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Application Engineering

B U L L E T I NAE4-1302 R6

© 2010 Emerson Climate Technologies

Printed in the U.S.A. 1


B U L L E T I N

Figure 1CZS**K4E Envelope (R-404A/R-507)

Conditions: 65°F Return Gas; 0°F Subcooling;95°F Ambient

Introduction

The Copeland Scroll® refrigeration compressor productoffering has expanded into the higher horsepower ranges. The scope of this bulletin will cover theapplication parameters unique to the new models.

Nomenclature

The Copeland Scroll model numbers include thenominal capacity at the standard 60 Hertz “ARI” ratingconditions. Please refer to product literature for modelnumber details.

Operating Envelope

These Copeland Scroll models can also be used witha variety of refrigerants. The following table showsthe selection options:

Table 1

Model Refrigerant Lubricant

ZF, ZS R22 MO

ZF, ZSR-404A,

R-507, R-22POE

The operating envelopes are depicted in Figures 1A

through 1D. See Oil Type on page 3 for recommendedlubricants.

Application Guidelines For

K4 Refrigeration Copeland Scroll ®

Compressors 7.5 - 15 Horsepower

AE4-1302 R6 March, 2005Reformatted November 2010

Note: The ZF can operate as a ZS by capping the injection port.

Figure 1B ZF**K4E Envelope (R-404A/R-507)Conditions: 65°F Return Gas;0°F Subcooling; 95°F Ambient

Figure 1AZF**K4 Envelope (R-22)

Conditions: 65°F Return Gas;0°F Subcooling; 95°F Ambient Figure 1D - ZS**K4/K4E Envelope (R-22)

Conditions: 65°F Return Gas

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Printed in the U.S.A.

• Filter/Drier - A filter/drier should be installed in theinjection circuit to avoid the possibility of capillarytube blockage due to contaminants.

Figures 2 and 3 are a representation of typical systemsdepicting the location of these components.

The advantage of this type of injection system is that ittends to self-regulate i.e., as the pressure differentialacross the capillary tube increases, the amount of liquid fed to the compressor also increases. Since morecooling is needed at high compression ratio conditions,this "automatic" increase in liquid feed is exactly whatis needed.

For the liquid injection system to be effective, aminmum of 5°F subcooled liquid at the capillary inletis required. However, do not use mechanically cooled

liquid refrigerant, such as found on supermarket rackapplications. The cap tube will be oversized and mayresult in feeding too much refrigerant into the scrolls.This condition can dilute the oil in the crankcase andcause lubrication issues.

Accumulators

Due to our Copeland Scroll compressor's inherentability to handle liquid refrigerant in flooded start anddefrost operation conditions, accumulators may notbe required. An accumulator is required on singlecompressor systems with charges over 17 lbs. Onsystems with defrost schemes or transient operationsthat allow prolonged, uncontrolled liquid return to thecompressor, an accumulator is required unless a suctionheader of suf ficient volume to prevent liquid migrationto the compressor is used.

Crankcase Heat

Crankcase heaters* are required, on outdoor systems,when the system charge exceeds 17 lbs.

*The above listed crankcase heaters are intended for use only where there is limited access. The heatersare not equipped for use with electrical conduit. Whereapplicable electrical safety codes require heater leadprotection, a crankcase heater terminal box should beused. Recommended crankcase heater terminal cover and box numbers are listed in Table 3B. If there areany questions concerning their application, contact theEmerson Climate Technologies Application EngineeringDepartment.

Liquid or Vapor Injection

The low temperature models are provided with aninjection port that can be used for either liquid or vapor

injection. Schematics are shown in Figures 2 and 3.The requirements are outlined below:

• Capillary Tube - Liquid must be fed through anappropriately sized capillary tube as defined inTable 2. The vapor injection method, in additionto the capillary tube, will require an external heatexchanger (Refer to Figure 3).

