AE-1302-R4

Copeland 4-1302® ® 4-1302 Application Engineering Bulletin AE-1302-R3 AE-1302-R4 October, 2004 Revised January, 1999 APPLICATION GUIDELINES FOR "GLACIER™" K4 & KA REFRIGERATION SCROLL COMPRESSORS 7.5-15 HORSEPOWER Introduction C apillary T ubes For Liquid or Vapor Injection: C ap T ube The Glacier™ refrigeration Scroll compressor prod- M odel I.D . Length C opeland uct offering has expanded into the higher horsepower (inches) (inches) K it ranges. The scope of this bulletin will cover the applica- num ber tion parameters unique to the new models. R -22 ZF24K4 0.05 5” 998-1586-00 Nomenclature ZF33K4 0.05 5” 998-1586-00 ZF40K4 0.07 30” 998-1586-05 The Glacier™ Scroll model numbers include the ZF48K4 0.07 10” 998-1586-06 nominal capacity at the standard 60 Hertz “ARI” rating R -404A /R -507 conditions. Please refer to product literature for model ZF24K4E 0.05 30” 998-1586-04 ZF33K4E 0.05 17.5” 998-1586-01 number details. ZF40K4E 0.07 30” 998-1586-05 ZF48K4E 0.07 30” 998-1586-05 Operating Envelope Table 2 These Glacier™ models can also be used with a • Solenoid Valve - A solenoid valve with a minimum .109 variety of refrigerants. The following table shows the inch orifice must be provided in the injection circuit that selection options: opens whenever the compressor is operative or cooling MODEL REFRIGERANT LUBRICANT is required during pumpdown. The solenoid must be ZB,ZF,ZS R22 MO closed when the compressor is cycled off. Failure to ZF R-404A, R-507, R-22 POE provide the solenoid valve can result in liquid refrigerant completely filling the Scroll during an “off” cycle. If power ZS R404A, R-507 POE is reapplied in this condition, the hydraulic effect produced Table 1 could result in pressure high enough to cause permanent The operating envelopes are depicted in damage to the compressor. Due to this, it is a condition Figures 1A through 1E. See Oil Type on page 3 for of warranty that the capillary tube and solenoid valve, recommended lubricants. properly installed, be provided whenever liquid or vapor injection is used. Liquid Or Vapor Injection The low temperature models are provided with an The following components are not required, but they are injection port that can be used for either liquid or vapor recommended for liquid injection. injection. Schematics are shown in Figure 2 and Figure 3. The requirements are outlined below: • Sight Glass - A sight glass should be installed just before the capillary tube inlet to allow visual inspection • Capillary Tube - Liquid must be fed through an for the presence of liquid refrigerant. appropriately sized capillary tube as defined in Table 2. The vapor injection method, in addition to the capillary tube, will require an external heat exchanger (Refer to Figure 3). © 1996 Copeland Corporation The heaters Module will sense the correct phase sequence of L1. Accumulators (ZB) High 381 PSIG Max. are not equipped for use with electrical conduit. Application Control Type R-404A/R-507 R-22 High Temp.P. protection module and will shut the compressor off if high discharge temperatures exist. Motor Protection External Wrap-Around Crancase Heater There are five PTC (Positive Temperature Coeffi- Numbers* cient) internal thermistors connected in series that react Part No. Medium Temp. Cover 005-7061-00 delay before reset after a thermistor trip. and the fifth is used as a discharge temperature sensor. 24 PSIG Min. 335 PSIG Max.. At completion of the compres- applicable electrical safety codes require heater lead sor installation. 018-0036-03 575 60 21 29 Table 3A When any thermistor reaches a limiting value. L2. An accumulator is required on single compres. However. Model Item Part Number it will reset. larger horsepower Scrolls. IPR Valve an accumulator is required unless a suction header of sufficient volume to prevent liquid migration to the There is no internal pressure relief valve in these compressor is used. handle liquid refrigerant in flooded start and defrost Medium Temp. The compressor features an internal and then only can be reset by reestablishing incoming temperature sensor which works in conjunction with the power to the module. 2 in. 10 PSIG Min. Copeland 4-1302 • Filter/Drier . defrost schemes or transient operations that allow Table 4 prolonged. questions concerning their application. tems. After the thermistor has cooled sufficiently. discharge Rotalock fitting to accommodate this control. There can A discharge line thermostat is not required on these be 10 attempts to restart before the module will lock out models. 