Emerson AE4-1317 User Manual

TABLE OF CONTENTS

Safety .............................. Error! Bookmark not defined.

Safety Instructions ....................................................... 3

Safety Icon Explanation

............................................. 3

Instructions Pertaining to Risk of Electrical Shock, Fire,

or Injury to Persons ...................................................... 4

Safety Statements ........................................................ 4

1. Introduction ................................................ 5

2. Nomenclature ............................................. 5

3. Operating Envelope ................................... 5

4. Use of R-513A Refrigerant ........................ 5

5. Accumulators ............................................. 5

6. Crankcase Heaters ..................................... 5

7. Discharge Line Thermostat ....................... 6

8. Pressure Controls ...................................... 6

9. Pump Down Recommendations ............... 6

10. IPR Valve ..................................................... 6

11. Internal Temperature Protection .............. 7

12. Motor Protection ........................................ 7

13. Oil Types ..................................................... 7

14. Oil Charges ................................................. 7

15. Oil Management for Rack Applications ... 7

16. Compressor Tubing and Mounting .......... 8

16.1. Mounting for Rack Systems ......................... 8

16.2. Condensing Unit Mounting ........................... 8

16.3. Tubing Considerations ................................. 8

17. Starting Characteristics ............................. 8

18. Fusite ........................................................... 8

19. Shell Temperature ...................................... 8

20. Connection Fittings .................................... 8

21. Three-Phase Rotation Direction ................ 8

22. Brief Power Interruptions .......................... 9

23. Deep Vacuum Operation ............................ 9

24. Unbrazing System Components ............... 9

25. High Potential (Hipot) Testing ................... 9

26. Copeland Scroll Functional Check ........... 9

27. New Installation ........................................ 10

28. Field Service ............................................. 10

28.1. To disconnect: ............................................ 10

28.1.1. To reconnect: .............................................. 10

29. General Guidelines and More Information 10

30. Oil Sight Glass Designs ........................... 13

30.1. Oil Sight Glass Design Change for 1.5 to 9 HP

Copeland Scroll™ Refrigeration Compressors .......... 13

30.2. Available Spare Parts Kit for Sightglass

Replacement: ............................................................. 14

31. OMB ........................................................... 14

TABLE OF FIGURES

Figure 1 - Scroll Tube Brazing ................................... 10

Figure 2 - ZB10KCE through ZB57KCE Application

Envelope for R-404A/R-507 (1.3 - 7.5 HP) ................ 11

Figure 3 - ZB10KCE through ZB57KCE Application Envelope for R-407A/R-407C/R-448A/R-449A (1.3 - 7.5

HP) ............................................................................. 11

Figure 4 - ZB10KCE through ZB57KCE Application

Envelope for R-407F (1.3 - 7.5 HP) ........................... 12

Figure 5 - ZB15KCE trough 57KCE Application

Envelope for 134a (2-7.5HP) ..................................... 12

Figure 6 - Sight glass design until November 30th, 2014

(14K and earlier) ........................................................ 13

Figure 7 – Sight glass design as of December 1st, 2014

(14K and after) ........................................................... 13

Figure 8 - Available OMB adapter Kit ........................ 14

Figure 9 - OMB Design until November 30th, 2014 (14K

and earlier) ................................................................. 14

Figure 10 - OMB Design as of December 1st, 2014 and

after (14K and after) ................................................... 14

Figure 11 - ZB10KC* through ZB57KC* (1.3-7.5 HP)

Refrigeration Scroll Rack Mounting ............................ 15

Figure 12 - ZB10KC* through ZB57KC* (1.3-7.5 HP)

Refrigeration Scroll Condensing Unit Mounting ......... 15

Figure 13 - Typical Suction Tubing ............................. 16

Figure 14 - Motor Terminal (Fusite) Connections for

Single Phase and Three Phase Scrolls ...................... 16

Figure 15 - Control Circuit Wiring Diagram ................ 17

AE4-1317 R14

July 2020

Application Guidelines for ZB*KC / ZB*KCE Refrigeration

Copeland Scroll™ Compressors ZB10KC* through ZB57KC* (1.3 to 7.5 HP)

