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AE4-1400 R2
1 to 5 Ton ZP*K6 R-410A Copeland Scroll
Section
Safety
Safety Instructions .................................................... 2
Safety Icon Explanation ........................................... 2
Fire, or Injury to Persons .......................................... 3
Safety Statements .................................................... 3
Introduction ................................................................. 4
Nomenclature ........................................................... 4
Internal Pressure Relief Valve .................................. 4
Discharge Temperature Protection ........................... 4
Heat Pump Protection .............................................. 5
Discharge Line Thermostat ...................................... 5
Air-Conditioning Unit Protection ............................... 5
High Pressure Control .............................................. 5
Shut Down Device .................................................... 5
Motor Overload Protection ....................................... 5
Operating Envelope ................................................. 6
Power Supply ........................................................... 6
Accumulators ........................................................... 6
Screens .................................................................... 6
Crankcase Heat-Single Phase ................................. 6
Crankcase Heat-Three Phase .................................. 7
Minimum Run Time .................................................. 7
Reversing Valves ..................................................... 7
Low Ambient Cut-Out ............................................... 7
Oil Type .................................................................... 7
Contaminant Control ................................................ 8
Long Line Sets/High Refrigerant Charge ................. 8
Discharge Mufflers ................................................... 8
Noise & Vibration ................................................... 8
Mounting Parts ......................................................... 9
Single Phase Starting Characteristics ...................... 9
PTC Start Components ............................................ 9
Electrical Connections .............................................. 9
Deep Vacuum Operation .......................................... 9
© 2015 Emerson Climate Technologies, Inc.
TABLE OF CONTENTS
Page
Section
Suction & Discharge Fittings ................................... 9
System Tubing Stress ............................................. 9
Three Phase Scroll Electrical Phasing .................. 10
Brief Power Interruptions ....................................... 10
Tandem Compressors ........................................... 10
Maximum Tilt Angle ............................................... 10
Application Summary............................................. 10
Continuous Floodback Test ................................... 11
Field Application Test ............................................ 11
Installing the Compressor ..................................... 11
Suction Funnel ...................................................... 12
Assembly Line Brazing Procedure ........................ 12
Pressure Testing ................................................... 12
Assembly Line System Charging Procedure ......... 12
High Potential (AC Hipot) Testing .......................... 12
Final Run Test ....................................................... 13
Unbrazing System Components ........................... 13
Copeland Scroll Functional Check ........................ 13
Compressor Replacement After Motor Burn ......... 14
Figures & Tables
R410A Scroll Operating Envelope ......................... 15
Oil Dilution Chart ................................................... 16
Time Delay Wiring ................................................. 17
Compressor Electrical Connection ........................ 17
Crankcase Heater ................................................. 18
Scroll Suction Tube Brazing .................................. 19
How a Scroll Works.. ............................................. 20
Suction Funnel Diagram ........................................ 21
Field Application Test ............................................ 22
Design Configurations ........................................... 22
Compressor Refrigerant Charge Limits... .............. 22
Compressor Accessories ...................................... 23
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February 2015
Compressors
™
AE4-1400 R1
Page
Table of Contents
Related Manuals for Emerson Copeland Scroll ZP K6 Series
Summary of Contents for Emerson Copeland Scroll ZP K6 Series
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Page 1: Table Of Contents
Field Application Test ..........22 Single Phase Starting Characteristics ...... 9 Design Configurations ........... 22 PTC Start Components ..........9 Compressor Refrigerant Charge Limits....22 Electrical Connections ..........9 Compressor Accessories ........23 Deep Vacuum Operation .......... 9 © 2015 Emerson Climate Technologies, Inc. -
Page 2: Safety Instructions
NOTICE NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices CAUTION not related to personal injury. © 2015 Emerson Climate Technologies, Inc. -
Page 3: Instructions Pertaining To Risk Of Electrical Shock, Fire, Or Injury To Persons
• 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. © 2015 Emerson Climate Technologies, Inc. -
Page 4: Introduction
