Application Engineering Application Engineering B L LL E L T EI BU U AE4-1318 R1 N T I N AE-1318 R1 June 2008 APPLICATION GUIDELINES FOR ZB*KC/ZB*KCE COPELAND SCROLL® REFRIGERATION COMPRESSORS 7 TO 15 HP Introduction Figure 1A ZB*KCE (excluding ZB95KCE & ZB114KCE) Application Envelope for R404A/R507 MT Applications 7-15Hp 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 Figure 1B ZB95KCE & ZB114KCE Application Envelope for R404A/R507 MT Applications 7-15Hp 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. 20 F SH 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 © 2008 Emerson Climate Technologies Printed in the U.S.A. 1 Application Engineering B U L L Figure 1C ZB95KCE & ZB114KCE Application Envelope for R404A/R507 HT Applications 7-15Hp E T I N AE-1318 R1 Figure 1F ZB*KCE Application Envelope for R134A HT Applications 7-15Hp 20 F SH 260° F DLT Limit, 20° F Superheat Evaporating Temperature Figure 1D ZB*KC (excluding ZB95KC & ZB114KC) Application Envelope for R22 HT Applications 7-15Hp , Voltage / Frequency Restrictions Due to inadequate cooling from refrigerant flow through the compressor, the following 50 Hz applications are not approved: 20 F Min. SH 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. Figure 1E ZB95KC & ZB114KC Application Envelope for R22 HT Applications 7-15Hp 20 F SH Accumulators Due to the inherent ability of scroll compressors to handle liquid refrigerant in flooded 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 TABLE 2 CHARGE LIMITS Model Family © 2008 Emerson Climate Technologies Printed in the U.S.A. 2 Charge Limits ZB50, 58, 66, 76, 88, 95, 114 KC/E 16 lbs ZB56,68,75,92KC/E & ZB11MC/E 17 lbs Application Engineering B U L L E suction header of sufficient volume to prevent liquid migration to the compressors is used. Excessive liquid floodback or repeated flooded starts will dilute the oil in the compressor causing inadequate lubrication and bearing wear. Proper system design will minimize liquid floodback, thereby ensuring maximum compressor life. T I N 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. If an accumulator must be used, an oil return orifice size in the range of 0.040 - 0.075 inches (1 - 1.9 mm) is recommended. A large-area protective screen no finer than 30 x 30 mesh (0.6 mm openings) is required to protect this small orifice from plugging with system debris. Tests have shown that a small screen with a fine mesh can easily become plugged causing oil starvation to the compressor bearings. Screens Advanced Scroll Temperature Protection (ASTP) The use of screens finer than 30 x 30 mesh (0.6 mm openings) anywhere in the system is not recommended. Field experience has shown that finer 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 flow of either oil or refrigerant to the compressor. Such blockage can result in compressor failure. After extensive research and trials Emerson Climate Technologies found a way to install a Therm-ODisc® temperature sensitive snap disc in the ZB50, ZB58, ZB66, ZB76, ZB95, ZB88 and ZB114 scroll compressors. This acts to protect the compressor from TABLE 3 CRANKCASE HEATERS Model Part No. Volts Watts 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 Leads 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 © 2008 Emerson Climate Technologies Printed in the U.S.A. AE-1318 R1 Figure 2 3 Application Engineering B U L L E 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. T I N 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 five PTC (positive temperature coefficient) 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 © 2008 Emerson Climate Technologies Printed in the U.S.A. 4 AE-1318 R1 Application Engineering B U L L E T I N AE-1318 R1 Figure 3 Scroll Wiring Schematic used to sense motor temperatures and the fifth is used as a discharge temperature sensor. For the INT69SU, there are four PTC (positive temperature coefficient) internal thermisters connected in series. All four are used to sense motor temperature. The thermister circuit is connected to the protector module terminals S1 and S2. PLC operated control circuits may not always provide this minimum current. In these cases modifications to the PLC control circuit are required. Consult your application engineering department for details. Phase Protection The INT69SCY module provides phase protection for the compressor. The module senses the correct phase sequence, phase loss and voltage sag for each leg (L1, L2 and L3) of the incoming power supplied to the compressor. At installation the three phases of the power supply must be wired in the correct 120° phase sequence. This will ensure the compressor will start and operate in the correct clockwise direction. When any thermister reaches a limiting value, the module interrupts the control circuit and shuts