• Solenoid Valve - A solenoid valve with a minimum.109 inch orifice must be provided in the injectioncircuit that opens whenever the compressor isoperative or cooling is required during pumpdown.The solenoid must be closed when the compressor is cycled off. Failure to provide the solenoid valve

can result in liquid refrigerant completely filling theScroll during an “off-cycle". If power is reappliedin this condition, the hydraulic effect producedcould result in pressure high enough to causepermanent damage to the compressor. Due to this,it is a condition of warranty that the capillary tubeand solenoid valve, properly installed, be providedwhenever liquid or vapor injection is used.

The following components are not required, but theyare recommended for liquid injection.

• Sight Glass - A sight glass should be installed just before the capillary tube inlet to allow visual

inspection for the presence of liquid refrigerant.

Table 2

Capillary Tubes for Liquid or Vapor Injection

Model

Cap TubeEmerson Kit

Number I.D.

(inches)

Length

(inches)

R-22

ZF24K4 0.05 5" 998-1586-00

ZF33K4 0.05 5" 998-1586-00

ZF40K4 0.07 30" 998-1586-05

ZF48K4 0.07 10" 998-1586-06

R-404A/R-507

ZF24K4E 0.05 30" 998-1586-04

ZF33K4E 0.05 17.5" 998-1586-01

ZF40K4E 0.07 30" 998-1586-05

ZF48K4E 0.07 30" 998-1586-05

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Discharge Line Thermostat

A discharge line thermostat is not required onthese models. The compressor features an internaltemperature sensor which works in conjunction withthe protection module and will shut the compressor off if high discharge temperatures exist.

Pressure Controls

Both high and low pressure controls are required and

the following are the minimum and maximum set points:

IPR Valve

There is no internal pressure relief valve in these larger horsepower scrolls. Therefore a high pressure controllocated prior to any shut-off valves is mandatory. Thereis an access port located on the compressor dischargeRotalock fitting to accommodate this control.

Motor Protection

There are five PTC (Positive Temperature Coef ficient)internal thermistors connected in series that react withavalanching resistance in the event of high temperatures.Four of the thermistors are used to sense motor temperatures, and the fifth is used as a dischargetemperature sensor. The thermistor circuit is connectedto the protector module terminals S1 and S2.

When any thermistor reaches a limiting value, themodule interrupts the control circuit and shuts off the

Model Item Part Number

7.5-15 H. P. Cover 005-7061-007.5-15 H.P. Box 062-7015-00

Table 3BConduit Ready Terminal Box Numbers

Part No. Volts Watts

Lead

Lengths

(in)

GroundWire

Lengths

(in)

018-0036-01

018-0036-00

018-0036-02

018-0036-03

120

240

480

575

70

70

70

60

21

21

21

21

29

29

29

29

Table 3AExternal Wrap-Around

Crankcase Heater Numbers*

compressor. After the thermistor has cooled suf ficiently,it will reset. However, the module has a 30 minute timedelay before reset after a thermistor trip.

Programmable Logic Controller Requirements

If the INT69SCY (071-0597-00) module is applied inconjunction with a Programmable Logic Controller, it isimportant that a minimum load is carried through theM1-M2 control circuit contacts.

The minimum required current through the modulerelay contacts needs to be greater than 100 milliampsbut not to exceed 5 amps. If this minimum current isnot maintained, this has a detrimental effect upon thelong-term contact resistance of the relay and may resultin false compressor trips.

PLC operated control circuits may not always provide

this minimum current. In these cases modifications to thePLC control circuit are required. Consult your ApplicationEngineering Department for details.

Phase Protection

The INT69-SCY module provides phase protectionfor the compressor. The module senses the correct phase sequence, phase loss and voltage sag for eachleg (L1, L2 and L3) of the incoming power supplied tothe compressor. At installation the three phases of thepower supply must be wired in the correct 120° phasesequence. This will ensure the compressor will start andoperate in the correct clockwise direction.

