Emerson Copeland Scroll Compressors Application Owner's Manual
Emerson Copeland Scroll compressors are designed for various refrigeration applications, delivering efficient and reliable performance. They feature advanced scroll technology, ensuring quiet operation and high energy efficiency. With a wide range of models available, these compressors are suitable for use with various refrigerants, including R-404A, R-507, R-407A/C, R-448A/9A, R-407F, and R-134a. The compressors are equipped with internal protection devices, including crankcase heaters, discharge line thermostats, and pressure controls, ensuring safe and reliable operation.
Advertisement
Advertisement
AE4-1317 R14
July 2020
Application Guidelines for ZB*KC / ZB*KCE Refrigeration
Copeland Scroll™ Compressors ZB10KC* through ZB57KC* (1.3 to 7.5 HP)
TABLE OF CONTENTS
Safety .............................. Error! Bookmark not defined.
Safety Instructions ....................................................... 3
Safety Icon Explanation ............................................. 3
Instructions Pertaining to Risk of Electrical Shock, Fire,
or Injury to Persons ...................................................... 4
Safety Statements ........................................................ 4
Introduction ................................................ 5
Nomenclature ............................................. 5
Operating Envelope ................................... 5
Use of R-513A Refrigerant ........................ 5
Accumulators ............................................. 5
Crankcase Heaters ..................................... 5
Discharge Line Thermostat ....................... 6
Pressure Controls ...................................... 6
Pump Down Recommendations ............... 6
IPR Valve ..................................................... 6
Internal Temperature Protection .............. 7
Motor Protection ........................................ 7
Oil Types ..................................................... 7
Oil Charges ................................................. 7
Oil Management for Rack Applications ... 7
Compressor Tubing and Mounting .......... 8
Mounting for Rack Systems ......................... 8
Condensing Unit Mounting ........................... 8
Tubing Considerations ................................. 8
Starting Characteristics ............................. 8
Fusite ........................................................... 8
Shell Temperature ...................................... 8
Connection Fittings .................................... 8
Three-Phase Rotation Direction ................ 8
Brief Power Interruptions .......................... 9
Deep Vacuum Operation ............................ 9
Unbrazing System Components ............... 9
High Potential (Hipot) Testing ................... 9
Copeland Scroll Functional Check ........... 9
New Installation ........................................ 10
Field Service ............................................. 10
To disconnect: ............................................ 10
To reconnect: .............................................. 10
General Guidelines and More Information
Oil Sight Glass Designs ........................... 13
Oil Sight Glass Design Change for 1.5 to 9 HP
Copeland Scroll™ Refrigeration Compressors .......... 13
Available Spare Parts Kit for Sightglass
Replacement: ............................................................. 14
OMB ........................................................... 14
TABLE OF FIGURES
Figure 1 - Scroll Tube Brazing ................................... 10
Figure 2 - ZB10KCE through ZB57KCE Application
Envelope for R-404A/R-507 (1.3 - 7.5 HP) ................ 11
Figure 3 - ZB10KCE through ZB57KCE Application
Envelope for R-407A/R-407C/R-448A/R-449A (1.3 - 7.5
HP) ............................................................................. 11
Figure 4 - ZB10KCE through ZB57KCE Application
Envelope for R-407F (1.3 - 7.5 HP) ........................... 12
Figure 5 - ZB15KCE trough 57KCE Application
Envelope for 134a (2-7.5HP) ..................................... 12
Figure 6 - Sight glass design until November 30 th , 2014
(14K and earlier) ........................................................ 13
Figure 7 – Sight glass design as of December 1 st , 2014
(14K and after) ........................................................... 13
Figure 8 - Available OMB adapter Kit ........................ 14
Figure 11 - ZB10KC* through ZB57KC* (1.3-7.5 HP)
Refrigeration Scroll Rack Mounting ............................ 15
Figure 12 - ZB10KC* through ZB57KC* (1.3-7.5 HP)
Refrigeration Scroll Condensing Unit Mounting ......... 15
Figure 13 - Typical Suction Tubing ............................. 16
Figure 14 - Motor Terminal (Fusite) Connections for
Single Phase and Three Phase Scrolls ...................... 16
Figure 15 - Control Circuit Wiring Diagram ................ 17
© 2020 Emerson Climate Technologies, Inc.
1
TABLES
Table 1 - Compressor Models and Approved
Refrigerants/Lubricants .............................................. 18
Table 2 - Charge Limitations ...................................... 18
Table 3 - Crankcase Heater ....................................... 19
Table 4 - Conduit Ready Heater Terminal Box Kits ... 19
Table 5 - Discharge Thermostat Line Kits ................. 19
Revision Tracking R14
Pg. 5 – Warning of using R-513A
Pg. 9 – Updated R-134a Envelope to Include R-513A
Pg. 18 – Added R-513A to list of approved refrigerants
Pg. 20 – Added R-513A to list of pressure cut-outs
Revision Tracking R13
– DLT position and general guideline Text updated.