off the compressor. After the thermister has cooled sufficiently, the resistance will decrease, thus allowing the module to reset. However, the module has a 30-minute time delay before reset after a thermister trip. For all other compressors, conventional internal line break motor protection is provided. The INT69SCY module trips (M1-M2 contacts open) when the module senses a phase loss. There is a 5 minute time delay before the module attempts a restart. If all three phases are present, then the module will reset (M1-M2 contacts will close) and the compressor will start and run. If not, the module will attempt a restart after another 5 minute time delay. After 10 failed attempts to restart, the module will lock-out (M1M2 contacts will remain open) and can only be reset by removing the power from T1-T2 for a minimum of 5 seconds. Programmable Logic Controller Requirements If the INT69SCY (071-0620-00) or INT69SU (0710641-00) module is applied in conjunction with a Programmable Logic Controller, it is important that a minimum load is carried through the M1-M2 control circuit contacts. The minimum required current through the module relay contacts needs to be greater than 100 milliamps but not to exceed 5 amps. If this minimum current is not maintained, this has a detrimental effect upon the long-term contact resistance of the relay and may result in false compressor trips. © 2008 Emerson Climate Technologies Printed in the U.S.A. The INT69SCY is intended to protect the compressor. The L1/L2/L3 and S1/S2 leads are pre-wired on the compressor and are engineered to work in conjunction with the motor protector module. The module 5 Application Engineering B U L L E T b. If the measurement is less than 1 volt and the compressor is not running, then the problem is external to the INT69SCY or INT69SU module. The following field troubleshooting procedure can be used to evaluate the solid state control circuit: Refer to Table 6 for a technical data summary. c. Module Voltage Supply Troubleshooting • Measure the voltage across T1-T2 to ensure proper supply voltage. • Determine the control voltage by using a voltmeter AE-1318 R1 a. If the measured voltage is equal to the control volts then the M1-M2 contacts are open. Module and Sensor Functional Check Verify that all wire connectors are maintaining a good mechanical connection. Replace any connectors that are loose. N and then measure the voltage across the M1-M2 contacts: leads should not be moved or extended because of the possibility of inducing electronic noise into the INT69SCY, which could cause false trips of the module. • I If the voltage is greater than 1 volt but less than the control voltage, the module is faulty and should be replaced. Sensor Troubleshooting • Remove the leads from S1-S2, and then by using an ohmmeter measure the resistance of the incoming leads. CAUTION: Use an Ohmmeter with a maximum TABLE 6 Emerson P/N 071-0520-07 071-0520-05 071-0620-00 071-0641-00 Manufacturer P/N T.I. 30AA201E Kriwan 69SC-DV Kriwan 69SCY Kriwan 69SU T1-T2 Module Power Voltage Supply 120V & 240V 120V & 240V 120V & 240V 120V & 240V Frequency 50Hz & 60Hz 50Hz & 60Hz 50Hz & 60Hz 50Hz & 60Hz M1-M2 Module Output Contacts Maximum Voltage N/A 250VAC 250VAC 250VAC Maximum Current 5 Amps 5 Amps 5 Amps 5 Amps Minimum Current 100 milliamps 100 milliamps 100 milliamps 100 milliamps Relay Output 2.5 A, 600 V 5 A, 300 VA 5 A, 300 VA 5 A, 300 VA Power Output < 5.5 VA <3 VA <3 VA <3 VA Trip Out Resistance N/A 4500W ± 20% 4500W ± 20% 4500W ± 20% Reset Resistance N/A 2750W ± 20% 2750W ± 20% 2750W ± 20% Reset Time 30 min ± 5 min 30 min ± 5 min 30 min ± 5 min 30 min ± 5 min Manual Reset T1-T2 interrupt for minimum of 5 sec T1-T2 interrupt for minimum of 5 sec T1-T2 interrupt for minimum of 5 sec T1-T2 interrupt for minimum of 5 sec Phase Sensor Non Phase Sensing Non Phase Sensing 3 Non Phase Sensing Phase Monitoring Circuit Rating Non Phase Sensing Non Phase Sensing 3 AC 50/60Hz 120V to 632V Non Phase Sensing Trip Delay Non Phase Sensing Non Phase Sensing 5 min delay before restart attempt Non Phase Sensing Lockout Non Phase Sensing Non Phase Sensing After 10 module trips Non Phase Sensing Reset For Lockout Non Phase Sensing Non Phase Sensing T1-T2 interrupt for minimum of 5 sec Non Phase Sensing S1-S2 Thermal Protection L1-L2-L3 Phase Monitoring © 2008 Emerson Climate Technologies Printed in the U.S.A. 6 Application Engineering B U L L E of 9 VDC for checking – do not attempt to check continuity through the sensors with any other type of instrument. Any external voltage or current may cause damage requiring compressor replacement. b. If the M1-M2 contacts are open, the measured S1-S2 value is above 2750 ohms ±20% and the compressor has been tripped less then 30 minutes then the module is functioning