from OPI AE4

from OPI AE4
AE4-1401 R1
AE4-1401 R1
March 2015
25 to 40 Ton ZP*KW Low Condensing Optimized
Copeland Scroll™ Air Conditioning Compressors
Section
TABLE OF CONTENTS
Page
Section
Safety
Safety Instructions....................................................... 2
Safety Icon Explanation............................................... 2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons........................................... 3
Safety Statements........................................................ 3
Page
Oil Recovery Cycle......................................................11
Variable Speed Manifolded Applications......................11
Application Tests
Application Test Summary...........................................11
Assembly Line Procedures
Compressor Handling..................................................11
Introduction
Mounting......................................................................11
Nomenclature............................................................... 4
Suction & Discharge Fittings....................................... 12
Assembly Line Brazing Procedure.............................. 12
Application Considerations
Operating Envelope..................................................... 4 Unbrazing System Components................................. 12
Pressure Testing......................................................... 12
Internal Pressure Relief (IPR) Valve............................ 4
Assembly Line System Charging Procedures............. 12
Discharge Temperature Protection.............................. 4
Electrical
Connections................................................ 12
High Pressure Control.................................................. 4
Hipot
Testing...............................................................
13
Low Pressure Control.................................................. 5
Tandem
Assembly.
.
.....................................................
13
Shut Down Device....................................................... 5
Discharge Check Valve................................................ 5
Service Procedures
Shell Temperature........................................................ 5
Field Replacement...................................................... 13
Compressor Cycling..................................................... 5
Mounting................................................................... 13
Long Pipe Lengths / High Refrigerant Charge............. 5
Oil Removal.............................................................. 13
Suction and Discharge Fittings.................................... 6
Electrical................................................................... 14
System Tubing Stress.................................................. 6
Module...................................................................... 14
Accumulators............................................................... 6
Compressor Replacement after a Motor Burn............ 14
Off Cycle Migration Control.......................................... 6
Manifolded Compressor Replacement........................ 14
Crankcase Heat......................................................... 6
Start-Up of a New or Replacement Compressor........ 14
Pump Down Cycle..................................................... 6
Field Troubleshooting CoreSense Module.................. 15
Pump Out Cycle......................................................... 6
Scroll Functional Check.............................................. 15
Reversing Valves......................................................... 6
Contaminant Control.................................................... 7
Figures & Tables
Oil Type........................................................................ 7
Nomenclature.............................................................. 16
Three Phase Electrical Phasing................................... 7
Operating Envelopes.................................................. 17
Power Factor Correction.............................................. 8 Suction Tube Brazing.................................................. 18
Soft Starters................................................................. 8
Crankcase Heater Location........................................ 18
Motor Overload Protection........................................... 8
Terminal Box Wiring Diagrams.................................... 19
Motor Overload Protection Specs................................ 8
Typical Rotalock Connected Tandem w/TPTL Oil
Manifolded Compressors............................................. 8
Manifold........................................................................ 20
Manifolded Applications............................................... 9
Typical Braze Connected Tandem w/OEL Oil
Manifold......................................................................... 20
Variable Speed Operation
Typical
Braze Connected Trio w/ TPTL Oil Manifold.... 21
Introduction.................................................................. 9
Drive
Output
- Frequency vs. Voltage......................... 21
Performance................................................................ 9
Torque
Values.............................................................
22
Operating Envelope.................................................... 10
Refrigerant
Charge
Limits...........................................
22
Drive Selection............................................................ 10
Compressor
Accessories............................................
23
Electrical Requirements.............................................. 10
Tandem
Quick
Reference
Guide.
.
...............................
24
Autotuning................................................................... 10
Trio Quick Reference Guide....................................... 25
Starting and Ramp Up................................................ 10
CoreSense Specifications........................................... 25
Stopping...................................................................... 10
CoreSense LED Flash Code Information..................26-27
Vibration...................................................................... 10
Control Techniques Drive Selections.......................... 28
© 2015 Emerson Climate Technologies, Inc.
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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
© 2015 Emerson Climate Technologies, Inc.
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.
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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.
© 2015 Emerson Climate Technologies, Inc.
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INTRODUCTION
Excursions outside of the envelope should be brief and
infrequent.