The INT69-SCY module trips (M1-M2 contacts open)when the module senses a phase loss. There is a 5minute time delay before the module attempts a restart.If all three phases are present, then the module will reset(M1-M2 contacts will close) and the compressor will startand run. If not, the module will attempt a restart after another 5 minute time delay. After 10 failed attempts to

ApplicationControl

TypeR-404A/R-507

R-22

Medium Temp.

(ZF)

Low 8 PSIG Min. 10 PSIG Min.

High 445 PSIG Max. 381 PSIG Max.

Medium Temp.

(ZS)

Low 8 PSIG Min. 24 PSIG Min.


Low Temp.

(ZF)

Low 0 PSIG Min. 2 in. Hg Min.


Table 4

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restart, the module will lock-out (M1-M2 contacts willremain open) and can only be reset by removing thepower from T1-T2 for a minimum of 5 seconds.

The INT69SCY is intended to protect the compressor.The L1/L2/L3 and S1/S2 leads are pre-wired on thecompressor and are engineered to work in conjunctionwith the motor protector module. The module leadsshould not be moved or extended because of thepossibility of inducing electronic noise into the INT69SCY,which could cause false trips of the module.

W h i t e

C

Compressor Contactor

CoilThermostat

(To 24 VAC Supply)

SuctionPressureSwitch

DischargePressureSwitch

(To Motor Overload Sensors)

M1 M2

S1 S2

T1 T2

Motor Overload Protector

L1

OMB OilLevel

Control

L2

R e d

B l a c k

(To Compressor Terminal Block)

Oil Control

Liquid/Vapor InjectionSolenoid

Figure 4Scroll Wiring Schematic

Refer to Figure 4 for wiring schematic details. Also,see the module and sensor functional check sectionfor proper operation procedures.

Module and Sensor Functional Check

The following field troubleshooting procedure can beused to evaluate the solid state control circuit:

Refer to Table 5 for a technical data summary.

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Table 5

Emerson P/N

Manufacture P/N

071-0520-07

T.I. 30AA201E

071-0520-05

Kriwan 69SC-DV

071-0597-00

Kriwan 69SCY

T1-T2 Module Power

Voltage Supply

Frequency

120V & 240V

50Hz 60 Hz

120V & 240V

50Hz 60 Hz

120V & 240V

50Hz 60 Hz

M1-M2 Module Output Contacts

Maximum Voltage

Maximum Current

Minimum Current

Relay Output

Power Output

N/A

5 Amps

100 milliamps

2.5 A, 600 V

< 5.5 VA

250VAC

5 Amps

100 milliamps

5 A, 300 VA

< 3 VA

250VAC

5 Amps

100 milliamps

5 A, 300 VA

< 3 VA

S1-S2 Thermal Protection

Trip Out Resistance

Reset Resistance

Reset Time

Manual Reset

N/A

N/A

30 min ± 5 min.

T1-T2 interrupt for minimum of 5 sec

4500/ ± 20%

2750/ ± 20%

30 min ± 5 min.


4500/ ± 20%

2750/ ± 20%

30 min ± 5 min.


L1-L2-L3 Phase Monitoring

Phase Sensor

Phase Monitoring

Circuit Rating

Trip Delay

LockoutReset for Lockout

Non Phase Sensing

Non Phase Sensing

Non Phase Sensing

Non Phase SensingNon Phase Sensing

Non Phase Sensing

Non Phase Sensing

Non Phase Sensing

Non Phase SensingNon Phase Sensing

3

3 AC 50/60Hz 120V to 632V

5 min delay before restart attempt

After 10 module tripsT1-T2 interrupt for minimum of 5 sec

Module Voltage Supply Troubleshooting

• Verify that all wire connectors are maintaining a goodmechanical connection. Replace any connectors thatare loose.

• Measure the voltage across T1-T2 to ensure proper supply voltage.

• Determine the control voltage by using a voltmeter and then measure the voltage across the M1-M2contacts:

a) If the measured voltage is equal to the controlvolts then the M1-M2 contacts are open.

b) If the measurement is less than 1 volt and thecompressor is not running, then the problem isexternal to the INT69-SCY module.

c) If the voltage is greater than 1 volt but less thanthe control voltage, the module is faulty and shouldbe replaced.