properly. Replace all wire leads and use a voltmeter to verify the M1-M2 contacts are closed. • If the M1-M2 contacts remain open and S1-S2 are less than 2500 ohms, remove leads from the M1M2 contacts and jumper together; Go to Compressor Troubleshooting. Supply AE-1318 R1 • Ensure proper voltage on each phase. • Remove power to the module for a minimum of 5 seconds to reset and replace all wire leads. Reenergize the module. If the M1-M2 contacts are open with proper voltage to T1-T2, L1/L2/L3 and proper resistance to S1-S2 then the module is faulty and should be replaced. Polyol ester lubricant (POE) must be provided if the refrigeration scroll is used with HFC refrigerants. Copeland Scroll refrigeration compressors intended for use with R22 are supplied with mineral oil. Reference Table 7 for proper oil charge. See Form 93-11 for a complete list of all Emerson approved lubricants. Oil Management for Single Compressor Applications CAUTION: Compressor should start at this time. HOWEVER DO NOT LEAVE JUMPER IN PLACE FOR NORMAL SYSTEM OPERATIONS. THE JUMPER IS USED FOR DIAGNOSTIC PURPOSES ONLY. • N Oil Type If the S1-S2 wire leads read less than 2750 ohms ±20% and the M1-M2 contacts are open, reset the module by removing the power to T1-T2 for a minimum of 5 seconds. • I be at a potential up to 600VAC. a. During normal operation, this resistance value should read less than 4500 ohms ±20%. • T If the oil level is above the sight glass, oil circulation rates greater than 1.5% may be experienced with the ZB50, ZB58, ZB66, ZB76, ZB88, ZB95 & ZB114 compressors. This is especially true in the larger compressors in 60 Hz applications. Voltage Compressor Voltage Supply Troubleshooting Oil Management for Rack Applications • Remove phase sensing leads from the module from L1/L2/L3. • Use a voltmeter to measure the incoming 3 phase voltage on L1/L2/L3. WARNING: L1/L2/L3 could Copeland Scroll refrigeration compressors may be used on multiple compressor parallel rack applications. This requires the use of an oil management system to maintain proper oil level in each compressor crankcase. The sight glass connection supplied can accommodate the mounting of the oil control devices. TABLE 7 COMPRESSOR OIL CHARGE Model Initial Recharge ZB50 ZB58 ZB66 ZB76 ZB88 ZB95 ZB114 ZB56 ZB68 ZB75 ZB92 ZB11M 85 85 110 110 110 110 110 140 140 140 140 140 81 81 106 106 106 106 106 137 137 137 137 137 © 2008 Emerson Climate Technologies Printed in the U.S.A. Unlike Semi-Hermetic compressors, the scrolls do not have an oil pump with accompanying oil pressure safety controls. Therefore, an external oil level control is required. The OMB Oil Level Management Control combines the functions of level control and timed compressor shutoff should the level not come back to normal within a set period of time. This device has been found to provide excellent performance in field tests on Scroll compressors and is recommended for parallel system applications. Note: Emerson Climate Technologies' Application Engineering Department should be contacted for approved oil management systems. 7 Application Engineering B U L L E T I N AE-1318 R1 Immediately after system start-up the oil reservoir level will fluctuate until equilibrium is reached. It is advisable to monitor the oil level during this time to assure sufficient oil is available. This will prevent unnecessary trips of the oil control system. Note: The use of standard soft grommets is not recommended for our refrigeration scroll rack installations. These “softer” mounts allow for excessive movement that will result in tube breakage unless the entire system is properly designed. Note: If oil management problems are occurring please refer to AE 17-1320 or contact the Emerson Climate Technologies Application Engineering Department. Connection Fittings Note: ZB50, 58, 66, 76, 88, 95, 114 are not approved for rack applications due to compressor limitations. Compressor Mounting Compressor mounting must be selected based on application. Consideration must be given to sound reduction tubing reliability. Some tubing geometry or “shock loops” may be required to reduce vibration transferred from the compressor to external tubing. Mounting for Rack Systems Specially designed steel spacers and rubber isolator pads are available for our refrigeration scroll 7.5-15 HP scroll rack applications. This mounting arrangement limits the compressors motion thereby minimizing potential problems of excessive tubing stress. Sufficient isolation is provided to prevent vibration from being transmitted to the mounting structure. This mounting arrangement is recommended for multiple compressor rack installations. See Figure 4 for a detail for this mounting system. Figure 4 7.5 - 15 HP Rack Mounting 027-0115-00 RUBBER PAD © 2008 Emerson Climate Technologies