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Copeland ZR24KRE Application Manuallines

Scroll compressors for comfort applications
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APPLICATION GUIDELINES
Copeland scroll compressors
for comfort applications
ZR24KRE to ZR190KRE

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Summary of Contents for Copeland ZR24KRE

  • Page 1 APPLICATION GUIDELINES Copeland scroll compressors for comfort applications ZR24KRE to ZR190KRE...

  • 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 Internal pressure relief valve ................14 3.10 Discharge check valve ..................14 3.11 Filter screens ..................... 15 3.12 Mufflers......................15 3.13 Sound and vibration ................... 15 3.14 Compressor oil return, oil balancing, refrigerant floodback & oil dilution tests ..15 3.15 Accumulators .....................
  • Page 4 Replacing a compressor ..................27 6.4.1 Compressor replacement................27 6.4.2 Start-up of a new or replacement compressor ..........27 Lubrication and oil removal ................27 Oil additives ....................... 28 Dismantling & disposal ................... 29 References......................29 Appendix 1: Tightening torques ..................30 AGL_AC_ST_ZRKRE_EN_Rev03...

  • 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

    1.3 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 2.1 Compressor range These application guidelines deal with all vertical single Copeland scroll compressors from ZR24KRE to ZR190KRE for air-conditioning applications. Cooling capacity (kW) Compressor Motor R450A R513A R134a R407C ZR24KRE 3.06 3.54 3,61 5.02 PFJ/TFD ZR28KRE 3.60 4.17...

  • Page 8: Bom Variations

    Braze connections, oil sight glass, oil service connection, IP65 T-box, no mounting parts. More information about available BOM versions can be found in the Copeland price list. Also refer to Technical Information TI_Scroll_BOM "Copeland scroll compressors – BOM Overview", available at www.copeland.com/en-gb...

  • Page 9: Dimensions

    244.5 1/2" 3/4" ZR28KRE ZR36KRE 386.7 361.1 222.8 75.3 49.4 264.4 1/2" 3/4" ZR42KRE 400.4 374.9 235.5 75.3 49.4 277.1 1/2" 3/4" ZR48KRE 417.4 391.9 252.5 75.3 49.4 294.1 1/2" 7/8" Figure 2: Dimensions of models ZR24KRE to ZR48KRE AGL_AC_ST_ZRKRE_EN_Rev03...
  • Page 10 Compressor model A (mm) B (mm) Ø C ZR61KRE to ZR72KRE 437.8 409.6 1/2" ZR81KRE & ZR92KRE 443.2 413.7 3/4" Figure 3: Dimensions of models ZR61KRE to ZR92KRE Compressor model A (mm) B (mm) C (mm) D (mm) ZR108KRE to ZR144KRE 533.2 501.1 122.1...
  • Page 11 Compressor model A (mm) B (mm) C (mm) D (mm) ZR108KRE to ZR144KRE 533.2 501.1 122.1 242.8 ZR160KRE & ZR190KRE 551.5 519.5 140.4 261.2 Figure 5: Dimensions of models ZR108KRE to ZR190KRE - BOM455 AGL_AC_ST_ZRKRE_EN_Rev03...

  • Page 12: Installation

    Installation WARNING High pressure! Injury to skin and eyes possible! Be careful when opening connections on a pressurized item. 3.1 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 13: Mounting Parts

    Mounting parts: ZR24KRE to ZR190KRE – Soft mountings Alternative mounting parts for ZR24KRE to ZR190KRE – Hard mountings Figure 7: Mounting parts NOTE: For more information, please refer to Technical Information TI_Scroll_Mounting_01 "Copeland scroll compressors – Mounting parts".

  • Page 14: Brazing Procedure For Zr*Kre Compressors In Parallel Applications

    For instance, if a connection is coated with flux then the residual oil will be removed when brazing due to the applied heat. If an active oil level control is to be used, eg, OM* Traxoil from Copeland Flow Controls, please refer to the product documentation when brazing the connection adaptor.

  • Page 15: Pressure Safety Controls

    A crankcase heater is used to prevent refrigerant migrating into the shell during standstill periods. Due to the Copeland scroll’s inherent ability to handle liquid refrigerant in flooded conditions a crankcase heater is not required as long as the system charge does not exceed the charge limits indicated in Table 6.

  • Page 16: Soft Starter And Single-Phase Compressor Start Assists

    ▪ Electrical security and safety measures are to be provided on site. 3.7 Soft starter and single-phase compressor start assists Copeland scroll can generally be operated with soft starters. Soft starter versions and sizes should be selected according to the soft starter manufacturer’s recommendations, taking into consideration the compressor amps.

  • Page 17: Excessive Discharge Gas Temperatures

    3.8.2 Internal thermo-disc ZR24KRE to ZR81KRE compressor models have an internal thermo-disc discharge gas temperature protection. This thermo-disc opens a gas passage from the discharge port to the suction side near the motor protector when the discharged gas reaches a critical temperature.

  • Page 18: Internal Pressure Relief Valve

    3.9 Internal pressure relief valve ZR24KRE to ZR92KRE compressors are equipped with an internal pressure relief valve. It opens at a differential pressure of 28 bar ± 3 bar between high- and low-pressure sides. A high-pressure protection must be provided by the system manufacturer/installer for each system and according to EN 378-2, clause 6.2.6.2.

  • Page 19: Filter Screens

    Gas flow through scroll compressors is continuous with relatively low pulsation. External mufflers may not necessarily 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 20: Accumulators

    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. The liquid level in the sight tube has to be observed and recorded too.
  • Page 21 with a fine mesh can easily become plugged causing oil starvation to the compressor bearings. The size of the accumulator depends upon the operating range of the system and the amount of sub-cooling and subsequent head pressure allowed by the refrigerant control. For the correct selection and size of the suction line accumulator, refer to the manufacturer’s specifications.

  • Page 22: Electrical Connection

    Electrical connection 4.1 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. 4.2 Electrical installation WARNING Conductor cables! Electrical shock! Shut off power supply before undertaking any task on electrical equipment.
  • 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 ..Contactor B3 ..Discharge gas thermostat R2 ..Crankcase heater F1 ..

  • Page 24: Terminal Box

    Ensure correct connection of cables to the compressor terminal Fusite to avoid local overheating. Cable glands have an influence on the protection class of the terminal box. Copeland strongly recommends to use appropriate cable glands according to EN 50262 in order to reach the rated protection class.

  • Page 25: Terminal Box - Ip65

    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 26: Start-Up & Operation

    5.1 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 27: System Evacuation

    5.3 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 28: 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. 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 29: 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 30: Maintenance & Repair

    Maintenance & repair WARNING Conductor cables! Electrical shock! 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 31: Replacing A Compressor

    Since POE holds moisture more readily than mineral oil it is more difficult to remove it through the use of vacuum. Copeland compressors contain oil with low moisture content, which however may rise during the system assembling process. Therefore, it is recommended to install a properly sized filter-dryer in all POE systems to maintain the moisture level in the oil to less than 50 ppm.

  • Page 32: Oil Additives

    6.6 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. Furthermore, the long-term chemical stability of any additive in the presence of refrigerant, low and high temperatures, and materials commonly found in refrigeration systems is complex and difficult to evaluate without rigorously controlled chemical laboratory testing.

  • Page 33: Dismantling & Disposal

    Application Guidelines and Technical Information. Performance and technical data: 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.

  • Page 34: Appendix 1: Tightening Torques

    Table 8: Tightening torques 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 35 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.

This manual is also suitable for:

Zr190kreZr28kreZr36kreZr42kreZr48kreZr61kre ... Show all

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