Emerson Copeland Scroll ZP KC Series User Manual

1
© 2016 Emerson Climate Technologies, Inc.
AE4-1303 R15
7 to 15 Ton ZR*KC and ZP*KC Copeland Scroll
™
Compressors
AE4-1303 R15
June 2016
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
Nomenclature .............................................................. 4
Application Considerations
Operating Envelope ....................................................4
Internal Pressure Relief (IPR) Valve ...........................4
Advanced Scroll Temperature Protection ....................5
Discharge Line Thermostat .........................................5
High Pressure Control .................................................5
Low Pressure Control .................................................5
Shut Down Device ......................................................5
Discharge Check Valve ...............................................5
 DischargeMufers ......................................................5
Compressor Cycling .................................................... 6
Piping Length & High Refrigerant Charge ...................6
Suction & Discharge Line Noise & Vibration ...............6
Suction & Discharge Fittings .......................................7
System Tubing Stress .................................................7
Accumulators ..............................................................7
Crankcase Heat ..........................................................7
Pump Down Cycle ......................................................8
Reversing Valves ........................................................8
System Screens & Strainers .......................................8
Contaminant Control ...................................................8
Oil Type & Removal ....................................................9
Three Phase Electrical Phasing .................................. 9
Power Factor Correction ............................................10
Deep Vacuum Operation ............................................ 10
Manifolded Compressors ...........................................10
Manifolded Applications .............................................10
Motor Protection .........................................................11
Application Tests
Application Test Summary .........................................11
Continuous Floodback Test ........................................ 12
Field Application Test .................................................12
Assembly Line Procedures
Compressor Handling ............................................... 12
Mounting ................................................................... 13
Suction & Discharge Fittings ..................................... 13
Assembly Line Brazing Procedure ............................ 13
Unbrazing System Components ............................... 13
Pressure Testing ....................................................... 13
Assembly Line System Charging Procedures ........... 14
Electrical Connections .............................................. 14
Hipot Testing ............................................................. 14
Tandem Assembly ..................................................... 14
Service Procedures
Field Replacement .................................................... 15
Mounting ................................................................. 15
Removing Oil .......................................................... 15
Electrical ................................................................. 15
Module .................................................................... 15
Compressor Replacement after a Motor Burn .......... 16
Manifolded Compressor Replacement ...................... 16
Start-Up of a New or Replacement Compressor ...... 16
Field Troubleshooting the Kriwan Module ................. 16
Field Troubleshooting the CoreSense
Communications Module ........................................ 17
Scroll Functional Check ............................................ 17
 RefrigerantRetrots .................................................. 18
Figures & Tables
How a Scroll Works.. ................................................. 19
Scroll Operating Envelopes ...................................... 20
Compressor Terminal Box Wiring ............................. 21
ASTP Label ............................................................... 22
Crankcase Heater Location ...................................... 23
Scroll Suction Tube Brazing ...................................... 24
Field Application Test ................................................ 25
 DesignCongurations ............................................... 25
Compressor Accessories & Service Parts ................ 26
Refrigerant Charge Limits... ...................................... 27
Torque Values ........................................................... 27
 ProtectorSpecications ............................................ 28
CoreSense LED Flash Code Information ................28-29
Tandem Oil Balancing ............................................... 30
Tilted Tandem ............................................................ 30
APPENDIX
 KriwantoCoreSenseRetrotInstructions ................ 31
TABLE OF CONTENTS
Section Page Section Page

Emerson Copeland Scroll ZP KC Series Specifications

General

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

Summary

Safety Information and Warnings

Safety Instructions

General safety guidelines and warnings for using the compressor.

Safety Icon Explanation

Explanation of safety symbols used in the document for hazard identification.

Risk of Electrical Shock, Fire, or Injury

Specific instructions for mitigating risks of electrical shock, fire, or personal injury.

General Safety Statements

Application Considerations

Operating Envelope

Defines the safe operating limits for temperature and pressure for compressor performance.

Advanced Scroll Temperature Protection (ASTP)

Describes the ASTP feature that protects the compressor from overheating by stopping pumping.

High Pressure Control

Requirements and settings for high-pressure cut-out controls for system protection.

Low Pressure Control

Recommendations and settings for low-pressure cut-out controls for fault condition protection.

Crankcase Heat

Discusses the requirement and installation of crankcase heaters for cold weather operation.

Oil Type & Removal

Three Phase Electrical Phasing

Proper electrical phasing for three-phase compressors to ensure correct rotational direction.

Deep Vacuum Operation

Motor Protection

Details on internal and external motor protection systems like TF and TW/TE codes.

Service Procedures

Field Replacement

Compressor Replacement after Motor Burn

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

Manifolded Compressor Replacement

Start-up of New or Replacement Compressor

Steps for correctly charging and starting new or replacement compressors to prevent damage.

Field Trouble Shooting the Kriwan Module

Field Troubleshooting CoreSense Communications Module

Copeland Scroll Compressor Functional Check