Emerson Copeland Scroll ZR KA 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
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Emerson Copeland Scroll ZR KA Series Specifications

General

Manufacturer	Emerson Copeland
Frequency	50/60 Hz
Type	Scroll
Refrigerant	R-22
Voltage	208-230/460V
Efficiency	High
Displacement (cu. in./rev)	Varies by model (Consult specific model datasheet)
Cooling Method	Air Cooled
Displacement	Varies by model (Consult specific model datasheet)
Power Input	Varies by model (Consult specific model datasheet)
Sound Level	Varies by model (Consult specific model datasheet)
Weight	Varies by model (Consult specific model datasheet)