Emerson ZR24KRE, ZR190KRE User Manual
Application Guidelines
Copeland Scroll™ Compressors for
Comfort, Precision and Process Cooling
ZR24KRE to ZR190KRE
AGL_AC_ST_ZRKRE_E_Rev01
About these guidelines ............................................................................................... 1
1 Safety instructions ........................................................................................... 1
1.1 Icon explanation ............................................................................................................... 1
1.2 Safety statements ............................................................................................................ 1
1.3 General instructions ......................................................................................................... 2
2 Product description ......................................................................................... 3
2.1 General information about Copeland Scroll™ compressors ........................................... 3
2.2 Nomenclature ................................................................................................................... 3
2.3 BOM Variation .................................................................................................................. 4
2.4 Application range ............................................................................................................. 4
2.4.1 Qualified refrigerants and oils .............................................................................. 4
2.4.2 Application limits ................................................................................................... 4
2.4.3 PED category and maximum allowable pressure PS .......................................... 4
2.5 Dimensions ...................................................................................................................... 5
3 Installation ........................................................................................................ 7
3.1 Compressor handling ....................................................................................................... 7
3.1.1 Transport and storage .......................................................................................... 7
3.1.2 Positioning and securing ...................................................................................... 7
3.1.3 Installation location ............................................................................................... 7
3.2 Mounting parts ................................................................................................................. 8
3.3 Brazing procedure ............................................................................................................ 8
3.3.1 General brazing procedure................................................................................... 8
3.3.2 Brazing procedures for ZR*KRE compressors in parallel applications ................ 9
3.4 Shut-off valves and adaptors ........................................................................................... 9
3.5 Pressure safety controls ................................................................................................ 10
3.5.1 High-pressure protection .................................................................................... 10
3.5.2 Low-pressure protection ..................................................................................... 10
3.6 Crankcase heater ........................................................................................................... 10
3.7 Soft starter and single-phase compressor start assists ................................................. 11
3.8 Discharge gas temperature protection ........................................................................... 12
3.8.1 Excessive discharge gas temperatures ............................................................. 12
3.8.2 Internal thermo-disc ............................................................................................ 12
3.8.3 Advanced Scroll Temperature Protection (ASTP) ............................................. 12
3.8.4 Discharge line thermostat................................................................................... 13
3.9 Internal pressure relief valve .......................................................................................... 14
3.10 Discharge check valve ................................................................................................... 14
3.11 Filter screens ................................................................................................................. 14
3.12 Mufflers .......................................................................................................................... 14
3.13 Sound and vibration ....................................................................................................... 15
3.14 Compressor oil return, oil balancing and flood-back tests ............................................. 15
AGL_AC_ST_ZRKRE_E_Rev01
3.15 Suction line accumulator ................................................................................................ 16
4 Electrical connection ..................................................................................... 17
4.1 General recommendations............................................................................................. 17
4.2 Electrical installation ...................................................................................................... 17
4.3 Terminal box .................................................................................................................. 19
4.3.1 Terminal box – IP21 ........................................................................................... 19
4.3.2 Terminal box – Metal IP65 ................................................................................. 20
4.4 Motor insulation .............................................................................................................. 20
4.5 Motor protection ............................................................................................................. 20
4.6 High-potential testing ..................................................................................................... 20
5 Start-up & operation ....................................................................................... 22
5.1 Strength pressure test .................................................................................................... 22
5.2 Compressor tightness test ............................................................................................. 22
5.3 System evacuation ......................................................................................................... 22
5.4 Preliminary checks – Pre-starting .................................................................................. 23
5.5 Charging procedure ....................................................................................................... 23
