Application Guidelines for Glacier K3 Copeland Scroll Refrigeration Compressors

AE4-1296 R3 March 2013 Application Guidelines for Glacier K3 Copeland Scroll Refrigeration Compressors TABLE OF CONTENTS Section Page Section Page 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 Operating Envelope... 4 Accumulators... 4 Superheat Requirements... 4 Crankcase Heat - Single Phase... 4 Crankcase Heat - Three Phase - Outdoor Only... 4 Discharge Line Thermostat... 4 Pressure Controls... 4 Liquid Injection... 4 Motor Protection... 5 Oil Type... 5 Oil Management... 5 Discharge Mufflers... 5 Compressor Mounting... 5 Starting Characteristics... 5 Fusite... 5 Deep Vacuum Operation... 5 Nomenclature... 5 Shell Temperature... 5 IPR Valve... 5 Shutoff Sound... 5 Suction Tubes... 6 Three Phase Scroll Compressors... 6 Brief Power Interruptions... 6 Assembly Line System Charging Procedure... 6 Unbrazing System Components... 6 High Potential (Hipot) Testing... 6 Compliant Scroll Functional Check... 7 Figures & Tables R-404A Envelope... 8 Accumulator Piping... 8 Motor Terminal (Fusite) Connections for Single Phase and Three Phase Scrolls... 8 Scroll Suction Tube Brazing... 9 Wiring Schematic... 10 Crankcase Heater Numbers 80 Watt Wrap Around... 11 Lubricant Field Recharge Values EAL ARCTIC 22 CC... 11 1

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 WARNING NOTICE DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury., 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., without the safety alert symbol, is used to address practices not related to personal injury. 2

Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons 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. WARNING 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. WARNING 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. 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. 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. 3

Introduction The Glacier K3 refrigeration scroll represents the industry s first application of scroll technology for refrigeration. This bulletin describes unique guidelines which must be followed to ensure proper, safe and durable service. Operating Envelope Glacier is currently released for R-404A refrigerant systems only. Because this refrigerant is an HFC, Emerson Climate Technologies approved polyol ester lubricant MOBIL EAL Arctic 22 CC must be used with this compressor. See Figure 1 at the end of this bulletin for the application envelope limitations. Accumulators Due to the Copeland Compliant Scroll s inherent ability to handle liquid refrigerant in flooded start and defrost cycle operation conditions, accumulators may not be required. On systems with extremely large refrigerant charges or defrost schemes that allow prolonged uncontrolled liquid return to the compressor, an accumulator would be recommended. Excessive liquid flood back or repeated flooded starts will dilute the oil in any compressor causing inadequate lubrication and bearing wear. Proper system design will ensure maximum compressor life. Superheat Requirements 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 floodback. 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 Heat - Single Phase No crankcase heat is required for single phase compressors. Crankcase Heat - Three Phase - Outdoor Only A crankcase heater is required for three phase compressors when the system charge exceeds 10 lbs. and no accumulator is used. A crankcase heater or pumpdown cycle is also required if the charge exceeds 10 lbs. and piping does not provide liquid drainage into an accumulator during the off cycle (See Figure 2 and Table 1 at the end of this bulletin). Discharge Line Thermostat A discharge line thermostat is required in the compressor control circuit. This thermostat has a cut-out setting of 200 F to 210 F with 50 F closing differential and should be installed approximately 7 inches from discharge tube outlet. If a service valve is installed at the discharge tube, the thermostat should be located 5 inches from the valve braze. Emerson recommends TOD thermostat part number 37TJ31X1976E. Pressure Controls Both high and low pressure controls are required and the following values are recommended: Low - Greater than 15 psia High - Less than 415 psia Liquid Injection For low temperature applications liquid injection is required. The compressor is supplied with a 1/4" diameter injection tube. A standard on-off solenoid should be wired to open when the compressor is running and close when (A) compressor shuts off (B) during a hot gas defrost (C) during a pump down cycle. In the event the internal motor protector trips, power to the injection solenoids must be dropped. Typically this is accomplished by the use of a current sensing relay. The liquid line leading to the on-off solenoid should pass through a filter dryer to avoid clogging the injection port. 4

