Related Manuals for Copeland ZH04KCU
Summary of Contents for Copeland ZH04KCU
- 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 3.17 Suction line accumulators ....................16 Electrical connection ..................17 4.1 General recommendations..................... 17 4.2 Electrical installation ...................... 17 4.3 Terminal box ........................19 Terminal box – IP54 ................... 20 4.3.1 Terminal box – IP65 ................... 20 4.3.2 4.4 Motor insulation ......................21 4.5 Motor protection ......................
- Page 4 Dismantling & disposal .................. 37 References ...................... 37 Appendix 1: Tightening torques ................38 DISCLAIMER ......................38 AGL_HP_ST_ZHKCU_EN_Rev02...
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Page 6: About These Guidelines
About these guidelines The purpose of these guidelines is to provide guidance in the application of Copeland scroll compressors in users’ systems. They are intended to answer the questions raised while designing, assembling and operating a system with these products. -
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 are permitted to commission, initiate and maintain the compressor or refrigeration systems;... -
Page 8: Product Description
▪ ATEX Directive 94/9/EC part: II 3G ▪ Standard part (EN 60079-0, EN 60079-15): Ex nA IIA T2 Please refer to the Copeland price list for more details. The Declaration of Conformity is available from the manufacturer upon request. AGL_HP_ST_ZHKCU_EN_Rev02... -
Page 9: Application Range
Servicing oil POE Hatcol 4467 (Ident Number 8410785) Table 3: Qualified refrigerant and oil Oil recharge values can be taken from the compressor nameplate or from Copeland Select software available at www.copeland.com/en-gb/tools-resources. NOTE: R290 is classified as A3 flammable refrigerant. -
Page 10: Dimensions
Figure 2: External dimensions BOM versions 424 & 524 – Front & top views Figure 3: External dimensions BOM versions 434 & 534 – Front & top views Model 534/434 168.85 247.5 252.6 ZH04KCU 364.4 69.6* 165.8 115.5 96.9 58.2 524/424 173.5... -
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 handling equipment according to weight. Keep in the upright position. -
Page 12: Mounting Parts
M9 5/16") are recommended. The mounting torque should be 27 ± 1 Nm. See Copeland spare parts catalogue at www.copeland.com/en-gb/tools-resources for references. Mounting parts ZH04KCU to ZH16KCU - Soft mountings Figure 5: Mounting parts Brazing procedure WARNING Air/flammable refrigerant mixture! Creation of a potentially flammable atmosphere! Fire hazard! Remove all refrigerant before opening the system. -
Page 13: Brazing Procedure For Zh*Kcu Compressors In Parallel Applications
Never braze pipes with oil inside. Only compressor models officially approved by Copeland 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
The minimum cut-out setting shall be determined according to the refrigerant and the allowed operation envelope – see Select software at www.copeland.com/en-gb/tools-resources. System protection for operation below atmospheric pressure... -
Page 15: Crankcase Heater
Caution: Crankcase heaters must be properly grounded! NOTE: Because of the continuous possibility of circuit leakage, only a crankcase heater proven as non-source of ignition can be used. Copeland has qualified crankcase heaters for individual compressor ranges and applications with flammable refrigerants. These crankcase heaters are verified as non-sources of ignition if properly installed. -
Page 16: Discharge Gas Temperature Protection
In order to ensure positive compressor protection, discharge gas temperature protection is required for any application with Copeland compressors. The maximum discharge gas temperature is 135 °C for models ZH04KCU to ZH08KCU and 130 °C... -
Page 17: Discharge Line Thermostat
Copeland 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 18: Internal Pressure Relief Valve
10 to 15 3.12 Sound shell At this time, no sound shell attenuation for ZH*KCU compressors is available from Copeland. 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: Reversing Valves
3.14 Reversing valves Since Copeland scroll compressors have a very high volumetric efficiency, their displacements are lower than those of comparable capacity reciprocating compressors. As a result, Copeland 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 reversing valve under all operating conditions. -
Page 20: Compressor Oil Return, Oil Balancing, Refrigerant Floodback And Oil Dilution Tests
Systems with multiple compressors (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 Copeland 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 21: Suction Line Accumulators
3.17 Suction line accumulators Due to Copeland scroll’s inherent ability to handle liquid refrigerant, for example in flooded start and defrost cycle operation, an accumulator is not required in most systems. To determine if a suction line accumulator is required, the system designer must check this with an appropriate test scenario. -
Page 22: Electrical Connection
For safety reasons, Copeland 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 23 Figure 15 The required parameters for the run capacitor for each single-phase compressor are shown in Table 9 below: Compressor Run capacitor Ident nr. Part nr. ZH04KCU-PFJN 45 µF / 370 V 8414743 914-0009-02 ZH06KCU-PFJN 50 µF / 370 V 8414754...