The 25 to 40 ton ZP*KW Copeland Scroll™ compressors
are designed and optimized for lower condensing
temperature applications versus the ZP*KC air cooled
condensing optimized compressors. Water cooled,
evaporative cooled, or air cooled condensers with
design condensing temperatures less than 110F will
benefit from the increased efficiency of the ZP*KW
compressors. Compressors in this family include a
number of features outlined in Table 1 below.
Internal Pressure Relief (IPR) Valve
WARNING
A high pressure control must be used in all
applications.
The 25 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.
Nomenclature
The model numbers of the 20 to 40 ton ZP*KC
compressors include the approximate, nominal 60 Hertz
capacity at the AHRI air conditioning condition (45°F
evaporating, 130°F condensing, 20°F superheat, 15F
subcooling). The ZP*KW compressors have the same
displacement as the equivalent ZP*KC compressors
and therefore have the same base model number.
However, the ZP*KW compressors are rated at a
different operating condition, 40°F evaporating, 100
condensing, 10°F superheat, 10°F subcooling. AHRI
air conditioning operating condition is outside of the
operating envelope of the ZP*KW compressors. See
Figure 1 for more information regarding nomenclature.
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.
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.
APPLICATION CONSIDERATIONS
Discharge Temperature Protection
The following application guidelines should be
considered during the design of a system using
ZP*KW 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.
High discharge temperature protection is provided by
an NTC thermistor probe in the discharge plenum of
the scroll. The CoreSense M1-M2 contacts are opened
if the discharge temperature exceeds the specified
temperature. Discharge temperature data are stored in
the CoreSense module and can be made available to a
system controller.
Operating Envelope
High Pressure Control
Figure 2 illustrates the operating envelope for the 25 to
40 ton ZP*KW compressors. Please take note of the
120F condensing temperature limit and the operating
frequency ranges. The envelopes were developed
with 10F suction superheat in the return gas. The
steady-state operating condition of the compressor
must remain inside the prescribed operating envelope.
A high pressure cut-out control must be used in all
applications. The maximum cut out setting is 450 psig
(31 bar) for R-410A. The high pressure control should
have a manual reset feature for the highest level of
system protection.
Table 1 – 20 to 40 Ton Copeland Scroll™ Family Features
Model
Refrigerant
Motor
Protection
Communications2
Tandem/Trio
Manifolded
Applications
Electrical
Frequency
Range
ZP296-485KWE-TE1
R-410A
CoreSense
Yes
Yes
35-75 Hertz
Last Character In Voltage Code (5=200/230-3-60, 200/220-3-50, D=460-3-60, 380/420-3-50, E=575-3-60, 7=380-3-60)
Modbus via RS485
1
2
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Low Pressure Control
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.
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.
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)
Shut Down Device
Long Pipe Lengths / High Refrigerant Charge
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 will rotate backwards for a brief period after
shutdown as the internal pressures equalize.
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 25 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:
Discharge Check Valve
High side to low side leak-back during the off cycle is
accomplished with the floating valve technology on the
muffler plate of the compressor. An external discharge
check valve should be considered in some applications.
The ZP*KW compressors do not have conventional
discharge check valves like the comparable ZP*KC
compressors.
Single compressor application: 0.5 fluid ounce of oil
per pound of refrigerant
Shell Temperature
Tandem compressor application: 0.7 fluid ounce of
oil per pound of refrigerant
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.
Trio compressor application: 1.0 fluid ounce of oil per
pound of refrigerant
CAUTION
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.
Compressor Cycling
There is no set answer to how often scroll compressors
can be started and stopped in an hour, since it is
© 2015 Emerson Climate Technologies, Inc.
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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.
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
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.
Suction and Discharge Fittings
25 to 40 ton ZP*KW 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.
System Tubing Stress
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.
Pump Down Cycle
Recycling pump down must not be used with ZP*KW
compressors. In lieu of a pump down cycle, 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.
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.
Pump Out Cycle
A pump out cycle has been successfully used by some
manufacturers of large air conditioning systems. 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. A pump out cycle is
usually initiated after a long compressor off-time, not
after normal off-cycles.
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, off-cycle
refrigerant migration must be minimized. The following
three sections summarize off-cycle migration techniques.
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.
Crankcase Heat
Reversing Valves
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
© 2015 Emerson Climate Technologies, Inc.
