Emerson Copeland Scroll ZB50KCE Manuals

Copeland Scroll™ Compressors for Refrigeration ZB50KCE to ZB114KCE, ZB66K5E to ZB114K5E ZF25K5E to ZF54K5E Application Guidelines C6.2.27/0716-0219/E About these guidelines ............................................................................................... 1 1 Safety instructions ........................................................................................... 1 1.1 Icon explanation ............................................................................................................... 1 1.2 Safety statements ............................................................................................................ 1 1.3 General instructions ......................................................................................................... 2 2 Product description ......................................................................................... 3 2.1 Common information about Copeland Scroll compressors ............................................. 3 2.2 Nomenclature ................................................................................................................... 3 2.3 BOM Variation .................................................................................................................. 3 2.4 Application range ............................................................................................................. 4 2.4.1 Qualified refrigerants and oils .............................................................................. 4 2.4.2 Comparison between ZB*KCE and ZB*K5E compressors .................................. 4 2.4.3 Application limits ................................................................................................... 4 3 Installation ........................................................................................................ 5 3.1 Compressor handling ....................................................................................................... 5 3.1.1 Transport and storage .......................................................................................... 5 3.1.2 Positioning and securing ...................................................................................... 5 3.1.3 Installation location ............................................................................................... 5 3.1.4 Mounting parts ...................................................................................................... 5 3.2 Brazing procedure ............................................................................................................ 6 3.3 Shut-off valves and adaptors ........................................................................................... 7 3.4 Suction accumulators ....................................................................................................... 7 3.5 Screens ............................................................................................................................ 8 3.6 Mufflers ............................................................................................................................ 8 3.7 Suction line noise and vibration ....................................................................................... 8 4 ZF*K5E compressors for low temperature applications ................................ 9 4.1 ZF*K5E compressors with liquid injection ........................................................................ 9 4.1.1 DTC valve specifications ...................................................................................... 9 4.1.2 Valve installation .................................................................................................. 9 4.1.3 Compressor or valve service .............................................................................. 10 4.2 ZF*K5E compressors with vapour injection ................................................................... 10 4.2.1 Economized Vapour Injection technology (EVI) ................................................. 10 4.2.2 Multiple compressor applications ....................................................................... 10 4.3 ZF*K5E compressors with wet vapour injection ............................................................ 11 5 Electrical connection ..................................................................................... 12 5.1 General recommendations............................................................................................. 12 5.2 Electrical installation ...................................................................................................... 12 5.3 Terminal box .................................................................................................................. 13 5.3.1 Motor windings ................................................................................................... 14 5.3.2 Protection devices .............................................................................................. 14 C6.2.27/0716-0219/E 5.3.3 Crankcase heaters ............................................................................................. 14 5.4 Pressure safety controls ................................................................................................ 14 5.4.1 High pressure control ......................................................................................... 14 5.4.2 Low pressure control .......................................................................................... 14 5.5 Discharge temperature protection ................................................................................. 15 5.5.1 ASTP Advanced Scroll Temperature Protection ................................................ 15 5.5.2 Discharge line thermostat................................................................................... 