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MAY 2024
Application Engineering
Application Guidelines for ZB*KCE and legacy ZB*KC Copeland Scroll
Refrigeration Compressors 7 to 15 HP
BULLETIN NO:
AE-1318 R13
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3.3.Field Application Test
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BULLETIN AE-1318 R13
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Table of Contents
Troubleshooting
Related Manuals for Copeland ZB KCE Series
Summary of Contents for Copeland ZB KCE Series
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Page 1: Table Of Contents
BULLETIN AE-1318 R13 MAY 2024 Application Engineering Application Guidelines for ZB*KCE and legacy ZB*KC Copeland Scroll Refrigeration Compressors 7 to 15 HP BULLETIN NO: AE-1318 R13 Contents Safety 2.19.System Screens & Strainers Important Safety Information 2.20.Contaminant Control 2.21.Oil Type & Removal Responsibilities, Qualifications and Training 2.22.Three Phase scroll Compressor Electrical... - Page 2 Table 1 - Kriwan Module P/N 5.4.Start-up of a New or Replacement Compressor 5.5.Field Trouble Shooting the Kriwan Module 5.6.Field Troubleshooting CoreSense Communications Module 5.7.Copeland Scroll Compressor Functional Check 5.8.Refrigerant Retrofits Tables and Figures Table 1 - ZR*KC,ZH*KC and ZP*KC...
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Page 3: Safety
Additionally, a compressor’s refrigerant lines copeland.com/terminal-venting 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
BULLETIN AE-1303 R18 MAY 2024 Introduction The 7 to 15 ton ZR*KC, ZH*KC and ZP*KC Copeland scroll the same compressor will have approximately 5/6 of this compressors are designed for a wide variety of light capacity or 74,500 Btu/hr (21.8kW) when operated at 50 commercial air-conditioning, heat pump, and chiller applications. -
Page 8: Internal Pressure Relief (Ipr) Valve
2.4. Discharge Line Thermostat A high pressure control must be used in all A discharge temperature thermostat is not an application applications. requirement because of the built-in ASTP feature that These models of Copeland scroll compressors do not protects compressor against abnormally high have internal pressure relief valves. -
Page 9: Low Pressure Control
2.7. Shut Down Device compressor equipped with a sight tube (available from Copeland) and install it in a system with the longest connecting lines that are approved for the system. The All scrolls in this size range have floating valve technology minimum on time becomes the time required for oil lost to mitigate shut down noise. -
Page 10: Suction And Discharge Fittings
A second difference of the Copeland scroll compressor is The oil level must be carefully monitored during system that under some conditions the normal rotational starting motion of the compressor can transmit an “impact”... -
Page 11: Accumulators
Table 4 lists Copeland crankcase heaters operating envelope. The low-pressure control should be by part number and voltage. See Figure 6for the proper set to open no lower than 5 to 10F°... -
Page 12: Reversing Valves
Reversing valve sizing must be within the guidelines of the Contaminant Control 2.20. valve manufacturer. Required pressure drop to ensure valve shifting must be measured throughout the operating Copeland scroll compressors leave the factory with a range of the unit and compared to the valve manufacturer's miniscule amount contaminants. -
Page 13: Three Phase Scroll Compressor Electrical Phasing
3MAF, or Nu Calgon 4314-66 (Emkarate RL32-3MAF) achieved when the system is installed and operated. should be used. Copeland Ultra 22 CC, Hatcol EAL 22CC, Verification of proper rotation direction is made by and Mobil EAL Arctic 22 CC are acceptable alternatives. -
Page 14: Manifolded Compressors
Tandem compressor assemblies are available for design allows the individual oil levels in each compressor purchase from Copeland. In lieu of purchasing the to be viewed, which isn't possible with the TPTL. assembled tandem, the OEM can choose to purchase the Manifolded Applications 2.26. -
Page 15: Motor Overload Protection
ZP182KCE-TWD) have a motor overload system that consists of an external electronic control module connected to a chain of four thermistors embedded in the motor windings. The module will trip and remain off for a © 2024 Copeland LP www.copeland.com... -
Page 16: Continuous Floodback
(disabling the defrost possibly be covered in this bulletin. Please consult with control and spraying water on the outdoor coil may be Application Engineering on applications outside of those outlined above for the appropriate application tests. © 2024 Copeland LP www.copeland.com... -
