Emerson Copeland Scroll ZBKC, Copeland Scroll ZBKCE Application Manuallines
Application Engineering
BULLETIN
Application Engineering
BULLETIN
AE4-1317 R10
AE4-1317 R10
April 2014
Application Guidelines for ZBKC / ZBKCE
Refrigeration Copeland Scroll™ Compressors 1.3 to 7.5 HP
TABLE OF CONTENTS
Section Page Section Page
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 ................................................................ 4
Nomenclature ............................................................ 4
Operating Envelope ................................................... 4
Accumulators ............................................................. 4
Crankcase Heaters .................................................... 4
Discharge Line Thermostat ....................................... 4
Pressure Controls ...................................................... 5
Pump Down Recommendations ................................ 5
IPR Valve .................................................................. 5
Internal Temperature Protection ............................... 5
Motor Protection ........................................................ 5
Oil Types .................................................................... 5
Oil Charges................................................................ 6
Oil Management for Rack Applications...................... 6
Compressor Tubing and Mounting ............................ 6
Mounting for Rack Systems....................................... 6
Condensing Unit Mounting ........................................ 6
Starting Characteristics ............................................. 6
Fusite ......................................................................... 7
Shell Temperature ..................................................... 7
Connection Fittings .................................................... 7
Three-Phase Rotation Direction ................................ 7
Brief Power Interruptions ........................................... 7
Deep Vacuum Operation ........................................... 7
Unbrazing System Components ................................ 7
High Potential (Hipot) Testing .................................... 7
Copeland Scroll Functional Check ............................. 8
Figures
ZB*KCE Application Envelopes ..................................9
Scroll Rack Mounting................................................10
Scroll Condensing Unit Mounting .............................10
Typical Suction Tubing..............................................11
Motor Terminal (Fusite) Connections for Single
Phase and Three Phase Scrolls .............................11
Scroll Wiring Schematic............................................12
Tables
Compressor Models and Approved Refrigerants/
Lubricants ...............................................................13
Charge Limitations....................................................13
Crankcase Heater.....................................................14
Conduit Ready Heater Terminal Box Kits .................14
Discharge Thermostat Line Kits ...............................14
Pressure Control Settings.........................................14
Check-Valve Type .....................................................15
Recommended Oil Charges by Model Family ..........15
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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AE4-1317 R10
Application Engineering
BULLETIN
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. Safey icons are explained below and safety
instructions applicable to the products in this bulletin are grouped on Page 3. These instructions should
be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety
instructions.
Safety Icon Explanation
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
CAUTION
NOTICE
CAUTION
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.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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Application Engineering
BULLETIN
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
AE4-1317 R10
WARNING
WARNING
WARNING
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.
•
• 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.
CAUTION
Safety Statements
• Refrigerant compressors must be employed only for their intended use.
•
install, commission and maintain this equipment.
•
• All valid standards and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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.
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AE4-1317 R10
Application Engineering
BULLETIN
Introduction
The ZBKC/ZBKCE Copeland Scroll™ compressor
represents the latest generation of compliant scroll
technology for the refrigeration industry.
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 accessible from
the Emerson Climate Technologies web site at www.
emersonclimate.com.
Operating Envelope
The ZBKC/ZBKCE 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 ZBKC and ZBKCE 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 Figures 1A, 1B and 1C at
the end of this bulletin.
Accumulators
Due to the scrolls’ inherent ability to handle liquid
refrigerant in fl ooded 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 suffi cient volume to prevent liquid
migration to the compressor is used.
Excessive liquid fl ood back or repeated fl ooded starts
will dilute the oil in the compressor causing inadequate
lubrication and bearing wear. Proper system design will
minimize liquid fl ood 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 fl oodback.
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.
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.
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 3A. If there
are any questions concerning their application, contact
the Emerson Climate Technologies, Inc. Application
Engineering department.
Discharge Line Thermostat
Figures 1A, 1B, 1C and 1D show 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.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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AE4-1317 R10
Application Engineering
BULLETIN
If the system is designed where operation with in these
guidelines cannot be guaranteed, then the discharge line
thermostat is required in the compressor control circuit.
The thermostats have a cut out setting that will insure
discharge line temperatures below the 260°F maximum
limit. It should be installed approximately 7 inches from
the discharge tube outlet. If a service valve is installed
at the discharge tube, the thermostat should be located
5 inches from the valve braze.
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 4
for a list of discharge line thermostat kit numbers.
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 5 for set points.
Application Note: There are exceptions to the pressure
settings listed in Table 5. Certain OEMs are approved
for LPC settings below our standard recommendations.
Pump Down Recommendations
Table 6 identifi es 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.
NOTICE
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 5. 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.
NOTICE
The ZB10 through ZB14 models will require the following
recommendations for pump down applications:
1. Install an external check-valve in the discharge
line to prevent back-fl ow from the high side to low
side. Install check-valve as close to the compressor
discharge fi tting as possible to minimize discharge
gas volume.
2. Set low pressure to recommended settings in
Table 5.
3. 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.
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 a low pressure control, since these models do not
have an IPR valve.
Internal Temperature Protection
Refrigeration Scroll compressors (1.3-7.5 HP)
ZB10-57KC/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.
Motor Protection
Conventional inherent internal line break motor protection
is provided.
Oil Types
Polyol ester lubricants must be provided if the scroll
compressor is to be used with HFC refrigerants. ZBKC
compressors are intended for use with R22 and are
supplied with mineral oil. See Form 93-11 for a complete
list of all Emerson approved lubricants.
© 2014 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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