15 5.6 Motor protection ............................................................................................................. 17 5.7 High-potential testing ..................................................................................................... 17 6 Starting up & operation.................................................................................. 18 6.1 Strength pressure test .................................................................................................... 18 6.2 Tightness/pressure test .................................................................................................. 18 6.3 System evacuation ......................................................................................................... 18 6.4 Preliminary checks – Pre-starting .................................................................................. 18 6.5 Charging procedure ....................................................................................................... 19 6.6 Initial start-up ................................................................................................................. 19 6.7 Rotation direction ........................................................................................................... 19 6.8 Starting sound ................................................................................................................ 20 6.9 Deep vacuum operation ................................................................................................. 20 6.10 Shell temperature ........................................................................................................... 20 6.11 Pump-down cycle ........................................................................................................... 20 6.12 Minimum run time .......................................................................................................... 20 6.13 Shut-off sound ................................................................................................................ 21 6.14 Frequency ...................................................................................................................... 21 6.15 Oil level .......................................................................................................................... 21 7 Maintenance & repair ..................................................................................... 22 7.1 Exchanging the refrigerant ............................................................................................. 22 7.2 Rotalock valves .............................................................................................................. 22 7.3 Replacing a compressor ................................................................................................ 22 7.3.1 Compressor replacement ................................................................................... 22 7.3.2 Start-up of a new or replacement compressor ................................................... 22 7.4 Lubrication and oil removal ............................................................................................ 22 7.5 Oil additives ................................................................................................................... 23 7.6 Unbrazing system components ..................................................................................... 23 8 Dismantling & disposal .................................................................................. 24 DISCLAIMER .............................................................................................................. 24 C6.2.27/0716-0219/E 1 About these guidelines The purpose of these application 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. Besides the support they provide, the instructions listed herein are also critical for the proper and safe functioning of the compressors. Emerson will not guarantee the performance and reliability of the product if it is misused in regard of these guidelines. These application guidelines cover stationary applications only. For mobile applications, contact Application Engineering as other considerations may apply. 1 Safety instructions Copeland Scroll compressors are manufactured according to the latest European and US Safety Standards. Particular emphasis has been placed on the user’s safety. These compressors are intended for installation in systems in accordance with the Machinery Directive MD 2006/42/EC. They may be put to service only if they have been installed in these systems according to instructions and conform to the corresponding provisions of legislation. For relevant standards please refer to the Manufacturers Declaration, available at www.climate.emerson.com/en-gb. These instructions should be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety instructions. 1.1 Icon explanation WARNING This icon indicates instructions to avoid personal injury and material damage. CAUTION This icon indicates instructions to avoid property damage and possible personal injury. High voltage This icon indicates operations with a danger of electric shock. IMPORTANT This icon indicates instructions to avoid malfunction of the compressor. Danger of burning or frostbite This icon indicates operations with a danger of burning or frostbite. NOTE This word indicates a recommendation for easier operation. Explosion hazard This icon indicates operations with a danger of explosion. 1.2 Safety statements ▪ Refrigerant compressors must be employed only for their intended use. ▪ Only qualified and authorized HVAC or refrigeration personnel are permitted to install, commission and maintain this equipment. ▪ Electrical connections must be made by qualified electrical personnel. ▪ All valid standards for connecting electrical and refrigeration equipment must be observed. ▪ The national legislation and regulations regarding personnel protection must be observed. Use personal safety equipment. Safety goggles, gloves, protective clothing, safety boots and hard hats should be worn where necessary.