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Page 24: Terminal Box
Fusite pins which might lead to refrigerant leaks. Cable glands have an influence on the protection class of the terminal box. Copeland strongly recommends using appropriate cable glands according to EN 50262 in order to reach the rated protection class. -
Page 25: Terminal Box - Ip54
4.3.1 Terminal box – IP54 ZH*KCU compressors with BOM 534 (single compressor) and BOM 434 (tandem-ready compressor) are supplied with an IP54 terminal box. This terminal box variation cannot be applied in an ATEX environment. Figure 17: IP54 T-Box with terminal block for ring terminal connectors Torque grounding Torque terminal Compressor... -
Page 26: Motor Insulation
The first two nuts already installed on the Peko bolts shall not be removed, as they will ensure good tightness of the terminal box assembly. Make sure to assemble the ground connection of the Peko bolt with a torque of 4 - 4.4 Nm and the ground connection between the cover and the body of the terminal box with a torque of 1.8 - 2 Nm. -
Page 27: High-Potential Testing
Copeland 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 28: Start-Up & Operation
DO NOT USE other industrial gases. 5.1.1 Compressor strength-pressure test The compressor has been strength-pressure tested in the Copeland 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 29: 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 Copeland factory. All compressors get a factory holding charge of dry air (about 1 to 2.5 bar, relative pressure). The presence of an intact holding charge serves as a proof of quality against penetrating moisture. -
Page 30: Charging Procedure
▪ pressure and compound gauges fitted; ▪ correctly charged with refrigerant; ▪ compressor electrical isolator location & position. 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. -
Page 31: Start-Up And Shut-Off Sound
During the very brief start-up, a clicking sound resulting from the initial contacting of the spirals is audible; this sound is normal. Due to the design of the Copeland scroll compressors, the internal compression components always start unloaded even if system pressures are not balanced. In addition, since internal compressor pressures are always balanced at start-up, low voltage starting characteristics are excellent for Copeland scroll compressors. -
Page 32: Shell Temperature
5.13 Minimum run time Copeland 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 33 Copeland for lab testing. 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. See also section 3.16 "Compressor oil return, oil balancing, refrigerant floodback and oil dilution tests".
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Page 34: Maintenance & Repair
Maintenance & repair WARNING Conductor cables! Electrical shock hazard! 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 35: Disassembling System Components
If any work is to be conducted on the refrigeration systems or any associated parts, appropriate fire extinguishing equipment shall be provided. Dry powder or CO fire extinguishers are considered appropriate. Verify that appropriate fire extinguishing equipment is available near the work area. Prior to starting to work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimized. -
Page 36: Replacing A Compressor
It is not necessary to replace the refrigerant unless contamination, for example due to an error such as topping up the system with a non-condensable gas or incorrect refrigerant, is suspected. To verify correct refrigerant composition, a sample can be taken for chemical analysis. A check can be made during shutdown by comparing the refrigerant temperature and pressure using precision measurements at a location in the system where liquid and vapour phases are present and when the temperatures have stabilised. -
Page 37: Lubrication And Oil Removal
Figure 23:Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 25°C and 50 % relative humidity (h= hours) The oil contained in Copeland compressors has a low moisture content, which however may rise during the system assembling process. Therefore, it is recommended to install a properly sized filter-... -
Page 38: Oil Additives
Oil additives Although Copeland 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 39: Troubleshooting
Troubleshooting WARNING Electrical cables! Electrical shock hazard! 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 40 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 41 Cause Corrective action Excessive Too high Make sure the compressor operates within the acceptable discharge compressor superheat range published by Copeland. temperature superheat Excessive cooling / Check the load design; make sure that proper insulation is applied. heating load or Correct as necessary.
- Page 42 The latest version of Copeland Select software with performance data and technical data is available from the webpage www.copeland.com/en-gb/tools-resources/copeland-select-software. Spare parts and accessories: An online version of the Copeland spare parts & accessories catalogue is available from the webpage www.copeland.com/en-gb/tools-resources. AGL_HP_ST_ZHKCU_EN_Rev02...
- Page 43 2. Copeland Europe GmbH and/or its affiliates (collectively "Copeland"), as applicable, reserve the right to modify the design or specifications of such products at any time without notice. 3. Copeland does not assume responsibility for the selection, use or maintenance of any product.
- Page 44 Tel. +49 (0) 2408 929 0 - Fax: +49 (0) 2408 929 570 - Internet: www.copeland.com/en-gb The Copeland logo is a trademark and service mark of Copeland LP or one of its affiliates. Copeland Europe GmbH shall not be liable for errors in the stated capacities, dimensions, etc., as well as typographic errors.
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