21-1388 PDF R3

21-1388 PDF R3
AE4-1388 R3
June 2014
AE4-1388 R3
20 to 40 Ton ZP*KC and ZR*KC Copeland Scroll™ Air Conditioning Compressors
Section
TABLE OF CONTENTS
Page
Section
Page
Safety
Safety Instructions....................................................... 2
Safety Icon Explanation............................................... 2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons........................................... 3
Safety Statements........................................................ 3
Application Tests
Application Test Summary...........................................11
Low Pressure Control.................................................. 5
Shut Down Device....................................................... 5
Discharge Check Valve................................................ 5
Shell Temperature........................................................ 5
Compressor Cycling..................................................... 5
Long Pipe Lengths / High Refrigerant Charge............. 5
Suction and Discharge Fittings.................................... 6
System Tubing Stress.................................................. 6
Accumulators............................................................... 6
Off Cycle Migration Control.......................................... 6
Crankcase Heat......................................................... 6
Pump Down Cycle..................................................... 6
Pump Out Cycle......................................................... 7
Reversing Valves......................................................... 7
Contaminant Control.................................................... 7
Oil Type........................................................................ 7
Three Phase Electrical Phasing................................... 8
Power Factor Correction.............................................. 8
Soft Starters................................................................. 8
Motor Overload Protection........................................... 8
Motor Overload Protection Specs................................ 9
Manifolded Compressors............................................. 9
Manifolded Applications............................................... 9
Service Procedures
Field Replacement...................................................... 14
Mounting................................................................... 14
Oil Removal.............................................................. 14
Electrical................................................................... 14
Module...................................................................... 14
Compressor Replacement after a Motor Burn............ 14
Manifolded Compressor Replacement........................ 14
Start-Up of a New or Replacement Compressor........ 15
Field Troubleshooting Kriwan Module......................... 15
Field Troubleshooting CoreSense Module.................. 16
Copeland Scroll Compressor Functional Check......... 16
Refrigerant Retrofits.................................................... 17
Figures & Tables
Nomenclature.............................................................. 18
Operating Envelopes.................................................. 19
Suction Tube Brazing.................................................. 20
Crankcase Heater Location........................................ 20
Terminal Box Wiring Diagram..................................... 21
Typical Rotalock Connected Tandem w/TPTL Oil
Manifold....................................................................... 22
Typical Braze Connected Tandem w/OEL Oil Manifold.. 22
Typical Braze Connected Trio w/ TPTL Oil Manifold.... 23
Drive Output - Frequency vs. Voltage......................... 23
Torque Values............................................................. 24
Refrigerant Charge Limits........................................... 24
Compressor Accessories............................................ 25
Tandem Quick Reference Guide................................. 26
Trio Quick Reference Guide....................................... 27
Protector Specifications.............................................. 28
CoreSense LED Flash Code Information..................29-30
Control Techniques Drive Selections.......................... 31
Assembly Line Procedures
Compressor Handling................................................. 12
Mounting..................................................................... 12
Suction & Discharge Fittings....................................... 12
Introduction
Assembly Line Brazing Procedure.............................. 12
Nomenclature............................................................... 4
Unbrazing System Components................................. 12
Pressure Testing......................................................... 13
Application Considerations
Assembly
Line System Charging Procedures............. 13
Operating Envelope..................................................... 4
Electrical
Connections................................................
13
Internal Pressure Relief (IPR) Valve............................ 4
Hipot
Testing...............................................................
13
Discharge Temperature Protection.............................. 5
Tandem
Assembly.
.
.....................................................
13
High Pressure Control.................................................. 5
Variable Speed Operation
Introduction................................................................. 10
Performance............................................................... 10
Operating Envelope.................................................... 10
Drive Selection............................................................ 10
Electrical Requirements.............................................. 10
Autotuning....................................................................11
Starting and Ramp Up.................................................11
Stopping.......................................................................11
Vibration.......................................................................11
Oil Recovery Cycle......................................................11
Variable Speed Manifolded Applications......................11
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
1
AE4-1388 R3
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 compessor. You are strongly advised
to follow these safety instructions.
Safety Icon Explanation
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION, used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
NOTICE
CAUTION
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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.
2
AE4-1388 R3
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
ELECTRICAL SHOCK HAZARD
WARNING
PRESSURIZED SYSTEM HAZARD
WARNING
BURN HAZARD
•
•
•
•
•
Failure to follow these warnings could result in serious personal injury
Disconnect and lock out power before servicing.
Use compressor with grounded system only.
Refer to original equipment wiring diagrams.
• Failure to follow these warnings could result in serious personal injury
• 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 or
property damage.
• Use caution when brazing system components.
• Ensure that materials and wiring do not touch high temperature areas of
the compressor.
• Personal safety equipment must be used.
CAUTION
COMPRESSOR HANDLING
• Failure to follow these warnings could result in personal injury or
property damage.
• Use the appropriate lifting devices to move compressors.
• Personal safety equipment must be used.
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.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
3
AE4-1388 R3
INTRODUCTION
(11K) superheat in the return gas. The steady-state
operating condition of the compressor must remain
inside the prescribed operating envelope. Excursions
outside of the envelope should be brief and infrequent.
Use of refrigerants other than R-22, R-407C, or R-134a
with ZR*KCE and R-410A with ZP*KCE voids the
compressor UL recognition.
The 20 to 40 ton ZR*KC and ZP*KC Copeland Scroll™
compressors are designed for a variety of commercial
air conditioning and chiller applications. This bulletin
describes the operating characteristics, design features,
and application requirements for these models.
The ZR*KC and ZP*KC scrolls outlined in this bulletin
range in size from 250,000 to 380,000 Btu/hr (73.3 to
111.4 kW) and 235,000 to 485,000 (68.9 to 142.1 kW)
respectively. These models include all of the standard
50 and 60 Hertz three phase voltages. Compressors
in this size range include a number of features outlined
in Table 1 below.
Figure 2 also illustrates the operating envelope for the
expanded frequency range of the 20 to 40 Copeland
Scroll compressors. Please note that the envelope is
truncated versus the standard 50/60 Hertz operating
envelope. In addition, please note the restrictions on
operating frequency/speed within the envelope. For
more information on the application of the expanded
frequency range compressors please refer to the
section Variable Speed Operation.
Nomenclature
The model numbers of the Copeland Scroll compressors
include the approximate nominal 60 Hz capacity at
standard operating conditions. An example would
be the ZP236KCE-TED, which has 236,000 Btu/hr
(69.1kW) cooling capacity at the AHRI high temperature
air conditioning rating point when operated at 60 Hz.
Note that the same compressor will have approximately
5/6 of this capacity or 196,000 Btu/hr (57.4kW) when
operated at 50 Hz. See Figure 1 for more information
regarding nomenclature.
Internal Pressure Relief (IPR) Valve
WARNING
A high pressure control must be used in all
applications.
The 20 to 40 ton Copeland Scroll compressors do
not have internal pressure relief valves. To avoid
abnormally high operating pressures, a high
pressure control must be used in all applications.
APPLICATION CONSIDERATIONS
If any type of discharge line shut-off valve is used,
the high pressure control must be installed between
the compressor discharge fitting and the valve.
Compressors with rotalock discharge fittings have
a connection on the rotalock fitting for the high
pressure cut-out switch connection.
The following application guidelines should be
considered during the design of a system using ZR*KC
and ZP*KC scroll compressors. Some of this information
is recommended, whereas other guidelines must be
followed. The Application Engineering department will
always welcome suggestions that will help improve
these types of documents.
ASHRAE Standard 15 and UL 984/60335-2-34 requires
a system pressure relief valve when the compressor
displacement is greater than 50 CFM. The floating seal
in the compressor effectively acts as a pressure-relief
device during blocked discharge conditions. Please
refer to UL File SA2337 to reference UL's acceptance
of this method.
Operating Envelope
Figure 2 illustrates the operating envelope for
the ZR*KC and ZP*KC compressors with R-22/R407C/R-134a and R-410A respectively. The operating
envelopes represent operating conditions with 20F°
Table 1 – 20 to 40 Ton Copeland Scroll™ Family Features
Model
Refrigerant
Motor
Protection
Communications2
ZR250-380KCE-TW1
R-407C, R-22, R-134a
Kriwan
No
ZR250-380KCE-TE1
R-407C, R-22, R-134a CoreSense™
Yes
ZP235-485KCE-TW1
R-410A
Kriwan
No
ZP236-485KCE-TE1
R-410A
CoreSense
Yes
1
Last Character In Voltage Code (5, C, D, E, or 7)
2
Modbus via RS485
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
4
Tandem/Trio
Manifolded
Applications
Yes
Yes
Yes
Yes
Electrical
Frequency
Range
35-75 Hertz
35-75 Hertz
35-75 Hertz
35-75 Hertz
AE4-1388 R3
Discharge Temperature Protection
Shut Down Device
High discharge temperature protection is provided
by a thermistor probe in the discharge plenum of the
scroll. Compressors with TW* motor nomenclature use
a positive temperature coefficient (PTC) thermistor
and compressors with TE* motor nomenclature use a
negative temperature coefficient (NTC) thermistor. In
either case the module M1-M2 contacts are opened
if the internal discharge temperature exceeds safe
limits. Discharge temperature data are stored in the
CoreSense module and can be made available to a
system controller.
All scrolls in this size range have floating valve
technology to mitigate shut down noise. Since Copeland
Scroll™ compressors are also excellent gas expanders,
they may run backwards for a brief period after
shutdown as the internal pressures equalize.
Discharge Check Valve
A spring assist, disk-type check valve in the discharge
fitting of the compressor prevents the high pressure
gas in the condenser from flowing back through the
compressor after shutdown. Performance of the check
valve for recycling pump down applications hasn't been
evaluated at all pressure differentials. Low pressure
differentials may result in unacceptable leak-back rates.
High Pressure Control
A high pressure cut-out control must be used in all
applications. The maximum cut out setting is 425 psig
(30 bar) for R-22, R-407C, and R-134a and 650 psig
(45 bar) for R-410A. The high pressure control should
have a manual reset feature for the highest level of
system protection.
Shell Temperature
CAUTION
Compressor top cap temperatures can be very
hot. Care must be taken to ensure that wiring or
other materials which could be damaged by these
temperatures do not come into contact with these
potentially hot areas.
Low Pressure Control
A low pressure control is highly recommended for loss of
charge protection and other system fault conditions that
may result in very low evaporating temperatures. Even
though these compressors have internal discharge
temperature protection, loss of system charge will result
in overheating and recycling of the motor overload
protector. Prolonged operation in this manner could
result in oil pump out and eventual bearing failure.
Compressor Cycling
There is no set answer to how often scroll compressors
can be started and stopped in an hour, since it is
highly dependent on system configuration. There
is no minimum off time because Copeland 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 startup. To establish the minimum run
time, obtain a sample compressor equipped with a sight
tube (available from Emerson) and install it in a system
with the longest connecting lines and highest internal
volume that the system may have. The minimum on time
becomes the time required for oil lost during compressor
startup to return to the compressor sump and restore
a minimal oil level that will assure oil pick up through
the crankshaft. The minimum oil level required in
the compressor is 1.5" (40 mm) below the center
of the compressor sight-glass. The oil level should
be checked with the compressor "off" to avoid the
sump turbulence when the compressor is running.
Cycling the compressor for a shorter period than this,
for instance to maintain very tight temperature control,
will result in progressive loss of oil and damage to the
compressor. CoreSense™ Communications provides a
configurable short cycle protection feature.
The low pressure cut-out setting will depend on the
application type and minimum expected evaporating
temperature. The low pressure cut-out should be
selected to prevent compressor overheating and
other system failure modes such as coil icing in air
conditioning systems and frozen heat exchangers in
chiller systems.
