Ae 1302 R4
Ae 1302 R4
® 4-1302
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
Copeland 4-1302
• Filter/Drier - 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.
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. Application Control Type R-404A/R-507 R-22
High Temp. Low 38 PSIG Min.
Accumulators (ZB) High 381 PSIG Max.
Medium Temp. Low 8 PSIG Min. 10 PSIG Min.
Due to our Compliant Scroll®’s inherent ability to (ZF) High 445 PSIG Max. 381 PSIG Max.
handle liquid refrigerant in flooded start and defrost Medium Temp. Low 8 PSIG Min. 24 PSIG Min.
operation conditions, accumulators may not be re- (ZS) High 445 PSIG Max. 381 PSIG Max.
quired. An accumulator is required on single compres- Low Temp Low 0 PSIG Min. 2 in. Hg Min.
sor systems with charges over 17 lbs. On systems with (ZF) High 400 PSIG Max. 335 PSIG Max.
defrost schemes or transient operations that allow Table 4
prolonged, uncontrolled liquid return to the compressor, 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. larger horsepower Scrolls. Therefore a high pressure
control located prior to any shut-off valves is manda-
Crankcase Heat tory
tory. There is an access port located on the compressor
Crankcase heaters* are required, on outdoor sys- discharge Rotalock fitting to accommodate this control.
tems, when the system charge exceeds 17 lbs. 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. 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. Four of the thermistors are used to sense
018-0036-00 240 70 21 29
motor temperatures, and the fifth is used as a discharge
temperature sensor. The thermistor circuit is connected
018-0036-02 480 70 21 29
to the protector module terminals S1 and S2.
018-0036-03 575 60 21 29
Table 3A When any thermistor reaches a limiting value, the
module interrupts the control circuit and shuts off the
Conduit Ready Terminal Box Numbers compressor. After the thermistor has cooled sufficiently,
Model Item Part Number it will reset. However, the module has a 30 minute time
7.5-15 H. P. Cover 005-7061-00 delay before reset after a thermistor trip.
7.5-15 H.P. 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. The heaters Module will sense the correct phase sequence of L1, L2,
are not equipped for use with electrical conduit. Where and L3 incoming power. At completion of the compres-
applicable electrical safety codes require heater lead sor installation, the three phase power must be wired in
protection, a crankcase heater terminal box should be the correct 120 degree phase sequence that will ensure
used. Recommended crankcase heater terminal cover the compressor will start and operate in the correct
and box numbers are listed in table 3B. If there are any clockwise rotation.
questions concerning their application, contact the
Copeland Application Engineering Dept. When the Int69SCY trips on phase loss a delay of
5 minutes is activated and then a new attempt to restart.
Discharge Line Thermostat If all three phases are present then the compressor will
continue to run, if not the module will lock out. There can
A discharge line thermostat is not required on these be 10 attempts to restart before the module will lock out
models. 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.
protection module and will shut the compressor off if
high discharge temperatures exist. Refer to Figure 4 for wiring schematic details. Also,
see the Module And Sensor Functional Check section
for proper operation procedures..
2
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.P/N T.I. 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 2.5A,600V 5 A, 300VA 5 A, 300VA
Power Output < 5.5 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. This
allows time for the motor to cool and the control
To check for proper control circuit operation,the circuit to reset.
following procedure is recommended:
2. Disconnect control circuit power to de-energize the
1. Disconnect power. module. Connect a jumper across the wires con-
nected to the M1 and M2 terminals on the module.
2. Disconnect one terminal either S1 or S2 on the
This will by-pass the module control contacts.
module
3. Reconnect control circuit power. If the compressor
3. Reapply power, the compressor should not start.
will not operate with the jumper installed, then the
4. Disconnect power problem is external to the module. If the compressor
operates with the module bypassed, but will not
5. Reconnect the sensor leads to the module operate when the jumper is removed, then the
module is defective.
6. Reapply power,the compressor should start.
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. Glacier™ Scroll is to be used with HFC refrigerants.
Copeland Ultra 22 CC™, Mobil EAL Arctic 22 CC, or ICI
1. Disconnect power EMKARATE RL 32CF are the only polyol ester oils
2. Check Verify correct phase lead orientation. Refer approved by Copeland at this time.
to figure 4 ZB**KA model Scrolls, intended for use with R-22,
3. Check all electrical terminal connections for pos- are supplied with mineral oil. The proper oils are Sontex
sible loose or broken connections 200LT, Witco LP-200, or ISO 3GS.