Since Copeland Scroll compressors have very high
volumetric efficiency, their displacements are lower
than those of comparable capacity reciprocating
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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
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.
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
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
Polyolester (POE) oil is used in ZP*KWE 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.
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.
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.
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).
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.
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.
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
It is generally accepted that system moisture levels
© 2015 Emerson Climate Technologies, Inc.
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way as to cause rotation in the reverse direction, it is
important to include notices and instructions in
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.
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.
Power Factor Correction
If power factor correction is necessary in the end-use
application, please see AE9-1249 for more information
on this topic.
Soft Starters
Soft starters can be used with the 25 to 40 ton ZP*KW
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.
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.
Motor Overload Protection
WARNING
The CoreSense Communications modules are
U.L. recognized safety devices and must be used
with all compressors that have TE* electrical
codes.
Models with Electrical Code TE
Compressors with an "E" in the electrical code
(i.e. ZP296KWE-TED) employ CoreSense ™
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.
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
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.
Motor Overload Protection Specs
Table 7 summarizes the features and specifications
for CoreSense Communications modules. Please see
the Field Troubleshooting section for information on
troubleshooting.
© 2015 Emerson Climate Technologies, Inc.
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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
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.
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.
VARIABLE SPEED OPERATION
Introduction
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.
The 25 to 40 ton ZP*KW 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
Ten coefficients are available for calculating
performance. Evaporating and condensing temperature
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
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
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.
© 2015 Emerson Climate Technologies, Inc.
9
AE4-1401 R1
should be wired upstream of the variable frequency
drive so the drive and compressor are immediately
stopped when a safety/protection control trips.
are available by contacting Application Engineering.
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
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.
Electrical Requirements
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
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 recommended switching frequency of the drive is
2 to 3 kHz. Higher switching frequencies can result in
motor overheating and reduced efficiency.
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 voltagefrequency curves for nominal 230, 460, and 575 volt
power supplies.
Vibration
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
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
© 2015 Emerson Climate Technologies, Inc.
10
AE4-1401 R1
program), such that there is no operation at resonant
frequencies between 35 and 75 Hertz.
lead to compressor failure.
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.
Oil Recovery Cycle
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 (35 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
WARNING
Use care and the appropriate material handling
equipment when lifting and moving compressors.
Personal safety equipment must be used.
Variable Speed Manifolded Applications
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 prior
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.
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. 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.
APPLICATION TESTS
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
© 2015 Emerson Climate Technologies, Inc.
Mounting
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
11
AE4-1401 R1
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.
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
Never pressurize the compressor to more than
475 psig (32.8 bar) for ZP*KWE compressors.
Never pressurize the compressor from a nitrogen
cylinder or other pressure source without an
appropriately sized pressure regulating and relief
valve.
Assembly Line Brazing Procedure
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.
Assembly Line System Charging Procedure
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.
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 not operate the compressor without
enough system charge to maintain at least 55
psig (3.8 bar) suction pressure for R-410A. 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.
Unbrazing System Components
WARNING
Before attempting to braze, it is important to recover
all refrigerant from both the high and low side of
the system.
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!
© 2015 Emerson Climate Technologies, Inc.
Electrical Connections
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.
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AE4-1401 R1
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.
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.
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.
4. Torque the compressor to rail mounting bolts to
the value specified in Table 2.
“Hipot” (AC High Potential) Testin
For a detailed instruction list of how to assemble a trio
of compressors, please contact Application Engineering.
CAUTION
Use caution with high voltage and never hipot
when compressor is in a vacuum.
SERVICE PROCEDURES
CAUTION
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. 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.
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).
Field Replacement
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.
Tandem Assembly
The following procedure outlines the basic steps to
assemble a tandem.
Removing Oil
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.
© 2015 Emerson Climate Technologies, Inc.
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
13
AE4-1401 R1
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.
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).
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.
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.
Note: See the locked rotor on the nameplate of
the new compressor and make sure the contactor
exceeds this locked rotor rating.
Module
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).
Please refer to AE8-1384 for information on
CoreSense module configuration.
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.
Start-up of a New or Replacement Compressor
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.
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. 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
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
© 2015 Emerson Climate Technologies, Inc.