The minimum, recommended low pressure cut-out
switch settings are:
Air conditioning and chiller:
55 psig/3.8 bar (R-410A), 25 psig/1.7 bar (R-22 &
R-407C), and 10 psig/0.7 bar (R-134a)
Heat pumps:
20 psig/1.4 bar (R-410A), 10 psig/0.7 bar (R-22,
R-407C, & R-134a)
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
5
AE4-1388 R3
Long Pipe Lengths / High Refrigerant Charge
System Tubing Stress
Some systems may contain higher-than-normal
refrigerant charges. Systems with large reheat coils,
low ambient condenser flooding, or systems with
multiple heat exchangers are among some system
configurations that may require additional lubricant.
Since the 20 to 40 ton scrolls have sight-glasses for oil
level viewing, the oil level should always be checked
during OEM assembly, field commissioning, and field
servicing. An estimation of the amount of additional
lubricant to add to the compressor(s) when the circuit
charge exceeds 20 pounds of refrigerant is as follows:
System tubing should be designed to keep tubing
stresses below 9.5 ksi (62 MPa), the endurance limit
of copper tubing. Start, stop and running (resonance)
cases should be evaluated.
Accumulators
The use of accumulators is very dependent on the
application. The Copeland Scroll ™ compressor’s
inherent ability to handle liquid refrigerant during
occasional operating flood back situations makes
the use of an accumulator unnecessary in most
applications. In applications where uncontrolled flooding
is common, an accumulator should be used to prevent
excessive oil dilution and oil pump out.
Single compressor application: 0.5 fluid ounce of oil
per pound of refrigerant
Tandem compressor application: 0.7 fluid ounce of
oil per pound of refrigerant
Off-Cycle Migration Control
Excessive migration of refrigerant to the compressor
during the off-cycle can result in oil pump-out on start
up, excessive starting noise and vibration, bearing
erosion, and broken scrolls if the hydraulic slugging
pressure is high enough. For these reasons, offcycle refrigerant migration must be minimized. The
following three sections summarize off-cycle migration
techniques.
Trio compressor application: 1.0 fluid ounce of oil per
pound of refrigerant
The oil level must be carefully monitored during system
development, and corrective action should be taken if
the compressor oil level falls more than 1.5" (40 mm)
below the center of the sight-glass. The compressor oil
level should be checked with the compressor "off"
to avoid the sump turbulence when the compressor
is running.
Crankcase Heat
A crankcase heater is required when the system charge
exceeds the values listed in Table 3. This requirement
is independent of system type and configuration. Table
4 lists Emerson crankcase heaters by part number and
voltage. See Figure 4 for the proper heater location
on the compressor shell. The crankcase heater must
remain energized during compressor off cycles.
These compressors are available to the OEM with a
production sight-glass that can be used to determine the
oil level in the compressor in the end-use application.
These compressors are also available to the OEM with
an oil Schrader fitting on the side of the compressor to
add additional oil if needed because of long lengths of
piping or high refrigerant charge. No attempt should
be made to increase the oil level in the sight-glass
above the 3/4 full level. A high oil level is not
sustainable in the compressor and the extra oil will
be pumped out into the system causing a reduction
in system efficiency and a higher-than-normal oil
circulation rate.
The initial start-up in the field is a very critical period for
any compressor because all load-bearing surfaces are
new and require a short break-in period to carry high
loads under adverse conditions. The crankcase heater
must be turned on a minimum of 12 hours prior to
starting the compressor. This will prevent oil dilution
and bearing stress on initial start up.
Suction and Discharge Fittings
To properly install the crankcase heater, the heater
should be installed in the location illustrated in Figure
4. Tighten the clamp screw carefully, ensuring that the
heater is uniformly tensioned along its entire length
and that the circumference of the heater element is
in complete contact with the compressor shell. It's
important that the clamp screw is torqued to the range
20 to 40 ton Copeland Scroll™ compressors have
copper plated steel suction and discharge or threaded
rotalock fittings. See Figure 3 for assembly line and
field brazing recommendations and Table 2 for rotalock
torque requirements.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
6
AE4-1388 R3
of 20-25 in-lb (2.3-8 N-m) to ensure adequate contact
and to prevent heater burnout. Never apply power to
the heater in free air or before the heater is installed
on the compressor to prevent overheating and burnout.
WARNING! Crankcase heaters must be properly
grounded.
a defrost cycle, when the reversing valve abruptly
changes the refrigerant flow direction, the suction
and discharge pressures will go outside of the normal
operating envelope. The sound that the compressor
makes during this transition period is normal, and
the duration of the sound will depend on the coil
volume, outdoor ambient, and system charge level.
The preferred method of mitigating defrost sound is to
shut down the compressor for 20 to 30 seconds when
the reversing valve changes position going into and
coming out of the defrost cycle. This technique allows
the system pressures to reach equilibrium without the
compressor running. The additional start-stop cycles do
not exceed the compressor design limits, but suction
and discharge tubing design should be evaluated.
Pump Down Cycle
Although not preferred, a recycling pump down cycle
can be used to minimize off-cycle refrigerant migration
to the compressor. The risk of a short cycling condition
that can lead to oil pump out, excessive contactor wear,
unnecessary energy use, and excessive low pressure
cut-out switch cycles makes recycling pump down
undesirable. If a pump down cycle is desired by the
system designer, a one time pump down at the end
of the cooling cycle is preferred over recycling pump
down. In lieu of the pump down cycles mentioned
above, simply closing a liquid line solenoid valve when
the compressor cycles off is a good, simple, and cost
effective method of minimizing off-cycle refrigerant
migration.
The reversing valve solenoid should be wired so
that the valve does not reverse when the system is
shut off by the operating thermostat in the heating
or cooling mode. If the valve is allowed to reverse at
system shutoff, suction and discharge pressures are
reversed to the compressor. This results in pressures
equalizing through the compressor which can cause
the compressor to slowly rotate backwards until the
pressures equalize. This condition does not affect
compressor durability but can cause unexpected sound
after the compressor is turned off.
Pump Out Cycle
A pump out cycle has been successfully used by some
manufacturers of large rooftop units. After an extended
off period, a typical pump out cycle will energize the
compressor for up to one second followed by an off
time of 5 to 20 seconds. This cycle is usually repeated
a second time, the third time the compressor stays on
for the cooling cycle.
Contaminant Control
Copeland Scroll™ compressors leave the factory with
a miniscule amount of contaminants. Manufacturing
processes have been designed to minimize the
introduction of solid or liquid contaminants. Dehydration
and purge processes ensure minimal moisture levels
in the compressor, and continuous auditing of lubricant
moisture levels ensures that moisture isn’t inadvertently
introduced into the compressor. During unit assembly
and field servicing, compressors shouldn't be left open
to the atmosphere for longer than 20 minutes.
If any of the above methods are employed, a
crankcase heater must be used if the circuit charge
amount exceeds the values listed in Table 3.
Reversing Valves
Since Copeland Scroll compressors have very high
volumetric efficiency, their displacements are lower
than those of comparable capacity reciprocating
compressors. CAUTION Reversing valve sizing must
be within the guidelines of the valve manufacturer.
Required pressure drop to ensure valve shifting
must be measured throughout the operating range
of the unit and compared to the valve manufacturer's
data. Low ambient heating conditions with low flow
rates and low pressure drop across the valve can
result in a valve not shifting. This can result in a
condition where the compressor appears to be
not pumping (i.e. balanced pressures). It can also
result in elevated compressor sound levels. During
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
It is generally accepted that system moisture levels
should be maintained below 50 ppm. A filter-drier is
required on all POE lubricant systems to prevent
solid particulate contamination, oil dielectric
strength degradation, ice formation, oil hydrolysis,
and metal corrosion. It is the system designer’s
responsibility to make sure that the filter-drier is
adequately sized to accommodate the contaminants
from system manufacturing processes which leave
solid or liquid contaminants in the evaporator coil,
condenser coil, and interconnecting tubing plus any
contaminants introduced during the field installation
7
AE4-1388 R3
appropriate locations on the equipment to ensure
that proper rotation direction is achieved when
the system is installed and operated. Verification
of proper rotation direction is made by observing that
suction pressure drops and discharge pressure rises
when the compressor is energized. Reverse rotation will
result in no pressure differential as compared to normal
values. A compressor running in reverse will sometimes
make an abnormal sound.
process. Molecular sieve and activated alumina are
two filter-drier materials designed to remove moisture
and mitigate acid formation. A 100% molecular sieve
filter can be used for maximum moisture capacity. A
more conservative mix, such as 75% molecular sieve
and 25% activated alumina, should be used for service
applications.
Oil Type
Mineral oil is used in the ZR*KC compressors for
R-22 applications. Polyolester (POE) oil is used in
the ZR*KCE compressors for use with R-22, R-407C,
and R-134a and in ZP*KCE compressors for use
with R-410A. See the compressor nameplate for the
original oil charge. A complete recharge should be
approximately four fluid ounces (118 ml) less than the
nameplate value.
There is no negative impact on durability caused by
operating three phase Copeland Scroll™ compressors in
the reversed direction for a short period of time (under
one hour). After a few minutes of reverse operation,
the motor and scroll thermistor circuit will exceed the
temperature trip point and the M1-M2 contacts will open,
shutting off the compressor. If allowed to repeatedly
restart and run in reverse without correcting the
situation, the compressor bearings will be permanently
damaged because of oil loss to the system. All threephase scroll compressors are wired identically internally.
As a result, once the correct phasing is determined for
a specific system or installation, connecting properly
phased power leads to the identified compressor
electrical (Fusite®) terminals will maintain the proper
rotational direction (see Figure 5).
If additional oil is needed in the field for POE
applications, Copeland ™ Ultra 32-3MAF, Lubrizol
Emkarate RL32-3MAF, Parker Emkarate RL32-3MAF/
(Virginia) LE32-3MAF, or Nu Calgon 4314-66 (Emkarate
RL32-3MAF) should be used. Copeland™ Ultra 22 CC,
Hatcol EAL 22CC, and Mobil EAL Arctic 22 CC are
acceptable alternatives.
If additional oil is needed in the field for mineral oil
applications, Sonneborn Suniso 3GS or Chevron
Texaco Capella WF32 should be used.
Power Factor Correction
If power factor correction is necessary in the end-use
application, please see AE9-1249 for more information
on this topic.
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).
Soft Starters
Soft starters can be used with the 20 to 40 ton Copeland
Scroll compressors to reduce inrush current. Soft
starters should be selected in accordance with the soft
starter manufacturer's recommendations, taking into
consideration ambient temperature, number of starts
per hour, and compressor amps. The maximum ramp
up time should not exceed 3 seconds.
Three Phase Scroll Compressor Electrical Phasing
NOTICE
Compressors that employ CoreSense technology
have phase protection and will be locked out after
one reverse phase event.
Motor Overload Protection
WARNING
The Kriwan and CoreSense Communications
modules are U.L. recognized safety devices and
must be used with all compressors that have TW*
and TE* electrical codes respectively.
Copeland Scroll compressors, like several other types
of compressors, will only compress in one rotational
direction. Three phase compressors will rotate in either
direction depending upon phasing of the power. Since
there is a 50% chance of connecting power in such a
way as to cause rotation in the reverse direction, it is
important to include notices and instructions in
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Models with Electrical Code TE
Compressors with an "E" in the electrical code
(i.e. ZP236KCE-TED) employ CoreSense ™
8
AE4-1388 R3
Communications as the motor overload protection
device. CoreSense Communications provides
advanced diagnostics, protection, and communications
that enhance compressor performance and reliability.
For more information please refer to the CoreSense
Communications application engineering bulletin,
AE8-1384.
for Kriwan and CoreSense modules. Please see the
Field Troubleshooting section for information on
troubleshooting the Kriwan and CoreSense modules.