5.6 Run-in time ..................................................................................................................... 23
5.7 Initial start-up ................................................................................................................. 23
5.8 Rotation direction ........................................................................................................... 24
5.9 Starting sound ................................................................................................................ 24
5.10 Deep vacuum operation ................................................................................................. 24
5.11 Shell temperature ........................................................................................................... 24
5.12 Pump-down cycle ........................................................................................................... 24
5.13 Minimum run time .......................................................................................................... 25
5.14 Shut-off sound ................................................................................................................ 25
5.15 Supply frequency and voltage ....................................................................................... 25
5.16 Oil level .......................................................................................................................... 25
6 Maintenance & repair ..................................................................................... 26
6.1 Disassembling system components .............................................................................. 26
6.2 Provisions of legislation & leak check requirements ...................................................... 26
6.3 Exchanging the refrigerant ............................................................................................. 27
6.4 Replacing a compressor ................................................................................................ 27
6.4.1 Compressor replacement ................................................................................... 28
6.4.2 Start-up of a new or replacement compressor ................................................... 28
6.5 Lubrication and oil removal ............................................................................................ 28
6.6 Oil additives ................................................................................................................... 29
7 Troubleshooting ............................................................................................. 30
8 Dismantling & disposal .................................................................................. 33
9 References ...................................................................................................... 33
Appendix 1: Tightening torques ............................................................................... 34
AGL_AC_ST_ZRKRE_E_Rev01
DISCLAIMER .............................................................................................................. 34
AGL_AC_ST_ZRKRE_E_Rev01 1
About these guidelines
The purpose of these guidelines is to provide guidance in the application of Copeland Scroll™
compressors in users’ systems. They are intended to answer the questions raised while designing,
assembling and operating a system with these products.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the compressors. The performance and reliability of the product may be impacted
if the product is not used according to these guidelines or is misused.
These application guidelines cover stationary applications only. For mobile applications, please
contact the Application Engineering department at Emerson as other considerations may apply.
1 Safety instructions
Copeland Scroll compressors are manufactured according to the latest relevant European safety
standards. Particular emphasis has been placed on the user’s safety.
These compressors are intended for installation in systems in accordance with the European
Machinery directive MD 2006/42/EC, the Pressure Equipment Directive PED 2014/68/EU and the
Low Voltage Directive LVD 2014/35/EU. They may be put to service only if they have been installed
in systems according to instructions and conform to the corresponding provisions of legislation.
The Material Safety Datasheet (MSDS) for the individual refrigerant shall be considered when
working with this type of refrigerant – please check this document provided by the gas supplier.
These instructions shall be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to avoid
property damage and possible
personal injury.
High voltage
This icon indicates operations with a
danger of electric shock.
IMPORTANT
This icon indicates instructions to avoid
malfunction of the compressor.
Danger of burning or frostbite
This icon indicates operations with a
danger of burning or frostbite.
NOTE
This word indicates a recommendation
for easier operation.
Explosion hazard
This icon indicates operations with a
danger of explosion.
1.2 Safety statements
▪ Refrigerant compressors must be employed only for their intended use. The system has
to be labelled according to the applicable standards and legislation.
▪ Only qualified and authorized RACHP personnel are permitted to install commission and
maintain this equipment.
▪ Electrical connections must be made by qualified electrical personnel.
▪ All valid standards for connecting electrical and refrigeration equipment must be
observed.
▪ The national legislation and regulations regarding personnel protection must be observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.
2 AGL_AC_ST_ZRKRE_E_Rev01
1.3 General instructions
WARNING
Pressurized system! Serious personal injuries and/or system
breakdown! Accidental system start before complete set-up must be avoided.
Never leave the system unattended without locking it out electrically when it is
on vacuum and has no refrigerant charge, when it has a holding charge of
nitrogen, or when the compressor service valves are closed.
WARNING
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils must be used.
WARNING
High shell temperature! Burning! Do not touch the compressor until it has
cooled down. Ensure that other materials in the area of the compressor do not
get in touch with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without
refrigerant charge or without being connected to the system.
CAUTION
Contact with POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE must not come into contact with any surface
or material that it might damage, including without limitation, certain polymers,
eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.
AGL_AC_ST_ZRKRE_E_Rev01 3
2 Product description
2.1 General information about Copeland Scroll™ compressors
These application guidelines deal with all vertical single Copeland scroll compressors from ZR24KRE
to ZR190KRE for air-conditioning applications.
