooting WARNING Electrical cables! Electrical shock! Before attempting any electrical troubleshooting, make sure all grounds are connected and secure and there is ground continuity throughout the compressor system. Also ensure the compressor system is correctly grounded to the power supply. If you are not a qualified service person familiar with electrical troubleshooting techniques, DO NOT PROCEED until a qualified service person is available. - Page 39 Condition Cause Corrective action Compressor Check if there is continuity on the compressor external protector. If motor the compressor is warm, it may require considerable time to cool protector open down. Defective Check if the pressure control or thermostat works properly or if the system control controls are open.
- Page 40 Cause Corrective action Excessive Too high Make sure the compressor operates within the acceptable discharge compressor superheat range published by Emerson. temperature superheat Excessive cooling / Check the load design; make sure that proper insulation is applied. heating load or Correct it as necessary.
- Page 41 Performance and technical data: The latest version of Copeland Select software with performance data and technical data is available from the webpage www.climate.emerson.com/en-gb. Spare parts and accessories: Visit www.climate.emerson.com/en-gb/tools-resources for an online version of the Emerson spare parts and accessories software. AGL_HP_ST_ZHKCU_E_Rev00...
- Page 42 3. Emerson does 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.
- Page 43 The Emerson logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners.
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