Manifolded Compressors
Tandem compressor assemblies are available for
purchase from Emerson. In lieu of purchasing the
assembled tandem, OEMs can purchase the manifoldready compressors and perform the assembly in their
factory. Trio compressor assemblies are not available
for purchase from Emerson. However, trio compressor
designs have been developed and qualified. Drawings
of tandem and trio compressor assemblies are available
from Emerson Climate Technologies by contacting your
Application Engineer. Tables 5 and 6 are quick reference
guides to tandem and trio compressor assemblies
respectively. Part numbers for manifolds and other
service parts are available by contacting Application
Engineering. Figures 6, 7 and 8 show manifolded
compressor assemblies. NOTICE: Customers who
choose to design and build their own manifolds
for tandem and trio compressor assemblies are
ultimately responsible for the reliability of those
manifold sets.
Models with Electrical Code TW
Models with a "W" in the electrical code (i.e.
ZP285KCE-TWD) have a Kriwan motor overload
system that consists of an external electronic control
module connected to a chain of thermistors embedded
in the motor windings and scroll discharge plenum.
The module will trip and remain off for a minimum of
30 minutes if the motor or scroll temperature exceeds
the maximum allowable temperature.
Note: Turning off power to the module will reset
it immediately, however, if the fault is still present
that caused the trip the module will lock out the
compressor for another 30 minutes.
The module has a 30 minute time delay to allow the
motor and scrolls to cool down after the temperature
limit has been reached. CAUTION Restarting the
compressor sooner may cause a destructive
temperature build up in the compressor. For this
reason, module power must never be switched off
with the control circuit voltage. Since the compressor
is dependent upon the contactor to disconnect it
from power in case of a fault, the contactor must
be selected in accordance with AE10-1244. The
contactor must meet both the Rated Load Amps
(RLA) and Locked Rotor Amps (LRA) specified for
the compressor.
The suction manifold is usually a symmetrical layout
with the design intent of equal pressure drop to each
compressor in the tandem or trio set. A straight length
of pipe 18" (450 mm) or longer is required directly
upstream of the suction manifold connection for all
tandems and trios. The straight pipe serves as a flow
straightener to make the flow as uniform as possible
going into the suction manifold. Some tandem and trio
assemblies use flow washers to assist with oil balancing
between the compressors. Please refer to Tables 5 and
6 for a complete list of all tandem and trios and required
flow washers. For reference, refer to Figures 6, 7, and
8 for compressor A-B-C identification in tandem and trio
configurations. Compressor "A" is always on the left side
of the assembly, when looking at the assembly from the
terminal box side of the compressors.
If the Kriwan module is applied in conjunction with a
programmable logic controller (PLC), 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 20 milliamps, but no more than 2.5 amps. If this
minimum current is not maintained, long-term contact
resistance of the relay may be compromised resulting
in nuisance, unexplained trips. PLC operated control
circuits may not always provide this minimum current.
In these cases modifications to the PLC control circuit,
or the addition of a relay, may be required.
The discharge manifold is the less critical of the
two manifolds in terms of pressure drop and flow.
Low pipe stress and reliability are its critical design
characteristics. Manifolded options with bidirectional
discharge manifolds will obviously need to have one
of the outlets capped by the OEM or end-user. The
overall length of the cap fitting shouldn't exceed 3"
(7.6 cm). If the bidirectional manifold is clamped to the
unit to provide discharge line stability, the clamp must
Motor Overload Protection Specs
Table 7 summarizes the features and specifications
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
9
AE4-1388 R3
the individual trio assembly drawings. The direction
of flow is critical for oil balancing between the
compressors and the noted direction of flow must
be followed.
be installed at least 15" (38 cm) downstream of the
manifold. Clamping in this method will provide some
flexibility between the manifold and the clamp.
Two different oil balancing techniques are used with
tandems in this family of compressors – two-phase
tandem line (TPTL) and oil equalization line (OEL).
For trio assemblies, only the TPTL design has been
qualified. The TPTL design is a larger diameter pipe
connecting the oil sumps of the individual compressors
allowing both gas and oil to flow between the
compressors at the same time. To install the TPTL, the
individual sight-glasses on each compressor must be
removed to allow the TPTL to screw on to the sight-glass
fitting on the compressors. A sight-glass is installed on
the TPTL to view the presence of oil (see Figure 6).
Oil levels in the individual sight-glasses will vary,
depending on whether one or more compressors in the
manifolded set are operating and if the manifolded set
is made up of equal or unequal compressor capacities.
Because of the unequal oil levels that can exist,
oil levels should be viewed with the compressors
off to allow the oil level to stabilize between the
compressor sumps. With the compressors off, oil
should be visible in the individual compressor sightglasses when the OEL is used, or in the sight-glass
on the TPTL. If oil is not visible, additional oil should
be added to the system. The above procedure is
extremely important during the unit commissioning
process in the field and must be performed. Failure
to add oil to the system to account for large
refrigerant charges and large internal surface areas
can result in compressor failure.
The OEL design is a 5/8" (16 mm) copper tube
connecting the oil sumps of the individual compressors
allowing the flow of oil between the compressor sumps.
To install the OEL, the oil drain Schrader fitting on
each compressor must be removed so the OEL line
can be screwed on to the individual rotalock oil fittings
(see Tandem Assembly section). The OEL has an oil
drain Schrader fitting on the 5/8" OEL tube for adding/
removing oil (see Figure 7). The OEL design allows the
individual oil levels in each compressor to be viewed,
which isn't possible with the TPTL.
Suction and discharge tandem manifolds are not
designed to support system piping. Support means
must be provided by the system designer to support
suction and discharge lines so that stress is not placed
on the manifolds.
Compressors in a manifolded set must be started and
stopped sequentially to keep manifold stresses as low
as possible.
Manifolded Applications
NOTICE
Manifolded compressor designs employ a
passive oil management system. All system
designs must be tested by the OEM to ensure
that the passive design will provide adequate
oil balancing between the compressors in the
manifolded set under all operating conditions. If
adequate oil balancing can't be demonstrated, an
active oil management system must be used.
Please consult with Application Engineering during
the development of systems with trio compressor
assemblies. Trio compressor assemblies are
sensitive to system operating conditions and
configurations which will affect oil balancing. Trio
compressor assemblies must be qualified for each
application.
VARIABLE SPEED OPERATION
Manifolded compressors follow the same application
guidelines as single compressors outlined in this
bulletin. The refrigerant charge limit for tandem
compressors is shown in Table 3. A tandem circuit with
a charge over this limit must have crankcase heaters
applied to both compressors.
Introduction
The 20 to 40 ton Copeland Scroll compressors
described in this bulletin are qualified for a speed range
of 2100 to 4500 RPM, which corresponds to an electrical
input frequency of 35 to 75 Hertz.
Performance
The direction of the suction gas flow into the 18" (457
mm) straight pipe, directly upstream of the suction
manifold, is critical for trio assemblies. The direction of
flow is noted for each trio assembly in Table 6 and on
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Ten coefficients are available for calculating
performance. Evaporating and condensing temperature
10
AE4-1388 R3
are the terms for the ten coefficient equation to calculate
mass flow, power, and capacity. Twenty coefficients are
also available for calculating performance. Evaporating
and condensing temperature and speed are the terms
of the equation. The coefficients are for the compressor
only and do not account for the drive. These coefficients
are available by contacting Application Engineering.
frequency curves for nominal 230, 460, and 575 volt
power supplies.
The CoreSense™ Communications M1-M2 contacts
and other safety/protection controls (i.e. high pressure
cut-out switch) should be wired in-series with the
compressor contactor coil. The compressor contactor
should be wired upstream of the variable frequency
drive so the drive and compressor are immediately
stopped when a safety/protection control trips.
Operating Envelope
The variable speed operating envelope is shown in
Figure 2. Please note that the 35 to 75 Hertz (2100 to
4500 RPM) range does not apply to the entire envelope.
The system controller must have the ability to keep the
operating condition inside of the prescribed operating
envelope.
Autotuning
If an Autotuning drive sequence is to be performed with
a compressor that has a Coresense Communication
module, the following steps must be taken.
1. De-energize control circuit and module power.
Remove the control circuit wires from the module
(terminals M1 & M2).Connect a jumper across
these "control circuit" wires. This will bypass the
"control contact" of the module.
Drive Selection
A third party drive must be selected and sourced
separately for the compressor. For convenience,
a list of Emerson Control Techniques drives is
listed in Table 9. These preselected drives offer a
variety of I/O for drive/compressor control. For more
information on Emerson Control Techniques drives
please visit http://www.emersonindustrial.com/en-US/
controltechniques/industries/hvac/Pages/heatingventilation-air-conditioning-refrigeration.aspx or call
800-367-8067 for technical assistance. Registration is
not required to use the website and users can download
manuals, user guides, drawings, software, and other
drive information.
CAUTION! The motor protection system
within the compressor is now bypassed. Use
only temporarily during autotuning sequence.
2. Run the Autotuning sequence of the drive.
3. Remove jumper and reconnect control circuit wires
to the module.
Starting and Ramp Up
Electrical Requirements
The starting frequency should be equal to or greater
than 35 Hertz. After starting the compressor at a
minimum of 35 Hertz, the frequency should be ramped
up to 50 or 60 Hertz within 3 seconds. The compressor
should operate at 50/60 Hertz for a minimum of 10
seconds before ramping the speed up or down to the
desired operating speed. A normal ramp speed is 200
revolutions per second.
The drive must be sized to accommodate the maximum
expected running amps of the compressor. The Control
Techniques Drives in Table 9 are selected based on the
maximum current published in the operating envelope
at rated voltage. For operation throughout the operating
envelope at +/-10% voltage variation the drive should
be selected based on the compressor maximum
continuous current (MCC).
Stopping
The recommended switching frequency of the drive is
2 to 3 kHz. Higher switching frequencies can result in
motor overheating and reduced efficiency.
Ramping down the frequency to 35 Hertz before
stopping the drive-compressor is considered a good
shutdown routine. However, given the operating
frequency and speed range of the compressor it is
not necessary to decelerate the compressor prior to
shutdown. Depending on the drive interface and control,
the drive should be given a "stop" command to stop the
compressor. In rare cases when a system protection
device trips (i.e. high pressure cut-out switch) power
to the drive input should be immediately interrupted.
The normal ratio of the voltage/frequency should be
kept constant throughout the 35 to 60 Hertz range.
At frequencies higher than 60 Hertz, the voltage/
frequency ratio cannot be kept constant because the
output voltage of the drive cannot be higher than the
drive input voltage. Figure 9 illustrates the voltage-
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
11
AE4-1388 R3
Vibration
APPLICATION TESTS
A compressor driven at a variable speed will impose
different frequencies at each speed, so the framework
and piping design to accommodate vibration throughout
the speed range can be more complex. As a rule
of thumb, the system should be designed, or the
drive control should be configured (skip frequencies
program), such that there is no operation at resonant
frequencies between 35 and 75 Hertz.
Application Test Summary
There are a minimal number of tests the system
designer will want to run to ensure the system operates
as designed. These tests should be performed during
system development and are dependent on the
system type and amount of refrigerant charge. These
application tests are to help identify gross errors in
system design that may produce conditions that could
lead to compressor failure.
Oil Recovery Cycle
For manifolded compressor assemblies, oil balancing
tests must be performed to demonstrate oil balancing
between the compressors. Compressors with sighttubes for viewing a wide range of oil levels is appropriate
for this type of testing. The least amount of testing will
evaluate the minimum and maximum flow conditions at
which the compressors will be required to operate, with
min and max suction superheat.
Particular attention must be given to the system
refrigerant pipe size with the variable speed scrolls.