Compressor
Cooling capacity [kW]
Motor
R450A
R513A
ZR24KRE
3.06
3.54
PFJ/TFD
ZR28KRE
3.60
4.17
PFJ/TFD
ZR36KRE
4.58
5.21
PFJ/TFD
ZR42KRE
5.24
6.20
PFJ/TFD
ZR48KRE
6.01
6.91
TFD
ZR61KRE
7.62
9.01
TFD
ZR69KRE
8.59
10.15
PFJ
ZR72KRE
9.08
10.55
TFD
ZR81KRE
10.0
11.60
TFD
ZR92KRE
11.3
13.50
TFD
ZR108KRE
-
15.80
TFD
ZR125KRE
-
18.40
TFD
ZR144KRE
-
20.80
TFD
ZR160KRE
-
22.90
TFD
ZR190KRE
-
27.40
TFD
Refrigerant dew temperature, evaporating temperature: 5 °C; condensing temperature: 50 °C; suction gas
superheat: 10 K; liquid sub-cooling: 0 K; frequency: 50 Hz
Table 1: ZR*KRE model overview for high temperature applications
2.2 Nomenclature
The model designation contains the following technical information about the compressors:
4 AGL_AC_ST_ZRKRE_E_Rev01
2.3 BOM Variation
The BOM (bill of material) number at the end of the compressor designation indicates the compressor
layout and details.
ZR24KRE to ZR92KRE:
BOM 455 braze connections, oil sight glass, oil service connection, IP21 T-box, no mounting parts.
ZR108KRE to ZR190KRE:
BOM 455 braze connections, oil sight glass, oil service connection, IP21 T-box, no mounting parts.
BOM 411 braze connections, oil sight glass, oil service connection, IP65 T-box, no mounting parts.
Please refer to the Emerson price list for more details.
2.4 Application range
2.4.1 Qualified refrigerants and oils
IMPORTANT
It is essential that the glide of refrigerant blends (primarily R450A) be carefully
considered when adjusting pressure and superheat controls.
IMPORTANT
Refrigerant blends with low GWP containing HFOs have a low chemical
stability in presence of air or humidity. This requires the same level of
cleanliness, dryness and evacuation of the refrigerant circuit as in HFC and
POE applications including the use of filter dryers.
Compressor
ZR24KRE to ZR92KRE
ZR108KRE to ZR190KRE
Qualified refrigerants
R450A, R513A
R513A
Copeland™ brand
products standard oil
Emkarate RL 32 3MAF
Emkarate RL 32 3MAF
Servicing oils
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Table 2: Qualified refrigerants and oils.
Oil recharge values can be taken from Copeland™ brand products Select software available at
www.climate.emerson.com/en-gb.
2.4.2 Application limits
CAUTION
Inadequate lubrication! Compressor breakdown! The superheat at the
compressor suction inlet must always be sufficient to ensure that no refrigerant
droplets enter the compressor. For a typical evaporator-expansion valve
configuration a minimum stable superheat of at least 5 K is required.
For application envelopes and technical data, please refer to Copeland™ brand products Select
software available at www.climate.emerson.com/en-gb.
2.4.3 PED category and maximum allowable pressure PS
Compressor models ZR24KRE to ZR92KRE are classified as category 1 and models ZR108KRE to
ZR190KRE are classified as category 2, according to the Pressure Equipment Directive
PED 2014/68/EU.
Compressor
PS
High-pressure
side
PS
Low-pressure
side
TS
Low-pressure
side
PED
category
ZR24KRE to
ZR92KRE
29 bar(g)
21 bar(g)
50 °C
1
ZR108KRE to
ZR190KRE
32 bar(g)
20.5 bar(g)
53 °C
2
Table 3: Maximum allowable pressures and temperatures
AGL_AC_ST_ZRKRE_E_Rev01 5
The pressure PS is the maximum allowable pressure at the low- and high-pressure sides of the
compressor. The maximum pressure value PS for the individual compressor type is printed on the
nameplate of the compressor. Safety is established in compliance with the relevant standards
applicable to the given product.
