Copeland ZB15, ZB19, ZF09, ZS21, ZB21 Replacement Guidelines

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Scroll Compressors
Replacement Guidelines
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1 Compressor Replacement...................................................................................................... 2
2 Scroll Compressor Replacement Procedure.........................................................................2
3 System Evacuation and Charging Procedure ....................................................................... 7
4 Performance / Visual Checks..................................................................................................7
R404A Application Envelopes................................ ....................................................................................... ....8
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1 Compressor Replacement
The following is intended to assist the service engineer to ensure the correct method for fitting of a new scroll compressor where replacement is necessary. In the event that a compressor ne eds replacement it is vital to diagnose and rectify the system fault which caused the problem in order to avoid the need for further replacements. It is important to ensure that when a scroll compressor replacement is required, certain procedures are carried out in the same manner as when first built and installed by the original manufacturer.
The main areas to note are correct torque values for service valves and the use of correct rubber mounts for the application. For ease and clarity the following procedure has been provided as a pictorial sequence (Our
thanks to Space Engineering Ltd, in the UK who provided the photo sequence).
In the case of a motor burn, the majority of contaminated oil will be removed with the compressor. The rest of the oil is cleaned through the use of suction and liquid line filter driers. A 100% activated alumina suction filter drier is recommended but must be removed after 72 hours. It is highly recommended that the suction accumulator be replaced if the system contains one. This is because the accumulator oil return orifice or screen may be plugged with debris or may become plugged shortly after a compressor failure. This will result in starvation of oil to the replacement compressor and a second failure.
2 Scroll Compressor Replacement Procedure
1
Begin by removing any waste or rubbish from the
2
… clean away any dirt or debris.
3
Remove all valve caps…
plant housin g …
4
… inspect for cracks or damage…
5
… and store saf el y.
6
Select compressor, fit service gauges, check pressures.
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7
Isolate the oil supply to the faulty compressor.
10
Fully 'front seat' the discharge and suction valves, isolate the compressor from the system.
8
Electrically isolate the compressor (3 phase
9
… and the supply to the crankcase heater).
supply…
11
Recover the compressor’s
12
Release the suction… contained refrigerant to a reclaim container.
13
… and discharge Rotalock nuts and oil management.
14
Remove compressor bolts…
15
… and discard the existing
rubber mounts and sleeves.
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16
Fit replacement hard rubber mounts to new compressor. Kit Part Number 8030450
17
… ensuring correct placement of washers and metal sleeve.
22
Apply thread lock paste to compressor discharge and suction connections.
23
Refit Rotalock nuts and using the correct valve retaining tool…
18
Refit mounting bolts and
tighten to correct torque
(see table). 2 mm gap
between bolt & rubber.
24
… tighten to correct torque
(see table). Ensure valve
position does not stress the
pipe work.
25
Remove oil sight glass and assemble oil management. Evacuate the compressor using vacuum pump.
26
Open the oil supply to the compressor.
27
'Back seat' the discharge
and suction ser v i ce valves
to remove service gauges.
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28
Leak test the Rot alock fittings.
29
Refit all valve caps.
30
31 32 Correct tools (L to R) 33
Clear and correctly dispose of all waste .
Valve retaining bar Discharge torque spanner Suction torque spanner ½” drive torque wrench
Restore the electrical power
supplies.
All Done!
(Return in 7 days to check
torque settings)
Torque Settings
Application Torque Nm
Compressor Mounting Bolt M8 12-14 Rotolock 3/4" - 16UNF 40-50 Rotolock 1" - 14UNF 70-80 Rotolock 1 1/4" - 12UNF 120-135 Rotolock 1 3/4" - 12UNF 135-160 Rotolock 2 1/4" - 12UNF 165-190 Sight glass 25
Copeland Replacement Part No’s
Description Part No.
Hard Mounts and Ferrules 8030450 PTFE Suction Gasket 2495939 PTFE Discharge Gasket 2495928 PTFE DTC Injection Gasket 8536083 DTC Injector Complete 8530541
NOTE: New PTFE gaskets are supplied and fitted to new compressors.