Sensor Troubleshooting

• Remove the leads from S1-S2, and then by using anohmmeter measure the resistance of the incomingleads.

CAUTION: Use an Ohmmeter with a maximumof 9 VDC for checking – do not attempt to checkcontinuity through the sensors with any other type of instrument. Any external voltage or current may cause damage requiring compressor replacement.

a) During normal operation, this resistance valueshould read less than 4500 ohms ±20%.

b) If the M1-M2 contacts are open, the measuredS1-S2 value is above 2750 ohms ±20% and thecompressor has been tripped less then 30 minutesthen the module is functioning properly.

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Copeland Scroll 7.5-15 H.P. scroll rack applications. Thismounting arrangement limits the compressors motionthereby minimizing potential problems of excessivetubing stress. Suf ficient isolation is provided to preventvibration from being transmitted to the mountingstructure. This mounting arrangement is recommendedfor multiple compressor rack installations. See Figure6A for a detail of this mounting system.

Note: The use of standard soft grommets is notrecommended for Copeland Scroll rack installations.These “softer” mounts allow for excessive movementthat will result in tube breakage unless the entire systemis properly designed.

Condensing Units- For 7.5-15 H.P. CopelandScroll condensing unit applications soft mounts arerecommended. See Figure 6B.

Tubing Considerations - Proper tube design must betaken into consideration when designing the tubingconnecting the scroll to the remaining system. Thetubing should provide enough “flexibility” to allow normalstarting and stopping of the compressor without exertingexcessive stress on the tube joints. In addition, it isdesirable to design tubing with a natural frequency awayfrom the normal running frequency of the compressor.Failure to do this can result in tube resonance andunacceptable tubing life. Figures 7A and 7B areexamples of acceptable tubing configurations.

Caution:These examples are intended only as guidelines

to depict the need for flexibility in tube designs. In order to properly determine if a design is appropriate for a given

application, samples should be tested and evaluated for stress under various conditions of use including voltage,frequency, and loadfluctuations, and shipping vibration.The guidelines above may be helpful; however, testingshould be performed for each system designed.

Connection Fittings

Larger horsepower Copelnd Scroll compressors aresupplied with Rotalock adapter spuds welded on theshell. The fitting sizes for 7.5 through 15 H.P. scrollsare as follows:

7.5 through 13 Horsepower SuctionRotolock Spud Connection 1 3/4-12Discharge Rotolock Spud Connection 1 1/4-12

15 Horsepower Suction Rotolock Spud Connection 2 1/4-12Discharge Rotolock Spud Connection 1 3/4-12

Low temperature “ZF” models are also equipped with a1/4 inch I.D. injection port. This fitting is a copper platedsteel connection. Brazing procedures for this type of fitting

is inherently different than brazing pure copper fittings.See the section on Field Service in the AE4-1299 for suggestions on how to properly make this connection.

Three Phase Scroll Compressors — DirectionalDependence

Scroll compressors are directional dependent; i.e. theywill compress in one rotational direction only. Threephase scrolls will rotate in either direction dependingon power phasing. Since there is a 50/50 chanceof connected power being “backwards”, contractorsshould be warned of this. Appropriate instructions or notices should be provided by the OEM. To eliminatethe possibility of reverse rotation a Copeland® PhaseControl line monitor, P/N 085-0160-00, or other phasemonitor is recommended on installations not using thephase sensing module. However, our newer modules

will prevent operation in the wrong direction. Refer toTable 5 for module features.

Verification of proper rotation can be made by observingthat the suction pressure drops and the dischargepressure rises when the compressor is energized.

Additionally, if operated in reverse the compressor isnoisier and its current draw is substantially reducedcompared to tabulated values.

No time delay is required on three phase models toprevent reverse rotation due to brief power interruptions.