4. Check the resistance of the sensors at S1 and S2 The factory oil charge for all 7.5-15 HP. models is
terminals. The resistance readings should be be- 140 ounces. Field recharge is 135 ounces.
tween 250 and 1250 ohms at room temperature. Note: Do not add mineral oil to compressors charged
The trip resistance is 10,000 ohms or higher and with POE oil intended for use with HFC refrigerants. Use
reset resistance is 3000 ohms +/- 500 ohms. only the Copeland approved POE lubricants for these
5. Reapply power. applications.
CAUTION: Use an Ohmmeter with a maximum of Oil Management For Rack Applications
9 VAC for checking, do not attempt to check continuity Glacier™ Scrolls may be used on multiple compres-
through the sensors with any other type of instrument. sor parallel rack applications. 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. each compressor crankcase. 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.
1. If the compressor has been operating and has Unlike Semi-Hermetic compressors, Scrolls do not
tripped on the protector, allow the compressor to have an oil pump with accompanying oil pressure safety
3
Copeland 4-1302
Deep Vacuum Operation immersed in refrigerant and does not present any safety
issue. To lower the current leakage reading operate the
WARNING: Do not run a Glacier™ compressor in system for a brief period of time, redistributing the
a deep vacuum. 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.
compressor.
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. See Pressure Control damaged by exposure to high voltage. Under no circum-
section for proper set points. 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. Damage to the sensors or module may result.
pressor) should never be used to evacuate a refrigera-
tion or air conditioning system. See Application Engi- Compliant Scroll Functional Check
neering Bulletin AE 24-1105 for proper system evacua-
tion procedures. Glacier™ Scroll compressors do not have internal
suction valves. It is not necessary to perform functional
Unbrazing System Components compressor tests to check how the compressor will pull
suction pressure. This type of test may damage a Scroll
If the refrigerant charge is removed from a Scroll
compressor. The following diagnostic procedure should
unit by bleeding the high side only, it is sometimes
be used to evaluate whether a Compliant Scroll com-
possible for the scrolls to seal, preventing pressure
pressor is functioning properly.
equalization through the compressor. This may leave
the low side shell and suction line tubing pressurized. If 1. Verify proper unit voltage.
a brazing torch is then applied to the low side, the
pressurized refrigerant and oil mixture could ignite as it 2. Normal motor winding continuity and short to ground
escapes and contacts the brazing flame. 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.
repair, remove refrigerant from both the high and low
sides. Instructions should be provided in appropriate 3. With service gauges connected to the suction and
product literature and assembly (line repair) areas. discharge pressure fittings, turn on the compressor.
If suction pressure falls below normal levels the
HiPot Testing system is either low on charge or there is a flow
blockage.
Compliant Scroll compressors are configured with
the motor in the bottom of the shell. Unlike most other 4. If the suction pressure does not drop and the
hermetic compressors, the Scroll motor can be im- discharge pressure does not rise, reverse any two
mersed in refrigerant when liquid is present in the shell. of the compressor power leads and reapply power
In this respect, 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- reverse direction.
merged in oil and refrigerant. 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. refrigerant vapor and oil. This phenom- ating conditions (pressures and voltages). Significant
enon can occur with any compressor when the motor is deviation (± 15%) from published values may indicate a
faulty compressor.
5
Copeland 4-1302
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
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
Figure 1B
6
Copeland 4-1302
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.
-10 10
-50 -40 -30 -20 -10 0 10 20 30 40 50 °F
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
7
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
Figure 1E
8
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
9
Copeland 4-1302
Scroll Wiring Schematic
Oil Control
Compressor
Contactor
Coil
L1 L2 L3
Black
White
Red
102-0119-00
WASHER
027-0115-00
RUBBER PAD
KIT #527-0158-00
027-0280-00
STEEL SPACER
Figure 5A
102-0008-21 027-0137-00
WASHER RUBBER SPACER
KIT #527-0159-00
027-0268-00 COMPRESSOR
RUBBER GROMMET MOUNTING
Figure 5B
10
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.
(4) Do not hang weights on tubing (e.g. filter drier on suction tubing) except after clamps or close to the header.
(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.
Copeland Corporation
Sidney, OH 45365-0669 Printed in U.S.A.
11