Related Manuals for Copeland ZR18K Series
Summary of Contents for Copeland ZR18K Series
- Page 1 APPLICATION GUIDELINES Copeland scroll compressors for air conditioning ZR18K to ZR380K ZP24K to ZP485K...
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Page 2: Table Of Contents
APPLICATION GUIDELINES Table of contents About these guidelines......................1 Safety instructions ....................1 Icon explanation....................1 Safety statements ....................1 General instructions ..................... 2 Product description....................3 Compressor range ....................3 Nomenclature ...................... 3 BOM variations ....................4 Application range ....................4 2.4.1 Qualified refrigerants and oils ............... - Page 3 Discharge check valve ..................14 Variable Volume Ratio or VVR discharge valve ..........14 3.10 Filter screens ..................... 14 3.11 Mufflers......................14 3.12 Reversing valves ....................14 3.13 Sound and vibration ................... 15 3.14 Compressor oil return, oil balancing, refrigerant floodback & oil dilution tests ..15 3.15 Accumulators .....................
- Page 4 5.14 Minimum run time ....................31 5.15 Supply frequency and voltage ................31 5.16 Oil level......................32 Maintenance & repair ..................... 33 Qualification of workers..................33 Disassembling system components ..............33 Exchanging the refrigerant ................. 33 Rotalock valves....................34 Replacing a compressor ..................34 6.5.1 Compressor replacement................
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Page 5: 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 6: General Instructions
General instructions WARNING Pressurized system! Serious personal injuries and/or system breakdown! Accidental system start before complete set-up must be avoided. Never leave the system unattended without locking it out electrically when it is under vacuum and has no refrigerant charge, when it has a holding charge of nitrogen, or when the compressor service valves are closed. -
Page 7: Product Description
Product description Compressor range These application guidelines deal with all vertical single Copeland scroll compressors for air- conditioning and heat-pump applications, from ZR18K* to ZR380K* and from ZP24K* to ZP485K*. These compressors have one scroll compression set driven by a single or three-phase induction motor. -
Page 8: Bom Variations
Mobil EAL Arctic 22 CC Mobil EAL Arctic 22 CC (max 50% of total oil charge) Table 3: Qualified refrigerants and oils Oil recharge values can be taken from Copeland scroll compressors brochures or Copeland Select software available at www.copeland.com/en-gb/tools-resources. 2.4.2 Application limits CAUTION... -
Page 9: Ped Category And Maximum Allowable Pressure Ps
PED category and maximum allowable pressure PS The nameplate of the compressor contains information about the maximum allowable pressure PS, the minimum and maximum allowed temperature TS, the internal free volumes and the refrigerants qualified for the compressor model range. Values are given for both pressure ranges on low- and high-pressure sides. -
Page 10: Dimensions
Dimensions Figure 1: Drawing A Figure 2: Drawing B Figure Drawing C Compressor model Drawing A ± 3 C ± 3 D ± 3 ZR18K5E 387.4 361.7 256.1 Ø 139.6 ZP24K5E, ZP29K5E, ZP31K5E 385-391 359.3-365.3 260.4-266.4 221.6-227.6 ZR22K3E, ZR28K3E 338.4 244.6 202.4 ZR34K3E... -
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. Respect stacking loads according to Figure 4. -
Page 12: Brazing Procedure
NOTE: For more information please refer to Technical Information TI_Scroll_Mounting_01 "Copeland scroll compressors – Mounting parts". NOTE: If the compressors are mounted in tandem or used in parallel, please refer to Technical Information TI_Scroll_ZR_ZP_Multiple "Copeland scroll compressors – Multiple-compressor assemblies in air-conditioning applications". Brazing procedure... -
Page 13: Shut-Off Valves And Adaptors
Refer to Appendix 1 for proper tightening torques. More information about adaptors and shut-off valves can be found in the Copeland spare parts catalogue, available at www.copeland.com/en-gb/tools-resources. Pressure safety controls 3.5.1 High-pressure protection... -
Page 14: Low-Pressure Protection
12 hours prior to starting the compressor. This will prevent oil dilution and bearing stress on initial start-up. The crankcase heater must remain energized during compressor off cycles. Please refer to the Copeland spare parts & accessories catalogue available at www.copeland.com/en- gb/tools-resources to select the correct crankcase heater model. - Page 15 Crankcase heater Refrigerant Compressors charge limit Position Height ZR18K5E ZP24K5E to ZP31K5E 2.7 kg 5 - 31 mm ZR223E to ZR48 3E ZP23K3E to ZP41K3E 4.5 kg 5 - 12 mm ZR61 KSE ZP36K5E to ZP61K5E ZP61KCE, ZP72KCE, ZR61KCE, ZR72KCE, ZP83KCE, ZP91KCE, 4.5 kg 9.5 - 41 mm...