14
AE4-1401 R1
unauthorized personnel from accidentally ruining the
compressor by operating with no refrigerant flow.
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.
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.
3. Proper indoor and outdoor blower/fan operation
should be verified.
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.
Field Troubleshooting CoreSense Communications
Module
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
T1-T2 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.
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.
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.
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.
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.
Copeland Scroll Compressor Functional Check
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.
1. Proper voltage to the unit should be verified.
© 2015 Emerson Climate Technologies, Inc.
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AE4-1401 R1
25 to 40 Ton Scroll Nomenclature
Compressor Family Series
"Z" for Scroll
Compressor Motor Types
Phase
3
3
3
Modulation
T - Even Tandem
U - Uneven Tandem
Y - Trio Configuration
Blank - No Modulation
Description
Code
6 Lead Part Winding Start Only
F
6 Lead Across The Line Starting Only D
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
© 2015 Emerson Climate Technologies, Inc.
Code
External Electronic ProtectionCoreSense™
16
AE4-1401 R1
Operating Envelope for 35 to 75 Hertz
Evaporang Temperature (°C)
-21
-16
-11
-6
-1
4
9
14
19
125
64
115
40 - 75 Hertz
54
95
44
85
34
75
35 - 75 Hertz
24
65
14
55
4
45
-5
5
15
25
35
45
Evaporang Temperature (°F)
Figure 2 – 25 to 40 Ton Scroll Operating Envelope
© 2015 Emerson Climate Technologies, Inc.
17
55
65
Condensing Temperature (°C)
Condensing Temperature (°F)
105
AE4-1401 R1
1
}
2
}
}
3
Figure 3
Scroll Suction Tube Brazing
New Installations
• As with any brazed joint, overheating may be
detrimental to the final result.
• The copper-coated steel suction tube on scroll
compressors can be brazed in approximately the
same manner as any copper tube.
Field Service
WARNING
• Recommended brazing materials: Any silfos
material is recommended, preferably with a
minimum of 5% silver. However, 0% silver is
acceptable.
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.
• 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, DichloroTrifluoroethane or other suitable solvent.
• To disconnect: Reclaim refrigerant from both the
high and low side of the system. Cut tubing near
compressor.
• Using a double-tipped torch apply heat in Area 1.
As tube approaches brazing temperature, move
torch flame to Area 2.
• To reconnect:
• 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.
○○ Recommended brazing materials: Silfos
with minimum 5% silver or silver braze
material with flux.
• 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.
○○ Follow New Installation brazing
32-50 mm
63-70 mm
○○ Insert tubing stubs into fitting and connect
to the system with tubing connectors.
ZP385-485KW
ZP296KW
Figure 4 – Crankcase Heater Location
© 2015 Emerson Climate Technologies, Inc.
18
AE4-1401 R1
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 – ZP385/485 Terminal Box Wiring Diagram
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 – ZP296 Terminal Box Wiring Diagram
© 2015 Emerson Climate Technologies, Inc.
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
19
AE4-1401 R1
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
© 2015 Emerson Climate Technologies, Inc.
20
AE4-1401 R1
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
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
© 2015 Emerson Climate Technologies, Inc.
21
65
70
75
AE4-1401 R1
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
ZP296KW
25
11.3
ZP385-485KW
30
13.6
ZP Tandems
45
20.4
ZP Trios
65
29.5
© 2015 Emerson Climate Technologies, Inc.