AE4-1317 R14

TABLES

Table 1 - Compressor Models and Approved

Refrigerants/Lubricants .............................................. 18

Table 2 - Charge Limitations ...................................... 18

Table 3 - Crankcase Heater ....................................... 19

Table 4 - Conduit Ready Heater Terminal Box Kits ... 19

Table 5 - Discharge Thermostat Line Kits ................. 19

Table 6 - Pressure Control Settings ........................... 20

Table 7 - Check-Valve Type ....................................... 20

Table 8 - Recommended Oil Charges by Model Family

.................................................................................... 21

Revision Tracking R14

Pg. 5 – Warning of using R-513A Pg. 9 – Updated R-134a Envelope to Include R-513A Pg. 18 – Added R-513A to list of approved refrigerants Pg. 20 – Added R-513A to list of pressure cut-outs

Revision Tracking R13

Pg. 6 – DLT position and general guideline Text updated. Pg. 7 – References to OMB updated to OMB/C in Section 16 Pg. 13 – Title of Figures 6 and 7 were updated. Pg. 17 – Title of Figures 15 was updated

Revision Tracking R12

Pg. 1 – ZB10KC* through ZB57KC designation applied on the Bulletin title and rest of the bulletin.

AE4-1317 R14

Safety Instructions

Copeland Scroll™ compressors are manufactured according to the latest U.S. and European Safety Standards.

Particular emphasis has been placed on the user's safety. Safety icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 4. These instructions should be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety instructions.

Safety Icon Explanation

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.

FLAMMABLE, Fire hazard! Sparking in a potentially explosive atmosphere! Explosion hazard!

WARNING

CAUTION

NOTICE

DANGER

CAUTION

AE4-1317 R14

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

ELECTRICAL SHOCK HAZARD

• Disconnect and lock out power before servicing.

• Discharge all capacitors before servicing.

• Use compressor with grounded system only.

• Molded electrical plug must be used when required.

• Refer to original equipment wiring diagrams.

• Electrical connections must be made by qualified electrical personnel.

• Failure to follow these warnings could result in serious personal injury.

PRESSURIZED SYSTEM HAZARD

• System contains refrigerant and oil under pressure.

• Remove refrigerant from both the high and low compressor side before

removing compressor.

• Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system.

• Use only approved refrigerants and refrigeration oils.

• Personal safety equipment must be used.

•

Failure to follow these warnings could result in serious personal injury.

BURN HAZARD

• Do not touch the compressor until it has cooled down.

• Ensure that materials and wiring do not touch high temperature areas of the

compressor.

• Use caution when brazing system components.

• Personal safety equipment must be used.

•

Failure to follow these warnings could result in serious personal injury or

property damage.

COMPRESSOR HANDLING

• Use the appropriate lifting devices to move compressors.

• Personal safety equipment must be used.

•

Failure to follow these warnings could result in personal injury or property

damage.

Safety Statements

• Refrigerant compressors must be employed only for their intended use.

• Only qualified and authorized HVAC or refrigeration personnel are permitted to install commission and

maintain this equipment.

• Electrical connections must be made by qualified electrical personnel.

• All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment

must be observed.

CAUTION

WARNING

AE4-1317 R14

1. Introduction

The ZB*KC/ZB*KCE Copeland Scroll™ compressor represents the latest generation of compliant scroll technology for the refrigeration industry.

2. Nomenclature

The refrigeration scroll model numbers include the nominal capacity at standard 60HZ ARI rating conditions for medium temperature (20/120°F). For additional information on this product, please refer to the Online Product Information at Emerson.com/OPI

3. Operating Envelope

The ZB*KC/ZB*KCE refrigeration scroll compressor models can be used with a variety of refrigerants depending on the model selected and the lubricant used. (See Table 1 at the end of this bulletin.)

The ZB*KC and ZB*KCE models are intended for medium temperature refrigeration type duty. The approved operating envelopes for these models are such that they are ideally suited for applications such as ice machines, bulk milk and FCB/FUB. The models and operating envelopes are depicted in Figure 2, Figure 3,

Figure 4 and Figure 5 at the end of this bulletin.

4. Use of R-513A Refrigerant

Note: Refrigerant migration of R-513A into the compressor crankcase could cause low oil viscosity which could lead to compressor damage.

• When using R-513A it is critical to meet the following requirements

• Maintain adequate superheat settings with a minimum superheat of 20°F at the compressor

• No liquid refrigerant migration into the compressor at any time, especially during standstill or during or after defrost

• Pump down recommended.