1 AE-1318 R1 © 2008 Emerson Climate Technologies Printed in the U.S.A. Application Engineering B U L L E T I N APPLICATION GUIDELINES FOR ZB*KC/ZB*KCE COPELAND SCROLL® REFRIGERATION COMPRESSORS 7 TO 15 HP AE4-1318 R1 June 2008 Application Engineering B U L L E T I N Introduction The Copeland Scroll® ZB*KC/ZB*KCE refrigeration compressor product offering has expanded to include higher horsepower models. These new models include 7-15 Hp and produce between 50,000 Btu/H and 114,000 Btu/H at 20/120°F using 60 Hz electrical power. This bulletin covers the application parameters recommended for operating these compressors properly. Nomenclature The ZB*KC/ZB*KCE refrigeration scroll model number includes two digits that indicate the amount of cooling capacity in thousands of Btu/H at the 60 Hz ARI rating point (20/120°F) with R404A in the third and fourth location. (e.g. ZB92KC produces approximately 92,000 Btu/H). For actual compressor performance information please visit Emerson Climate Technologies Online Product Information at www.emersonclimate.com Operating Envelope The Copeland Scroll refrigeration models can be used with a variety of refrigerants. Table 1 shows these selection options. The operating envelopes are depicted in Figures 1A, 1B, 1C, 1D, 1E and 1F. Figure 1B ZB95KCE & ZB114KCE Application Envelope for R404A/R507 MT Applications 7-15Hp TABLE 1 Model Refrigerant Lubricant ZB50KC/E R22/407/R404A/507/134a MO/POE ZB58KC/E R22/407/R404A/507/134a MO/POE ZB66KC/E R22/407/R404A/507/134a MO/POE ZB76KC/E R22/407/R404A/507/134a MO/POE ZB88KC/E R22 MO/POE ZB95KC/E R22/R404A/507/134a MO/POE ZB114KC/E R22/R404A/507/134a MO/POE ZB56KC/E R22/R404A/507/134a MO/POE ZB68KC/E R22/R404A/507/134a MO/POE ZB75KC/E R22/R404A/507/134a MO/POE ZB92KC/E R22/R404A/507/134a MO/POE ZB11MC/E R22/R404A/507/134a MO/POE Figure 1A ZB*KCE (excluding ZB95KCE & ZB114KCE) Application Envelope for R404A/R507 MT Applications 7-15Hp 20 F SH 2 © 2008 Emerson Climate Technologies Printed in the U.S.A. AE-1318 R1 Application Engineering B U L L E T I N Voltage / Frequency Restrictions Due to inadequate cooling from refrigerant fl ow through the compressor, the following 50 Hz applications are not approved: ZB95KC / ZB95KCE / ZB114KC / ZB114KCE-TWD 420 V 50 Hz ZB95KC / ZB95KCE / ZB114KC / ZB114KCE-TW5 200-220 V 50 Hz Compressor Lubrication The compressors can be used with different lubricants depending upon the refrigerant used. See Form 93-11 for a complete list of all Emerson approved lubricants. Accumulators Due to the inherent ability of scroll compressors to handle liquid refrigerant in fl ooded start and defrost cycle operation conditions, accumulators may not be required. An accumulator is required on single compressor systems when the charge limitations exceed those values listed in Table 2. On systems with defrost schemes or transient operations that allow prolonged uncontrolled liquid return to the compressor, an accumulator is required unless a Figure 1D ZB*KC (excluding ZB95KC & ZB114KC) Application Envelope for R22 HT Applications 7-15Hp Figure 1E ZB95KC & ZB114KC Application Envelope for R22 HT Applications 7-15Hp Figure 1F ZB*KCE Application Envelope for R134A HT Applications 7-15Hp TABLE 2 CHARGE LIMITS Model Family Charge Limits ZB50, 58, 66, 76, 88, 95, 114 KC/E 16 lbs ZB56,68,75,92KC/E & ZB11MC/E 17 lbs Figure 1C ZB95KCE & ZB114KCE Application Envelope for R404A/R507 HT Applications 7-15Hp 20 F SH , 20 F Min. SH Evaporating Temperature 260° F DLT Limit, 20° F Superheat 20 F SH 3 AE-1318 R1 © 2008 Emerson Climate Technologies Printed in the U.S.A. Application Engineering B U L L E T I N suction header of suffi cient volume to prevent liquid migration to the compressors is used. Excessive liquid fl oodback or repeated fl ooded starts will dilute the oil in the compressor causing inadequate lubrication and bearing wear. Proper system design will minimize liquid fl oodback, thereby ensuring maximum compressor life. If an accumulator must be used, an oil return orifi ce size in the range of 0.040 - 0.075 inches (1 - 1.9 mm) is recommended. A large-area protective screen no fi ner than 30 x 30 mesh (0.6 mm openings) is required to protect this small orifi ce from plugging with system debris. Tests have shown that a small screen with a fi ne mesh can easily become plugged causing oil starvation to the compressor bearings. Screens The use of screens fi ner than 30 x 30 mesh (0.6 mm openings) anywhere in the system is not recommended. Field experience has shown that fi ner mesh screens used to protect thermal expansion valves, capillary tubes, or accumulators can become temporarily or permanently plugged with normal system debris and block the fl ow of either oil or refrigerant to the compressor. Such blockage can result in compressor failure. Crankcase Heater Crankcase heaters are required on systems when the system charge exceeds the recommended charge limit. See Table 2. The listed crankcase heaters (Table 3) are intended for use only when there is limited access. The heaters are not equipped for use with electrical conduit. Where applicable, electric safety codes require heater lead protection, a crankcase heater terminal box should be used. Recommended crankcase heater terminal cover and box numbers are listed in Table 3A. If there are any questions concerning the application, contact the Emerson Climate Technologies Application Engineering department. Advanced Scroll Temperature Protection (ASTP) After extensive research and trials Emerson Climate Technologies found a way to install a Therm-O- Disc® temperature sensitive snap disc in the ZB50, ZB58, ZB66, ZB76, ZB95, ZB88 and ZB114 scroll compressors. This acts to protect the compressor from Figure 2 TABLE 3 CRANKCASE HEATERS Model Part No. Volts Watts Leads ZB50, ZB58, ZB66, ZB76 ZB88, ZB95 ZB114 