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MAY 2024
Application Engineering
20 to 40 Ton ZP*KC, ZR*KC, & ZH*KC Copeland Scroll
Air Conditioning Compressors
BULLETIN NO:
AE4 -1388 R1
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Table of Contents
Related Manuals for Copeland ZP KC Series
Summary of Contents for Copeland ZP KC Series
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Page 1: Table Of Contents
BULLETIN AE4-1388 R1 MAY 2024 Application Engineering 20 to 40 Ton ZP*KC, ZR*KC, & ZH*KC Copeland Scroll Air Conditioning Compressors BULLETIN NO: AE4 -1388 R1 Contents Safety Reversing Valves Important Safety Information Contaminant Control Responsibilities, Qualifications and Training Oil Type... - Page 2 BULLETIN AE4-1388 R1 MAY 2024 SERVICE PROCEDURES Field Replacement Removing Oil Electrical Compressor Replacement After a Motor Burn Manifolded Compressor Replacement Start-Up of a New or Replacement Compressor Field Troubleshooting the Kriwan Module Refrigerant Retrofits New Installations Field Service Tables and Figures Table 1 - Compressor Features Table 2 - Torque...
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Page 3: Safety
Additionally, a compressor’s refrigerant lines keep refrigerant and oil under pressure. When removing or recharging refrigerant from this component during service, this can pose a pressurized fluid hazard. © 2024 Copeland LP www.copeland.com... -
Page 4: Flammable Refrigerant Hazards
- IMMEDIATELY GET AWAY if you hear unusual sounds in the compressor. They can indicate that terminal pin ejection may be imminent. This may sound like electrical arcing (sizzling, sputtering or popping). However, terminal venting may still occur even if you do not hear any unusual sounds. © 2024 Copeland LP www.copeland.com... - Page 5 POE lubricant. Handle POE oil with care. Refer to the Safety Data Sheet (SDS) for further details. • Before energizing the system: 1. Securely fasten the protective terminal cover or molded plug to the compressor, and 2. Check that the compressor is properly grounded per the applicable system and compressor requirements. © 2024 Copeland LP www.copeland.com...
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Page 6: Signal Word Definitions
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Revision Tracking R1 The document format has been updated to the new Copeland format. All occurrences of "Emerson" have been removed. A note regarding A3 and R290 venting has been update. -
Page 7: Introduction
Figure 5 illustrates the operating envelope for the ZR*KC, ZP*KC and ZH*KC compressors. The operating envelopes The 20 to 40 ton Copeland Scroll compressors do not have represent operating conditions with 20°F (11K) superheat internal pressure relief valves. To avoid abnormally high in the return gas. -
Page 8: Discharge Temperature Protection
All scrolls in this size range have floating valve technology High discharge temperature protection is provided by a to mitigate shut down noise. Since Copeland scroll thermistor probe in the discharge plenum of the scroll. compressors are also excellent gas expanders, they may... -
Page 9: Long Pipe Lengths / High Refrigerant Charge
(available from high refrigerant charge. No attempt should be made to Copeland) and install it in a system with the longest increase the oil level in the sight-glass above the 3/4 full connecting lines and highest internal volume that the level. -
Page 10: Crankcase Heaters
The crankcase heater must be turned on a minimum of 12 hours prior to starting the Since Copeland scroll compressors have very high compressor. This will help prevent oil dilution and bearing volumetric efficiency, their displacements are lower than stress on initial startup. -
Page 11: Contaminant Control
It is generally accepted that system moisture phase event. levels should be maintained below 50 ppm. A filter-drier is required on all POE lubricant systems to prevent solid Copeland Scroll compressors, like several other types of particulate contamination, dielectric... -
Page 12: Power Factor Correction
U.L. recognized safety devices and must be used with all compressors that have TW* and TE* electrical codes Tandem and trio compressor assemblies are available for respectively. Compressors with an "E" in the electrical purchase from Copeland. In lieu of purchasing the code (i.e. ZP236KCE-TED) employ CoreSense™... -
Page 13: Variable Speed Operation Introduction
Drive Selection compressor is now bypassed. Use only temporarily during autotuning sequence. A Copeland EVM or EVH drive can be used with the Run the Autotuning sequence of the drive. compressors. Contact Application Engineering 3. Remove jumper and reconnect control circuit wires... -
Page 14: Vibration
The 20 to 40 ton Copeland scroll compressors are used speed range can be more complex. As a rule of thumb, the WARNING Copeland. 13 AE4-1388 with a CoreSense system should be designed, or the drive control should be protection module. -
Page 15: Installing The Compressor
Copeland’s run test and may also result in oil mist coating thermal expansion valves, and accumulator oil return the suction tube making brazing difficult. The inside of both holes. -
Page 16: Removing Compressors
When Copeland scroll cover distortion and/or shell rupture. compressors are hipot tested with liquid refrigerant in the shell, they can show higher levels of leakage current than Assembly Line System Charging Procedure compressors with the motor on top. -
Page 17: Final Run Test
A 100% activated alumina suction filter drier is ratios and/or long test times. Copeland scroll compressors recommended but must be removed after 72 hours. See are designed for use with refrigerant and testing with... -
Page 18: Field Troubleshooting The Kriwan Module
The thermistor specifications. Recover all of the refrigerant from the protection chain now needs to be tested to determine if the system including the high and low side. Use a tubing cutter © 2024 Copeland LP www.copeland.com... -
Page 19: New Installations
ZP compressors are UL recognized and use with any other refrigerant than originally intended for use will void the compressor UL recognition. For a list of Copeland approved refrigerants please refer to Form 93-11, Refrigerants and Lubricants... -
Page 20: Field Service
✓ Recommended brazing materials: Silfos with minimum 5% silver or silver braze material with flux ✓ Insert tubing stubs into fitting and connect to the system with tubing connectors. ✓ Follow New Installation brazing instructions above. Figure 2 - Nomenclature © 2024 Copeland LP www.copeland.com... - Page 21 BULLETIN AE4-1388 R1 MAY 2024 Figure 3 - ZR & ZP 50/60Hz Operating Envelope Figure 4 - ZP Variable Speed Operating Envelope © 2024 Copeland LP www.copeland.com...
- Page 22 BULLETIN AE4-1388 R1 MAY 2024 Figure 5 - Crankcase Heater Locations Figure 6 - Typical Rotalock Connected Tandem with TPTL Manifold © 2024 Copeland LP www.copeland.com...
- Page 23 BULLETIN AE4-1388 R1 MAY 2024 Figure 7 - Typical Braze Connected Tandem with OEL Manifold Figure 8 - Typical Braze Connected Trio with TPTL Manifold © 2024 Copeland LP www.copeland.com...
- Page 24 BULLETIN AE4-1388 R1 MAY 2024 Figure 9 - Drive Output – Frequency vs. Voltage © 2024 Copeland LP www.copeland.com...
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Page 25: Table 1 - Compressor Features
Table 3 - Refrigerant Charge Limits Charge Limit Model Pounds ZR250KC, ZH100KC 11.3 ZR300-380KC 13.6 ZR & ZH Tandems 20.4 29.5 ZR & ZH Trios ZP235, 236, 296KC 11.3 13.6 ZP285, 295, 385, 485KC ZP Tandems 20.4 ZP Trios 29.5 © 2024 Copeland LP www.copeland.com...
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