– References to OMB updated to OMB/C in
Section 16
– Title of Figures 6 and 7 were updated.
– Title of Figures 15 was updated
© 2020 Emerson Climate Technologies, Inc.
2
Table 6 - Pressure Control Settings ........................... 20
Table 7 - Check-Valve Type ....................................... 20
Table 8 - Recommended Oil Charges by Model Family
.................................................................................... 21
Revision Tracking R12
Pg. 1 – ZB10KC* through ZB57KC designation applied on the Bulletin title and rest of the bulletin.
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. Safety icons are explained below and safety instructions applicable to the products in this bulletin are grouped on
Page 4 . These instructions should be retained throughout
the lifetime of the compressor. You are strongly advised to follow these safety instructions.
Safety Icon Explanation
DANGER
CAUTION
WARNING
CAUTION
NOTICE
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.
FLAMMABLE, Fire hazard! Sparking in a potentially explosive atmosphere! Explosion hazard!
© 2020 Emerson Climate Technologies, Inc.
3
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
WARNING
ELECTRICAL SHOCK HAZARD
•
Disconnect and lock out power before servicing.
•
Discharge all capacitors before servicing.
•
Use compressor with grounded system only.
•
Molded electrical plug must be used when required.
•
Refer to original equipment wiring diagrams.
•
Electrical connections must be made by qualified electrical personnel.
•
Failure to follow these warnings could result in serious personal injury.
PRESSURIZED SYSTEM HAZARD
•
System contains refrigerant and oil under pressure.
•
Remove refrigerant from both the high and low compressor side before removing compressor.
•
Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system.
•
Use only approved refrigerants and refrigeration oils.
•
Personal safety equipment must be used.
•
Failure to follow these warnings could result in serious personal injury.
WARNING
CAUTION
BURN HAZARD
•
Do not touch the compressor until it has cooled down.
•
Ensure that materials and wiring do not touch high temperature areas of the compressor.
•
Use caution when brazing system components.
•
Personal safety equipment must be used.
•
Failure to follow these warnings could result in serious personal injury or property damage.
COMPRESSOR HANDLING
•
Use the appropriate lifting devices to move compressors.
•
Personal safety equipment must be used.
•
Failure to follow these warnings could result in personal injury or property damage.
Safety Statements
•
Refrigerant compressors must be employed only for their intended use.
•
Only qualified and authorized HVAC or refrigeration personnel are permitted to install commission and maintain this equipment.
•
Electrical connections must be made by qualified electrical personnel.
•
All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed.
© 2020 Emerson Climate Technologies, Inc.
4
1. Introduction
The ZB*KC/ZB*KCE Copeland Scroll™ compressor represents the latest generation of compliant scroll technology for the refrigeration industry.
2. Nomenclature
The refrigeration scroll model numbers include the nominal capacity at standard 60HZ ARI rating conditions for medium temperature (20/120°F). For additional information on this product, please refer to the Online
Product Information at Emerson.com/OPI
3. Operating Envelope
The ZB*KC/ZB*KCE refrigeration scroll compressor models can be used with a variety of refrigerants depending on the model selected and the lubricant
used. (See Table 1 at the end of this bulletin.)
The ZB*KC and ZB*KCE models are intended for medium temperature refrigeration type duty. The approved operating envelopes for these models are such that they are ideally suited for applications such as ice machines, bulk milk and FCB/FUB . The models and
operating envelopes are depicted in Figure 2 , Figure 3 ,
Figure 4 and Figure 5 at the end of this bulletin.
4. Use of R-513A Refrigerant
WARNING
Note: Refrigerant migration of R-513A into the compressor crankcase could cause low oil viscosity which could lead to compressor damage.
•
When using R-513A it is critical to meet the following requirements
•
Maintain adequate superheat settings with a minimum superheat of 20°F at the compressor
•
No liquid refrigerant migration into the compressor at any time, especially during standstill or during or after defrost
•
Pump down recommended.
•
The use of a crankcase heater is recommended.
•
Retrofit R-513A is only allowed for compressors which are approved for these refrigerants
5. Accumulators
Due to the scrolls’ inherent ability to handle liquid refrigerant in flooded start and defrost cycle operation conditions, accumulators may not be required. An accumulator is required on single compressor systems when the charge limitations exceed those values listed
© 2020 Emerson Climate Technologies, Inc.