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The above sc roll compress or replacement procedure sho ws replacement typically for ZB medium temperature application. For replacement of Copeland ZF Scroll typically low temperature application the same procedure can be used but for one exception. The ZF scroll has a DTC valve fitted or for older models possibly capillary injection.
IMPORTANT: Liquid line feed to the compressor injection port has to be isolated and compressor evacuated before attempting to remove the injector.
Assembly Procedure
1 Verify Coil Spring is seated in the “Groove” located in the well on top of the compressor. 2 Thread the Discharge Temperature (DTC) valve onto the injection stub on the side of the compressor. Torque setting 24-27N/M (216-240 in/Lbs) 3 Press the DTC bulb into the well on top of the compressor until the DTC bottoms out in the well. 4 Snap the Thermo. cap onto the DTC bulb on top of the compressor. 5 The copper tube from the DTC bulb should be approximately 0.125mm (1/8”) from the top of the compressor.
Compressor Mounts
New compressor mounts are recommended when a compressor is replaced. When purchasing a replacement scroll compressor soft mounts are included. These soft mounts should not be used for multiple compressor pack / rack application.
Scroll compressors used in pack / rack design must use harder mounts which allow more load to be transmitted via the feet. This will give flexibility and minimise the risk of resonance to connecting pipe work.
Hard Rubber Mount Set Part Number 8030450 Steel Mount Set Part Number 8522911
Approved Oils
Copeland only approves the use of the following polyolester lubricants: Mobil Arctic EAL 22CC or Emkarate RL32-3MAF. Either oil can be used for top up and are suitable for use with both HCFC and HFC systems.
Service Refill Quantity
Model Name HP
Oil charge
supplied [l]
Oil charge Service [l]
ZB15 2 1,0 1,0 ZB19 2,5 1,0 1,0 ZF09 ZS21 ZB21 3 1,24 1,12 ZF11 ZS26 ZB26 3,5 1,24 1,12 ZF13 ZS30 ZB30 4 1,95 1,83 ZF15 ZS38 ZB38 5 1,95 1,83 ZF18 ZS45 ZB45 6 1,77 1,66 ZF24 ZS56 ZB56 7,5 4,14 4,05 ZF33 ZS75 ZB75 10 4,14 4,05 ZF40 ZS92 ZB92 13 4,14 4,05 ZF48 ZS11M ZB11M 15 4,14 4,05
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Lubricant Handling
Polyolester lubricant products should pose little or no significant adverse health effects when properly used or handled properly. Prolonged repeated skin contact should always be avoided. The lubricant supplier should be contacted for specific health and safety documentation.
3 System Evacuation and Charging Procedure
Evacuating the system only on the suction side of a scroll compressor can occasionally result in a temporary no­start condition for the compressor. The reason for this is that the floating seal c ould axially seal with the scroll set, with the higher pressure on the floating seal. Consequently, until the pressures equalize, the floating seal and scroll set can be held tightly together.
The installation should be evacuated down to 0.3 mbar / 0.22 Torr or lower. Subsequently, the factory holding charge of dry air in the compressor is released to the ambient. The shutoff valves are opened and the installation, including the compressor, are once more evacuated as described after the system has been recharged with dry nitrogen.
Highest demands are placed on the leak proof design of the installation and also on the leak testing methods (please refer to EN378).
Rapid charging on the suction side of scroll compressors can occasionally result in a temporary no-start condition for the compressor. The reason for this is that if the flanks of the spirals happen to be in a sealed position, rapid pressurization of the low side without opposing high s ide pressure can cause the spirals to seal axially. Consequently, until the pressures eventually equalize, the spirals can be held tightly together, preventing rotation. The best way to avoid this situation is to charge on both the high and low side simultaneously at a rate which does not result in axial loading of the spirals.