ASHRAE guidelines for pipe sizing should be followed
to ensure that refrigerant velocities are high enough
at low speeds to ensure oil return to the compressor.
At the same time, high refrigerant velocities at high
speed operation can result in excessive pressure drop
and loss of system efficiency. A careful evaluation
and compromise in pipe sizing will likely have to be
settled upon. A compressor sample with a sight-tube
for monitoring the oil level should be used during
system development to ensure an adequate oil level is
maintained during all operating conditions and speeds.
For variable speed applications, the above oil balancing
and system oil return tests must be performed. The
concern is a very low oil level after extended hours
of operation at low speed (40 Hertz). In addition to oil
balancing and system oil return tests, the suction and
discharge tubing must be evaluated to determine the
resonant frequencies. Once the resonant frequencies
are known, they can be shifted to a safe range by
changing the mass of the line for constant speed
applications or they can be avoided for variable speed
applications.
If testing shows a gradual, continuous loss of oil in
the compressor sight-tube over long run cycles at low
speed, an oil recovery cycle should be incorporated
into the system logic. A recovery cycle is accomplished
by ramping the compressor up to a higher speed to
increase the refrigerant flow rate to flush or sweep oil
back to the compressor. How often a recovery cycle is
initiated depends on many variables and would have
to be determined through testing for each system type
and configuration. A default method could be to initiate
a recovery cycle at regular intervals.
As always, Application Engineering is available to
recommend additional tests and to evaluate test results.
ASSEMBLY LINE PROCEDURES
Compressor Handling
Variable Speed Manifolded Applications
WARNING
The most favorable oil balancing occurs when a VFD
is applied to both compressors in the tandem set and
the two-phase tandem line (TPTL) is used. See the
following section on Manifolded Compressors for
a complete description of manifolded compressors
and oil balancing. If only one VFD is applied to one
compressor in a tandem set, the VFD should be applied
to the compressor in the "A" position (see Figure 7).
Trio manifolded compressor configurations have not
been tested and qualified for variable speed operation.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Use care and the appropriate material handling
equipment when lifting and moving compressors.
Personal safety equipment must be used.
The suction and discharge plugs should be left in place
until the compressor is set into the unit. If possible, the
compressor should be kept vertical during handling.
The discharge connection plug should be removed
first before pulling the suction connection plug to allow
the dry air pressure inside the compressor to escape.
Pulling the plugs in this sequence prevents oil mist
from coating the suction tube making brazing difficult.
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AE4-1388 R3
Unbrazing System Components
The copper coated steel suction tube should be
cleaned before brazing (see Figure 3). No object
(e.g. a swaging tool) should be inserted deeper than
two inches (51 mm) into the suction tube, or it might
damage the suction screen and motor.
WARNING
Before attempting to braze, it is important to recover
all refrigerant from both the high and low side of
the system.
Mounting
If the refrigerant charge is removed from a scrollequipped unit by evacuating the high side only, it is
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 while
the low side shell and suction line contain pressure,
the pressurized refrigerant and oil mixture could ignite
when it escapes and contacts the brazing flame.
CAUTION! It is important to check both the high
pressure and low pressure sides with manifold
gauges before unbrazing. Instructions should be
provided in appropriate product literature and assembly
(line repair) areas. If compressor removal is required,
the compressor should be cut out of system rather than
unbrazed. See Figure 3 for the proper compressor
removal procedure.
The tested rubber mounting grommet and sleeve kit is
listed in Table 4.
Many OEM customers buy the mounting parts directly
from the supplier, but Emerson's grommet design and
durometer recommendations should be followed for best
vibration reduction through the mounting feet. Please
see AE4-1111 for grommet mounting suggestions and
supplier addresses.
Suction and Discharge Fittings
These compressors are available with stub tube
or rotalock connections. The stub tube version has
copper-plated steel suction and discharge fittings. Due
to the different thermal properties of steel and copper,
brazing procedures may have to be changed from
those commonly used. See Figure 3 for assembly line
and field brazing procedures and Table 2 for Rotalock
torque values.
Pressure Testing
WARNING
Assembly Line Brazing Procedure
Never pressurize the compressor to more than
400 psig (27.6 bar) for ZR*KCE and 475 psig (32.8
bar) for ZP*KCE compressors. Never pressurize
the compressor from a nitrogen cylinder or other
pressure source without an appropriately sized
pressure regulating and relief valve.
WARNING
Personal safety equipment must be used during
brazing operation. Heat shields should be
used to prevent overheating or burning nearby
temperature sensitive parts. Fire extinguishing
equipment should be accessible in the event of a
fire.
Higher pressure may result in permanent deformation of
the compressor shell and possibly cause misalignment
or bottom cover distortion.
Figure 3 discusses the proper procedures for brazing
the suction and discharge lines to a scroll compressor.
NOTICE: It is important to flow nitrogen through
the system while brazing all joints during the
system assembly process. Nitrogen displaces the
air and prevents the formation of copper oxides in the
system. If allowed to form, the copper oxide flakes can
later be swept through the system and block screens
such as those protecting capillary tubes, thermal
expansion valves, and accumulator oil return holes. The
blockage – whether it is of oil or refrigerant – is capable
of doing damage resulting in compressor failure.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Assembly Line System Charging Procedure
Systems should be charged with liquid on the high side
to the extent possible. The majority of the charge should
be pumped in the high side of the system to prevent low
voltage starting difficulties, hipot failures, and bearing
washout during the first-time start on the assembly line.
If additional charge is needed, it should be added as
liquid to the low side of the system with the compressor
operating. Pre-charging on the high side and adding
liquid on the low side of the system are both meant to
protect the compressor from operating with abnormally
low suction pressures during charging. NOTICE: Do
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AE4-1388 R3
not operate the compressor without enough system
charge to maintain at least 55 psig (3.8 bar) suction
pressure for R-410A and 20 psig (1.4 bar) for R-22
& R-407C. Do not operate the compressor with the
low pressure cut-out disabled. Do not operate with
a restricted suction or liquid line. Do not use the
compressor to test the opening set point of a high
pressure cutout. Bearings are susceptible to damage
before they have had several hours of normal running
for proper break in.
This phenomenon can occur with any compressor when
the motor is immersed in refrigerant. The level of current
leakage does not present any safety issue. To lower the
current leakage reading, the system should be operated
for a brief period of time to redistribute the refrigerant
to a more normal configuration and the system hipot
tested again. See AE4-1294 for Megohm testing
recommendations. Under no circumstances should
the hipot test be performed while the compressor
is under a vacuum.
Electrical Connections
Tandem Assembly
The orientation of the electrical connections on the
Copeland Scroll™ compressors is shown in Figure 5.
The T-block screw terminals used on this compressor
should be fastened with a torque of 21 to 25 in-lb (2.37
to 2.82 Nm). See Table 2.
The following procedure outlines the basic steps to
assemble a tandem.
1. Mount both compressors to the rails using the
appropriate hardware. Mounting bolts should be
snug, but not tight, so some movement of the
compressor is possible for aligning the manifolds.
Every effort should be made to keep the terminal
box completely sealed. Oversized conduits, poor
conduit connections to the terminal box, an incorrectly
installed terminal box cover or a missing terminal box
cover gasket are a few possible air leakage paths.
CAUTION! Moisture from warm, moist air that
is permitted to freely enter the terminal box can
condense into droplets of water inside the cooler
terminal box of the compressor. To alleviate this
problem, the warm, moist air must be prevented
from entering the terminal box. Sealing conduits and
eliminating other air leakage paths must be taken.
Dow Corning 3165 RTV is ideally suited for sealing
around wires in a conduit at the compressor terminal
box. Drilling a hole in the bottom of the terminal box
to allow the moisture to escape is not acceptable.
2. Install the suction and discharge manifolds. If the
manifolds are brazed to the compressors following
the brazing guide in Figure 3. If the manifolds are
connected to the compressors with rotalocks torque
the rotalocks to the value specified in Table 2.
3. Tilt the tandem assembly back approximately
12 degrees from horizontal so the oil flows
away from the oil fittings and sight-glasses on
the compressors. This can be accomplished by
placing 4x4 wood blocks under the tandem rail
closest to the oil fittings on the compressors. Install
the oil manifold (TPTL or OEL) to the individual
compressors and torque the rotalock fittings to the
value specified in Table 2.
“Hipot” (AC High Potential) Testing
4. Torque the compressor to rail mounting bolts to the
value specified in Table 2.
CAUTION
Use caution with high voltage and never hipot
when compressor is in a vacuum.
For a detailed instruction list of how to assemble a trio
of compressors, please contact Application Engineering.
Copeland Scroll compressors are configured with the
motor down and the pumping components at the top
of the shell. As a result, the motor can be immersed
in refrigerant to a greater extent than hermetic
reciprocating compressors when liquid refrigerant is
present in the shell. In this respect, the scroll is more like
semi-hermetic compressors which can have horizontal
motors partially submerged in oil and refrigerant. When
Copeland Scroll compressors are hipot tested with liquid
refrigerant in the shell, they can show higher levels of
leakage current than compressors with the motor on top.
SERVICE PROCEDURES
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
CAUTION
POE oil 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).
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AE4-1388 R3
Field Replacement
Compressor Replacement after Motor Burn
In the case of a motor burn, the majority of contaminated
oil will be removed with the compressor. The rest of the
oil is cleaned through use of suction and liquid line filter
dryers. A 100% activated alumina suction filter drier is
recommended but must be removed after 72 hours. See
AE24-1105 for clean up procedures and AE11-1297 for
liquid line filter-drier recommendations.
WARNING
Use care and the appropriate material handling
equipment when lifting and moving compressors.
Personal safety equipment must be used.
Mounting
Soft or semi-hard mounting grommets, if used,
should be replaced when the compressor is
replaced. Grommet hardness can change over time
when exposed to various ambient conditions. Rigid
mounting hardware can probably be reused with the
replacement compressor and should be evaluated by
the service technician.
NOTICE: It is highly recommended that the suction
accumulator be replaced if the system contains
one. This is because the accumulator oil return orifice
or screen may be plugged with debris or may become
plugged shortly after a compressor failure. This will
result in starvation of oil to the replacement compressor
and a second failure.
Removing Oil
If the oil level is higher than the oil Schrader fitting on
the sump of the compressor oil can be drained from
this fitting until the oil level reaches the level of the
Schrader fitting. To remove oil from the compressor
when the oil level is below the oil Schrader fitting
one of two different procedures can be used. The
first procedure is to remove the compressor from the
system and drain the oil from the compressor suction
connection. This method ensures complete removal
of the oil from the compressor. The second procedure
is to remove the compressor sight-glass and insert a
hose into the sump of the compressor and draw the
oil out with a hand-held pump (Yellow Jacket Pump
UPC#77930).
Manifolded Compressor Replacement
WARNING
When lifing manifolded compressor assemblies,
all compressors must be lifted by their respective
lifting rings. Use care and exercise extreme caution
when lifting and moving compressors. Personal
safety equipment must be used.
In the event that a compressor should fail in a
manifolded set, only the failed compressor should be
replaced. The oil from the failed compressor will stay
mostly in the failed compressor. Any contaminated oil
that does enter the other compressor sumps will be
cleaned by the liquid line filter drier, and when used,
the suction line filter drier.
Electrical
When replacing a compressor, especially one that has
been in the field for a number of years, it is always a
good idea to replace the contactor.
Changing a compressor in a manifolded set that uses
rotalock connected manifolds simplifies the changeout process. After the refrigerant is recovered, and it
is verified through the use of gauges that no residual
refrigerant pressure is in the section of the system
being serviced, the suction and discharge rotalock
fittings can be disconnected from the failed compressor.