Select by voltage 018-0067-00 018-0067-01 018-0067-02 018-0067-03 120 240 480 575 90 90 90 90 48" 48" 48" 48" Select by voltage and lead length ZB56 ZB68 ZB75 ZB92 ZB11M 018-0077-00 018-0077-01 018-0077-02 018-0077-03 018-0077-04 018-0077-05 018-0077-06 240 120 480 575 240 480 575 70 70 70 70 70 70 70 26" 26" 26" 26" 34" 34" 34" TABLE 3A CONDUIT READY HEATER BOX KITS Model Number Kit Number ZB50, ZB58, ZB66 ZB76, ZB88, ZB95, ZB114 998-7029-00 ZB56, ZB68, ZB75 ZB92, ZB11M 998-7015-00 4 © 2008 Emerson Climate Technologies Printed in the U.S.A. AE-1318 R1 Application Engineering B U L L E T I N discharge gas overheating. Events such as loss of charge, evaporator blower failure, or low side charging with inadequate pressure will cause the discharge gas to quickly rise above a critical temperature. Once this critical temperature is reached, the ASTP feature will cause the scrolls to separate and stop pumping but allow the motor to continue to run. After the compressor runs for some time without pumping gas, the motor protector will open. Depending on the heat build up in the compressor, it may take up to two hours for the ASTP to reset. The addition of the Advanced Scroll Temperature Protection makes it possible to eliminate the discharge line thermostat previously required. A graphic explanation and a short video clip are available on the web site, www.emersonclimatecontractor.com/ ASTP. Compressors with this feature will have the Advanced Scroll Temperature Protection label (Figure 2) located directly above the terminal box. Discharge Line Thermostat The addition of the Advanced Scroll Temperature Protection on the ZB50, ZB58, ZB66, ZB76, ZB88, ZB95 and ZB114, as well as the internal discharge temperature protection described in the section titled “Motor Protection” for the ZB56, ZB68, ZB75, ZB92, and ZB11M, makes it possible to eliminate the discharge line thermostat in most applications. Pressure Controls Both high and low pressure controls are required and the following are the minimum and maximum set points. Refer to Table 4 for proper settings. IPR Valve The 7 through 15 horsepower refrigeration scroll compressors DO NOT have an internal high pressure relief valve. To provide safe operation, a high pressure control set no higher than 445 psig must be used in all applications (reference Table 4). Motor Protection The larger horsepower refrigeration scroll compressors have either line break protection or the use of sensors with an electronic module. The type of protection is obtained from the protector code in the model number. Table 5 lists the various models protector number and the type of protection. For the INT69SCY, there are fi ve PTC (positive temperature coeffi cient) internal thermisters connected in series that react with avalanche resistance in the event of high temperatures. Four of the thermisters are TABLE 4 PRESSURE CONTROL SETTINGS Model Control Type R404A/R507 R134a R22 ZB50, ZB58, ZB66, ZB76, ZB95, ZB114 Low High 17 psig min. 454 psig max. 4 psig min. 263 psig max 37 psig min. 381 psig max ZB88 Low High N/A N/A N/A N/A 37 psig min. 381 psig max ZB56, ZB75, ZB68, ZB92, ZB11M Low High 17 psig min. 454 psig max. 4 psig min. 263 psig max 37 psig min. 381 psig max TABLE 5 MOTOR PROTECTION Models with Line Break Protection ZB50, ZB58, ZB66, ZB76, ZB88, ZB95, ZB114 (note: electric code = TF*) No module Models with Electronic Module ZB56, ZB68, ZB75, ZB92, ZB11M (note: electric code = TW*) p/n: 071-0620-00 Model: INT69SCY Models with Electronic Module ZB95, ZB114 (note: electric code = TW*) p/n: 071-0641-00 Model: INT69SU

Copeland Scroll™ Compressors for comfort, precision and process cooling ZR24KRE to ZR92KRE Application Guidelines C6.2.41/0219/E About these guidelines ............................................................................................... 1 1 Safety instructions ........................................................................................... 1 1.1 Icon explanation ............................................................................................................... 1 1.2 Safety statements ............................................................................................................ 1 1.3 General instructions ......................................................................................................... 2 2 Product description ......................................................................................... 3 2.1 Common information about Copeland Scroll™ compressors .......................................... 3 2.2 Nomenclature ................................................................................................................... 3 2.3 BOM Variation .................................................................................................................. 3 2.4 Dimensions ...................................................................................................................... 4 2.5 Application range ............................................................................................................. 7 2.5.1 Qualified refrigerants and oils .............................................................................. 7 2.5.2 Application limits ................................................................................................... 7 3 Installation ........................................................................................................ 8 3.1 Compressor handling ....................................................................................................... 8 3.1.1 Transport and storage .......................................................................................... 8 3.1.2 Positioning and securing ...................................................................................... 8 3.1.3 Installation location ............................................................................................... 