Qualified Refrigerants
R404A, R507, R22 and R134a are qualified for all refrigeration scroll compressors. The ZB compressor family is also qualified for R407C. It is essential that the glide of R407C refrigerant blends be given careful consideration when adjusting p ressure
controls.
4 Performance / Visual Checks
When having to replace a compressor installed in a pack design it is worthwhile to visually check the condition of the remaining compressors, the rubber mounts and associated pipe work.
Check the gauge pressure readings.
Is the pack operating correctly?
Is the operation within the manufacturer’s specification? (Check with the application envelope shown on
the following pages).
Ensure the low pressure switch is set correctly if system pump down is applied. If the setting is too low the compressor might be operating outside its operating envelope.
Compressor mounts
Check to see that all mounts are secure and not damaged.
Are the correct hard mounts fitted?
Lubrication
Check that the regulator oil levels are correct including oil reservoir.
Check the oil is still in an acceptable condition i.e. check for dirt and acidic content.
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Electrical
Check all electrical connections for tightness.
Check contactors for spring tension and contactor wear. If connectors are pitted, replace, DO NOT
FILE.
Check overload functioning correctly.
Check the compressor run current values.
Check operation of crankcase heater, if fitted.
R404A Application Envelopes
ZF09K4E to ZF18K4E
Tc °C
Te °C
Tc °C
ZB15KC to ZB45KC
Te °C
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Benelux
Deltakade 7 NL-5928 PX Venlo Tel. +31 (0) 77 324 0234 Fax +31 (0) 77 324 0235
UK & Ireland
17 Theale Lakes Business Parc
GB-Theale, Nr Reading-Berkshire RG7 4GB Tel. +44 (0)1189 83 8000 Fax +44 (0)1189 83 8001
Asia/Pacific
10/F, Pioneer Building, 213 Wai Yip Street, Kwun Tong, Kowloon - Hong Kong Tel. +852 28 66 31 08 Fax +852 25 20 62 27
Deutschland/Österreich & Schweiz
Senefelder Straße 3 D-63477 Maintal Tel. +49 (0)6109 6059 0 Fax +49 (0)6109 6059 40
France/Greece & Maghreb
8, Allee Du Moulin Berger F-69130 Ecully Tel. +33 (0)4 78668570 Fax +33 (0)4 78668571
Italia
Via Ramazzotti, 26 I-21047 Saronno (va) Tel. +39 02 961781 Fax +39 02 96178888
España & Portugal
Diputacion, 238 AT.8 E-08007 Barcelona Tel. +34 93 4123752 Fax +34 93 4124215
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Sweden/Denmark/Norway & Finland
Pascalstr. 65 D-52076 Aachen Tel. +49 (0) 2408 929 127 Fax +49 (0) 2408 929 528
Eastern Europe, Turkey & Iran
Pascalstr. 65 D-52076 Aachen Tel. +49 (0) 2408 929 0 Fax +49 (0) 2408 929 525
Poland
11A, Konstruktorska PL-02-673 Warszawa Tel. +48 22 458 9205 Fax +48 22 458 9255
Russia & CIS
Letnikovskaya, 10, building 2, 5th floor RUS-113114 Moscow Tel. +7 495 981 9811 Fax +7 495 981 9816
Latin America
7975 North West 154Th Street - Suite 300 Miami Lakes, FL, 33016 - USA Tel. +1 305 818 8880 Fax +1 305 818 8888
Middle East & Africa
PO BOX 26382, R/A 8, FD-2 Jebel Ali, Dubai - UAE Tel. +9714 883 2828 Fax +9714 883 2848
Emerson Climate Technologies - European Headquarters - Pascalstrasse 65 - 52076 Aachen, Germany Phone: +49 (0) 2408 929 0 - Fax: +49 (0) 2408 929 570 - Internet: www.eCopeland.com
The Emerson Climate Technologies logo is a trademark and service mark of Emerson Electric Co. Copeland Corporation is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Copeland Corporation. All other trademarks are property of their respective owners. Information contained in this brochure is subject to change without notification.
© 2006 Copeland
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