2.5 Dimensions
Compressor
model
A [mm]
B [mm]
C [mm]
D [mm]
E [mm]
F [mm]
Ø G
Ø H
ZR24KRE &
ZR28KRE
364.1
338.5
202.9
69.6
43.7
244.5
1/2"
3/4"
ZR36KRE
386.7
361.1
222.8
75.3
49.4
264.4
1/2"
3/4"
ZR42KRE
400.4
374.9
235.5
75.3
49.4
277.1
1/2"
3/4"
ZR48KRE
417.4
391.9
252.5
75.3
49.4
294.1
1/2"
7/8"
Figure 1: Dimensions for models ZR24KRE to ZR48KRE
Compressor
model
A [mm]
B [mm]
Ø C
ZR61KRE to
ZR72KRE
437.8
409.6
1/2"
ZR81KRE &
ZR92KRE
443.2
413.7
3/4"
Figure 2: Dimensions for models ZR61KRE to ZR92KRE
6 AGL_AC_ST_ZRKRE_E_Rev01
Compressor
model
A [mm]
B [mm]
C [mm]
D [mm]
ZR108KRE to
ZR144KRE
533.2
501.1
122.1
252.7
ZR160KRE &
ZR190KRE
551.5
519.5
140.4
271
Figure 3: Dimensions for models ZR108KRE to ZR190KRE BOM411
Compressor
model
A [mm]
B [mm]
C [mm]
D [mm]
ZR108KRE to
ZR144KRE
533.2
501.1
122.1
242.8
ZR160KRE &
ZR190KRE
551.5
519.5
140.4
261.2
Figure 4: Dimensions for models ZR108KRE to ZR190KRE BOM455
AGL_AC_ST_ZRKRE_E_Rev01 7
3 Installation
WARNING
High pressure! Injury to skin and eyes possible! Be careful when opening
connections on a pressurized item.
3.1 Compressor handling
3.1.1 Transport and storage
WARNING
Risk of collapse! Personal injuries! Move compressors only with
appropriate mechanical or handling equipment according to weight. Keep in
the upright position. Respect stacking loads according to Figure 5. Check the
tilting stability and if needed take action to ensure the stability of the stacked
loads. Keep the packaging dry at all times.
Respect the maximum number of identical packages which may be stacked on one
another, where "n" is the limiting number:
▪ Transport: n = 1
▪ Storage: n = 2
Figure 5: Maximum stacking loads for transport and storage
The compressor tilt angle should not be more than 30° during transport and handling. This will
prevent oil from exiting through the suction stub. A tilt angle of maximum 45° is allowed for a very
short time. Tilting the compressor more than 45° might affect its lubrication at start-up.
NOTE: The compressor is pre-charged with dry air to avoid any moisture contamination.
3.1.2 Positioning and securing
IMPORTANT
Handling damage! Compressor malfunction! Only use the lifting eyes
whenever the compressor requires positioning. Using discharge or suction
connections for lifting may cause damage or leaks.
The compressor should be kept vertical during handling.
The discharge connection plug should be removed first before pulling the suction connection plug to
allow the dry air pressure inside the compressor to escape. Pulling the plugs in this sequence
prevents oil mist from coating the suction tube making brazing difficult. The copper-coated steel
suction tube should be cleaned before brazing.
The plugs must be removed as late as possible before brazing so that the air humidity does not affect
the oil characteristics.
For models ZR108KRE to ZR190KRE, as oil might spill out of the suction connection located low on
the shell, the suction connection plug must be left in place until the compressor is set into the unit.
No object, eg, a swaging tool should be inserted deeper than 51 mm into the suction tube as it might
damage the suction screen and motor.
3.1.3 Installation location
Ensure the compressors are installed on a solid level base. For single compressor applications, the
compressor tilt angle during operation should not exceed 15° to allow adequate lubrication. For
multiple compressor parallel configurations, the compressors must be positioned completely
vertically on a totally horizontal surface or rail.
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