5 in
Table 2 . On systems with defrost schemes or
transient operations that allow prolonged uncontrolled liquid return to the compressor, an accumulator is required unless a suction header of sufficient volume to prevent liquid migration to the compressor is used.
Excessive liquid flood back or repeated flooded starts will dilute the oil in the compressor causing inadequate lubrication and bearing wear. Proper system design will minimize liquid flood back, thereby ensuring maximum compressor life.
In order to assure that liquid refrigerant does not return to the compressor during the running cycle, attention must be given to maintaining proper superheat at the compressor suction inlet. Emerson recommends a minimum of 20°F (11°C) superheat, measured on the suction line 6 inches (152mm) from the suction valve, to prevent liquid refrigerant floodback.
Another method to determine if liquid refrigerant is returning to the compressor is to accurately measure the temperature difference between the compressor oil crankcase and the suction line. During continuous operation we recommend that this difference be a minimum of 50°F (27°C). This “crankcase differential temperature” requirement supersedes the minimum suction superheat requirement in the last paragraph. To measure oil temperature through the compressor shell, place a thermocouple on the bottom center (not the side) of the compressor shell and insulate from the ambient.
During rapid system changes, such as defrost or ice harvest cycles, this temperature difference may drop rapidly for a short period of time. When the crankcase temperature difference falls below the recommended
50°F (27°C), our recommendation is the duration should not exceed a maximum (continuous) time period of two minutes and should not go lower than a 25°F (14°C) difference.
Contact your Emerson Climate Technologies representative regarding any exceptions to the above requirements.
6. Crankcase Heaters
•
Single-phase
No crankcase heaters are required on single-phase scroll compressors.
•
Three-phase - outdoor only
Crankcase heaters are required on three phase compressors where the system charge exceeds 10 lbs.
The listed crankcase heaters are intended for use only
when there is limited access (See Table 3 ). The heaters
are not equipped for use with electrical conduit. Where applicable, electrical safety codes require lead protection, a crankcase heater terminal box should be used. Recommended crankcase heater terminal box
and cover kit numbers are listed in Table 4 . If there are
any questions concerning their application, contact to
Emerson, Application Engineering department.
7. Discharge Line Thermostat
saturated suction temperature, maximum condensing temperature, maximum return gas temperature, and maximum discharge line temperature. Operation beyond these limits can cause high compression ratios or excessive internal compressor temperatures. This will result in overheating the scroll members, causing excessive wear resulting in premature compressor failure.
If the system is designed where operation within these guidelines cannot be guaranteed, then a discharge line thermostat is required in the compressor control circuit.
When installed approximately 6-7 inches from the discharge tube outlet, depending on tubing configuration. The thermostats have a cut-out setting that will ensure the external discharge line temperature does not exceed the 260°F limit. If a Rotalock service valve is installed on the discharge port connection, the thermostat should be located approximately 5-6 inches from the valve braze connection.
Kits have been set up to include the thermostat, retainer, and installation instructions. These thermostats must be used with ½” O.D. discharge lines to ensure proper thermal transfer and temperature control. They work with either 120 or 240-volt control circuits and are available with or without an alarm circuit capability. See
Table 5 for a list of discharge line thermostat kit
numbers.
8. Pressure Controls
Both high and low-pressure controls are required on the following models, (1.3-2 HP) ZB10-14KCE. Only lowpressure controls are required on the following models,
(2-7.5 HP) ZB15-57KC/E. See Table 6 for set points.
Application Note: There are exceptions to the pressure
settings listed in Table 6 . Certain OEMs are approved
for LPC settings below our standard recommendations.
9. Pump Down Recommendations
identifies the “ZB” models that incorporate the low-leak check valve suitable for pump-down
© 2020 Emerson Climate Technologies, Inc.
6 applications. The standard disc is not intended for use with a pump down.
NOTICE
Typically, the compressors that use the low-leak discharge check valve are suitable for pump down applications. This valve prevents system pressures from equalizing and pump down can be achieved. However, during laboratory testing, we have observed a potential short cycling condition on the ZB15 through ZB29 models. This phenomenon can be attributed to several factors:
1. Location of low-pressure control sensor. If it is located right at the suction inlet of the compressor, it will be more sensitive to pressure spikes.
2. Actual low-pressure setting. Refer to our
recommended setting in Table 6 . If the differential
pressure setting is too close, this will increase the possibility of short cycling.
3. Type of Low-pressure control can have an effect on cycling. The encapsulated non-adjustable type is more susceptible to causing excessive cycling due to tolerances.
4. If short cycling cannot be avoided, using a 3-minute time delay will limit the cycling of the compressor to an acceptable level.