2 . Therefore a high pressure control located prior to any shut-off valves is manda- Crankcase Heat tory tory. Box 062-7015-00 Phase Protection Table 3B *The above listed crankcase heaters are intended The phase protection capabilities of the INT69SCY for use only where there is limited access. (ZS) High 445 PSIG Max. the three phase power must be wired in protection. when the system charge exceeds 17 lbs. uncontrolled liquid return to the compressor. the module has a 30 minute time 7. quired.5-15 H. sor systems with charges over 17 lbs.5-15 H. Due to our Compliant Scroll®’s inherent ability to (ZF) High 445 PSIG Max. Volts Watts Lead Lengths Ground Wire (in) Lengths (in) with avalanching resistance in the event of high tem- 018-0036-01 120 70 21 29 peratures. on outdoor sys. There is an access port located on the compressor Crankcase heaters* are required. a crankcase heater terminal box should be the correct 120 degree phase sequence that will ensure used. 7. contact the Copeland Application Engineering Dept. Low 8 PSIG Min. the module interrupts the control circuit and shuts off the Conduit Ready Terminal Box Numbers compressor. P. Hg Min. if not the module will lock out. see the Module And Sensor Functional Check section for proper operation procedures. Where and L3 incoming power. Low Temp Low 0 PSIG Min. Low 38 PSIG Min. 381 PSIG Max.A filter/drier should be installed in the Pressure Controls injection circuit to avoid the possibility of capillary tube Both high and low pressure controls are required blockage due to contaminants. The thermistor circuit is connected 018-0036-02 480 70 21 29 to the protector module terminals S1 and S2. Four of the thermistors are used to sense 018-0036-00 240 70 21 29 motor temperatures. Recommended crankcase heater terminal cover the compressor will start and operate in the correct and box numbers are listed in table 3B. Discharge Line Thermostat If all three phases are present then the compressor will continue to run. When the Int69SCY trips on phase loss a delay of 5 minutes is activated and then a new attempt to restart. Also. accumulators may not be re. operation conditions. and the following are the minimum and maximum set points: Figure 2 and Figure 3 are a representation of typical systems depicting the location of these components. Low 8 PSIG Min. Refer to Figure 4 for wiring schematic details. If there are any clockwise rotation. On systems with (ZF) High 400 PSIG Max. 381 PSIG Max. Witco LP-200. 300VA 5 A. then the 4. do not attempt to check continuity Glacier™ Scrolls may be used on multiple compres- through the sensors with any other type of instrument. CAUTION: Use an Ohmmeter with a maximum of Oil Management For Rack Applications 9 VAC for checking.the circuit to reset. Disconnect power. Reapply power. Reapply power. the compressor should not start. applications. sor parallel rack applications.600V 5 A. Check all electrical terminal connections for pos. Disconnect one terminal either S1 or S2 on the This will by-pass the module control contacts. or ISO 3GS.5A. Use reset resistance is 3000 ohms +/. Check Verify correct phase lead orientation.000 ohms or higher and with POE oil intended for use with HFC refrigerants. Copeland 4-1302 The following Table lists the solid state modules and their specifications: Copeland P/N 071-0520-07 071-0520-05 071-0547-00 Mfg. If the compressor has been operating and has Unlike Semi-Hermetic compressors.500 ohms.5 VA < 3VA < 3VA Phase sensor N/A N/A 3 Phase monitoring 3 AC 50/60 Hz circuit rating N/A N/A >120 / <632 volts Table 5 Module and Sensor Functional Check cool for at least one hour before checking. If the compressor 3. Reconnect the sensor leads to the module operate when the jumper is removed. or ICI 1. 300VA Power Output < 5. Check the resistance of the sensors at S1 and S2 The factory oil charge for all 7.I. Mobil EAL Arctic 22 CC.5-15 HP. models is terminals. allow the compressor to have an oil pump with accompanying oil pressure safety 3 . Disconnect power problem is external to the module. This requires the use of an Any external voltage or current applied to the sensors oil management system to maintain proper oil level in may cause damage requiring compressor replacement. The sight glass connec- The following field trouble shooting procedure can tion supplied can accommodate the mounting of the oil be used to evaluate the solid state control circuit. control devices. Disconnect control circuit power to de-energize the 1. Disconnect power EMKARATE RL 