Related Manuals for Emerson ZB15K Series
Summary of Contents for Emerson ZB15K Series
- Page 1 Application Guidelines Scroll Compressors for Refrigeration ZB15K* to ZB220K*, ZS21K* to ZS11M* ZF06K* to ZF48K*, ZF13KVE to ZF48KVE...
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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 ........................4 2.3 Application range ....................... - Page 3 4.5 Motor protection ....................... 19 4.6 Phase protection ......................20 4.7 Protector functional check and failure detection .............. 20 4.7.1 Checking the connection ..................20 4.7.2 Checking the compressor thermistor chain ............20 4.7.3 Checking the protection module ................21 4.8 High-potential testing .......................
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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 Climate Technologies will not 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 and refrigeration. These application guidelines deal with all vertical single Copeland Scroll compressors for refrigeration applications from ZB15K* to ZB220K*, ZS21K* to ZS11M* and ZF06K* to ZF48K*, including vapour injection compressors. -
Page 7: Nomenclature
* EN 12900 Conditions for medium temperature: Evaporating temperature ..-10°C Suction gas return temperature ..20°C Condensing temperature ..45°C Liquid sub-cooling ......0K ** EN 12900 Conditions for low temperature: Evaporating temperature ..-35°C Suction gas return temperature ..20°C Condensing temperature .. -
Page 8: Application Range
Application range 2.3.1 Qualified refrigerants and oils IMPORTANT It is essential that the glide of refrigerant blends (primarily R407C and R407F) is carefully considered when adjusting pressure and superheat controls. Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland™ brand products Select software. -
Page 9: 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 10: Brazing Procedure
Mounting parts: ZB15K* to ZB48K* & ZB57K*, ZS21K* to ZS45K*, ZF06K* to ZF18K* - Soft mountings Mounting parts: ZB56K* to ZB11M*, ZS56K* to ZS11M*, ZF24K* to ZF48K* - Soft mountings Mounting parts: ZB220K* - Soft mountings Figure 2: Mounting parts Brazing procedure IMPORTANT Blockage! Compressor breakdown! Maintain a flow of oxygen-free... -
Page 11: Copeland Scroll Compressors With Liquid Injection
DTC valve can be used for all compressors and approved refrigerants. For the selection of adequate liquid injection parts such as DTC valve and discharge thermostat, refer to the Emerson Climate Technologies spare parts software at www.emersonclimate.eu. The ZF compressors include a well in the top cap combined with a valve cap. The Copeland DTC valve is equipped with a custom bulb profile, which must be installed in the top well of the compressor sensing the temperature closest to the discharge port. -
Page 12: Current Sensing Relay
3.3.2 Current sensing relay The current sensing relay only concerns ZF compressors, namely models ZF06K* to ZF18K* with liquid injection and models ZF13KVE to ZF18 KVE with vapour injection using capillary tubes. Power to the injection solenoid must be cut if the internal motor protector trips and the danger of flooding the compressor arises. -
Page 13: Copeland Scroll Compressors With Vapour Injection
R404A/R507 I.D. Length I.D. Length Model (inch) (inch) (inch) (inch) ZF24K4E 0.050" 30" 0.050" 5" ZF33K4E 0.050" 17.5" 0.050" 5" ZF40K4E 0.070" 30" 0.070" 30" ZF48K4E 0.070" 30" 0.070" 10" Table 4: Capillary tube details A standard On/Off solenoid valve such as Alco 110 RB 2T2 should be used. The valve should have a port diameter of at least 1.4 mm and should be wired to open when the compressor is running and to close: ... -
Page 14: Shut-Off Valves And Adaptors
Shut-off valves and adaptors CAUTION Leaking system! System breakdown! It is strongly recommended to periodically re-torque all pipe and fixing connections to the original setting after the system has been put into operation. Figure 9 Copeland Scroll compressors are delivered with a discharge check valve fitted inside the discharge port and rubber plugs fitted to the suction and discharge ports as standard. -
Page 15: Screens
accumulator must be used, the oil-return orifice should be from 1 to 1.4 mm in diameter for models ZB15K* to ZB48K*, ZB57K*, ZS19K* to ZS45K*, ZF06K* to ZF18K* and 2.0 mm for models ZB56K* to ZB11M*, ZS56K* to ZS11M*, ZF24K* to ZF48K* depending on compressor size and compressor flood-back results. - Page 16 Recommended configuration Tubing configuration: ...small shock loop Service valve: ....."angled” valve fastened to unit / wall Suction muffler: ....not required Alternative configuration Tubing configuration: ...small shock loop Service valve: ......."straight through" valve fastened to unit / wall ...