Deep Vacuum Operation

WARNING: Do not run a Copeland Scroll compressor in a deep vacuum. Failure to heed this advice can resultin arcing of the Fusite pins and permanent damage tothe compressor.

A low pressure control is required for protection againstdeep vacuum operation. See Pressure Control sectionfor proper set points. (Table 4)

Scroll compressors (as with any refrigerant compressor)should never be used to evacuate a refrigeration or air conditioning system. See AE24-1105 for proper systemevacuation procedures.

Unbrazing System Components

If the refrigerant charge is removed from a Scroll unitby bleeding the high side only, it is sometimes possiblefor the scrolls to seal, preventing pressure equalizationthrough the compressor. This may leave the low side shelland suction line tubing pressurized. If a brazing torch isthen applied to the low side, the pressurized refrigerantand oil mixture could ignite as it escapes and contactsthe brazing flame. It is important to check both the highand low sides with manifold gauges before unbrazing or in the case of assembly line repair, remove refrigerant

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from both the high and low sides. Instructions should beprovided in appropriate product literature and assembly(line repair) areas.

HiPot Testing

Copeland Scroll compressors are configured withthe motor in the bottom of the shell. Unlike mostother hermetic compressors, the Scroll motor can beimmersed in refrigerant when liquid is present in theshell. In this respect, the Scroll is more like the semi-hermetic compressors that have horizontal motorspartially submerged in oil and refrigerant. HiPot testwith liquid refrigerant in the shell can show higher levelsof current leakage due to higher electrical conductivityof liquid refrigerant vs. refrigerant vapor and oil. Thisphenomenon can occur with any compressor when themotor is immersed in refrigerant and does not present

any safety issue. To lower the current leakage readingoperate the system for a brief period of time, redistributingthe refrigerant to a more normal configuration and testagain.

Note: The solid state electronic module components andinternal sensors are delicate and can be damaged byexposure to high voltage. Under no circumstances shoulda high potential test be made at the sensor terminals or sensor leads connected to the module. Damage to the

sensors or module may result.

Copeland Scroll Functional Check

Copeland Scroll compressors do not have internalsuction valves. It is not necessary to perform functionalcompressor tests to check how the compressor willpull suction pressure. This type of test may damage aScroll compressor. The following diagnostic procedureshould be used to evaluate whether a Copeland Scrollcompressor is functioning properly.

1. Verify proper unit voltage.

2. Normal motor winding continuity and short toground checks can be used to determine proper motor resistance or if an internal short to groundhas developed.

3. With service gauges connected to the suction anddischarge pressurefittings, turn on the compressor.If suction pressure falls below normal levels thesystem is either low on charge or there is a flowblockage.

4. If the suction pressure does not drop and thedischarge pressure does not rise, reverse any twoof the compressor power leads and reapply power to verify the compressor was not wired to run inthe reverse direction.

The operational compressor current draw shouldbe compared to published performance curves at

the operating conditions (pressures and voltages).Significant deviation (± 15%) from published valuesmay indicate a faulty compressor.

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Figure 2Copeland Scroll K4

Liquid Injection*

Figure 3Copeland Scroll K4

Vapor Injection*

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Figure 5

OMB Electronic Oil Level Management System Installation and Service Instructions

FEATURES Self contained unit with oil level sensor

and integral solenoid to manage oil levelsupply

• Hall-effect sensor for precisemeasurement of oil level

• Alarm and status indication by LEDs

• SPDT output contact for compressor shutdown or alarming

• Easy installation by sightglassreplacement

• Adapters suitable for various types of compressors including conventional andscroll compressors

• Signal generated by gravity based float-not prone to errors from foaming likeoptical sensors

• Sacrificial magnet for reliable operation

SAFETY INSTRUCTIONSWARNING : Before opening any system,make sure the pressure in the system isbrought to and remains at atmosphericpressure. Failure to comply can result inpersonal injury and/or system damage.

1. Read installation instructionsthoroughly. Failure to followinstructions may result in productfailure, system damage, or personalinjury.