NOTICE
The ZB10 through ZB14 models will require the following recommendations for pump down applications:
5. Install an external check-valve in the discharge line to prevent back-flow from the high side to low side.
Install check-valve as close to the compressor discharge fitting as possible to minimize discharge gas volume.
6. Set low pressure to recommended settings in Table
7. Since these models are single-phase only, add a time delay relay to prevent reverse rotation. Refer to
Brief Power Interruptions section of this bulletin
for additional information.
10. IPR Valve
Refrigeration scroll compressors (2-7.5 HP) ZB15-
57KC/E have internal pressure relief valves, which open at a discharge to suction differential pressure of 375 to
450 psi. This action will trip the motor protector and remove the motor from the line. The ZB10-14KCE models DO require a high pressure control in addition to
a low pressure control, since these models do not have an IPR valve.
11. Internal Temperature Protection
Refrigeration Scroll compressors (1.3-7.5 HP) ZB10-
57KC/E incorporate a Thermo-disc which is a temperature-sensitive snap disc device located at the scroll discharge port. It is designed to open and route hot discharge gas back to the motor protector thus removing the compressor from the line.
12. Motor Protection
Conventional inherent internal line break motor protection is provided.
13. Oil Types
Polyol ester lubricants must be provided if the scroll compressor is to be used with HFC refrigerants. ZBKC compressors that are to be used with R22 should be supplied with mineral oil. See Form 93-11 for a complete list of all Emerson approved lubricants.
WARNING
POE may cause an allergic skin reaction and 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). Refer to the Safety Data Sheet
(SDS) for further details.
14. Oil Charges
The recommended oil charges for these compressors
15. Oil Management for Rack Applications
Copeland Scroll refrigeration compressors may be used on multiple compressor parallel rack applications. This requires the use of an oil management system to maintain proper oil level in each compressor crankcase.
The sight glass connection supplied can accommodate the mounting of the oil control devices.
Unlike semi-hermetic compressors, scroll compressors do not have an oil pump with accompanying oil pressure safety controls. Therefore, an external oil level control is required.
The Emerson OMB/C Oil Level Management Control combines the functions of level control and timed compressor shut-off should the level not come back to normal within a set period of time. This device has been
© 2020 Emerson Climate Technologies, Inc.
7 found to provide excellent performance in field tests on
Copeland Scroll compressors and is recommended for parallel system applications.
For Technical details about OMB/C Oil Level
Management Control follow these links or scan their QR code:
- OMB/C Instruction Sheet https://climate.emerson.com/documents/ombc--pa-00388-en-4858298.pdf
- OMB/C & OLC Adapter Kits Installation
Instructions Sheet https://climate.emerson.com/documents/ombadapter-instructions-en-4924792.pdf
See Table 8 order to select appropiate Adapter Kit.
Note: Emerson Climate Technologies' Application
Engineering Department should be contacted for approved oil management systems.
Immediately after system start-up the oil reservoir level will fluctuate until equilibrium is reached. It is advisable to monitor the oil level during this time to assure sufficient oil is available. This will prevent unnecessary trips of the oil control system.
Note: If oil management problems are occurring please refer to AE17-1320 or contact to Emerson, Application
Engineering Department.
16. Compressor Tubing and Mounting
Compressor mounting must be selected based on application. Consideration must be given to sound reduction and tubing reliability. Some tubing geometry or “shock loops” may be required to reduce vibration transferred from the compressor to external tubing.
16.1. Mounting for Rack Systems
For ZB10KC* through ZB57KC* (1.3-7.5 HP) compressors, specially designed rubber grommets are available for refrigeration scroll compressor applications. These grommets are formulated from a durometer material specifically designed for refrigeration applications. The durometer limits the compressor motion, thereby minimizing potential problems of excessive tubing stress. Sufficient isolation is provided to prevent vibration from being transmitted to the mounting structure. This mounting arrangement is recommended for multiple compressor rack
installations. See Figure 11 for a detail of this mounting
system.
NOTICE
The use of standard soft grommets is not recommended for most refrigeration scroll rack installations. These softer mounts allow for excessive movement that will result in tube breakage, unless the entire system is properly designed.
16.2. Condensing Unit Mounting
For ZB10KC* through ZB57KC* (1.3-7.5 HP) refrigeration scroll condensing unit applications, soft
mounts are recommended. See Figure 12 .
16.3. Tubing Considerations
Proper tube design must be taken into consideration when designing the tubing connecting the scroll to the remaining system. The tubing should provide enough
“flexibility” to allow normal starting and stopping of the compressor without exerting excessive stress on the tube joints. In addition, it is desirable to design tubing with a natural frequency away from the normal running frequency of the compressor. Failure to do this can result in tube resonance and unacceptable tubing life.
