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Emerson Copeland Scroll ZR KC Series User Manual

Emerson Copeland Scroll ZR KC Series
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© 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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Table of Contents

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Emerson Copeland Scroll ZR KC Series Specifications

General IconGeneral
BrandEmerson
ModelCopeland Scroll ZR KC Series
CategoryAir Compressor
LanguageEnglish

Summary

Safety Instructions and Overview

Safety Icon Explanation

Explains the meaning of various safety warning icons used in the document.

Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

Details critical safety instructions for electrical, pressurized systems, and burn hazards.

Safety Statements

General safety statements regarding product usage, personnel qualifications, and standards compliance.

Introduction to Copeland Scroll Compressors

Nomenclature

Explains the breakdown and meaning of compressor model numbers.

Application Considerations Overview

Introduces general guidelines for system design using these compressors.

Operating Envelope

Defines the acceptable operating pressure and temperature limits for the compressors.

Internal Pressure Relief (IPR) Valve

Notes the absence of internal relief valves and the requirement for high-pressure controls.

Application Considerations: Features and Controls

Advanced Scroll Temperature Protection (ASTP)

Describes the ASTP feature for compressor protection against discharge overheating.

High Pressure Control

Specifies the requirement and settings for high-pressure cut-out controls.

Low Pressure Control

Recommends low-pressure cut-out for system fault protection and operational limits.

Discharge Mufflers

Discusses the use and placement of discharge mufflers for noise reduction.

Application Considerations: System Dynamics and Noise

Compressor Cycling

Addresses minimum run time requirements to prevent oil loss and compressor damage.

Long Pipe Lengths / High Refrigerant Charge

Provides guidance on adding lubricant for systems with high refrigerant charges.

Suction & Discharge Line Noise and Vibration

Explains scroll compressor sound characteristics and vibration mitigation.

Application Considerations: System Components

Accumulators

Details the use of accumulators for liquid refrigerant management in specific applications.

Crankcase Heat

Specifies crankcase heater requirements based on system charge and importance for start-up.

Suction and Discharge Fittings

Describes the copper-plated steel fittings and brazing considerations.

Application Considerations: System Operation

Pump Down Cycle

Discourages pump down cycles for scroll compressors due to potential oil issues.

Reversing Valves

Discusses reversing valve sizing, defrost cycles, and potential noise mitigation.

Contaminant Control

Emphasizes system cleanliness, moisture levels, and the use of filter-driers.

Oil, Electrical, and Vacuum Handling

Oil Type & Removal

Details recommended oil types for different refrigerants and procedures for oil removal.

Three Phase Scroll Compressor Electrical Phasing

Highlights the importance of correct electrical phasing for compressor rotation and operation.

Deep Vacuum Operation Warning

Warns against using compressors for system evacuation due to potential damage.

Manifolded Systems and Testing Introduction

Manifolded Compressors

Covers the availability and design of tandem and trio compressor assemblies.

Manifolded Applications

Discusses oil balancing and testing requirements for manifolded compressor systems.

Application Test Summary

Outlines essential system tests for design validation and identifying potential issues.

Application Testing Procedures

Continuous Floodback Test

Details the procedure for testing continuous liquid refrigerant floodback.

Field Application Test

Describes testing for liquid refrigerant migration during system off-cycles.

Assembly Line Procedures: Handling and Joining

Compressor Handling

Provides safety instructions and procedures for lifting and moving compressors.

Mounting

Describes compressor mounting methods and adapters for different applications.

Assembly Line Brazing Procedure

Outlines recommended brazing materials and techniques for assembly.

Pressure Testing

Specifies pressure testing limits and precautions for the compressors.

Assembly Line Procedures: System Connections

Assembly Line System Charging Procedure

Details best practices for charging systems with refrigerant during assembly.

Electrical Connections

Covers wiring procedures, torque values, and sealing terminal boxes.

Tandem Assembly

Describes the initial steps for assembling tandem compressor units.

Service Procedures: Component Replacement

Removing Oil

Explains methods for draining oil from the compressor.

Electrical Component Replacement

Advises on replacing contactors and motor protection modules.

Field Replacement Mounting

Details how to adapt new compressors to existing mounting dimensions.

Service Procedures: Troubleshooting and Start-up

Compressor Replacement after Motor Burn

Describes cleanup procedures and filter drier recommendations after a motor failure.

Start-up of a New or Replacement Compressor

Provides critical instructions for initial system start-up and operation.

Field Trouble Shooting the Kriwan Module

Offers steps for diagnosing issues with the Kriwan motor protection module.

Troubleshooting and Functional Checks

Field Troubleshooting CoreSense Communications Module

Guides troubleshooting of CoreSense module status and error codes.

Copeland Scroll Compressor Functional Check

Outlines a diagnostic procedure to verify compressor operational health.

Refrigerant Retrofit Guidelines

Refrigerant Retrofits

Provides considerations and requirements for retrofitting systems with new refrigerants.

Understanding Scroll Compressor Operation

How a Scroll Works

Explains the fundamental compression mechanism of a scroll compressor.

Visual Aids: Operating Envelopes and Wiring

Scroll Operating Envelopes

Presents graphical representations of compressor operating limits for different refrigerants.

Compressor Terminal Box Wiring

Illustrates the terminal box layout and wiring for CoreSense protection.

Visual Aids: Component Identification

ASTP Label Identification

Shows the location and appearance of the Advanced Scroll Temperature Protection label.

Crankcase Heater Location

Illustrates the correct placement for installing crankcase heaters on compressors.

Installation Procedures: Brazing and Disconnect

New Installations Brazing

Details brazing procedures for new installations, including materials and techniques.

Field Service Disconnect

Explains the process for safely disconnecting and reconnecting system components.

System Specifications and Data Tables

Table 2 Field Application Test Parameters

Lists the specific parameters for conducting field application tests.

Table 3 Design Configurations

Presents recommended and alternate system design configurations.

Compressor Data and Limits

Table 5 Refrigerant Charge Limits

Provides maximum refrigerant charge limits for various compressor models.

Table 6 Torque Values

Lists recommended torque values for specific fittings and connections.

Protector Specifications and CoreSense Troubleshooting

Table 7 - Protector Specifications

Details specifications for different motor protector modules.

Table 8 - CoreSense Communications LED Codes

Explains CoreSense LED flash codes for status and fault conditions.

CoreSense LED Fault Code Details

CoreSense Alert/Lockout LED Flash Codes

Continues the detailed description of CoreSense LED fault codes and troubleshooting.

Tandem System Visuals

Figure 9 Tandem Oil Balancing

Illustrates oil equalization line and two-phase tandem line configurations.

Figure 10 Tilted Tandem

Shows the tilting procedure for installing oil equalization lines.

Appendix: Retrofit Instructions

Replacing Kriwan Module with CoreSense Communications

Provides step-by-step instructions for retrofitting Kriwan modules to CoreSense.

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