22
AE4-1401 R1
Table 4 – Compressor Accessories
Part Category
Mounting
Crankcase
Heater
Oil
Part Description
ZP296
ZP385
ZP485
Spacer-Mounting Kit
527-0175-02
527-0175-02
527-0175-02
Crankcase Heater, 120V
018-0091-27
018-0091-10
018-0091-10
Crankcase Heater, 240V
018-0091-25
018-0091-09
018-0091-09
Crankcase Heater, 480V
018-0091-26
018-0091-08
018-0091-08
Crankcase Heater, 575V
018-0091-28
018-0091-11
018-0091-11
Crankcase Heater Junction Box
962-0001-03
962-0001-03
962-0001-03
Oil Sight-Glass
070-0040-00
970-0021-00
970-0021-00
510-0715-00
510-0370-00
510-0715-00
Terminal Block
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
CoreSense Module3 120/240V
971-0064-05
971-0064-05
971-0064-05
CoreSense Module 24V
971-0065-04
971-0065-04
971-0065-04
Suct & Disch 1/4" Schrader Fittings
510-0370-00
510-0370-00
510-0370-00
Discharge Rotalock O-Ring Seal
020-0028-05
020-0028-05
020-0028-03
Suction Rotalock O-Ring Seal
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
Rotalock Service Valve, Suct 1-5/8"
998-0510-68
998-0510-68
998-0510-68
Disc Rotalock Adapter to 1-3/8" Sweat
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
Oil Access Fitting
Terminal Box Assembly
Electrical
Protection
Suction &
Discharge
1
2
3
1
3
Terminal boxes are rarely replaced; please contact Application Engineering if replacement part numbers are required
Can be purchased locally
Includes phase sensing wires and thermistor harness
© 2015 Emerson Climate Technologies, Inc.
23
© 2015 Emerson Climate Technologies, Inc.
24
ZP385
ZP385
ZP485
ZP485
ZP485
ZP485
ZP385
ZP385
ZP385
ZP385
ZP485
ZP485
ZP385
ZP385
ZP296
ZP296
ZP296
ZP296
ZP296
ZP385
"B"
"A"
Compressor
497-1486-00
497-1122-00
497-1484-00
497-0814-00
497-1346-00
497-1348-00
497-3589-00
497-1316-00
497-1185-00
497-1184-00
Drawing #
X
X
X
X
X
X
X
X
X
X
Rotalock Brazed Flanged
Compressor Connections
bi-directional
bi-directional
bi-directional
one direction
bi-directional
bi-directional
one direction
bi-directional
bi-directional
bi-directional
Discharge
Manifold
X
X
X
X
X
X
X
X
X
X
X
X
Flow Washers1
A minimum
of 18" of
straight
piping
upstream of
the suction
"T" is
required
Piping
Comp. Comp. Restrictions
OEL TPTL
"A"
"B"
Oil Line
Compressor "A" is the compressor on the left, when looking at the assembly from the terminal box side of
the compressor.
1
Notes:
ZPT970KW
ZPU870KW
ZPT770KW
ZPU681KW
ZPT592KW
Tandem
Model
Table 5 – Tandem Quick Reference Guide
AE4-1401 R1
AE4-1401 R1
Table 6 – Trio Quick Reference Guide
Trio
Model
Compressor
3X
Drawing #
Compressor
Connections
Rotalock Brazed
497-0385-04
X
497-0385-05
497-0385-06
ZPY115MW
ZP385KW
X
X
497-0385-07
497-0385-02
X
X
497-0385-03
497-1389-00
ZPY888KW
ZP296KW
X
X
497-1390-00
497-1265-00
ZPY145MW
Discharge
Manifold
X
Oil
Line
Flow Washers3
TPTL
Comp. Comp. Comp.
"A"
"B"
"C"
unidirectional
X
X
unidirectional
X
X
unidirectional
X
X
unidirectional
X
X
unidirectional
X
X
unidirectional
X
unidirectional
X
unidirectional
X
bidirectional
X
bidirectional
X
X
X
suction flow direction
from the "C"
compressor direction
suction flow direction
from the "A"
compressor direction
X
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
ZP485KW
497-1264-00
Piping Restrictions
1
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.
Table 7 – CoreSense Specifications
Module P/N
Compressor Motor Code
Type
571-0065-05
571-0064-06
TE
TE
CoreSense
1
CoreSense1
T1-T2 Voltage (AC)
24
120/240
Power Consumption (VA)
5
5
M1-M2 Contact Rating (A)
2.5
2.5
M1-M2 Minimum Current (A)
N/A
N/A
M1-M2 Maximum Voltage
240
240
Trip Point (Ω)
>4.5KΩ (motor) <2.4KΩ (scroll)
>4.5KΩ (motor) <2.4KΩ (scroll)
Reset Point (Ω)
<2.75KΩ (motor) >5.1KΩ (scroll)
<2.75KΩ (motor)
>5.1KΩ (scroll)
30 minutes
30 minutes
Reset Time
Features
1
Motor & Scroll Temperature, Phase Protection, Communications
Refer to AE8-1384
© 2015 Emerson Climate Technologies, Inc.