Figure 13 shows examples of acceptable tubing
configurations.
CAUTION
These examples are intended only as guidelines to depict the need for flexibility in tube designs. In order to properly determine if a design is appropriate for a given application, samples should be tested and evaluated for
© 2020 Emerson Climate Technologies, Inc.
8 stress under various conditions of use including voltage, frequency, and load fluctuations, and shipping vibration.
The guidelines above may be helpful; however, testing should be performed for each system designed.
17. Starting Characteristics
Single-phase scroll compressors are designed with
PSC type motors and therefore will start without the need of start assist devices in most applications.
However, if low voltage conditions exist at start up, protector trips can result. Therefore, start assist devices
(start capacitors and relays) are available to maximize starting characteristics under abnormal conditions.
18. Fusite
Fusite pin orientation for single-phase and three- phase
refrigeration scroll compressors are shown in Figure 14
and inside the terminal box.
19. Shell Temperature
CAUTION
System component failure may cause the top shell and discharge line to briefly reach temperatures above
300°F. Wiring or other materials, which could be damaged by these temperatures, should not come in contact with the shell.
20. Connection Fittings
Scroll compressors are provided with either braze connections or roto-lock adapters depending on the bill of material selected (reference AE4-1219 for roto-lock torque values). Consult your District Sales Manager or
Application Engineer for details.
All ZBKC/E models have copper plated steel suction and discharge fittings for a more rugged, leak resistant connection.
See section on New Installation (see Figure 1)
for suggestions on how to properly braze these fittings.
21. Three-Phase Rotation Direction
Scroll compressors are directional dependent: i.e., they will compress in one rotational direction only. On singlephase compressors, this is not an issue since they will only start and run in the proper direction (except as described in the Labeled Brief Power Interruptions).
Three-phase scrolls, however, will rotate in either direction depending on the power of the phasing. So there is a 50/50 chance of connected power being
“backwards.” Contractors should be warned of this.
Appropriate instructions or notices should be provided by the Original Equipment Manufacturer.
Verification of proper rotation can be made by observing that the suction pressure drops and the discharge pressure rises when the compressor is energized.
Additionally, if operated in reverse the compressor is noisier and its current draw is substantially reduced compared to tabulated values.
Although operation of scroll in reverse direction for brief periods of time is not harmful, continued operation could result in failure.
All three-phase compressors are wired identically internally. Once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same fusite terminals will maintain the proper rotation.
22. Brief Power Interruptions
Brief power interruptions (less than ½ second) may result in powered reverse rotation of single-phase refrigeration scroll compressors. High-pressure discharge gas expands backward through the scrolls at power interruption causing the scroll to orbit in the reverse direction. If power is reapplied while this reversal is occurring, the compressor may continue to run noisily in the reverse direction for several minutes until the compressor internal protector trips. This has no negative effect on durability. When the protector resets, the compressor will start and run normally.
Emerson strongly encourages the use of a timer which can sense brief power interruptions and lock the compressor out of operation for two minutes. A typical
timer circuit is shown in Figure 15 .
No time delay is required on three phase models to prevent reverse rotation due to power interruptions
23. Deep Vacuum Operation
WARNING
Do not run a refrigeration scroll compressor in a vacuum. Failure to heed this advice can result in permanent damage to the compressor.
A low-pressure control is required for protection against vacuum operation. See the section on
for the proper set points. (See Table 6 )
Scroll compressors (as with any refrigeration compressor) should never be used to evacuate refrigeration or air conditioning systems. See AE24-
1105 for proper system evacuation procedures.
24. Unbrazing System Components
CAUTION
© 2020 Emerson Climate Technologies, Inc.
9
If the refrigerant charge is removed from a scroll unit by bleeding the high side only, it is sometimes possible for the scrolls to seal, preventing pressure equalization through the compressor. This may leave the low side shell and suction line tubing pressurized. If a brazing torch is then applied to the low side, the pressurized refrigerant oil mixture could ignite as it escapes and contacts the brazing flame. It is important to check both the high and low sides with manifold gauges before unbrazing. In the case of an assembly line repair, remove the refrigerant from both the high and low sides.
Instructions should be provided in appropriate product literatures and assembly areas.
25. High Potential (Hipot) Testing
Many of the Copeland brand compressors are configured with the motor below the compressor. As a result, when liquid refrigerant is within the compressor shell the motor can be immersed in liquid refrigerant to a greater extent than with compressors with the motor mounted above the compressor. When Copeland brand compressors are Hipot tested and liquid refrigerant is in the shell, they can show higher levels of leakage current than compressors with the motor on top because of the higher electrical conductivity of liquid refrigerant than refrigerant vapor and oil. 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 bulletin AE4-1294 for Megohm testing recommendations. Under no circumstances should the
Hipot or Megohm test be performed while the compressor is under a vacuum.