Page 17: Assembly Line Procedures
Many OEM customers buy the mounting parts directly from Before attempting to braze, it is important to recover all the supplier, but Copeland's grommet design and refrigerant from both the high and low side of the system. durometer recommendations should be followed for best If the refrigerant charge is removed from a scroll equipped vibration reduction through the mounting feet. -
Page 18: Pressure Testing
55 psig (3.8 bar) suction escape is not acceptable. pressure for R-410A and 20 psig (1.4 bar) for R-22 & R407C. Do not operate the compressor with the low © 2024 Copeland LP www.copeland.com... -
Page 19: Hipot" (Ac High Potential) Testing
OEL option the Schrader fittings can now be removed by unscrewing Copeland scroll compressors are configured with the motor them. Removing the Schrader fittings exposes the stub down and the pumping components at the top of the shell. -
Page 20: Electrical
This is because the charge liquid into the low side of the system with the compressor operating. accumulator oil return orifice or screen may be plugged with debris or may become plugged shortly after a © 2024 Copeland LP www.copeland.com... -
Page 21: Field Trouble Shooting The Kriwan Module
Re-energize the control circuit and module power. If the compressor will not operate with the jumper © 2024 Copeland LP www.copeland.com... -
Page 22: Field Troubleshooting Coresense Communications Module
Copeland for compressor. The following diagnostic procedure should be warranty analysis are determined to have nothing used to evaluate whether a Copeland scroll compressor is found wrong. They were misdiagnosed in the field as working properly. -
Page 23: Liquid Line Filter-Driers
R-22 system. Only those bulletins listed below, or contact your Application Engineer. refrigerants approved by Copeland and the OEM should be considered. For a list of Copeland approved refrigerants please refer to Form 93-11, Refrigerants and Lubricants CoreSense Communications for 13 Approved for Use in Copeland Compressors. - Page 24 BULLETIN AE-1303 R18 MAY 2024 Figure 1 - How a scroll Works © 2024 Copeland LP www.copeland.com...
- Page 25 BULLETIN AE-1303 R18 MAY 2024 Figure 2 - ZR R407C, R22 and R134a 50/60 Hertz Operation Envelope Figure 3 - ZP R410A 50/60 Hertz Operation © 2024 Copeland LP www.copeland.com...
- Page 26 BULLETIN AE-1303 R18 MAY 2024 Figure 4 - ZH R134A/R513A 50/60 Hertz Operation © 2024 Copeland LP www.copeland.com...
- Page 27 BULLETIN AE-1303 R18 MAY 2024 Figure 5 - ASTP Label © 2024 Copeland LP www.copeland.com...
- Page 28 BULLETIN AE-1303 R18 MAY 2024 Figure 6 - Crankcase Heater Location © 2024 Copeland LP www.copeland.com...
- Page 29 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 30 BULLETIN AE-1303 R18 MAY 2024 Figure 8 - Tandem Oil Balancing Figure 9 - Tilted Tandem © 2024 Copeland LP www.copeland.com...
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Page 31: Table 2 - Field Application Test
"Angled valve" fastened to unit Suction muffler Not required Alternate Configuration Component Description Tubing Configuration Shock loop Service Valve "Straight through" valve not fastened to unit Suction muffler May be required (acts as dampening mass) © 2024 Copeland LP www.copeland.com... -
Page 32: Table 4 - Compressor Accessories & Service Parts
Suction Rotalock O-Ring Seal 020-0028-03 Rotalock Service Valve, Suction 1- 998-0510-46 3/8" Suction & Rotalock Service Valve, Discharge Discharge 998-0510-90 7/8" Discharge Rotalock Adapter to 7/8" 998-0034-08 Sweat Suction Rotalock Adapter to 1-3/8" 998-0034-13 Sweat © 2024 Copeland LP www.copeland.com... -
Page 33: Table 5 - Refrigerant Charge Limits
885-975 100-110 Discharge Rotalock Valve 95-103 1150-1240 130-140 Suction Rotalock Valve 125-132 1505-1593 170-180 Schrader Valve 3.3-5.0 40-60 4.5-6.8 Terminal Block Screws 10-32 Green Ground Screw M6 Terminal Box Mounting Stud Nuts 2.6-3.2 31.9-38.9 3.6-4.4 © 2024 Copeland LP www.copeland.com... -
Page 34: Kriwan To Coresense Communications Retrofit Instructions For Zr160-190Kc & Zp154-182Kc Compressors
Kriwan modules that are non- operational and out of warranty should be field scrapped in the appropriate manner. If you have any questions, please contact your Copeland Engineer or visit Copeland Mobile. - Page 35 Install the CoreSense module in the Revision Tracking R18 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 ©...
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