• The use of a crankcase heater is

recommended.

• Retrofit R-513A is only allowed for compressors which are approved for these refrigerants

5. Accumulators

Due to the scrolls’ inherent ability to handle liquid

refrigerant in flooded start and defrost cycle operation conditions, accumulators may not be required. An accumulator is required on single compressor systems when the charge limitations exceed those values listed

in Table 2. On systems with defrost schemes or transient operations that allow prolonged uncontrolled liquid return to the compressor, an accumulator is required unless a suction header of sufficient volume to prevent liquid migration to the compressor is used.

Excessive liquid flood back or repeated flooded starts will dilute the oil in the compressor causing inadequate lubrication and bearing wear. Proper system design will minimize liquid flood back, thereby ensuring maximum compressor life.

In order to assure that liquid refrigerant does not return to the compressor during the running cycle, attention must be given to maintaining proper superheat at the compressor suction inlet. Emerson recommends a minimum of 20°F (11°C) superheat, measured on the suction line 6 inches (152mm) from the suction valve, to prevent liquid refrigerant floodback.

Another method to determine if liquid refrigerant is returning to the compressor is to accurately measure the temperature difference between the compressor oil crankcase and the suction line. During continuous operation we recommend that this difference be a

minimum of 50°F (27°C). This “crankcase differential temperature” requirement supersedes the minimum

suction superheat requirement in the last paragraph. To measure oil temperature through the compressor shell, place a thermocouple on the bottom center (not the side) of the compressor shell and insulate from the ambient.

During rapid system changes, such as defrost or ice harvest cycles, this temperature difference may drop rapidly for a short period of time. When the crankcase temperature difference falls below the recommended 50°F (27°C), our recommendation is the duration should not exceed a maximum (continuous) time period of two minutes and should not go lower than a 25°F (14°C) difference.

Contact your Emerson Climate Technologies representative regarding any exceptions to the above requirements.

6. Crankcase Heaters

• Single-phase No crankcase heaters are required on single-phase

scroll compressors.

• Three-phase - outdoor only Crankcase heaters are required on three phase

compressors where the system charge exceeds 10 lbs.

WARNING

AE4-1317 R14

The listed crankcase heaters are intended for use only when there is limited access (See Table 3). The heaters are not equipped for use with electrical conduit. Where applicable, electrical safety codes require lead protection, a crankcase heater terminal box should be used. Recommended crankcase heater terminal box and cover kit numbers are listed in Table 4. If there are any questions concerning their application, contact to Emerson, Application Engineering department.

7. Discharge Line Thermostat

Figure 2, Figure 3, Figure 4 and Figure 5 how

saturated suction temperature, maximum condensing temperature, maximum return gas temperature, and maximum discharge line temperature. Operation beyond these limits can cause high compression ratios or excessive internal compressor temperatures. This will result in overheating the scroll members, causing excessive wear resulting in premature compressor failure.

If the system is designed where operation within these guidelines cannot be guaranteed, then a discharge line thermostat is required in the compressor control circuit.

When installed approximately 6-7 inches from the discharge tube outlet, depending on tubing configuration. The thermostats have a cut-out setting that will ensure the external discharge line temperature does not exceed the 260°F limit. If a Rotalock service valve is installed on the discharge port connection, the thermostat should be located approximately 5-6 inches from the valve braze connection.

Kits have been set up to include the thermostat, retainer, and installation instructions. These thermostats must be

used with ½” O.D. discharge lines to ensure proper

thermal transfer and temperature control. They work with either 120 or 240-volt control circuits and are available with or without an alarm circuit capability. See Table 5 for a list of discharge line thermostat kit numbers.

8. Pressure Controls

Both high and low-pressure controls are required on the following models, (1.3-2 HP) ZB10-14KCE. Only lowpressure controls are required on the following models, (2-7.5 HP) ZB15-57KC/E. See Table 6 for set points.

Application Note: There are exceptions to the pressure settings listed in Table 6. Certain OEMs are approved for LPC settings below our standard recommendations.

9. Pump Down Recommendations

Table 7 identifies the “ZB” models that incorporate the

low-leak check valve suitable for pump-down

applications. The standard disc is not intended for use with a pump down.