8 3.1.4 Mounting parts ...................................................................................................... 8 3.2 Brazing procedure ............................................................................................................ 9 3.3 Shut-off valves and adaptors ......................................................................................... 10 3.4 Suction accumulators ..................................................................................................... 10 3.5 Screens .......................................................................................................................... 11 3.6 Mufflers .......................................................................................................................... 11 3.7 Suction line noise and vibration ..................................................................................... 11 4 Electrical connection ..................................................................................... 13 4.1 General recommendations............................................................................................. 13 4.2 Electrical installation ...................................................................................................... 13 4.2.1 Terminal box ....................................................................................................... 15 4.2.2 Motor windings ................................................................................................... 15 4.2.3 Protection devices .............................................................................................. 15 4.2.4 Crankcase heaters ............................................................................................. 15 4.3 Pressure safety controls ................................................................................................ 16 4.3.1 High-pressure control ......................................................................................... 16 4.3.2 Low-pressure control .......................................................................................... 16 4.3.3 Internal pressure relief valve .............................................................................. 16 4.4 Discharge temperature protection ................................................................................. 16 4.5 High-potential testing ..................................................................................................... 17 5 Starting up & operation.................................................................................. 18 5.1 Strength pressure test .................................................................................................... 18 C6.2.41/0219/E 5.2 Tightness/pressure test .................................................................................................. 18 5.3 System evacuation ......................................................................................................... 18 5.4 Preliminary checks – Pre-starting .................................................................................. 18 5.5 Charging procedure ....................................................................................................... 19 5.6 Initial start-up ................................................................................................................. 19 5.7 Rotation direction ........................................................................................................... 19 5.8 Starting sound ................................................................................................................ 20 5.9 Deep vacuum operation ................................................................................................. 20 5.10 Shell temperature ........................................................................................................... 20 5.11 Pump-down cycle ........................................................................................................... 20 5.12 Minimum run time .......................................................................................................... 20 5.13 Shut-off sound ................................................................................................................ 21 5.14 Frequency ...................................................................................................................... 21 5.15 Oil level .......................................................................................................................... 21 6 Maintenance & repair ..................................................................................... 22 6.1 Exchanging the refrigerant ............................................................................................. 22 6.2 Rotalock valves .............................................................................................................. 22 6.3 Replacing a compressor ................................................................................................ 22 6.3.1 Compressor replacement ................................................................................... 22 6.3.2 Start-up of a new or replacement compressor ................................................... 22 6.4 Lubrication and oil removal ............................................................................................ 23 6.5 Oil additives ................................................................................................................... 23 6.6 Unbrazing system components ..................................................................................... 23 7 Dismantling & disposal .................................................................................. 24 DISCLAIMER .............................................................................................................. 24