26. Copeland Scroll Functional Check
Refrigeration scroll compressors do not have internal suction valves. It is not necessary to perform functional compressor tests to check how low the compressor will pull suction pressure. This type of test may damage a scroll compressor. The following diagnostic procedure should be used to evaluate whether a Copeland Scroll compressor is functioning properly.
1. Verify proper unit voltage.
2. Normal motor winding continuity and short to ground checks will determine if the inherent overload motor protector has opened or if an internal short to ground has developed. If the protector has opened, the compressor must cool sufficiently to reset.
3. 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.
4. ASingle-Phase Compressors
If the suction pressure does not drop and the discharge pressure does not rise to normal levels the compressor is faulty.
B- Three-Phase Compressors
If the suction pressure does not drop and the discharge pressure does not rise, reverse any two of the compressor power leads and reapply power to make sure the compressor was not wired to run in the reverse direction.
The compressor current draw must be compared to published compressor performance curves at the compressor operating conditions (pressures and voltages). Significant deviations (±15%) from published values may indicate a faulty compressor.
27. New Installation
•
The copper-coated steel suction, discharge, and injection tubes on scroll compressors can be brazed in approximately the same manner as any copper tube.
•
Recommended brazing material - Any Silfos® material is recommended, preferably with a minimum of 5% silver. However, 0% silver is acceptable.
•
Use of a dry nitrogen purge to eliminate possibility of carbon buildup on internal tube surfaces is recommended.
•
Be sure process tube fitting I.D. and process tube
O.D. are clean prior to assembly.
•
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 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.
•
As with any brazed joint, overheating may be detrimental to the final result.
Figure 1 - Scroll Tube Brazing
28. Field Service
28.1. To disconnect:
•
Recover refrigerant from both the high and low side of the system. Cut tubing near compressor.
28.1.1. To reconnect:
•
Recommended brazing materials - Silfos® with minimum 5% silver or silver braze material with flux.
•
Reinsert tubing fitting.
•
Heat tube uniformly in Area 1, moving slowly to Area
2. When joint reaches brazing temperature, apply brazing material.
•
Heat joint uniformly around the circumference to flow braze material completely around the joint.
•
Slowly move torch in Area 3 to draw braze material into the joint.
Do not overheat joint.
29. General Guidelines and More Information
For general Copeland ™ compressor information please log in to Online Product Information at
Emerson.com/OPI , refer to the Application Engineering bulletins listed below, or contact your Application
Engineer.
AE17-1320
AE4-1219
Oil Management for Copeland
Scroll™ Compressors in Parallel
Applications
Torque Values on Copeland™
Brand Products Recommended
Torque with Lubricated Bolts
AE4-1294
Form 93-11
Megohm Values of Copeland®
Compressors
Refrigerants and lubricants approved for use in Copeland™ compressors
© 2020 Emerson Climate Technologies, Inc.
10
Figure 2 - ZB10KCE through ZB57KCE Application Envelope for R-404A/R-507 (1.3 - 7.5 HP)
Figure 3 - ZB10KCE through ZB57KCE Application Envelope for R-407A/R-407C/R-448A/R-449A
(1.3 - 7.5 HP)
© 2020 Emerson Climate Technologies, Inc.
11
Figure 4 - ZB10KCE through ZB57KCE Application Envelope for R-407F (1.3 - 7.5 HP)
Figure 5 - ZB15KCE trough 57KCE Application Envelope for 134a / 513A (2-7.5HP)
© 2020 Emerson Climate Technologies, Inc.
12
30. Oil Sight Glass Designs
30.1. Oil Sight Glass Design Change for 1.5 to 9 HP Copeland Scroll™ Refrigeration Compressors
In order to communize design across platforms and improve product quality, Emerson Climate Technologies Inc. has implemented a new sightglass design on 1.5 – 9 HP Copeland Scroll refrigeration compressor. Emerson Climate
Technologies has significant experience with this design, which aligns with other platform designs.
The production implementation of the new design was December 1th, 2014. All compressors with serial numbers beginning with 14L will have the new sightglass fitting.
Example: Serial Number – 14L 259554 => December 2014
Figure 6 - Sight glass design until November 30 th , 2014 (14K and earlier)
Kit includes: Threaded, PTFE coated, sightglass.
Compressor sightglass connection: conical ¾” – 14 NPTF
Recommended sightglass torque: 80 – 100 in-lbs.