Typically, the compressors that use the low-leak discharge check valve are suitable for pump down applications. This valve prevents system pressures from equalizing and pump down can be achieved. However, during laboratory testing, we have observed a potential short cycling condition on the ZB15 through ZB29 models. This phenomenon can be attributed to several factors:

1. Location of low-pressure control sensor. If it is located right at the suction inlet of the compressor, it will be more sensitive to pressure spikes.

2. Actual low-pressure setting. Refer to our recommended setting in Table 6. If the differential pressure setting is too close, this will increase the possibility of short cycling.

3. Type of Low-pressure control can have an effect on cycling. The encapsulated non-adjustable type is more susceptible to causing excessive cycling due to tolerances.

4. If short cycling cannot be avoided, using a 3-minute time delay will limit the cycling of the compressor to an acceptable level.

The ZB10 through ZB14 models will require the following recommendations for pump down applications:

5. Install an external check-valve in the discharge line to prevent back-flow from the high side to low side. Install check-valve as close to the compressor discharge fitting as possible to minimize discharge gas volume.

6. Set low pressure to recommended settings in Table

7. Since these models are single-phase only, add a time delay relay to prevent reverse rotation. Refer to Brief Power Interruptions section of this bulletin for additional information.

10. IPR Valve

Refrigeration scroll compressors (2-7.5 HP) ZB1557KC/E have internal pressure relief valves, which open at a discharge to suction differential pressure of 375 to 450 psi. This action will trip the motor protector and remove the motor from the line. The ZB10-14KCE models DO require a high pressure control in addition to

NOTICE

AE4-1317 R14

a low pressure control, since these models do not have an IPR valve.

11. Internal Temperature Protection

Refrigeration Scroll compressors (1.3-7.5 HP) ZB1057KC/E incorporate a Thermo-disc which is a temperature-sensitive snap disc device located at the scroll discharge port. It is designed to open and route hot discharge gas back to the motor protector thus removing the compressor from the line.

12. Motor Protection

Conventional inherent internal line break motor protection is provided.

13. Oil Types

Polyol ester lubricants must be provided if the scroll compressor is to be used with HFC refrigerants. ZBKC compressors that are to be used with R22 should be supplied with mineral oil. See Form 93-11 for a complete list of all Emerson approved lubricants.

POE may cause an allergic skin reaction and must be handled carefully and the proper protective equipment (gloves, eye protection, etc.) must be used when handling POE lubricant. POE must not come into contact with any surface or material that might be harmed by POE, including without limitation, certain polymers (e.g. PVC/ CPVC and polycarbonate). Refer to the Safety Data Sheet (SDS) for further details.

14. Oil Charges

The recommended oil charges for these compressors are shown in Table 8.

15. Oil Management for Rack Applications

Copeland Scroll refrigeration compressors may be used on multiple compressor parallel rack applications. This requires the use of an oil management system to maintain proper oil level in each compressor crankcase. The sight glass connection supplied can accommodate the mounting of the oil control devices.

Unlike semi-hermetic compressors, scroll compressors do not have an oil pump with accompanying oil pressure safety controls. Therefore, an external oil level control is required.

The Emerson OMB/C Oil Level Management Control combines the functions of level control and timed compressor shut-off should the level not come back to normal within a set period of time. This device has been

found to provide excellent performance in field tests on Copeland Scroll compressors and is recommended for parallel system applications.

For Technical details about OMB/C Oil Level Management Control follow these links or scan their QR code:

- OMB/C Instruction Sheet

https://climate.emerson.com/documents/ombc--pa-00388-en-4858298.pdf

- OMB/C & OLC Adapter Kits Installation

Instructions Sheet

https://climate.emerson.com/documents/ombadapter-instructions-en-4924792.pdf

See Table 8 order to select appropiate Adapter Kit.

Note: Emerson Climate Technologies' Application Engineering Department should be contacted for approved oil management systems.

Immediately after system start-up the oil reservoir level will fluctuate until equilibrium is reached. It is advisable to monitor the oil level during this time to assure sufficient oil is available. This will prevent unnecessary trips of the oil control system.

Note: If oil management problems are occurring please refer to AE17-1320 or contact to Emerson, Application Engineering Department.

WARNING

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Emerson AE4-1317 User Manual

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