Always use new rotalock o-ring seals when connecting
the replacement compressor (see Table 4 for part
numbers). If the suction and discharge manifolds are
brazed to the compressor, carefully cutting the piping
connections close the compressor stubs usually
allows connection of the replacement compressor
with couplings and short lengths of copper piping. Do
not attempt to unbraze the piping from the failed
compressor.
Note: See the locked rotor on the nameplate of
the new compressor and make sure the contactor
exceeds this locked rotor rating.
Module
If the replacement compressor is the same as the
model being replaced (i.e. ZP235KCE-TWD is being
replaced by ZP235KCE-TWD) the motor protection
scheme will be the same and won't require any
special configuration during the change-out. If the
replacement compressor is equipped with CoreSense
and the failed compressor has a Kriwan module, the
CoreSense module must be configured to operate
in standalone mode. Please refer to AE8-1384 for
information on CoreSense module configuration.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
15
AE4-1388 R3
Care must be used when removing the oil line
connecting the compressor sumps. Catch pans should
be placed under the compressor oil fittings to catch oil
that may flow out of the compressors when the oil line
is removed. It is highly recommended to place plastic
(polyethylene plastic that is available at any hardware
store) under the compressors to catch any spilled oil.
Always use new rotalock o-ring seals when connecting
the oil line to the replacement compressor (see Table
4 for part numbers).
1. De-energize control circuit and module power.
Remove the control circuit wires from the module
(Terminals M1 & M2). Connect a jumper across
these “control circuit” wires. This will bypass the
“control contact” of the module.
CAUTION! The motor protection system within
the compressor is now bypassed. Use this
configuration to temporarily test module only.
Re-energize the control circuit and module power.
Start-up of a New or Replacement Compressor
If the compressor will not operate with the jumper
installed, then the problem is external to the solid
state protection system.
It is good service practice, when charging a system with
a scroll compressor, to charge liquid refrigerant into
the high side only. It is not good practice to dump liquid
refrigerant from a refrigerant cylinder into the crankcase
of a stationary compressor. If additional charge is
required, charge liquid into the low side of the system
with the compressor operating. WARNING! Do not
start the compressor while the system is in a deep
vacuum. Internal arcing may occur when any type of
compressor is started in a vacuum. NOTICE: Do not
operate the compressor without enough system
charge to maintain at least 55 psig (3.8 bar) suction
pressure for R-410A and 20 psig (1.4 bar) for R-22
& R-407C. Do not operate with a restricted suction
or liquid line. Do not operate with the low pressure
cut-out disabled. Never install a system in the field and
leave it unattended with no charge, a holding charge, or
with the service valves closed without securely locking
out the system. This will prevent unauthorized personnel
from accidentally ruining the compressor by operating
with no refrigerant flow.
If the compressor operates with the module
bypassed but will not operate when the module
is reconnected, then the control circuit relay in
the module is open. The thermistor protection
chain now needs to be tested to determine if
the module’s control circuit relay is open due
to excessive internal temperatures or a faulty
component.
2. Check the thermistor protection chain located in
the compressor as follows:
De-energize control circuit and module power.
Remove the sensor leads from the module (S1
& S2). Measure the resistance of the thermistor
protection chain through these sensor leads with
an ohmmeter.
NOTICE: Use an Ohmmeter with a maximum
of 9 volts to check the sensor chain. The
sensor chain is sensitive and easily damaged;
no attempt should be made to check continuity
through it with anything other than an
ohmmeter. The application of any external
voltage to the sensor chain may cause damage
requiring the replacement of the compressor.
As mentioned in the Manifolded Applications section,
attention must be given to compressor oil levels
when commissioning a new system and servicing an
existing system. Oil levels should be checked with the
compressor "off" and after the oil has had a chance
to equalize between the compressors (for manifolded
applications). If oil can't be seen in the sight-glass
of the compressor, add oil until the sight-glass is
approximately half full.
The diagnosis of this resistance reading is as
follows:
Field Troubleshooting the Kriwan Module
• 200 to 2250 ohms – Normal operating range
Follow the steps listed below to troubleshoot the module
in the field. See the wiring diagram in Figure 5 or in the
terminal box cover.
• 2750 ohms or greater – Compressor
overheated – Allow time to cool
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
• zero resistance – Shorted sensor circuit –
Replace the compressor
16
AE4-1388 R3
Copeland Scroll Compressor Functional Check
• infinite resistance – Open sensor circuit –
Replace the compressor
A functional compressor test with the suction service
valve closed to check how low the compressor will pull
suction pressure is not a good indication of how well a
compressor is performing. Such a test may damage a
scroll compressor. The following diagnostic procedure
should be used to evaluate whether a Copeland Scroll
compressor is working properly.
If the resistance reading is abnormal, remove the
sensor connector plug from the compressor and
measure the resistance at the sensor fusite pins.
This will determine if the abnormal reading was
due to a faulty connector
On initial start-up, and after any module trip, the
resistance of the sensor chain must be below the
module reset point before the module circuit will
close. The reset value is less than 2750 ohms.
1. Proper voltage to the unit should be verified.
2. The normal checks of motor winding continuity
and short to ground should be made to determine
if the inherent overload motor protector has
opened or if an internal motor short or ground fault
has developed. If the protector has opened, the
compressor must be allowed to cool sufficiently to
allow it to reset.
3. If the sensor chain has a resistance that is
below 2250 ohms, and the compressor will run
with the control circuit bypassed, but will not
run when connected properly, the solid state
module is defective and should be replaced. The
replacement module must have the same supply
voltage rating as the original module.
3. Proper indoor and outdoor blower/fan operation
should be verified.
Field Troubleshooting CoreSense Communications
Module
4. With service gauges connected to suction
and discharge pressure fittings, turn on the
compressor. If suction pressure falls below normal
levels, the system is either low on charge or there
is a flow blockage in the system.
A solid green LED indicates the module is powered
and operation is normal. A solid red LED indicates an
internal problem with the module. If a solid red LED is
encountered, power down the module (interrupt the T1T2 power) for 30 seconds to reboot the module. If a solid
red LED is persistent, change the CoreSense module.
5. If suction pressure does not drop and discharge
pressure does not rise to normal levels, reverse
any two of the compressor power leads and
reapply power to make sure compressor was not
wired to run in reverse direction. If pressures still
do not move to normal values, either the reversing
valve (if so equipped) or the compressor is faulty.
Reconnect the compressor leads as originally
configured and use normal diagnostic procedures
to check operation of the reversing valve.
CoreSense communicates Warning codes via a green
flashing LED. Warning codes do not result in a trip
or lockout condition. Alert codes are communicated
via a red flashing LED. Alert codes will result in a trip
condition and possibly a lockout condition.
Separate motor and scroll thermistor circuits are used
with CoreSense (See the wiring diagram in Figure 5).
Table 7 lists the trip and reset values for motor and
scroll thermistor circuits. With the CoreSense module
in stand-alone mode (dip switch 8 turned "off" or down),
similar troubleshooting procedures that are used with
the Kriwan module can be applied to the CoreSense
module.
6. To test if the compressor is pumping properly,
the compressor current draw must be compared
to published compressor performance curves
using the operating pressures and voltage of
the system. If the measured average current
deviates more than ±15% from published values,
a faulty compressor may be indicated. A current
imbalance exceeding 15% of the average on the
three phases should be investigated further. A
more comprehensive trouble-shooting sequence
for compressors and systems can be found in
Section H of the Emerson Electrical Handbook,
Form No. 6400.
Table 8 lists the flash code information for Warning and
Alert codes along with code reset and troubleshooting
information. For more information on CoreSense please
refer to AE8-1384.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
17
AE4-1388 R3
7. Before replacing or returning a compressor: Be
certain that the compressor is actually inoperable.
As a minimum, recheck a compressor returned
from the field in the shop or depot for Hipot,
winding resistance, and ability to start before
returning. More than one third of compressors
returned to Emerson Climate Technologies, Inc.
for warranty analysis are determined to have
nothing found wrong. They were misdiagnosed in
the field as being inoperable. Replacing working
compressors unnecessarily costs everyone.
Only those refrigerants approved by Emerson Climate
Technologies, Inc. and the OEM should be considered.
For a list of Emerson approved refrigerants please
refer to Form 93-11, Refrigerants and Lubricants
Approved for Use in Copeland Compressors. Please
consult with the OEM to obtain their input and approval
on refrigerant retrofitting.
If the compressor lubricant is mineral oil, it must be
changed to POE for a successful retrofit. See the section
Removing Oil for instructions on how to remove the oil
charge from the compressor.
Refrigerant Retrofits
POE oil should be added to the compressor through the
oil charging connection on the sump of the compressor.
The compressor should be filled to 1/2 sight-glass.
NOTICE
ZR compressors are UL recognized for use
with R-22, R-407C, or R-134a only. Use of any
other refrigerants will void the compressor UL
recognition.
For detailed R-407C retrofit instructions please refer
to Form 95-14, Refrigerant Changeover Guidelines
for R-22 to R-407C. For other retrofit guidelines please
refer to the equipment OEM.
Only those systems that are in need of service should
be considered for a refrigerant retrofit if R-22 is not
available. Systems that are operating without issue
should be maintained and not be considered for a
refrigerant retrofit. In most if not all cases, the retrofitted
system will not be as energy efficient as the R-22
system.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
18
AE4-1388 R3
20 to 40 Ton Scroll Nomenclature
Compressor Family Series
"Z" for Scroll
Compressor Motor Types
Phase
Modulation
T - Even Tandem
U - Uneven Tandem
Y - Trio Configuration
Blank - No Modulation
Description
Code
3
3
6 Lead Part Winding Start Only
F
6 Lead Across The Line Starting Only D
3
3 Lead Across The Line Starting
T
Product Variations
1. -200 series indicates OEM
compressor.
2. -500 series indicates export
compressor.
E - 3MA Poe Oil
Compressor nominal
capacity at rating
condition to two or
three significant digits.
3. -700 and -900 series
indicates service compressor
for aftermarket use.
XXXXXXXXX-XXX-XXX
Code
P
R
Refrig.
R-410A
R-22/407C/134a
Electrical Codes
Model Variation
Application Range
Description
Code
Air Cooled Optimized
C
Low Condensing Optimized W
Description
Air Conditioning
Air Conditioning
60 Hz.
50 Hz.
208/230-3
200-3
460-3
380/420-3
575-3
-
Code
C
D
E
200/230-3 200/220-3
380-3
-
5
7
Capacity Multiplier
K: 1,000
M: 10,000
Compressor Motor Protection
Type Protection
E
External Electronic Protection Kriwan Module
W
Figure 1 – Nomenclature
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Code
External Electronic ProtectionCoreSense™
19
AE4-1388 R3
Operating Envelope
R-410A, R407C, R-22, & R-134a 50/60 Hertz Operation
-29
-19
Evaporating Temperature (°C)
1
-9
11
21
31
170
160
140
54
130
120
44
110
100
34
90
80
Condensing Temperature (°C)
Condensing Temperature (°F)
64
Extension for R-134a Only
150
24
70
60
14
50
40
4
-20
-10
0
10
20
30
40
50
60
70
80
Evaporating Temperature (°F)
Operang Envelope For 35 To 75 Hertz
-29
-19
Evaporang Temperature (°C)
1
-9
11
21
31
160
150
64
50 - 70 Hertz
140
45 - 70 Hertz
54
120
40 - 75 Hertz
44
110
100
34
90
35 - 75 Hertz
80
24
70
60
14
50
40
4
-20
-10
0
10
20
30
40
Evaporang Temperature (°F)
Figure 2 – 20 to 40 Ton Scroll Operating Envelopes
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
20
50
60
Condensing Temperature (°C)
Condensing Temperature (°F)
130
AE4-1388 R3
1
}
2
}
}
3
Figure 3 – Scroll Suction Tube Brazing
Field Service
New Installations
• The copper-coated steel suction tube on scroll
compressors can be brazed in approximately the
same manner as any copper tube.