Figure 7 – Sight glass design as of December 1 st , 2014 (14K and after)
Kit i ncludes: Gasket / sightglass / 1 ¼ “ nut
Compressor sightglass connection: external thread 1 ¼” – 12 UNF.
Recommended sightglass torque: 300 – 360 in-lbs.
* The different designs cannot be used interchangeably.
© 2020 Emerson Climate Technologies, Inc.
13
30.2. Available Spare Parts Kit for Sightglass Replacement:
Sight Glass Replacement Kit: P/N 998-0010-02
Note: Contains both internal and external thread design sightglasses.
New Design: Emerson Flow Controls P/N 066650
(KS30394-2)
Contains:
• 1 1/2 “ Nut OMB Adapter
•
Gasket
•
O-ring
Compressor Sightglass connection: external thread 1
¼” – 12 UNF
Recommended sightglass torque: 960 – 1200 in-lbs.
Figure 8 - Available OMB adapter Kit
31. OMB
This external thread design will hold the OMB the same distance away from the compressor as the previous internal thread design, resulting in no change of the compressor’s footprint.
Figure 9 - OMB Design until November 30 th , 2014 (14K and earlier)
Figure 10 - OMB Design as of December 1 st , 2014 and after (14K and after)
For additional information please refer to Marketing Bulletin MB2014CC-6
© 2020 Emerson Climate Technologies, Inc.
14
Figure 11 - ZB10KC* through ZB57KC* (1.3-7.5 HP) Refrigeration Scroll Rack Mounting
Figure 12 - ZB10KC* through ZB57KC* (1.3-7.5 HP) Refrigeration Scroll Condensing Unit Mounting
© 2020 Emerson Climate Technologies, Inc.
15
Figure 13 - Typical Suction Tubing
NOTES:
1. The above tubing configurations are guidelines to minimize tube stress.
2. Follow similar guidelines for discharge tubing and oil return tubing as needed.
3. If a run of over 20” is required, intermediate clamps may be necessary.
4. Do not hang weights on tubing (e.g. filter drier on suction tubing) except after clamps or close to the header.
5. Tube runs of less than 8” are not recommended.
6. This dimension should be made as short as possible (e.g. 2” or less) but still insuring a proper braze joint.
7. The above tubing recommendations are based on “no elbow joints”. The use of continuous tubing is preferred.
Figure 14 - Motor Terminal (Fusite) Connections for Single Phase and Three Phase Scrolls
16
© 2020 Emerson Climate Technologies, Inc.
Figure 15 - Control Circuit Wiring Diagram
© 2020 Emerson Climate Technologies, Inc.
17
Table 1 - Compressor Models and Approved Refrigerants/Lubricants
Model
ZB10KCE
ZB11KCE
ZB13KCE
ZB14KCE
ZB15KCE
ZB19KCE
HP
1.3
1.5
1.8
2.0
2.0
2.5
Refrigerant
R-404A/ R-507
R-404A/ R-507
R-404A/ R-507
R-404A/ R-507
R-22/ R-404A/ R-507/ R-134a/ R-407A/ R-407C/
R-407F/ R-448A/ R-449A/ R-513A
R-22/ R-404A/ R-507/ R-134a/ R-448A/ R-449A/
R-513A
Lubricant
POE
POE
POE
POE
MO/POE
MO/POE
ZB21KCE
ZB26KCE
ZB29KCE
ZB30KCE
ZB38KCE
ZB42KCE
ZB45KCE
3.0
3.5
4.0
4.0
5.0
5.5
6.0
R-22/ R-404A/ R-507/ R-134a/ R-407A/ R-407C/
R-407F/ R-448A/ R-449A/ R-513A
R-22/ R-404A/ R-507/ R-134a/ R-407A/ R-407C/
R-407F/ R-448A/ R-449A/ R-513A
R22/ R404A/ R507/ R134a/ R407A/ R407C/
R407F/ R-448A/ R-449A/ R-513A
R-22/ R-404A/ R-507/ R-134a/ R-407A/ R-407C/
R-407F/ R-448A/ R-449A/ R-513A
R-22/ R-404A/ R-507/ R-134a/ R-407A/ R-407C/
R-407F/ R-448A/ R-449A/ R-513A
R-22/ R-404A/ R-507/ R-134a/ R-448A/ R-449A/
R-513A
R-22/ R-404A/ R-507/ R-134a/ R-407A/ R-
407C/R-407F/ R-448A/ R-449A/ R-513A
MO/POE
MO/POE
POE
MO/POE
MO/POE
MO/POE
MO/POE
ZB48KCE 6.5
R-22/ R-404A/ R-507/ R-134a/ R-407A/ R-407C/
R-407F/ R-448A/ R-449A/ R-513A
POE
ZB57KCE 7.5
R-22/ R-404A/ R-507/ R-134a/ R-407A/ R-407C/
R-407F/ R-448A/ R-449A/ R-513A
POE
See Emerson Climate Technologies Form 93-11 for a complete list of all Emerson approved lubricants.