The solenoid valve orifice diameter should be at least.056 inches. Motor Protection Conventional inherent internal line break motor protection is provided. Oil Type Polyol ester lubricant must be used in CopelandGlacier scroll compressors. MOBIL EAL Arctic 22 CC is approved for Copeland compressors. See Table 2 at the end of this bulletin for field oil recharge values. Glacier models equipped with a sight glass and oil drain/fill Schraeder valve should be recharged to the glass mid-point. POE must be handled carefully and the proper protective equipment (gloves, eye protection, etc.) must be used when handling POE lubricant. POE must not come into contact with any surface or material that might be harmed by POE, including without limitation, certain polymers (e.g. PVC/CPVC and polycarbonate). Oil Management Glaciers may be used on multiple compressor parallel rack applications. This requires the use of an oil management system to maintain proper oil level in each compressor crankcase. There are several manufacturers of conventional oil control systems that have successfully been applied to glacier compressors. The sight glass connections supplied on ZF and ZS models can accommodate the mounting of these oil control devices. Discharge Mufflers Flow through Glacier scroll compressors is continuous with relatively low pulsation s. External mufflers applied to piston compressors may not be required on Glacier scroll. Because of system variability individual system tests should be performed to verify acceptable sound levels. Compressor Mounting Compressors may be mounted either with grommets or solid mounted. However, consideration should be given for sound attenuation and tubing reliability. Unlike a hermetic reciprocating compressor, the scroll motor is pressed into the shell and not internally sprung. Some tubing geometry or shock loop may be required to reduce start-up vibration transferred from the compressor to external tubing. Starting Characteristics No start assist devices are required, even in systems utilizing non-bleed expansion valves. Due to inherent scroll design, internal compression components always start unloaded even if system pressures are not balanced. Since internal compressor pressures are always balanced at startup, scrolls exhibit excellent low voltage starting characteristics. Fusite Fusite pin orientation for single phase and three phase Glacier scroll compressors are shown in Figure 3 and inside the terminal box. Screw terminals are also available as an option. Deep Vacuum Operation WARNING If the suction side of the compressor is closed or severely restricted, arcing damage to the Fusite pins may result. Glacier models require a low pressure control for deep vacuum protection. Scroll compressors (as with any refrigerant compressor) should never be used to evacuate a refrigeration or air conditioning system. (See AE24-1105 for proper system evacuation procedures.) Nomenclature The Glacier scroll model numbers include the nominal capacity at standard operating conditions. Please refer to the product literature for model number details. Shell Temperature System component failure, may cause the top shell and discharge line to briefly reach temperatures above 350 F as the compressor cycles on its internal protection devices. Wiring or other materials which could be damaged by these temperatures should not come in contact with the shell. IPR Valve Refrigeration scroll compressors have internal pressure relief valves which open at a discharge to suction differential pressure of 375 to 450 psi. Shutoff Sound Since the scroll compressor is an excellent gas expander, it may run backwards for a brief period at shutoff as the internal pressures equalize. A low mass disc type check 5