• Recommended brazing materials: Any silfos material
is recommended, preferably with a minimum of 5%
silver. However, 0% silver is acceptable.
• Be sure suction tube fitting I.D. and suction tube O.D.
are clean prior to assembly. If oil film is present wipe
with denatured alcohol, Dichloro-Trifluoroethane or
other suitable solvent.
• Using a double-tipped torch apply heat in Area 1. As
tube approaches brazing temperature, move torch
flame to Area 2.
• Heat Area 2 until braze temperature is attained,
moving torch up and down and rotating around
tube as necessary to heat tube evenly. Add braze
material to the joint while moving torch around joint
to flow braze material around circumference.
• After braze material flows around joint, move torch
to heat Area 3. This will draw the braze material
down into the joint. The time spent heating Area 3
should be minimal.
WARNING
Remove refrigerant charge from both the
low and high side of the compressor before
cutting the suction and discharge lines to
remove the compressor. Verify the charge
has been completely removed with manifold
gauges.
• To disconnect: Reclaim refrigerant from both the
high and low side of the system. Cut tubing near
compressor.
• To reconnect:
○○ Recommended brazing materials: Silfos
with minimum 5% silver or silver braze
material with flux.
○○ Insert tubing stubs into fitting and connect
to the system with tubing connectors.
○○ Follow New Installation brazing
32-50 mm
63-70 mm
• As with any brazed joint, overheating may be
detrimental to the final result.
ZR250-380
ZP235, 285, 385, & 485
ZP236 & ZP296
Figure 4 – Crankcase Heater Location
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
21
AE4-1388 R3
ALERT CODE (RED)
/ CODIGO DE ALERTA (ROJO)
TYPE / TIPO
LOCKOUT /
BLOQUEADO
TRIP /
DISPARO
SOLID / SOLIDO
1
LOCKOUT /
BLOQUEADO
3
N/A
LOCKOUT/TRIP /
BLOQUEADO / DISPARO
LOCKOUT /
BLOQUEADO
5
6
7
8
9
WARNING (GREEN) /
PRECAUCIÓN (VERDE)
N/A
TRIP /
DISPARO
1
2
3
4
WARNING /
PRECAUCIÓN
5
WARNING /
PRECAUCIÓN
9
10
M2 M1
SHORT CYCLING /
CICLOS CORTOS
4
L2
S1
3 S2 S3
T2 T1 L1 L2 L3
L3
FUTURE USE / USO FUTURO
MISSING PHASE /
PERDIDA DE FASE
REVERSE PHASE /
INVERSIÓN DE FASE
FUTURE USE / USO FUTURO
MODULE LOW VOLTAGE /
BAJO VOLTAJE AL MÓDULO
TYPE / TIPO
NORMAL /
NORMAL
WARNING /
PRECAUCIÓN
WARNING /
PRECAUCIÓN
WARNING /
PRECAUCIÓN
SOLID / SOLIDO
TEMP SENSORS / 3
SENSORES DE TEMP.
JUMPER / CONECTOR DE PUENTE
COMMUNICATION PORT /
PUERTO DE COMUNICACION
L1
2
LOCKOUT/TRIP / SCROLL HIGH TEMPERATURE /
BLOQUEADO / DISPARO ALTA TEMPERATURA DEL ESPIRALES
4
8
1 2 3 4 5 6 7 8 9 10
LOCKOUT/TRIP / OPEN / SHORT MOTOR THERMISTOR /
BLOQUEADO / DISPARO TERMISTOR DEL MOTOR EN CIRCUITO
ABIERTO O CORTOCIRCUITO
2
DIP SWITCH /
INTERRUPTOR "DIP"
1 -LSB
2
3
4
5 - MSB
6
7
LED’S /
DIODOS LUMINOSOS
DIP SWITCHES /
INTERRUPTORES "DIP"
EVENT / EVENTO
LOSS OF FUNCTION /
PERDIDA DE FUNCION
MOTOR HIGH TEMPERATURE /
TEMPERATURA DEL MOTOR ELEVADA
1
MOTOR WINDINGS
CONNECTIONS / CONEXIONES
DE DEVANADO DEL MOTOR
4
4
L1: RED / ROJO
L2: BLACK / NEGRO
L3: WHITE / BLANCO
WARNING: GREEN FLASHING + PAUSE 2 SEC. /
PRECAUCIÓN: LUZ VERDE DESTELLANTE + PAUSA DE 2 SEG.
TRIP: RED FLASHING + PAUSE 2 SEC. /
DISPARO: LUZ ROJA DESTELLANTE + PAUSA DE 2 SEG.
LOCKOUT: RED FLASHING + PAUSE 2 SEC. + SOLID 3 SEC. + PAUSE 2 SEC. /
BLOQUEO: LUZ ROJA DESTELLANTE + PAUSA DE 2 SEG. + LUZ SOLIDA POR
3 SEG. + PAUSA DE 2 SEG.
EVENT / EVENTO
NORMAL OPERATION /
OPERACION NORMAL
LOSS OF COMMUNICATION /
PERDIDA DE COMUNICACIÓN
1
2
3
FUTURE USE / USO FUTURO
SHORT CYCLING /
CICLOS CORTOS
OPEN / SHORT SCROLL THERMISTOR /
TERMISTOR DEL MOTOR ABIERTO
O EN CORTO
4
FUTURE USE / USO FUTURO
UP = 1 /
ARRIBA = 1
PURPOSE / PROPOSITO
UNIQUE ADDRESS / DIRECCION UNICA
RANGE 1 TO 32 / RANGO DE 1 A 32
(EXAMPLE = 12) / (EJEMPLO: 12)
1
1
9,600
BAUD RATE / FRECUENCIA DE TRANSMISIÓN EN BAUDIOS
EVEN / PAR
PARITY / PARIDAD
COMMUNICATION / COMUNICACION NETWORK /
EN RED
TEMP. CONNECTOR CONFIGURATION /
TE*
CONFIG. DEL CONECTOR DEL SENSOR DE TEMPERAURA
ENABLE /
SHORT CYCLE PROTECTION /
ACTIVADO
PROTECCIÓN CONTRA CICLOS CORTOS
DOWN = 0 /
ABAJO = 0
0
0
0
19,200
NONE / IMPAR
STANDALONE /
INDEPENDIENTE
TW*
DISABLE /
DESACTIVADO
SYMBOLS / SIMBOLOS
PROTECTOR MODULE VOLTAGE / VOLTAJE DEL MODULO DE PROTECCION
TO CONTROL CIRCUIT / AL CIRCUITO DE CONTROL
THERMAL SENSORS DO NOT SHORT / SENSORES DE TEMPERATURA – NO CONECTAR
EN CORTOCIRCUITO
PHASE SENSING / SENSOR DE FASES
USE COPPER CONDUCTORS ONLY.
USE MINIMUM 75º C WIRE FOR AMPACITY DETERMINATION.
USE THIS EQUIPMENT ON A GROUNDED SYSTEM ONLY.
PRIMARY SINGLE PHASE FAILURE PROTECTION IS PROVIDED.
PROTECTOR MODULE AND OPTIONAL CRANKCASE HEATER MUST
BE CONNECTED ONLY TO THEIR RATED VOLTAGE.
OVERCURRENT PROTECTION DEVICE RATING AND TYPE MUST
BE IN ACCORDANCE WITH REGULATORY AGENCY END PRODUCT APPROVALS
- SEE SYSTEM NAMEPLATE.
UTILICE CONDUCTORES DE COBRE ÚNICAMENTE.
UTILICE CABLE DE 75°C COMO MÍNIMO PARA DETERMINAR LA AMPACIDAD.
UTILICE ESTE EQUIPO EN SISTEMAS CONECTADOS A TIERRA SOLAMENTE.
SE PROVEE PROTECCION DE FALLA MONOFASICA EN EL CIRCUITO PRIMARIO.
EL MODULO DE PROTECCION Y EL CALENTADOR DE CARTER OPCIONAL DEBERAN
CONECTARSE A SU VOLTAJE NOMINAL RESPECTIVO.
EL TIPO Y LAS CARACTERISTICAS NOMINALES DEL DISPOSITIVO DE PROTECCIÓN DE
SOBRECORRIENTE DEBERÁN RESPETAR LAS APROBACIONES DE LA AGENCIA
REGLAMENTARIA PARA EL PRODUCTO FINAL
– VEA LA PLACA DE DATOS
01-14 052-2820-00
Figure 5a – 20 to 40 Ton Terminal Box Wiring Diagram (excluding ZP236/296)
ALERT CODE (RED)
/ CODIGO DE ALERTA (ROJO)
SOLID / SOLIDO
1
2
3
4
5
6
7
8
9
WARNING (GREEN) /
PRECAUCIÓN (VERDE)
SOLID / SOLIDO
1
2
3
EVENT / EVENTO
LOCKOUT /
BLOQUEADO
TRIP /
DISPARO
LOCKOUT/TRIP /
BLOQUEADO /
DISPARO
LOCKOUT /
BLOQUEADO
LOCKOUT/TRIP /
BLOQUEADO /
DISPARO
N/A
LOCKOUT/TRIP /
BLOQUEADO /
DISPARO
LOCKOUT /
BLOQUEADO
LOSS OF FUNCTION /
PERDIDA DE FUNCION
MOTOR HIGH TEMPERATURE /
TEMPERATURA DEL MOTOR ELEVADA
OPEN / SHORT MOTOR THERMISTOR /
TERMISTOR DEL MOTOR EN CIRCUITO
ABIERTO O CORTOCIRCUITO
SHORT CYCLING /
CICLOS CORTOS
N/A
TRIP /
DISPARO
EVENT / EVENTO
4
5
WARNING /
PRECAUCION
L1
M2 M1
1
4
L3
MOTOR WINDINGS
CONNECTIONS / CONEXIONES
DE DEVANADO DEL MOTOR
4
L1: RED / ROJO
L2: BLACK / NEGRO
L3: WHITE / BLANCO
WARNING: GREEN FLASHING + PAUSE 2 SEC. /
PRECAUCIÓN: LUZ VERDE DESTELLANTE +PAUSA DE 2 SEG.
TRIP: RED FLASHING + PAUSE 2 SEC. /
DISPARO: LUZ ROJA DESTELLANTE + PAUSA DE 2 SEG.
LOCKOUT: RED FLASHING + PAUSE 2 SEC. + SOLID 3 SEC. + PAUSE 2 SEC. /
BLOQUEO: LUZ ROJA DESTELLANTE + PAUSA DE 2 SEG. + LUZ SOLIDA POR
3 SEG. + PAUSA DE 2 SEG.
1
2
3
FUTURE USE / USO FUTURO
SHORT CYCLING /
CICLOS CORTOS
OPEN / SHORT SCROLL THERMISTOR /
TERMISTOR DEL SCROLL EN CIRCUITO
ABIERTO O CORTOCIRCUITO
4
FUTURE USE / USO FUTURO
DOWN = 0 /
APAGADO = 0
0
0
0
19,200
NONE / NINGUNA
STANDALONE /
INDEPENDIENTE
TW*
ENABLE / DISABLE /
SHORT CYCLE PROTECTION /
PROTECCIÓN CONTRA CICLOS CORTOS ACTIVADO DESACTIVADO
SYMBOLS / SIMBOLOS
PROTECTOR MODULE VOLTAGE / VOLTAGE DEL MODULO DE PROTECCION
TO CONTROL CIRCUIT / AL CIRCUITO DE CONTROL
THERMAL SENSORS DO NOT SHORT / SENSORES DE TEMPERATURA – NO CONECTAR
EN CORTO CIRCUITO
PHASE SENSING / SENSOR DE FASES
USE COPPER CONDUCTORS ONLY.