32CF are the only polyol ester oils 2. The proper oils are Sontex sible loose or broken connections 200LT. Glacier™ Scroll is to be used with HFC refrigerants. module. Reapply power. If the compressor operates with the module bypassed. Scrolls do not tripped on the protector. to figure 4 ZB**KA model Scrolls. Refer approved by Copeland at this time. Reconnect control circuit power. Note: Do not add mineral oil to compressors charged The trip resistance is 10. The resistance readings should be be. are supplied with mineral oil. each compressor crankcase.the compressor should start. only the Copeland approved POE lubricants for these 5. tween 250 and 1250 ohms at room temperature. then the module is defective. following procedure is recommended: 2. 1. 2. Connect a jumper across the wires con- nected to the M1 and M2 terminals on the module. 140 ounces. This allows time for the motor to cool and the control To check for proper control circuit operation. Copeland Ultra 22 CC™. will not operate with the jumper installed. 30AA201E Kriwan 69SC-DV Kriwan 69SCY Voltage Supply 120V&240V 120V&240V 120V&240V Frequency 50HZ & 60Hz 50HZ & 60Hz 50HZ & 60Hz Time Delay Reset 30minutes 30minutes 30minutes Relay Output 2. intended for use with R-22. 6. but will not 5. 3. module 3. Oil Type If the compressor fails to start after this procedure the sensor circuit and the correct phasing should be Polyol ester lubricant (POE) must be provided if the evaluated using the following procedures. Field recharge is 135 ounces.P/N T. 4. . refrigerant vapor and oil. stances should a high potential test be made at the sensor terminals or sensor leads connected to the Scroll compressors (as with any refrigerant com- module. repair. pressor) should never be used to evacuate a refrigera- tion or air conditioning system. 5 . Compliant Scroll compressors are configured with the motor in the bottom of the shell. If 1. It is important checks can be used to determine proper motor to check both the high and low sides with manifold resistance or if an internal short to ground has gauges before unbrazing or in the case of assembly line developed. a brazing torch is then applied to the low side. preventing pressure pressor is functioning properly. If suction pressure falls below normal levels the HiPot Testing system is either low on charge or there is a flow blockage. remove refrigerant from both the high and low sides. reverse direction. it is sometimes be used to evaluate whether a Compliant Scroll com- possible for the scrolls to seal. Instructions should be provided in appropriate 3. Failure to heed this advice can result in refrigerant to a more normal configuration and test arcing of the Fusite pins and permanent damage to the again. ating conditions (pressures and voltages). It is not necessary to perform functional Unbrazing System Components compressor tests to check how the compressor will pull suction pressure. of the compressor power leads and reapply power In this respect. compressor. merged in oil and refrigerant. Copeland 4-1302 Deep Vacuum Operation immersed in refrigerant and does not present any safety issue. the Scroll motor can be im. Significant enon can occur with any compressor when the motor is deviation (± 15%) from published values may indicate a faulty compressor. the Scroll is more like the semi-hermetic to verify the compressor was not wired to run in the compressors that have horizontal motors partially sub. See Pressure Control damaged by exposure to high voltage. This phenom. redistributing the a deep vacuum. equalization through the compressor. Verify proper unit voltage. Compliant Scroll Functional Check neering Bulletin AE 24-1105 for proper system evacua- tion procedures. This may leave the low side shell and suction line tubing pressurized. Glacier™ Scroll compressors do not have internal suction valves. The following diagnostic procedure should unit by bleeding the high side only. With service gauges connected to the suction and product literature and assembly (line repair) areas. Damage to the sensors or module may result. Under no circum- section for proper set points. HiPot test with liquid refrigerant in the shell can show higher levels of current The operational compressor current draw should be leakage due to higher electrical conductivity of liquid compared to published performance curves at the oper- refrigerant vs. turn on the compressor. See Application Engi. To lower the current leakage reading operate the WARNING: Do not run a Glacier™ compressor in system