Related Manuals for Copeland ZB50KCE
Summary of Contents for Copeland ZB50KCE
- Page 1 APPLICATION GUIDELINES Copeland scroll compressors for refrigeration ZB50KCE to ZB114KCE, ZB66K5E to ZB114K5E ZF34K5E to ZF54K5E...
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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 ...................... 3 Application range....................4 2.4.1 Qualified refrigerants and oils ................ - Page 3 3.11 Suction accumulators ..................14 3.12 ZF*K5E compressors for low temperature applications ........14 3.12.1 ZF*K5E compressors with liquid injection ............ 14 3.12.2 ZF*K5E compressors with vapour injection ..........15 3.12.3 ZF*K5E compressors with wet vapour injection ........... 16 Electrical connection ....................17 General recommendations ..................
- Page 4 6.5.2 Start-up of a new or replacement compressor ..........25 6.5.3 Compressor return procedure ..............25 Lubrication and oil removal.................. 26 Oil additives ......................26 Dismantling & disposal..................... 27 References....................... 27 Appendix 1: Tightening torques ................... 28 AGL_Ref_ST_ZB_ZF_Sum_EN_Rev00...
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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 vertical single Copeland scroll compressors ZB50KCE to ZB114KCE & ZB66K5E to ZB114K5E for medium temperature refrigeration applications, and ZF34K5E to ZF54K5E for low temperature refrigeration applications. These compressors have one scroll compression set driven by a three-phase induction motor. The scroll set is mounted at the upper end of the rotor shaft of the motor. -
Page 8: Application Range
Servicing oils Emkarate RL32 3MAF, Mobil EAL Arctic 22 CC Table 2: 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 Comparison between ZB*KCE and ZB*K5E compressors ZB*KCE and ZB*K5E models are based on the same compressor platform, but there are slight differences. -
Page 9: Dimensions
Internal free volume PS low PS high TS max. low Compressor pressure side pressure side pressure side LP side HP side ZB50KCE to ZB76KCE 22.6 bar(g) 32 bar(g) 50 °C 12.6 L 1.5 L ZB95KCE, ZB114KCE 22.6 bar(g) 32 bar(g) 50 °C 12.9 L... -
Page 10: 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 3. -
Page 11: Brazing Procedure
If the compressors are mounted in tandem or used in parallel, then the hard mountings (bolt M9 5/16") are recommended. The mounting torque should be 27 ± 1 Nm. It is possible to deliver these hard-mounting parts as a kit. See Copeland spare parts and accessories catalogue at www.copeland.com/en-gb/tools-resources references. -
Page 12: Shut-Off Valves And Adaptors
Copeland scroll compressors are delivered with a discharge check valve fitted inside the discharge port and rubber plugs fitted to the suction and discharge ports as standard. There are options to fit either Rotalock valves or Rotalock adaptors. -
Page 13: Pressure Safety Controls
The crankcase heater must be mounted below the oil Schraeder valve located on the bottom shell, 40 mm above compressor feet – see Figure 7. Figure 7: Crankcase heater location 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 14: Discharge Gas Temperature Protection
In order to ensure positive compressor protection, discharge gas temperature protection is required for any application with Copeland compressors. -
Page 15: Advanced Scroll Temperature Protection (Astp)
3.7.2 Advanced Scroll Temperature Protection (ASTP) Copeland scroll compressor models ZB50KCE to ZB114KCE 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 16: Screens
Discharge thermostat DTC valve cap DTC valve Figure 14: Example of ZF*K5E-TFD installation, liquid injection with DTC valve and discharge thermostat on the discharge line Assembly of the discharge line thermostat For installation, please follow the recommendations below. ▪ Install the discharge line thermostat on the discharge tube 120 mm from top cap. -
Page 17: Mufflers
A second difference of the Copeland scroll is that under some conditions the normal rotational starting motion of the compressor can transmit an "impact" noise along the suction line. This may be particularly pronounced in three-phase models due to their inherently higher starting torque. -
Page 18: Suction Accumulators
Suction accumulators 3.11 CAUTION Inadequate lubrication! Bearing destruction! Minimise liquid refrigerant returning to the compressor. Too much refrigerant dilutes the oil. Liquid refrigerant can wash the oil off the bearings leading to overheating and bearing failure. Irrespective of system charge, oil dilution may occur if large amounts of liquid refrigerant repeatedly flood back to the compressor during: ▪... -
Page 19: Zf*K5E Compressors With Vapour Injection
3.12.1.1 DTC valve specifications ▪ Opening setpoint: 121 °C ± 3 K ▪ Liquid line connection: 3/8" 3.12.1.2 Valve installation The valve bulb must be installed in the top cap to adequately control scroll temperatures. The DTC valve should be tightened on the injection fitting to a torque of 24-27 Nm. It is recommended that the valve be located perpendicular to the compressor orientation. -
Page 20: Zf*K5E Compressors With Wet Vapour Injection
During the sub-cooling process a small amount of refrigerant is evaporated and superheated, then injected into the mid-compression cycle of the scroll compressor and compressed to discharge pressure. This injected vapour also provides cooling at higher compression ratios, similar to liquid injection of standard ZF* scroll compressors. -
Page 21: 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 22: 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 23: Motor Windings
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 24: Starting 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 25: System Evacuation
System evacuation Before the installation is put into commission, it has to be evacuated with a vacuum pump. Proper evacuation reduces residual moisture to 50 ppm. During the initial procedure, suction and discharge shut- off valves on the compressor remain closed. The installation of adequately sized access valves at the furthest point from the compressor in the suction and liquid lines is advisable. -
Page 26: 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 27: Pumpdown Cycle
Minimum run time 5.13 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 28: 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 29: Replacing A Compressor
6.5.3 Compressor return procedure Compressors from systems with A1 refrigerant can be sent back to Copeland for diagnosis with closed connections and the oil filling inside. However, the refrigerant should be removed. ▪ The compressor must be kept in the upright position – mark the box accordingly. -
Page 30: Lubrication And Oil Removal
Figure 23: Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 25 °C and 50 % relative humidity (h=hours) 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 31: 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 32: Appendix 1: Tightening Torques
2.4 - 2.6 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 33 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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