USE MINIMUM 75º C WIRE FOR AMPACITY DETERMINATION.
USE THIS EQUIPMENT ON A GROUNDED SYSTEM ONLY.
PRIMARY SINGLE PHASE FAILURE PROTECTION IS PROVIDED.
PROTECTOR MODULE AND OPTIONAL CRANKCASE HEATER MUST
BE CONNECTED ONLY TO THEIR RATED VOLTAGE.
OVERCURRENT PROTECTION DEVICE RATING AND TYPE MUST
BE IN ACCORDANCE WITH REGULATORY AGENCY END PRODUCT APPROVALS
- SEE SYSTEM NAMEPLATE.
UTILICE CONDUCTORES DE COBRE ÚNICAMENTE.
UTILICE CABLE DE 75º C COMO MÍNIMO PARA DETERMINAR LA AMPACIDAD.
UTILICE ESTE EQUIPO EN SISTEMAS CONECTADOS A TIERRA SOLAMENTE.
SE PROVEE PROTECCION DE FALLA MONOFASICA EN EL CIRCUITO PRIMARIO.
EL MODULO DE PROTECCION Y EL CALENTADOR DE CARTER OPCIONAL DEBERAN
CONECTARSE A SU VOLTAJE NOMINAL RESPECTIVO.
EL TIPO Y LAS CARACTERISTICAS NOMINALES DEL DISPOSITIVO DE PROTECCIÓN DE
SOBRECORRIENTE DEBERÁN RESPETAR LAS APROBACIONES DE LA AGENCIA
REGLAMENTARIA PARA EL PRODUCTO FINAL
– VEA LA PLACA DE DATOS
02-14 052-2895-00
Figure 5b – ZP236/296 Terminal Box Wiring Diagram
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
S1S2
3
L2
T2 T1 L1 L2 L3
REVERSE PHASE /
INVERSIÓN DE FASE
FUTURE USE / USO FUTURO
MODULE LOW VOLTAGE /
BAJO VOLTAJE AL MÓDULO
NORMAL OPERATION /
OPERACION NORMAL
LOSS OF COMMUNICATION /
PERDIDA DE COMUNICACIÓN
WARNING /
PRECAUCION
4
MISSING PHASE /
PERDIDA DE FASE
NORMAL /
NORMAL
WARNING /
PRECAUCION
WARNING /
PRECAUCION
WARNING /
PRECAUCION
TEMP SENSORS / 3
SENSORES DE TEMPERATURA
JUMPER / CONECTOR DE PUENTE
COMMUNICATION PORT /
PUERTO DE COMUNICACION
2
FUTURE USE / USO FUTURO
TYPE / TIPO
LED’S / DIODOS LUMINOSOS
1 2 3 4 5 6 7 8 9 10
SCROLL HIGH TEMPERATURE /
TEMPERATURA DEL SCROLL ELEVADA
DIP SWITCH /
UP = 1 /
PURPOSE / PROPOSITO
INTERRUPTORES “DIP”
PRENDIDO = 1
1 -LSB
UNIQUE ADDRESS / DIRECCION UNICA
2
1
3
RANGE 1 TO 32 / RANGO DE 1 A 32
1
4
(EXAMPLE = 12) / (EJEMPLO = 12)
5 - MSB
6
9,600
BAUD RATE / FRECUENCIA DE TRANSMISIÓN EN BAUDIOS
EVEN / PAR
PARITY / PARIDAD
7
COMMUNICATION / COMUNICACION NETWORK /
8
EN RED
TEMP.
CONNECTOR
CONFIGURATION
/
9
TE*
CONFIG. DEL CONECTOR DEL SENSOR DE TEMPERATURA
10
DIP SWITCHES /
INTERRUPTORES “DIP”
TYPE / TIPO
22
AE4-1388 R3
Discharge Manifold
Compressor
B
Compressor
A
Oil Access Fitting
(On Both Compressors)
Suction Manifold
Oil Sight-Glass
(On Manifold)
Figure 6 – Typical Rotalock Connected Tandem with TPTL Oil Manifold
Bidirectional
Discharge Manifold
Compressor
B
Compressor
A
Oil Access Fitting
(On Manifold)
Suction Manifold
Oil Sight-Glass
(On Both Compressors)
Figure 7 – Typical Braze Connected Tandem with OEL Oil Manifold
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
23
AE4-1388 R3
Compressor
C
Bidirectional
Discharge
Manifold
Compressor
B
Compressor
A
Oil Access Fitting
(On Each Compressor)
Oil Sight-Glass
(On Manifold)
Suction Manifold
Figure 8 – Typical Braze Connected Trio with TPTL Oil Manifold
Drive Output Voltage
Drive Output - Frequency vs. Voltage
610
595
580
565
550
535
520
505
490
475
460
445
430
415
400
385
370
355
340
325
310
295
280
265
250
235
220
205
190
175
160
145
130
35
40
45
50
55
60
Drive Output Frequency
230 Volts
460 Volts
575 Volts
Figure 9 – Drive Output - Frequency vs. Voltage
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
24
65
70
75
AE4-1388 R3
Table 2
Torque Values
Torque
Part
ft-lb
in-lb
N-m
50-58
600-690
68-78
TPTL Rotalock Fitting
125-133
1500-1590
170-180
OEL Rotalock Fitting
50-58
600-690
68-78
Sight-Glass
Suction Rotalock (Valve or Adapter)
140-148
1680-1770
190-200
Discharge Rotalock (Valve or Adapter)
125-133
1500-1590
170-180
17-18
200-220
22.6-24.0
40-60
4.5-6.8
25
2.8
398-487
45-55
Schrader Valves
Oil Access Fitting (Threads Into Oil Rotalock)
Terminal Block Screws
Tandem Mounting Bolts (M10)
33-41
Table 3
Refrigerant Charge Limits
Charge Limit
Model
Pounds
kg
ZR250KC
25
11.3
ZR300-380KC
30
13.6
ZR Tandems
45
20.4
ZR Trios
65
29.5
ZP235, 236, 296KC
25
11.3
ZP285, 295, 385, 485KC
30
13.6
ZP Tandems
45
20.4
ZP Trios
65
29.5
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
25
AE4-1388 R3
Table 4 – Compressor Accessories
Part
Category
Suction & Discharge
Protection
Electrical
Oil
Crankcase
Heater
Mounting
1
2
3
Part Description
ZR250
ZP235
ZP236
ZP296
ZR300
ZP285
ZR310
ZR380
ZP295
ZP385
ZP485
Spacer-Mounting Kit
527-0175-02
527-0175-02 527-0175-00
527-0175-02
527-0175-02
Crankcase Heater, 120V
018-0091-06
018-0091-27 018-0091-10
018-0091-10
018-0091-10
Crankcase Heater, 240V
018-0091-04
018-0091-25 018-0091-09
018-0091-09
018-0091-09
Crankcase Heater, 480V
018-0091-05
018-0091-26 018-0091-08
018-0091-08
018-0091-08
Crankcase Heater, 575V
018-0091-07
018-0091-28 018-0091-11
018-0091-11
018-0091-11
Crankcase Heater Junction Box
962-0001-03
962-0001-03 962-0001-03
962-0001-03
962-0001-03
Oil Sight-Glass
970-0021-00
070-0040-00 970-0021-00
970-0021-00
970-0021-00
Oil Access Fitting
510-0370-00
510-0715-00 510-0370-00
510-0370-00
510-0715-00
Terminal Block
021-0332-00
021-0332-00 021-0332-00
021-0332-00
021-0332-00
Terminal Block Screws
(Zinc Plated 10-32 UNF-2A x .5"
Long) 2
100-0550-01
100-0550-01 100-0550-01
100-0550-01
100-0550-01
Kriwan Module 120/240V
998-0520-00
998-0520-00
998-0520-00
998-0520-00
Kriwan Module 24 V
998-0520-04
998-0520-04
998-0520-04
998-0520-04
3
971-0064-05
971-0064-05 971-0064-05
971-0064-05
971-0064-05
3
CoreSense Module 24V
971-0065-04
971-0065-04 971-0065-04
971-0065-04
971-0065-04
Suct & Disch 1/4" Schrader
Fittings
510-0370-00
510-0370-00 510-0370-00
510-0370-00
510-0370-00
Discharge Rotalock O-Ring Seal
020-0028-03
020-0028-05 020-0028-03
020-0028-05
020-0028-03
Suction Rotalock O-Ring Seal
020-0941-00
020-0941-00 020-0941-00
020-0941-00
020-0941-00
Rotalock Service Valve, Disc
1-3/8"
998-0510-46
998-0510-46 998-0510-46
998-0510-46
998-0510-46
Rotalock Service Valve, Suct
1-5/8"
998-0510-68
998-0510-68 998-0510-68
998-0510-68
998-0510-68
Terminal Box Assembly
1
CoreSense Module 120/240V
Flange Service Valve, Suct
2-1/8"
998-0511-01
Disc Rotalock Adapter to 1-3/8"
Sweat
934-0002-00
934-0002-00 934-0002-00
934-0002-00
934-0002-00
Suct Rotalock Adapter to 1-5/8"
Sweat
934-0002-01
934-0002-01 934-0002-01
934-0002-01
934-0002-01
Terminal boxes are rarely replaced; please contact Application Engineering if replacement part numbers are required
Can be purchased locally
-TE* motor codes only
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
26
AE4-1388 R3
Table 5 – Tandem Quick Reference Guide
Tandem
Model
Compressor
Connections
Compressor
Drawing #
"A"
"B"
RotaBrazed Flanged
lock
Discharge
Manifold
Oil Line
Comp.
OEL TPTL
"A"
ZPU417KC
ZP182
ZP235 497-0685-00
X
one direction
X
ZPU418KC
ZP182
ZP236 497-1298-00
X
one direction
X
ZPU449KC
ZP154
ZP295 497-0577-00
X
one direction
X
ZPT470KC
ZP235
ZP235 497-2830-00
one direction
X
ZPT472KC
X
ZP236
497-1184-00
ZP236
497-1185-00
ZPU477KC
ZP182
ZP295 497-0682-00
X
one direction
ZPU532KC
ZP296
ZP236
497-1189-00
X
bi-directional
X
X
ZP296
ZP236
497-1190-00
bi-directional
X
X
ZPU567KC
ZP182
ZP385 497-0577-00
ZPT570KC
ZP285
ZP285 497-3589-00
X
ZPT590KC
ZP295
ZP295 497-3589-00
X
ZPT592KC
ZP296
ZP296
497-1184-00
ZP296
ZP296
497-1185-00
ZPU680KC
ZP295
ZP385 497-3585-03
ZPT770KC
ZPU870KC
X
X
X
X
one direction
X
one direction
X
one direction
X
X
X
bi-directional
X
X
one direction
ZP385
ZP296 497-1316-00
ZP385 497-3589-00
X
X
X
bi-directional
X
ZP385 497-1348-00
bi-directional
X
ZP385 497-1346-00
X
bi-directional
X
ZP385
ZP485 497-0814-00
X
one direction
X
bi-directional
X
bi-directional
X
ZP485 497-1484-00
ZP485
ZP485 497-1486-00
ZRU441KC
ZR190
ZR250 497-0685-00
X
497-1122-00
X
X
X
bi-directional
X
X
X
X
one direction
X
ZRT500KC
ZR250
ZR250 497-0350-00
X
one direction
X
ZRU560KC
ZR250
ZR310 497-2825-00
X
one direction
X
X
ZRU571KC
ZR190
ZR380 497-0577-00
X
ZRT600KC
ZR300
ZR300 497-0348-00
X1
ZRT620KC
ZR310
ZR310 497-3585-00
ZRU690KC
ZR310
ZRT760KC
ZR380
X
one direction
X
one direction
X
X
one direction
X
ZR380 497-3585-03
X
one direction
X
ZR380 497-3589-00
X
one direction
X
X2
A minimum
of 18" of
straight
piping
upstream of
the suction
"T" is
required
X
ZP385
ZP485
X
X
one direction
ZP385
ZP385
X
X
bi-directional
ZP385
ZP485
ZPT970KC
X
bi-directional
Piping
Restrictions
X
ZP236
X
bi-directional
Comp.