Table 2 - Charge Limitations
Model Family
ZB10,11,13,14KCE
Chrg. Lmts
6 lbs
10 lbs ZB15,19, 21, 26, 29, 30, 38, 45, 48, 57KC/E
© 2020 Emerson Climate Technologies, Inc.
18
Kit Number
998-0540-00
998-0548-00
998-7022-02
998-7022-04
998-7022-07
ZB48 & ZF25 only
Table 3 - Crankcase Heater
Model
ZB10,11, 13, 14
ZB10,11, 13, 14
ZB15, 19, 21, 26, 29, 30,
38, 45, 48, 57
ZB15, 19, 21, 26, 29, 30,
38, 45, 48, 57
ZB15, 19, 21, 26, 29, 30,
38, 45, 48, 57
ZB15, 19, 21, 26, 29, 30,
38, 45, 48, 57
Part No.
018-0052-00
918-0041-01
018-0052-01
918-0041-00
018-0057-04
918-0043-00
018-0057-05
918-0043-01
018-0057-06
918-0043-02
018-0057-07
918-0043-07
Volts
120
240
240
480
575
120
Watts
40
40
70
70
70
70
Table 4 - Conduit Ready Heater Terminal Box Kits
Length
21”
21”
48”
48”
48”
48”
Model Number Kit Number
ZB10-ZB14 N/A
ZB15-ZB29
ZB30-ZB57
998-7026-00
998-7024-00
Table 5 - Discharge Thermostat Line Kits
Conduit Lead
Connector
No
No
Yes
Yes
Yes
Alarm
Contact
No
Yes
No
No
No
Discharge Line
Diameter
½”
½”
½”
5/8”
¾”
© 2020 Emerson Climate Technologies, Inc.
19
Model
ZB10/11/
13/14KCE
ZB*KC*
Control
Type
Low
High
Low
High
Table 6 - Pressure Control Settings
R-404A/R-507 R-134a / R-513A R-22
R-407A/R-407F/
R-448A/R-449A
17 PSIG min.
450 PSIG max.
17 PSIG min.
450 PSIG max.
N/A N/A
4 PSIG min.
263 PSIG max.
37 PSIG min.
382 PSIG max.
Table 7 - Check-Valve Type
Model Number
ZB10KCE
ZB11KCE
ZB13KCE
ZB14KCE
ZB15KC/E
ZB19KC/E
ZB21KC/E
ZB26KC/E
ZB29KC/E
ZB30KC/E
ZB38KC/E
ZB42KC/E
ZB45KC/E
ZB48KCE
ZB57KCE
Check Valve Type
Standard Disc
Standard Disc
Standard Disc
Standard Disc
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
Spring Loaded Low-Leak
N/A
8.5 PSIG min.
428 PSIG max.
R-407C
N/A
6.5 PSIG min.
402 PSIG max.
© 2020 Emerson Climate Technologies, Inc.
20
Flow Control
Adapter Kit #
065668
Table 8 - Recommended Oil Charges by Model Family
Model Family
ZB10KCE
ZB11, 13, 14KCE
ZB15KC/E
ZB19, 21, 26, 29KC/E
ZB30KC/E
ZB38KC/E
Initial Recharge
25
25
44
49
64
64
22
21
40
45
60
60
ZB45KC/E
ZB48KCE
64
60
60
56
ZB57KCE 64 60
Note: The oil level of refrigeration scroll compressors should be adjusted to the mid-point of the sightglass during normal operation.
Adapter
Description
Compressor
Compatibility
Figure
3/4"-NPTF
Adapter Kit
OM ACA
Compressor
Type
Copeland
Scroll 1.5 -
9 HP ZF, ZS,
ZB
066650
1 1/4" -12UNF
Rotalock
Adapter Kit
OM ACF
Compressor
Type
Copeland
Scroll
1.5 - 9 HP
ZF, ZS, ZB
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.
21
© 2020 Emerson Climate Technologies, Inc.
Advertisement
Key features
- Wide operating envelope for various refrigerants, including R-404A, R-507, R-407A, R-407C, R-448A, R-449A, R-407F, R-134a and R-513A
- Built-in crankcase heaters prevent oil migration during off-cycle
- Internal temperature protection safeguards the compressor from overheating
- Oil sight glass allows for easy oil level monitoring
- Rugged construction ensures durability and longevity
- Versatile mounting options for rack and condensing unit applications
- Meets industry standards for safety and performance
