Emerson Copeland Scroll ZBKC Manuals

1 © 2014 Emerson Climate Technologies, Inc. Printed in the U.S.A. AE4-1317 R10 Application Engineering B U L L E T I N AE4-1317 R10 April 2014 Application Engineering B U L L E T I N Application Guidelines for ZBKC / ZBKCE Refrigeration Copeland Scroll™ Compressors 1.3 to 7.5 HP Safety Safety Instructions ...................................................2 Safety Icon Explanation ..........................................2 Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons ........................................3 Safety Statements ...................................................3 Introduction ................................................................ 4 Nomenclature ............................................................ 4 Operating Envelope ................................................... 4 Accumulators ............................................................. 4 Crankcase Heaters .................................................... 4 Discharge Line Thermostat ....................................... 4 Pressure Controls ...................................................... 5 Pump Down Recommendations ................................ 5 IPR Valve .................................................................. 5 Internal Temperature Protection ............................... 5 Motor Protection ........................................................ 5 Oil Types .................................................................... 5 Oil Charges................................................................ 6 Oil Management for Rack Applications...................... 6 Compressor Tubing and Mounting ............................ 6 Mounting for Rack Systems....................................... 6 Condensing Unit Mounting ........................................ 6 Starting Characteristics ............................................. 6 Fusite ......................................................................... 7 Shell Temperature ..................................................... 7 Connection Fittings .................................................... 7 Three-Phase Rotation Direction ................................ 7 Brief Power Interruptions ........................................... 7 Deep Vacuum Operation ........................................... 7 Unbrazing System Components ................................ 7 High Potential (Hipot) Testing .................................... 7 Copeland Scroll Functional Check ............................. 8 TABLE OF CONTENTS Section Page Section Page Figures ZB*KCE Application Envelopes ..................................9 Scroll Rack Mounting................................................10 Scroll Condensing Unit Mounting .............................10 Typical Suction Tubing..............................................11 Motor Terminal (Fusite) Connections for Single Phase and Three Phase Scrolls .............................11 Scroll Wiring Schematic............................................12 Tables Compressor Models and Approved Refrigerants/ Lubricants ...............................................................13 Charge Limitations....................................................13 Crankcase Heater.....................................................14 Conduit Ready Heater Terminal Box Kits .................14 Discharge Thermostat Line Kits ...............................14 Pressure Control Settings.........................................14 Check-Valve Type .....................................................15 Recommended Oil Charges by Model Family ..........15 2 © 2014 Emerson Climate Technologies, Inc. Printed in the U.S.A. AE4-1317 R10 Application Engineering B U L L E T I N Safety Instructions Copeland Scroll™ compressors are manufactured according to the latest U.S. and European Safety Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These instructions should be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety instructions. Safety Icon Explanation DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. 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. NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. DANGER WARNING CAUTION NOTICE CAUTION 3 © 2014 Emerson Climate Technologies, Inc. Printed in the U.S.A. AE4-1317 R10 Application Engineering B U L L E T I N ELECTRICAL SHOCK HAZARD • Disconnect and lock out power before servicing. • Discharge all capacitors before servicing. • Use compressor with grounded system only. • Molded electrical plug must be used when required. • Refer to original equipment wiring diagrams. • • Failure to follow these warnings could result in serious personal injury. PRESSURIZED SYSTEM HAZARD • System contains refrigerant and oil under pressure. • Remove refrigerant from both the high and low compressor side before removing compressor. • • Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system. • Use only approved refrigerants and refrigeration oils. • Personal safety equipment must be used. • Failure to follow these warnings could result in serious personal injury. BURN HAZARD • Do not touch the compressor until it has cooled down. • Ensure that materials and wiring do not touch high temperature areas of the compressor. • Use caution when brazing system components. • Personal safety equipment must be used. • Failure to follow these warnings could result in serious personal injury or property damage. COMPRESSOR HANDLING • Use the appropriate lifting devices to move compressors. • Personal safety equipment must be used. • Failure to follow these warnings could result in personal injury or property damage. Safety Statements • Refrigerant compressors must be employed only for their intended use. • install, commission and maintain this equipment. • • All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed. Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons WARNING WARNING WARNING CAUTION 4 © 2014 Emerson Climate Technologies, Inc. Printed in the U.S.A. AE4-1317 R10 Application Engineering B U L L E T I N Introduction The ZBKC/ZBKCE Copeland Scroll™ compressor represents the latest generation of compliant scroll technology for the refrigeration industry. Nomenclature The refrigeration scroll model numbers include the nominal capacity at standard 60HZ ARI rating conditions for medium temperature (20/120°F). For additional information on this product, please refer to the Online Product Information accessible from the Emerson Climate Technologies web site at www. emersonclimate.com. Operating Envelope The ZBKC/ZBKCE refrigeration scroll compressor models can be used with a variety of refrigerants depending on the model selected and the lubricant used. (See Table 1 at the end of this bulletin.) The ZBKC and ZBKCE models are intended for medium temperature refrigeration type duty. The approved operating envelopes for these models are such that they are ideally suited for applications such as ice machines, bulk milk and FCB/FUB. The models and operating envelopes are depicted in Figures 1A, 1B and 1C at the end of this bulletin. Accumulators Due to the scrolls’ inherent ability 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 suction header of suffi cient volume to prevent liquid migration to the compressor is used. Excessive liquid fl ood back 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 ood back, thereby ensuring maximum compressor life. In order to assure that liquid refrigerant does not return to the compressor during the running cycle, attention must be given to maintaining proper superheat at the compressor suction inlet. Emerson recommends a minimum of 20°F (11°C) superheat, measured on the suction line 6 inches (152mm) from the suction valve, to prevent liquid refrigerant fl oodback. Another method to determine if liquid refrigerant is returning to the compressor is to accurately measure the temperature difference between the compressor oil crankcase and the suction line. During continuous operation we recommend that this difference be a minimum of 50°F (27°C). This “crankcase differential temperature” requirement supersedes the minimum suction superheat requirement in the last paragraph. To measure oil temperature through the compressor shell, place a thermocouple on the bottom center (not the side) of the compressor shell and insulate from the ambient. During rapid system changes, such as defrost or ice harvest cycles, this temperature difference may drop rapidly for a short period of time. When the crankcase temperature difference falls below the recommended 50°F (27°C), our recommendation is the duration should not exceed a maximum (continuous) time period of two minutes and should not go lower than a 25°F (14°C) difference. Contact your Emerson Climate Technologies representative regarding any exceptions to the above requirements. Crankcase Heaters • Single-phase No crankcase heaters are required on single-phase scroll compressors. • Three-phase – outdoor only Crankcase heaters are required on three phase compressors where the system charge exceeds 10 lbs. The listed crankcase heaters are intended for use only when there is limited access (See Table 3). The heaters are not equipped for use with electrical conduit. Where applicable, electrical safety codes require lead protection, a crankcase heater terminal box should be used. Recommended crankcase heater terminal box and cover kit numbers are listed in Table 3A. If there are any questions concerning their application, contact the Emerson Climate Technologies, Inc. Application Engineering department. Discharge Line Thermostat Figures 1A, 1B, 1C and 1D show saturated suction temperature, maximum condensing temperature, maximum return gas temperature, and maximum discharge line temperature. Operation beyond these limits can cause high compression ratios or excessive internal compressor temperatures. This will result in overheating the scroll members, causing excessive wear resulting in premature compressor failure.