Emerson Copeland Scroll ZP K6 Series - User Manual

1
© 2015 Emerson Climate Technologies, Inc.
AE4-1400 R1
1 to 5 Ton ZP*K6 R-410A Copeland Scroll
™
Compressors
AE4-1400 R2
February 2015
Safety
Safety Instructions .................................................... 2
Safety Icon Explanation ........................................... 2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons .......................................... 3
Safety Statements ....................................................3
Introduction .................................................................4
Nomenclature ...........................................................4
Application Considerations
Internal Pressure Relief Valve .................................. 4
Discharge Temperature Protection ........................... 4
Heat Pump Protection .............................................. 5
Discharge Line Thermostat ...................................... 5
Air-Conditioning Unit Protection ............................... 5
High Pressure Control .............................................. 5
Shut Down Device .................................................... 5
Motor Overload Protection ....................................... 5
Operating Envelope ................................................. 6
Power Supply ........................................................... 6
Accumulators ...........................................................6
Screens .................................................................... 6
Crankcase Heat-Single Phase ................................. 6
Crankcase Heat-Three Phase .................................. 7
Minimum Run Time .................................................. 7
Reversing Valves .....................................................7
Low Ambient Cut-Out ............................................... 7
Oil Type ....................................................................7
Contaminant Control ................................................ 8
Long Line Sets/High Refrigerant Charge ................. 8
 DischargeMufers ................................................... 8
Air-Conditioning System Suction Line
Noise & Vibration ...................................................8
Mounting Parts ......................................................... 9
Single Phase Starting Characteristics ...................... 9
PTC Start Components ............................................ 9
Electrical Connections .............................................. 9
Deep Vacuum Operation .......................................... 9
Suction & Discharge Fittings ................................... 9
System Tubing Stress ............................................. 9
Three Phase Scroll Electrical Phasing .................. 10
Brief Power Interruptions ....................................... 10
Tandem Compressors ........................................... 10
Maximum Tilt Angle ............................................... 10
Application Tests
Application Summary.............................................10
Continuous Floodback Test ................................... 11
Field Application Test ............................................ 11
Assembly Line Procedures
Installing the Compressor ..................................... 11
Suction Funnel ...................................................... 12
Assembly Line Brazing Procedure ........................ 12
Pressure Testing ................................................... 12
Assembly Line System Charging Procedure ......... 12
High Potential (AC Hipot) Testing .......................... 12
Final Run Test ....................................................... 13
Unbrazing System Components ........................... 13
Service Procedures
Copeland Scroll Functional Check ........................ 13
Compressor Replacement After Motor Burn ......... 14
Start Up of a New or Replacement Compressor .... 14
Figures & Tables
R410A Scroll Operating Envelope ......................... 15
Oil Dilution Chart ................................................... 16
Time Delay Wiring ................................................. 17
Compressor Electrical Connection ........................ 17
Crankcase Heater ................................................. 18
Scroll Suction Tube Brazing .................................. 19
How a Scroll Works.. ............................................. 20
Suction Funnel Diagram ........................................ 21
Field Application Test ............................................ 22
 DesignCongurations ........................................... 22
Compressor Refrigerant Charge Limits... .............. 22
Compressor Accessories ...................................... 23
TABLE OF CONTENTS
Section Page Section Page

Emerson Copeland Scroll ZP K6 Series Specifications

General

Brand	Emerson
Model	Copeland Scroll ZP K6 Series
Category	Air Compressor
Language	English

Summary

Introduction

Nomenclature

Provides details on how to interpret the model numbers of the Copeland Scroll compressors.

Application Considerations

Internal Pressure Relief Valve

Explains the function and operation of the internal pressure relief valve for compressor protection.

Operating Envelope

Defines the acceptable operating conditions for the ZP*K6 compressor family with R-410A.

Crankcase Heat - Single Phase

Details recommendations and requirements for using crankcase heaters with single-phase compressors.

Oil Type

Specifies the type of POE oil used and recommended alternatives for ZP*K6 compressors.

Electrical Connections

Provides guidance on proper electrical connections and the use of molded plugs for ZP*K6 compressors.

APPLICATION TESTS

Application Test Summary

Provides an overview of tests recommended for system design and compressor failure identification.

Continuous Floodback Test

Details the procedure for testing continuous liquid refrigerant floodback in heat pump systems.

Field Application Test

Outlines the test procedure to verify liquid level in the compressor during system off-cycles.

ASSEMBLY LINE PROCEDURES

Installing the Compressor

Provides safety warnings and guidance for lifting and moving compressors during installation.

Assembly Line Brazing Procedure

Details proper safety precautions and nitrogen flow procedures for brazing compressor lines.

Assembly Line System Charging Procedure

Guides on charging systems with liquid refrigerant to prevent operational issues and protect the compressor.

SERVICE PROCEDURES

Copeland Scroll Compressor Functional Check

Outlines the diagnostic procedure to evaluate whether a Copeland Scroll compressor is functioning properly.

Compressor Replacement After a Motor Burn

Details procedures for cleaning the system and replacing components after a motor burn.

Start-Up of a New or Replacement Compressor

Provides guidance on proper start-up procedures for new or replacement compressors.