2. Do not open system under pressure.

3. Ensure supply voltage is withinspecified OMB limits.

4. Disconnect supply voltage fromsystem/OMB before installation/service. Comply with local electricalregulations when wiring OMB.

5. Do not exceed maximum workingpressure.

6. Keep temperature within nominallimits.

7. Work should be performed by qualifiedservice personnel or a licensedcontractor

SPECIFICATIONSMaximum Working Pressure: 500 psigSolenoid MOPD: 350 psigSupply Voltage: 24 VAC,

zH06/05Solenoid Coil:

,C AV42L2CS A50/60 HzCurrent Consumption: 0.6ATime Delay for Low Level

Signal: 10 secondsTime Delay After SetpointRecovery: 5 seconds

Alarm Delay Time: 120 seconds(including alarm contact)

Alarm Switch:SPDT

Alarm Contact Rating: 10A-125V,V052- A5

Refrigerant Compatibility: HFC, HCFC,(not for use with flammable CFCrefrigerants or ammonia)Refrigerant Temperature: -40°F TO

F°081Storage and Ambient Temp.: -40°F TO

F°021

Ambient Temp. (Housing): -40°F TOF°021Oil Supply fitting: ¼ Male SAECompressor Adapter: See Table 1

TABLE 1

Mounting Adapter Kit Applications

Adapter Kit ACA

Compressor TypeCopeland Glaciers,ZF, ZS, ZB

INSTALLATION INSTRUCTIONS1. Read installation instructions thoroughly.

2. Assure that you have the appropriate

mounting adapter kit for the compressor.See Table 1. For semi-hermetic

compressors see steps 1A through 5A

below. For Copeland compressors using

adapter kit ACA see steps 1B through 6B

For Copeland compressors using adapte

kit ACB see steps 1C through 6C.

Kit ACA (pipe Thread) for ScrollCompressors

1B. Assure there is no pressure in thecompressor crankcase and unscrew the ¾pipe thread attaching the original sight glassto the compressor. Take note of the originaloil level since oil may be lost when the sight

glass is removed. Tip the compressor toavoid oil loss if possible.

2B. Using PTFE tape as a sealant, threadthe adapter into the compressor with thethree hole flange installed on the adapter to capture in the assembly. The chamferedside of the threaded bolt holes should faceoutward. Torque the pipe thread to 30-40 ft.lbs. Take care not to scratch the o-ring sealsurface of the adapter.

3B. Using the O-ring and bolts provided,install the control unit to the adapter flange.The top of the control unit must be perfectlyhorizontal with the oil inlet fitting to the left.Torque the bolts to 120 in.-lbs.

4B. Connect the oil supply line to the ¼ inchmale flare fitting. A clean-able strainer isincorporated into the fitting.

5B. Make wiring connections in accordancewith Figure 1. Important: The screw clampstyle connector plugs used for the power supply and solenoid coil must be unpluggedfrom the circuit board to gain access to thewire clamp screws. Use a small screwdriver to pry them outward.

6B. Assure there is a proper oil level in thecrankcase.

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Printed in the U S A

COMPRESSORMOUNTING027-0268-00RUBBER GROMMET

102-0008-21WASHER 027-0137-00RUBBER SPACER

030-0142-00SLEEVE

KIT #527-0159-00

027-0115-00

RUBBER PAD

102-0119-00WASHER

027-0280-00STEEL SPACER

KIT #527-0158-00

Figure 6B7.5 - 15 HP Copeland Scoll Condensing Unit

Mounting

Figure 6A7.5 - 15 HP Copeland Scroll Rack Mounting

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.

(3) If a run over 30” is required, intermediate clamps may be necessary.

(4) Do not hang weights on tubing (e.g. filter drier on suction tubing) except after clamps or close to the header.

(5) Tube runs of less than 12” are not recommended.

(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”. The use of continuous tubing is preferred.

Figure 7A

Typical Suction Tubing

Figure 7B

Typical Injection Tubing

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