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Page 16: Soft Starters
Normally, the ramp-up time should not exceed 1 second. Due to the inherent design of the Copeland scroll, the internal compression components start unloaded, even if system pressures are not balanced. Since the compressor internal pressures are balanced at start-up, low voltage starting characteristics are excellent, and starting components are normally not required. -
Page 17: Advanced Scroll Temperature Protection (Astp)
3.6.3 Advanced Scroll Temperature Protection (ASTP) ZR94K* to ZR190K*, ZP90K*, ZP103K*, ZP120K*, ZP137K*, ZP154K* and ZP182K* (Summit range), ZP232K* and ZP292K* compressors are equipped with an Advanced Scroll Temperature Protection (ASTP). ASTP is a temperature sensitive thermo-disc that acts to protect the compressor from discharge gas overheating. -
Page 18: Discharge Check Valve
Gas flow through scroll compressors is continuous with relatively low pulsation. External mufflers may not be required on Copeland scroll compressors. Due to system variability, individual tests should be conducted by the system manufacturer to verify acceptable levels of sound and vibration. -
Page 19: Sound And Vibration
Sound and vibration 3.13 Copeland scroll compressors inherently have low sound and vibration characteristics. However, in some respects, the sound and vibration characteristics differ from reciprocating compressors and in rare instances could result in unexpected sound generation. One difference is that the vibration characteristic of the scroll compressor, although low, includes two very close frequencies, one of which is normally isolated from the shell by the suspension of an internally suspended compressor. -
Page 20: Accumulators
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 If an accumulator is used, the oil-return orifice should be sized based on compressor size and compressor floodback results. To protect this small orifice from plugging with system debris a large-area protective screen no finer than 30 x 30 mesh (0.6 mm openings) is required. Tests have shown that a small screen with a fine mesh can easily become plugged causing oil starvation to the compressor bearings.
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Page 22: Electrical Connection
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. 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. - Page 23 Three-phase compressors (TF*) with internal motor protection: Power circuit Control circuit Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend B1 ....Room thermostat K1, K2 ..Contactors B3 ....Discharge gas thermostat Q1 ....Main switch F1, F6, F8 ..
- Page 24 Three-phase compressors (TW*) with external motor protection INT69SC2: Power circuit Control circuit T1/L S1 S2 T2/N P> P< Motor terminal connections Three-phase compressors are connected to the T1, T2 and T3 connections Legend A1 ....Motor protection module INT69SC2 K1, K2 ..Contactors B1 ....
- Page 25 Three-phase compressors (TE*) with external motor protection CoreSense™ Communications module (compressors ZP232/292KZE, ZP233/293KZE): Power circuit 3~, 50/60Hz, 400V CoreSense PTC 1… 9 Control circuit Motor terminal connections T1/L S1 S2 T2/N P> Three-phase compressors are connected to the T1, T2 and T3 P<...