for a brief period of time. This type of test may damage a Scroll If the refrigerant charge is removed from a Scroll compressor. Normal motor winding continuity and short to ground escapes and contacts the brazing flame. reverse any two mersed in refrigerant when liquid is present in the shell. Note: The solid state electronic module compo- A low pressure control is required for protection nents and internal sensors are delicate and can be against deep vacuum operation. discharge pressure fittings. Unlike most other 4. the pressurized refrigerant and oil mixture could ignite as it 2. If the suction pressure does not drop and the hermetic compressors. discharge pressure does not rise. Copeland 4-1302 ZB**KA Envelope (R-22) Conditions: 65°F Return Gas. 0°F Subcooling. 95°F Ambient °C °F 65 150 60 140 Condensing Temperature 55 130 50 120 45 110 40 100 35 30 90 25 80 20 70 15 60 20 30 40 50 60 °F -10 -5 0 5 10 15 °C Evaporating Temperature Figure 1A ZF**K4 Envelope (R-22) Conditions: 65°F Return Gas. 0°F Subcooling. 95°F Ambient °C °F 65 150 Liquid 60 140 Injection Condensing Temperature 55 130 50 120 45 110 40 Vapor or Liquid 100 35 Injection 30 90 25 80 20 70 15 60 -50 -40 -30 -20 -10 0 10 20 30 40 50 °F -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 °C Evaporating Temperature Figure 1B 6 . 95°F Ambient °C °F 65 150 Liquid 60 140 Injection 55 130 Condensing Temperature 50 120 45 110 Vapor or 40 Liquid 100 Injection 35 30 90 25 80 20 70 15 60 Low Condensing Temperature 10 50 Note: The ZF can 5 40 operate as a ZS 0 30 by capping the -5 20 injection port. Copeland 4-1302 ZF**K4E Envelope (R-404A/R-507) Conditions: 65°F Return Gas. 95°F Ambient °C °F 65 150 60 140 55 130 Condensing Temperature 50 120 45 110 40 100 35 30 90 25 80 20 70 15 60 Low Condensing Temperature 10 50 5 40 0 30 -5 20 -10 10 -50 -40 -30 -20 -10 0 10 20 30 40 50 °F -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 °C Evaporating Temperature Figure 1D 7 . -10 10 -50 -40 -30 -20 -10 0 10 20 30 40 50 °F -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 °C Evaporating Temperature Figure 1C ZS**K4E Envelope (R-404A/R-507) Conditions: 65°F Return Gas. 0°F Subcooling. 0°F Subcooling. Copeland 4-1302 ZS**K4/K4E Envelope (R-22) 65 et u G s Conditions: 65°F Return Gas °C °F 65 150 Condensing Tem pe rature 60 140 55 130 50 120 45 110 40 100 35 30 90 25 80 20 70 15 60 -30 -20 -10 0 10 20 30 40 50 °F -35 -30 -25 -20 -15 -10 -5 0 5 10 °C Evaporating Temperature Figure 1E 8 . 9 .401 for part information. Copeland 4-1302 GLACIER™ K4 Liquid Injection* RECEIVER CONDENSER FILTER HIGH PRESSURE CUTOUT DUAL PRESSURE CONTROL ON/OFF SOLENOID VALVE TO BE USED CAP TUBE WITH CURRENT ASSEMBLY SENSING RELAY S FILTER (OPTIONAL) SCROLL LOW PRESSURE CUTOUT THERMOSTATIC EVAPORATOR EXPANSION VALVE Figure 2 FIGURE 2 GLACIER K4 VAPOR GLACIER™ INJECTION* K4 Vapor Injection* RECEIVER CONDENSER FILTER HIGH PRESSURE CUTOUT DUAL PRESSURE CONTROL CAP TUBE S ASSEMBLY ON/OFF SOLENOID VALVE TO BE USED WITH CURRENT SENSING RELAY HEAT EXCHANGER LINE TO BE INSULATED SCROLL LOW PRESSURE CUTOUT THERMOSTATIC EVAPORATOR EXPANSION VALVE Figure 3 * See catalog 1. 5 .5 .15 HP Glacier™ Condensing Unit Mounting 030-0142-00 SLEEVE 102-0008-21 027-0137-00 WASHER RUBBER SPACER KIT #527-0159-00 027-0268-00 COMPRESSOR RUBBER GROMMET MOUNTING Figure 5B 10 .15 HP Glacier™ Rack Mounting 102-0119-00 WASHER 027-0115-00 RUBBER PAD KIT #527-0158-00 027-0280-00 STEEL SPACER Figure 5A 7.Copeland 4-1302 Scroll Wiring Schematic Oil Control Compressor Contactor Coil L1 L2 L3 Black White Red (To Motor Overload Sensors) (To Compressor Terminal Block) Figure 4 7. (4) Do not hang weights on tubing (e. OH 45365-0669 Printed in U.A. Copeland 4-1302 Typical Suction Tubing Typical InjectionTubing FILTER DRIER SUCTION MANIFOLD CAPILLARY TUBE KEEP MIN (SEE NOTE 6) CLAMP < 20" < 20" SOLENOID (MUST BE SECURED) < 30" CONTINUOUS TUBING (NO ELBOWS) Figure 6A Figure 6B NOTES: (1) The above tubing configurations are guidelines to minimize tube stress. (2) Follow similar guidelines for discharge tubing and oil return tubing as needed. (5) Tube runs of less than 12” are not recommended. The use of continuous tubing is preferred. Copeland Corporation Sidney. (6) This dimension should be made as short as possible but still insuring a proper braze joint. (7) The above tubing recommendations are based on “no elbow joints”. (3) If a run over 30” is required.g. 11 .S. intermediate clamps may be necessary. filter drier on suction tubing) except after clamps or close to the header.