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JUNE 2024
Application Engineering
1 to 5 Ton ZP*K6 R-410A Copeland Scroll Compressors
BULLETIN NO:
AE4-1400 R3
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Related Manuals for Copeland ZP K6 Series
Summary of Contents for Copeland ZP K6 Series
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Page 1: Table Of Contents
BULLETIN AE4-1400 R3 JUNE 2024 Application Engineering 1 to 5 Ton ZP*K6 R-410A Copeland Scroll Compressors BULLETIN NO: AE4-1400 R3 Contents Safety Oil Type Important Safety Information Contaminant Control Responsibilities, Qualifications and Training Long Line Sets/High Refrigerant Charge Terminal Venting and Other Pressurized System... - Page 2 BULLETIN AE4-1400 R3 JUNE 2024 Start-Up of a New or Replacement Compressor: 19 Figures & Tables Figure 1 R-410A Scroll Operating Envelope Figure 2 Oil Dilution Chart Figure 3 Time Delay Wiring Figure 4 Compressor Electrical Connection Figure 5 Crankcase Heater Figure 6 Scroll Suction Tube Brazing Figure 7 How Scroll Works Figure 8 Suction Funnel Diagram...
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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
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. © 2024 Copeland LP www.copeland.com... -
Page 7: Introduction
JUNE 2024 Introduction Application Considerations ZP*K6 Copeland scroll compressors are designed with a The following application guidelines should be considered number of patented features to deliver a 2 to 4% in the design of a system using ZP*K6 scroll compressors. -
Page 8: Heat Pump Protection
See Table pressure cut-out should have a manual reset feature for 4 for recommended Copeland part numbers. the highest level of system protection. If a compressor is allowed to cycle after a fault is detected, there is a high... -
Page 9: Shut Down Device
ZP*K6 compressors employ a unitary shutdown device to The use of accumulators is very dependent on the manage the flow of top-cap discharge gas back through application. The Copeland Scroll compressor’s inherent the scrolls after shutdown. Development testing should ability to handle liquid refrigerant during occasional... -
Page 10: Crankcase Heat - Single Phase
(available from Copeland) and install it in a compressor may start and trip the internal overload system with the longest connecting lines that are approved protector several times before running. -
Page 11: Low Ambient Cut-Out
25% activated alumina, should be used for ounces (118 ml) less than the nameplate value. If service applications. additional oil is needed in the field, Copeland Ultra 32-3MAF, Lubrizol Emkarate RL32-3MAF,... -
Page 12: Discharge Mufflers
When no testing is performed, mufflers are recommended accommodate the down turned lip of the hole. Table 4 lists in heat pumps. A hollow shell muffler such as the Copeland the mounting parts kits to be used with these compressors. -
Page 13: Ptc Start Components
10 to 25 ohms may be used to facilitate starting for Suction and Discharge Fittings any of these compressors. SecureStar is sold by Copeland to reduce inrush current Copeland scroll compressors have copper plated steel by up to 75% on single phase Copeland scroll suction and discharge fittings. -
Page 14: Brief Power Interruptions
At this time, ZPK*6 compressors have not been qualified for tandem applications. There is no negative impact on durability caused by operating three phase Copeland scroll compressors in the Maximum Tilt Angle reversed direction for a short period of time (under one hour). -
Page 15: Continuous Floodback Test
The tests outlined above are for the common air fall below 0°F (-18°C). The compressor sump temperature conditioning heat pump applications © 2024 Copeland LP www.copeland.com... -
Page 16: Assembly Line Procedures
Copeland’s run test. The inside of both fittings should be wiped with a lint free cloth to remove Never pressurize the compressor to more than 475 residual oil prior to brazing. -
Page 17: Assembly Line System Charging Procedure
BULLETIN AE4-1400 R3 JUNE 2024 submerged in oil and refrigerant. When Copeland scroll Assembly Line System Charging Procedure compressors are hipot tested with liquid refrigerant in the shell, they can show higher levels of leakage current than Systems should be charged with liquid on the high side to compressors with the motor on top. -
Page 18: Unbrazing System Components
"Scott-T" connection and don't have equal seconds. The following diagnostic procedure should be used to evaluate whether a Copeland scroll compressor resistances on all three windings. Two windings will have equal resistances and the third winding will be up is functioning properly: ©... -
Page 19: Compressor Replacement After A Motor Burn
Start-Up of a New or Replacement Compressor: It is good service practice, when charging a system with a scroll compressor, to charge liquid refrigerant into the high side only. It is not good practice to dump liquid refrigerant © 2024 Copeland LP www.copeland.com... - Page 20 BULLETIN AE4-1400 R3 JUNE 2024 Figures & Tables Figure 1 R-410A scroll Operating Envelope © 2024 Copeland LP www.copeland.com...
- Page 21 Note 1: Operation in this refrigerant dilution area is safe in air-to-air heat pump heating mode. For other applications, such as AC only, review expansion device to raise superheat. A cold sump may result in high refrigerant migration after shut down. © 2024 Copeland LP www.copeland.com...
- Page 22 BULLETIN AE4-1400 R3 JUNE 2024 Figure 3 Time Delay Wiring Figure 4 Compressor Electrical Connection © 2024 Copeland LP www.copeland.com...
- Page 23 BULLETIN AE4-1400 R3 JUNE 2024 Figure 5 Crankcase Heater © 2024 Copeland LP www.copeland.com...
- Page 24 Area 3. This will draw the braze material down into the joint. The time spent heating Area 3 should be minimal. • As with any brazed joint, overheating may be detrimental to the final result © 2024 Copeland LP www.copeland.com...
- Page 25 BULLETIN AE4-1400 R3 JUNE 2024 Figure 7 How scroll Works © 2024 Copeland LP www.copeland.com...
- Page 26 BULLETIN AE4-1400 R3 JUNE 2024 Figure 8 Suction Funnel Diagram Suc on Funnel Typical Funnel Suc on Tube Back of Funnel Oil Drain Hole © 2024 Copeland LP www.copeland.com...
- Page 27 Service Valve "Straight through" valve not fastened to unit Mass/Suction muffler May be required (Acts as dampening mass) Table 3 Refrigerant Charge Limits Compressor Charge Limit System Charge Limit Model Pounds Pounds ZP10-31K6 ZP34-54K6 10.0 12.0 © 2024 Copeland LP www.copeland.com...
- Page 28 1-Phase Only, has "L" Terminal Comfort Alert Module 543-0038-02 3-Phase Only Comfort Alert Module 543-0038-02 1-Phase Only, Geothermal Discharge Line Thermostat 998-7022-02 Conduit Ready, fits 1/2" tube Suction Manifold Discharge Manifold Future Offering Oil Equalization Tube © 2024 Copeland LP www.copeland.com...
- Page 29 Tandem Mounting Kit, Rails to Unit Tandem Rails Revision Tracking R3 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 updated © 2024 Copeland LP...
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