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Page 26: Terminal Box
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. Copeland recommends that installers/service providers pay attention to this aspect and use cable glands according to EN standards or any other relevant standard of application in their country/region every time they install or replace a scroll compressor. -
Page 27: Motor Insulation
Figure 22: Electrical installation with cable glands, terminal box IP54 Examples of correct electrical installation for compressor models ZR94K* to ZR190K* and ZP90K* to ZP182K* with molded plug are shown in Figure 23: Figure 23: Electrical installation with cable glands, terminal box IP66 Motor insulation The ZR*/ZP* scroll compressors are offered either with a single-phase or a three-phase induction motor, depending on the size. -
Page 28: Kriwan Module
4.5.2 Kriwan module For protection in case of blocked rotor one thermistor for each phase is embedded in the winding heads on the upper (suction gas) side of the compressor motor. A fourth thermistor is located in a winding head at the lower end of the motor. -
Page 29: Kriwan Protector Functional Check And Failure Detection
Kriwan protector functional check and failure detection WARNING Conductor cables! Electrical shock hazard! Shut off power supply before and between each test. Prior to start-up of the fully connected compressor a functional check shall be carried out: ▪ Disconnect one terminal either S1 or S2 of the protection module. If the compressor is now switched on, the motor should not start (simulation of an open thermistor chain). -
Page 30: Coresense Communications Module
CoreSense Communications module Compressor models ZP232/292KZE and ZP233/293KZE (TE*) are equipped with a CoreSense Communications module. The CoreSense Communications module has the following key features: ▪ Motor protection (PTC) ▪ Missing phase protection ▪ Reverse phase protection ▪ Low control circuit voltage protection ▪... -
Page 31: 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 32: Start-Up & Operation
Strength pressure test 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 33: System Evacuation
System evacuation Before the installation is put into commission, it has to be evacuated with a vacuum pump. The installation should be evacuated down to an absolute pressure of 3 mbar. Proper evacuation reduces residual moisture to 50 ppm. During the initial procedure, suction and discharge shut-off valves on the compressor remain closed. -
Page 34: Initial Start-Up
During the very brief start-up, a clicking sound resulting from the initial contacting of the spirals is audible; this sound is normal. Thanks 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 35: Pumpdown Cycle
Minimum run time 5.14 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. To establish the minimum run time, a sample compressor equipped with an external oil sight glass is available from Copeland. -
Page 36: Oil Level
Oil level 5.16 Some systems may contain higher than normal refrigerant charges. Systems with large coils, low ambient condenser flooding, or systems with multiple heat exchangers are among some system configurations that may require additional lubricant. On the scroll compressor models provided with a sight-glass for oil level viewing, the oil level should always be checked during OEM assembly, field commissioning and field servicing. -
Page 37: 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 38: Rotalock Valves
NOTE: If R22 in a system with mineral oil is to be replaced with R407C, the oil must also be changed. Please refer to Technical Information TI_Retrofit_01 "Copeland scroll compressors – Refrigerant changeover from HCFC to HFC refrigerants". -
Page 39: Compressor Return Procedure
Mobil EAL Arctic 22 CC if 3MAF is not available. The standard mineral oil for R22 is Suniso 3GS or Copeland White Oil according to compressor model. See nameplate for original oil charge shown in litres. A field recharge is from 0.05 to 0.1 litre less. -
Page 40: Dismantling & Disposal
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. Spare parts and accessories: An online version of the Copeland spare parts and accessories catalogue is available from the webpage www.copeland.com/en-gb/tools-resources. AGL_AC_ST_ZR_ZP_EN_Rev02... -
Page 41: Appendix1: Tightening Torques
Terminal block screw DISCLAIMER: 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. Products, specifications, assumptions, designs and technical data contained in this document are subject to modification by us without prior notice. - Page 42 Tel. +49 (0) 2408 929 0 - Fax: +49 (0) 2408 929 570 – Internet: copeland.com/en-gb The Copeland logo is a trademark and service mark of Copeland LP or one of its affliates. Copeland Europe GmbH shall not be liable for errors in the stated capacities, dimensions, etc., as well as typographic errors.
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