valve in the compressor discharge tube prevents it from running backwards for more than a second or two. This momentary reversal of scroll direction has no effect on compressor durability. Development testing should include a review of the shutoff sound for acceptability in a particular system. Suction Tubes Scroll compressors have copper plated steel suction tubes. These tubes are more rugged and less prone to leaks than copper tubes used on other compressors. Due to the different thermal properties of steel and copper, brazing procedures may have to be changed from those commonly used. See Figure 4 for assembly line and field brazing procedures suggestions. Three Phase Scroll Compressors Scroll compressors are directional dependent, i.e., they will only compress in one rotational direction. Single phase compressors will always start and run in the proper direction (except as described in the section Brief Power Interruptions ). Three phase compressors will rotate in either direction depending on power phasing. Since there is a 50-50 chance of connecting power causing reverse rotation, it is important to include notices and instructions in appropriate locations on the equipment to ensure proper rotational direction is achieved when the system is installed and operated. Verification of proper rotational direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over correct rotation, as well as substantially reduced current draw compared to tabulated values. Durability is not effected by reversed rotation. After several minutes of operation the compressor s internal protector will trip. All three phase compressors are wired identically internally. Once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminals should maintain proper rotational direction. Brief Power Interruptions Brief power interruptions (less than 1/2 second) may result in powered reverse rotation of single phase Glacier scroll compressors. High pressure discharge gas expands backwards through the scrolls at power interruption, causing the scroll to orbit in the reverse direction. When the power is applied while reverse rotation is occurring, the compressor may continue to run noisily in the reverse direction for several minutes until the compressor s internal protector trips. This has no effect on durability. When the protector resets the compressor will start and run normally. To avoid the noise and loss of space temperature from single phase powered reverse rotation, Emerson strongly encourages use of an electronic control which can sense brief power interruptions and lock the compressor out of operation for two minutes. This control could be incorporated in other system controls (such as defrost or thermostat), or be a stand alone control. Functional specifications for this control as well as suggested wiring diagram are shown in Figure 5. No time delay is required on three phase models to prevent reverse rotation due to power interruptions. Assembly Line System Charging Procedure Rapid charging only on the suction side of a scroll system or condensing unit can occasionally result in a temporary no-start condition for the compressor. If the flanks of the compressor happen to be in a sealed position, rapid pressurization of the low side without opposing high side pressure can cause the scrolls to seal axially. Until the pressures eventually equalize, the scrolls can be held tightly together, preventing rotation. The best way to avoid this situation is to charge on both the high and low side simultaneously at a rate which does not result in axial loading of the scrolls. The maximum charging rate can be determined through simple tests. Unbrazing System Components If the refrigerant charge is removed from a scroll unit by bleeding the high side only, it is sometimes possible for the scrolls to seal, preventing pressure equalization through the compressor. This may leave the low side shell and suction line tubing pressurized. If a brazing torch is then applied to the low side, the pressurized refrigerant and oil mixture could ignite when it escapes and contacts the brazing flame. It is important to check both the high and low side with manifold gauges before unbrazing, or in the case of assembly line repair, remove refrigerant from both the high and low side. Instructions should be provided in appropriate product literature and assembly (line repair) areas. High Potential (Hipot) Testing Many of the Copeland brand compressors are configured with the motor below the compressor. As a result when liquid refrigerant is within the compressor shell the motor can be immersed in liquid refrigerant to a greater extent than with compressors with the motor mounted above 6

the compressor. When Copeland brand compressors are Hipot tested and liquid refrigerant is in the shell, they can show higher levels of leakage current than compressors with the motor on top because of the higher electrical conductivity of liquid refrigerant than refrigerant vapor and oil. This phenomenon can occur with any compressor when the motor is immersed in refrigerant. The level of current leakage does not present any safety issue. To lower the current leakage reading the system should be operated for a brief period of time to redistribute the refrigerant to a more normal configuration and the system Hipot tested again. See bulletin AE4-1294 for Megohm testing recommendations. Under no circumstances should the Hipot or Megohm test be performed while the compressor is under a vacuum. Compliant Scroll Functional Check Glacier scroll compressors do not have internal suction valves. It is not necessary to perform functional compressor tests to check how low the compressor will pull suction pressure. This type of test may damage a scroll compressor. The following diagnostic procedure should be used to evaluate whether a Compliant Scroll compressor is functioning properly. 3. With service gauges connected to suction and discharge pressure fittings, turn on the compressor. If suction pressure falls below normal levels the system is either low on charge or there is a flow blockage. 4. Single Phase Compressors If suction pressure does not drop and discharge pressure does not rise to normal levels the compressor is faulty. Three Phase Compressors If suction pressure does not drop and discharge pressure does not rise to normal levels, reverse any two of the compressor power leads and reapply power to make sure compressor was not wired to run in reverse direction. If pressures still do not move to normal values the compressor is faulty. 5. The compressor current draw must be compared to published compressor performance curves at the compressor operating conditions (pressures and voltages). Significant deviations (±15%) from published values may indicate a faulty compressor. 1. Verify proper unit voltage. 2. Normal motor winding continuity and short to ground checks will determine if the inherent overload motor protector has opened or if an internal short to ground has developed. If the protector has opened, the compressor must cool sufficiently to reset. 7