"B"
ZP236
ZPU681KC
X
Flow Washers3
X
A minimum
of 18" of
straight
piping
upstream of
the suction
"T" is
required
Not in production, drawings only
Notes: 1
2
3
Compressor discharge connections only.
Compressor suction connections only.
Compressor "A" is the compressor on the left, when looking at the assembly from the terminal box side of the compressor. © 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
27
AE4-1388 R3
Table 6 – Trio Quick Reference Guide
Trio
Model
Compressor
3X
Compressor Connections
Drawing #
Rotalock
497-0391-00
497-0391-02
ZP235KC
ZPY708KC
ZP236KC
497-1389-00
497-0385-04
ZPY855KC
ZP285KC
497-0385-06
497-0385-02
ZP295KC &
ZP385KC
497-0385-06
ZP296KC
ZP296KC
ZPY145MC
ZP485KC
497-1389-00
ZR250KC
497-0391-02
ZR300KC
497-0385-00
ZR310KC &
ZR380KC
497-0385-06
497-0385-03
unidirectional
X
unidirectional
X
unidirectional
X
X
unidirectional
X
X
unidirectional
X
X
X
unidirectional
X
X
X
unidirectional
X
X
unidirectional
X
unidirectional
X
X
X
unidirectional
X
X
unidirectional
X
X
X
unidirectional
X
X
X
unidirectional
X
unidirectional
X
unidirectional
X
unidirectional
X
bidirectional
X
bidirectional
X
unidirectional
X
X
X
unidirectional
X
X
unidirectional
X
X
X
X
unidirectional
X
X
X
unidirectional
X
unidirectional
X
unidirectional
X
unidirectional
X
unidirectional
X
X
unidirectional
X
X
unidirectional
X
X
X
unidirectional
X
X
X
unidirectional
X
unidirectional
X
X
X
X
X
X
X
X
X1
X2
X
X
X
X
497-0385-07
497-0385-02
X
X
497-0385-05
ZRY930KC &
ZRY114MC
unidirectional
X
497-0385-01
497-0385-04
X
X
497-0701-01
ZRY900KC
unidirectional
X
497-0391-03
497-0701-00
X
X
497-0391-01
ZRY750KC
X
X
X
497-1264-00
497-0391-00
X
X
X
497-1390-00
497-1265-00
X
unidirectional
X
497-0385-03
ZPY888KC
unidirectional
X
X
497-0385-07
497-0385-02
X
X
497-0385-05
ZPY885KC &
ZPY115MC
X
X
497-0385-01
497-0385-04
unidirectional
X
497-0385-07
Comp. Comp. Comp.
"A"
"B"
"C"
X
X
497-0385-05
TPTL
X
X
497-1390-00
Flow Washers3
X
X
497-0701-01
Oil
Line
unidirectional
X
497-0391-03
497-0701-00
Flanged
X
497-0391-01
ZPY705KC
Brazed
Discharge
Manifold
X
X
X
Piping Restrictions
suction flow direction from the
"C" compressor direction
suction flow direction from the
"A" compressor direction
3-5/8" suction connection, 18" of
straight suction piping required
3-5/8" suction connection, 18" of
straight suction piping required
suction flow direction from the
"C" compressor direction
suction flow direction from the
"A" compressor direction
3-5/8" suction connection, 18" of
straight suction piping required
suction flow direction from the
"C" compressor direction
suction flow direction from the
"A" compressor direction
3-5/8" suction connection, 18" of
straight suction piping required
3-5/8" suction connection, 18" of
straight suction piping required
3-5/8" suction connection, 18" of
straight suction piping required
suction flow direction from the
"C" compressor direction
suction flow direction from the
"A" compressor direction
3-5/8" suction connection, 18" of
straight suction piping required
3-5/8" suction connection, 18" of
straight suction piping required
suction flow direction from the
"C" compressor direction
suction flow direction from the
"A" compressor direction
3-5/8" suction connection, 18" of
straight suction piping required
Notes: 1 Compressor discharge connections only
2
Compressor suction connections only
3
Compressor "A" is the compressor on the left, when looking at the assembly from the terminal box side of the compressor.
Compressor "B" is the middle compressor and compressor "C" is on the right.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
28
AE4-1388 R3
Table 7 – Protector Specifications
Module P/N
071-0649-01
071-0649-00
071-0684-01
071-0684-00
071-0650-00
071-0685-00
571-0065-05
571-0064-06
Compressor
Motor Code
TW
TW
TW
TW
TW
TW
TE
TE
Kriwan
Kriwan
Kriwan
Diagnose*
Kriwan
Diagnose*
Kriwan
Kriwan
Diagnose*
CoreSense
CoreSense
T1-T2 Voltage
(AC)
24
120/240
24
120/240
115/230
115/230
24
120/240
Power
Consumption
(VA)
3
3
3
3
3
3
5
5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
> 0.02
> 0.02
> 0.02
> 0.02
> 0.02
> 0.02
N/A
N/A
240
240
240
240
240
240
240
240
>4.5KΩ
>4.5KΩ
(motor)
<2.4KΩ
(scroll)
>4.5KΩ
(motor)
<2.4KΩ
(scroll)
<2.75KΩ
(motor)
>5.1KΩ
(scroll)
30 minutes
Type
M1-M2 Contact
Rating (A)
M1-M2
Minimum
Current (A)
M1-M2
Maximum
Voltage
Trip Point (Ω)
Reset Point (Ω)
Reset Time
Features
>4.5KΩ
>4.5KΩ
>4.5KΩ
>4.5KΩ
>4.5KΩ
<2.75KΩ
<2.75KΩ
<2.75KΩ
<2.75KΩ
<2.75KΩ
<2.75KΩ
<2.75KΩ
(motor)
>5.1KΩ
(scroll)
30 minutes
30 minutes
30 minutes
30 minutes
30 minutes
30 minutes
30 minutes
Motor & Scroll Temperature
+ Phase Protection
Motor & Scroll Temperature Protection
* Diagnose features not supported
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
29
Motor & Scroll Temperature,
Phase Protection,
Communications
AE4-1388 R3
Table 8 – CoreSense™ Communications LED Flash Code Information
The flash code number corresponds to the number of LED flashes, followed by a pause, and then the flash code is repeated. A
lockout condition produces a red flash, followed by a pause, a solid red, a second pause, and then repeated.
Code Reset
Description
Code Fault Description
Troubleshooting Information
Status
Fault Condition
Solid Green
Normal Operation
Module is powered and
operation is normal
N/A
N/A
Solid Red
Module
Malfunction
Module has internal fault
N/A
1) Reset module by removing
power from T2-T1
2) Replace module
Warning LED Flash
Green
Flash Code 1
Loss of
Communication
Green
Flash Code 2
Future Use
Green
Flash Code 3
Short Cycling
Green
Flash Code 4
Open/Shorted
Scroll Thermistor
Green
Flash Code 5
Future Use
Module and master controller
have lost communications
with each other for more than
5 minutes
When
communications
are confirmed
N/A
N/A
Run time of less than 1
minute; number of short
cycles exceeds 48 in 24
hours
Ω > 370K or Ω < 1K
1) Check the control wiring
2) Verify dipswitch 8 is "on"
N/A
1) Check system charge and
pressure control setting
< 48 short cycles in
24 hours
2) Adjust set-point of
temperature controller
3) Install anti-short cycling
control
5.1K < Ω < 370K
N/A
N/A
1) Check for poor connections
at module and thermistor fusite
2) Check continuity of
thermistor wiring harness
N/A
Alert/Lockout LED Flash
1) Check supply voltage
Red
Flash Code 1
Motor High
Temperature
Ω > 4.5K; Lockout after 5
Alerts
Ω < 2.75K and 30
minutes
2) Check system charge &
superheat
3) Check contactor
Red
Flash Code 2
Red
Flash Code 3
Open/Shorted
Motor Thermistor
Short Cycling
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
1) Check for poor connections at
40 < Ω < 2.75K and module and thermistor fusite
30 minutes
2) Check continuity of thermistor
wiring harness
Ω > 220K or Ω < 40;
lockout after 6 hours
Run time of less than
1 minute; lockout if the
number of Alerts exceeds
the number configured by
the user in 24 hours
30
Interrupt power to
T2-T1 or perform
Modbus reset
command
1) Check system charge and
pressure control setting
2) Adjust set-point of
temperature controller
3) Install anti-short cycling
control
AE4-1388 R3
Table 8 Continued
Status
Fault Condition
Code Fault Description
Code Reset
Description
Troubleshooting Information
Alert/Lockout LED Flash
Red
Flash Code 4
Scroll High
Temperature
Red
Flash Code 5
Future Use
Red
Flash Code 6
Missing Phase
Red
Flash Code 7
Reverse Phase
Red
Flash Code 8
Future Use
Ω < 2.4K; Lockout if the
number of Alerts exceeds
the number configured by
the user in 24 hours
N/A
Interrupt power to
T2-T1 or perform
Modbus reset
command
N/A
Missing phase; Lockout
after 10 consecutive Alerts
After 5 minutes
and missing phase
condition is not
present
Reverse phase; Lockout
after 1 Alert
Interrupt power to
T2-T1 or perform
Modbus reset
command
N/A
N/A
1) Check system charge and
superheat
2) Check system operating
conditions
3) Check for abnormally low
suction pressure
N/A
1) Check incoming power
2) Check fuses/breakers
3) Check contactor
1) Check incoming phase
sequence
2) Check contactor
3) Check module phasing wires
A-B-C
N/A
1) Verify correct module p/n
Red
Flash Code 9
1
Module Low
Voltage
Low voltage on T2-T1
terminals1
This Alert does not result in a Lockout
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
31
After 5 minutes and 2) Check VA rating of
the voltage is back transformer
in the normal range 3) Check for blown fuse in
transformer secondary
AE4-1388 R3
Table 9 – Control Techniques Drive Selections
Model
Compressor
Voltage
Frequency
Phase
Drive Name
Drive Model
Number
Maximum
Continuous
Ouput Current
ZP235KCE-TWC
208/230
60
3
Commander HSK
HSK4203
104
ZP235KCE-TWD
460
60
3
Commander HSK
HSK3402
43
ZP236KCE-TE5
200/230
60
3
Commander HSK
HSK4203
104
ZP236KCE-TED
460
60
3
Commander HSK
HSK3402
43
ZP285KCE-TW5
200/230
60
3
Commander HSK
HSK4203
104
ZP285KCE-TWD
460
60
3
Commander HSK
HSK3403
56
ZP295KCE-TWD
460
60
3
Commander HSK
HSK3403
56
ZP296KCE-TE5
200/230
60
3
Commander HSK
HSK4203
104
ZP296KCE-TED
460
60
3
Commander HSK
HSK3403
56
ZP385KCE-TE5
ZP385KCE-TW5
200/230
60
3
Affinity
BA5201
130
ZP385KCE-TED
ZP385KCE-TWD
460
60
3
Commander HSK
HSK4401
68
ZP485KCE-TED
ZP485KCE-TWD
460
60
3
Commander HSK
HSK4402
83
The contents of this publication are presented for informational purposes only and they 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. reserves the right to modify the designs or specifications of such products at any time without
notice. Emerson Climate Technologies, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of
any Emerson Climate Technologies, Inc. product remains solely with the purchaser and end-user.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
32
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