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Page 17: Electrical Connection
Electrical connection General recommendations The compressor terminal box has a wiring diagram on the inside of its cover. Before connecting the compressor, ensure the supply voltage, the phases and the frequency match the nameplate data. Electrical installation Single-phase (PF*) compressors: Power circuit Control circuit Motor terminal connections... - Page 18 Three-phase compressors (TF*) with internal motor protection: For the ZB15K* to ZB48K*, ZB57K*, ZS19K* to ZS45K*, ZF06K* to ZF18K* TF* range of compressors the following circuit diagrams can be used: Power circuit Control circuit Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend B1 ..
- Page 19 Three-phase compressors (TW*) with external motor protection INT69SCY2: For the ZB56K* to ZB220K*, ZS56K* to ZS11M*, ZF24K* to ZF48K* TW* range of compressors the following circuit diagrams can be used: Power circuit Control circuit Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend A ..
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Page 20: Terminal Box
4.2.1 Terminal box The standard terminal box is IP21 for all models with internal motor protection (TF*/PF*) and IP54 for all models with external motor protection (TW*), enclosure class according to IEC 60034-5. Cable glands have an influence on the protection class of the terminal box. It is strongly recommended to use appropriate cable glands in order to reach the rated protection class. -
Page 21: Protection Devices
4.2.3 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 269-1or EN 60-269-1. 4.2.4 Crankcase heaters IMPORTANT Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours before starting the compressor. -
Page 22: Discharge Temperature Protection
Discharge temperature protection The use of an external discharge thermostat is required for compressor models ZF06K* to ZF18K*, ZF13KVE to ZF18KVE and ZS21K* to ZS45K*. A discharge thermostat can be used but is not mandatory for compressor models ZB15K* to ZB45K* because these models have an internal thermodisc which is positioned next to the discharge port of the scroll set. -
Page 23: Phase Protection
Module The INT69SCY2 hermetic motor protection module complies with IEC/EN 60335. module features mean that refrigeration system would still be in a safe condition even if two faults were to occur. Backup is provided if the first fault protection should fail. An additional control contactor should be fitted to the system. -
Page 24: Checking The Protection Module
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. IMPORTANT Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours before starting the compressor. Strength pressure test The compressor has been strength-tested in the factory. -
Page 26: Preliminary Checks - Pre-Starting
Preliminary checks – Pre-starting Discuss details of the installation with the installer. If possible, obtain drawings, wiring diagrams, etc. It is ideal to use a check-list but always check the following: Visual check of the electrics, wiring, fuses etc ... -
Page 27: 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 reversed direction for a short period of time (under one hour) but oil may be lost. Oil loss can be prevented during reverse rotation if the tubing is routed at least 15 cm above the compressor. -
Page 28: Minimum Run Time
To establish the minimum run time obtain a sample compressor equipped with a sight tube (available from Emerson Climate Technologies) and install it in a system with the longest connecting lines that are approved for the system. The minimum on time becomes the time required for oil lost during compressor start-up to return to the compressor sump and restore a minimal oil level that will ensure oil pick-up through the crankshaft. -
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: Lubrication And Oil Removal
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: Unbrazing System Components
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 32 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.
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