For additional information, please refer to our Online with refrigerant, and thermostatic expansion devices Product Information, accessible from the Emerson will attempt to control superheat and result in higher Climate Technologies website at www.emersonclimate. compressor top cap temperatures. Fan failure testing com. -
Page 5: Heat Pump Protection
The low pressure cut-out can provide protection against well. See Table 5 for recommended Emerson Climate indoor blower failure in cooling, outdoor fan failure in Technologies part numbers. heating, closed liquid or suction line service valves, or a blocked liquid line screen, filter, orifice, or TXV. All... -
Page 6: Operating Envelope
Ideally the heater would come © 2015 Emerson Climate Technologies, Inc. -
Page 7: Crankcase Heat-Three Phase
(Figure 1) the minimum run time, obtain a sample compressor causing overheating or excessive wear. equipped with a sight tube (available from Emerson) and install it in a system with the longest connecting lines Oil Type that are approved for the system. -
Page 8: Contaminant Control
When no testing is performed, mufflers hydrolysis, and metal corrosion. It is the system are recommended in heat pumps. A hollow shell muffler designer’s responsibility to make sure the filter-drier is such as the Emerson Flow Controls APD-1 or APD-054 adequately sized to accommodate the contaminants will work quite well. The mufflers should be located a from system manufacturing processes that leave minimum of six inches (15 cm) to a maximum of 18... -
Page 9: Mounting Parts
Table 5 lists the mounting parts kits to be used applications. with these compressors. Many OEM customers buy the mounting parts directly from the supplier, but Emerson’s The orientation of the electrical connections on the grommet design and durometer recommendation Copeland Scroll compressors is shown in Figure 4. -
Page 10: Three Phase Scroll Electrical Phasing
This control could be incorporated in other system controls (such Field Application Test: as defrost control board or the system thermostat), or Required for any unit where both the design system can be a stand-alone control. Functional specifications © 2015 Emerson Climate Technologies, Inc. -
Page 11: Continuous Floodback Test
Use care and the appropriate material handling refrigerant flood back. equipment when lifting and moving compressors. Personal safety equipment must be used. Field Application Test To test for repeated, excessive liquid flood back © 2015 Emerson Climate Technologies, Inc. -
Page 12: Suction Funnel
The pressure used on the line to meet the UL burst compressor after Emerson’s run test. The inside of both pressure requirement must not be higher than 475 fittings should be wiped with a lint free cloth to remove psig (33 Bar). -
Page 13: Final Run Test
With the start winding removed, the opened, the compressor must be allowed to cool compressor will remain on locked rotor long enough sufficiently to allow it to reset. to read the supply voltage. If the voltage sags below © 2015 Emerson Climate Technologies, Inc. -
Page 14: Compressor Replacement After Motor Burn
If additional systems can be found in Section H of the Emerson charge is required, charge liquid into the low side of Climate Technologies Electrical Handbook, the system with the compressor operating. -
Page 15: R410A Scroll Operating Envelope
This will prevent unauthorized personnel from accidentally ruining the compressor by operating with no refrigerant flow. Evaporating Temperature (°C) Note: PFV Voltage Tolerance +10% to -5% Evaporating Temperature (°F) Figure 1 R-410A Scroll Operating Envelope © 2015 Emerson Climate Technologies, Inc. -
Page 16: Oil Dilution Chart
Note 1: Operation in this refrigerant dilution area is safe in air-to-air heat pump heating mode. For other applications, such as AC only, review expansion device to raise superheat. A cold sump may result in high refrigerant migration after shut down. Figure 2 Oil Dilution Chart © 2015 Emerson Climate Technologies, Inc. -
Page 17: Time Delay Wiring
Greater than 5 seconds later, whether (.016 Sec. With 60 HZ Operation) power is restored or not after power is removed Figure 3 Time Delay Wiring T1,C T2,S T3,R Figure 4 Compressor Electrical Connection © 2015 Emerson Climate Technologies, Inc. -
Page 18: Crankcase Heater
Connect the heater so that the connection point straddles the compressor seam weld Seam Weld Seam Weld ZP10-31K6 ZP34-54K6 WARNING Verify the correct crankcase heater voltage for the application and ensure heater is properly grounded. Figure 5 Crankcase Heater © 2015 Emerson Climate Technologies, Inc. -
Page 19: Scroll Suction Tube Brazing
Area 3. This will draw the braze material down into the joint. The time spent heating Area 3 should be minimal. • As with any brazed joint, overheating may be detrimental to the final result. © 2015 Emerson Climate Technologies, Inc. -
Page 20: How A Scroll Works
AE4-1400 R1 Figure 7 © 2015 Emerson Climate Technologies, Inc. -
Page 21: Suction Funnel Diagram
AE4-1400 R1 Suc on Funnel Typical Funnel Suc on Tube Back Of Funnel Oil Drain Hole Figure 8 – Suction Funnel Diagram © 2015 Emerson Climate Technologies, Inc. -
Page 22: Field Application Test
Service Valve "Straight through" valve not fastened to unit Mass / Suction muffler May be required (Acts as dampening mass) Table 4 – Refrigerant Charge Limits Compressor Charge Limit System Charge Limit Model Pounds Pounds ZP10-31K6 ZP34-54K6 © 2015 Emerson Climate Technologies, Inc. -
Page 23: Compressor Accessories
The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regard- ing the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or its affiliates (collectively "Emerson"), as appli- cable, reserve the right to modify the design or specifications of such products at any time without notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user. © 2015 Emerson Climate Technologies, Inc.