Medium Temperature No Injection Extended Temperature Liquid Injection Conditions: 0º F Subcooling, Air Over 95º F Ambient, 65º F Return Gas Figure 1 R-404A Envelope Liquid Level Drainage In Off Cycle Scroll Figure 2 Accumulator Piping Accumulator Figure 3 Motor Terminal (Fusite) Connections for Single Phase and Three Phase Scrolls 8

3 2 }1 } } Figure 4 Scroll Suction Tube Brazing New Installations The copper-coated steel suction tube on scroll compressors can be brazed in approximately the same manner as any copper tube. Recommended brazing materials: Any silfos material is recommended, preferably with a minimum of 5% silver. However, 0% silver is acceptable. Be sure suction tube fitting I.D. and suction tube O.D. are clean prior to assembly. Using a double-tipped torch apply heat in Area 1. As tube approaches brazing temperature, move torch flame to Area 2. Heat Area 2 until braze temperature is attained, moving torch up and down and rotating around tube as necessary to heat tube evenly. Add braze material to the joint while moving torch around joint to flow braze material around circumference. After braze material flows around joint, move torch to heat 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. Field Service To disconnect: Heat joint Areas 2 and 3 slowly and uniformly until braze material softens and tube can be pulled out of suction fitting. To reconnect: Recommended brazing materials: Silfos with minimum 5% silver or silver braze material with flux. Reinsert tube into fitting. Heat tube uniformly in Area 1, moving slowly to Area 2. When joint reaches brazing temperature, apply brazing material. Heat joint uniformly around the circumference to flow braze material completely around the joint. Slowly move torch into Area 3 to draw braze material into the joint. Do not overheat joint. 9

230/240 VAC Transformer if Required Typical Solid State Timer Fuse System Operating Thermostat Discharge Line Thermostat Compressor Contactor Coil C1 Other Protective Devices (if used) CSR Liquid Injection Solenoid Time Delay Relay Specifications Timer Opens: 1 Electrical Cycle (.016 Seconds with 60 HZ Operation) After Power is Removed Condenser Fan Contactor Coil (if used) C2 Timer Closes: 2 Minutes (ň 20%) Later, Whether Power is Restored or Not CSR = Current Sensing Relay Contact Figure 5 Wiring Schematic 10

Emerson Part No. Table 1 Crankcase Heater Numbers 80 Watt Wrap Around Voltage Springfield Wire No. 018-0042-02 240V SW 2994-3 018-0042-05 480V SW 2994-6 018-0042-08 577V SW 2994-9 Table 2 Lubricant Field Recharge Values EAL ARCTIC 22 CC Compressor Model Number Oil Recharge (Fl. Ounces) Factory Oil Charge ZS30K* -PFV 48 52 ZF13K* -TF5 48 52 ZF13K* -TFD 48 52 ZB30K* -TFE 48 52 ZS38K* -PFV 60 64 ZF15K* -TF5 60 64 ZF15K* -TFD 60 64 ZB38K* -TFE 60 64 The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or its affiliates (collectively "Emerson"), as applicable, 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. 11