25
AE4-1401 R1
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.
Status
Fault
Condition
Code Fault
Description
Code Reset
Description
Troubleshooting
Information
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
< 48 short cycles in
24 hours
1) Check the control wiring
2) Verify dipswitch 8 is "on"
N/A
1) Check system charge and pressure
control setting
2) Adjust set-point of temperature
controller
3) Install anti-short cycling control
Ω > 370K or Ω < 1K
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
Red
Flash Code 1
Red
Flash Code 2
Red
Flash Code 3
Motor High
Temperature
Ω > 4.5K; Lockout
after 5 Alerts
Ω < 2.75K and 30
minutes
2) Check system charge & superheat
3) Check contactor
1) Check for poor connections at
40 < Ω < 2.75K and module and thermistor fusite
30 minutes
2) Check continuity of thermistor wiring
harness
Open/Shorted
Motor Thermistor
Ω > 220K or Ω < 40;
lockout after 6 hours
Short Cycling
Run time of less than
1 minute; lockout if
the number of Alerts
exceeds the number
configured by the
user in 24 hours
© 2015 Emerson Climate Technologies, Inc.
1) Check supply voltage
26
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
AE4-1401 R1
Table 8 Continued
Fault
Condition
Code Fault
Description
Code Reset
Description
Troubleshooting
Information
Scroll High
Temperature
Interrupt power to
T2-T1 or perform
Modbus reset
command
1) Check system charge and superheat
Red
Flash Code 4
Ω < 2.4K; Lockout if
the number of Alerts
exceeds the number
configured by the
user in 24 hours
Red
Flash Code 5
Future Use
Status
Red
Flash Code 6
Missing Phase
Red
Flash Code 7
Reverse Phase
Red
Flash Code 8
Future Use
Red
Flash Code 9
1
Module Low
Voltage
N/A
2) Check system operating conditions
3) Check for abnormally low suction
pressure
N/A
N/A
Missing phase;
Lockout after 10
consecutive Alerts
After 5 minutes
and missing phase
condition is not
present
1) Check incoming power
Reverse phase;
Lockout after 1 Alert
Interrupt power to
T2-T1 or perform
Modbus reset
command
1) Check incoming phase sequence
N/A
2) Check fuses/breakers
3) Check contactor
2) Check contactor
3) Check module phasing wires A-B-C
N/A
N/A
1) Verify correct module p/n
After 5 minutes and
2) Check VA rating of transformer
the voltage is back
in the normal range 3) Check for blown fuse in transformer
secondary
Low voltage on T2T1 terminals1
This Alert does not result in a Lockout
Table 9 – Emerson Drive Selections
Model
Compressor
Voltage
Frequency
(Hz)
Phase
Drive
Name
Drive
Model Number
Maximum
Continuous
Ouput Current
ZP296KWE-TE5
200/230
60
3
H Series
H300-072 01170A
117
ZP296KWE-TE7
380/400
60
3
H Series
H300-074 00790A
79
ZP296KWE-TED
380/420
50
3
H Series
H300-064 00630A
63
ZP296KWE-TED
460
60
3
H Series
H300-064 00630A
63
ZP296KWE-TEE
575
60
3
H Series
H300-065 00430A
43
ZP385KWE-TE5
200/230
60
3
H Series
H300-082 01490A
149
ZP385KWE-TE7
380/400
60
3
H Series
H300-074 00940A
94
ZP385KWE-TED
460
60
3
H Series
H300-074 00790A
79
ZP385KWE-TEE
575
60
3
H Series
H300-075 00730A
73
ZP485KWE-TED
460
60
3
H Series
H300-074 00940A
94
ZP485KWE-TE7
380/400
60
3
H Series
H300-084 01550A
155
ZP485KWE-TEE
575
60
3
H Series
H300-075 00730A
73
ZP485KWE-DE5
200/220
60
3
H Series
H300-092 02160E
216
The drive selections are for a maximum frequency of 60 Hz. If operating at greater than 60 Hz, please contact Application
Engineering for drive selections.
The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees,
express or implied, regarding the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or
its affiliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifications of such products at any time without
notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use
and maintenance of any Emerson product remains solely with the purchaser or end user.
© 2015 Emerson Climate Technologies, Inc.
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