Printed in the U.S.A. Three Phase Scroll Compressors – Directional Dependents Scroll compressors are directional dependent; i.e. they will compress in one rotational direction only. Three phase Scrolls will rotate in either direction depending on power phasing. Since there is a 50/50 chance of connected power being “backwards”, contractors should be warned of this. Appropriate instructions or notices should be provided by the OEM. To eliminate the possibility of reverse rotation a Copeland Phase Control line monitor, P/N 085-0160-00, or other phase monitor is recommended. Verification of proper rotation can be made by observing that the suction pressure drops and the discharge pressure rises when the compressor is energized. Additionally, if operated in reverse the compressor is noisier and its current draw is substantially reduced compared to tabulated values. TABLE 8 Model 102-0119-00 WASHER 027-0280-00 STEEL SPACER There are various connection fittings available for Copeland Scroll refrigeration compressors. The various options are shown in Table 8. KIT #527-0158-00 8 Rotalock Spud Connection Stub Connection Suction Discharge Suction Discharge ZB50 1-3/4 - 12 1-1/4 - 12 1-1/8" 7/8" ZB58 1-3/4 - 12 1-1/4 - 12 1-1/8" 7/8" ZB66 1-3/4 - 12 1-1/4 - 12 1-3/8" 7/8" ZB76 1-3/4 - 12 1-1/4 - 12 1-3/8" 7/8" ZB88 1-3/4 - 12 1-1/4 - 12 1-3/8" 7/8" ZB95 1-3/4 - 12 1-1/4 - 12 1-3/8" 7/8" ZB114 1-3/4 - 12 1-1/4 - 12 1-3/8" 7/8" ZB56 1-3/4 - 12 1-1/4 - 12 not offered ZB68 1-3/4 - 12 1-1/4 - 12 not offered ZB75 1-3/4 - 12 1-1/4 - 12 not offered ZB92 1-3/4 - 12 1-1/4 - 12 not offered ZB11M 2-1/4 - 12 1-3/4 -12 not offered Application Engineering B U L L E No time delay is required on three phase models to prevent reverse rotation due to brief power interruptions. I N AE-1318 R1 both the high and low sides with manifold gauges before unbrazing or in the case of assembly line repair, remove refrigerant from both the high and low sides. Instructions should be provided in appropriate product literature and assembly (line repair) areas. Deep Vacuum Operation WARNING: Do not run a Copeland Scroll refrigeration compressor in a deep vacuum. Failure to heed this advice can result in arcing of the Fusite pins and permanent damage to the compressor. Hi-Pot Testing Copeland Scroll compressors are configured with the motor in the bottom of the shell. Unlike most other hermetic compressors, the scroll motor can be immersed in refrigerant when liquid is present in the shell. Hi-Pot test with liquid refrigerant in the shell can show higher levels of current leakage due to higher electrical conductivity of liquid refrigerant vs. refrigerant vapor and oil. This phenomenon can occur with any compressor when the motor is immersed in refrigerant and does not present any safety issue. To lower the current leakage reading operate the system for a brief period of time, redistributing the refrigerant in a more normal configuration and test again. A low pressure control is required for protection against deep vacuum operation. See Pressure Control section for proper set points. Scroll compressors (as with any refrigerant compressor) should never be used to evacuate a refrigeration or air conditioning system. See Application Engineering Bulleting AE 24-1105 for proper system evacuation procedures. Unbrazing System Components Note: The solid state electronic module components and internal sensors are delicate and can be damaged by exposure to high voltage. Under no circumstances should a high potential test be made at the sensor terminals or sensor leads connected to the module. Damage to the sensors or module may result. If the refrigerant charge is removed from a scroll unit by bleeding the high side only, it is sometimes possible for the scrolls to seal, preventing pressure equalization through the compressor. This may leave the low side shell and suction line tubing pressurized. If a brazing torch is then applied to the low side, the pressurized refrigerant and oil mixture could ignite as it escapes and contacts the brazing flame. It is important to check © 2008 Emerson Climate Technologies Printed in the U.S.A. T 9 Application Engineering B U L L E T I N ADDENDUM The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or its affiliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifications of such products at any time without notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user. CAUTION POE must be handled carefully and the proper protective equipment (gloves, eye protection, etc.) must be used when handling POE lubricant. POE must not come into contact with any surface or material that might be harmed by POE, including without limitation, certain polymers (e.g. PVC/CPVC and polycarbonate). © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.