EMERSON Copeland Water Cooled Scroll Condensing Units User Manual

Copeland Water Cooled Scroll Condensing Units
User Manual

Introduction

Emerson Water-Cooled Scroll Condensing Units are fitted with high efficient Copeland Scroll Compressors.
This document is designed to help the contractor and customer for the installation, commissioning & operation of Emerson’s Water-Cooled Scroll Condensing Unit.
Scope of supply – Check page number 10 of this manual for detailed scope of supply.

Disclaimer
Thank you for purchasing the Emerson™ Water-Cooled Scroll Condensing Unit. We hope that this product meets your intended refrigeration requirement. Please read  through this operation manual to familiarize yourself with the installation, commissioning, and operation of this product. Please do read the following information in this  page before proceeding with the rest of the manual.
The Emerson™ Water-Cooled Scroll refrigeration condensing units should only be installed by suitably qualified and experienced refrigeration technicians. No responsibility  can be accepted for damage caused by inexperienced or inadequately trained site technicians or improper system design. All instructions and procedures described in this  manual are based on good refrigeration trade practices as applicable to this particular product.
The installation contractor may prefer to use variations to these recommendations. However, the methods described in this manual represent the minimum requirements to  avoid any subsequent warranty claims for this equipment and its components. These instructions do not cover the fundamentals of good electrical or refrigeration practice  and are therefore intended for use only by qualified and/or experienced personnel or technicians.
For any additional query, please consult your local sales office, quoting unit model and serial number as shown on the nameplate. In case of ambiguity, the wiring diagram  supplied with each unit takes precedence over the diagram in this manual.

Safety Information

1.1 Installation and commissioning work on CDU shall be carried out only by qualified, refrigeration personnel who have been trained and instructed.
1.2 Water Cooled Scroll Condensing Unit is manufactured according to the latest safety standards. Emphasis has been placed on the user’s safety. For relevant standards  please refer to the manufacturer’s declaration, available on request. You are strongly advised to follow these safety instructions.
1.3 Icon explanation

1.4 Safety Statements
a. Only qualified and authorized refrigeration personnel are permitted to install, commission and maintain this equipment.
b. Electrical connections must be made by qualified electrical personnel.
c. All valid standards for connecting electrical and refrigeration equip- ment must be observed.
d. The national legislation and regulations regarding personnel protection must be observed.

Use personal safety equipment. Safety goggles, gloves, protective clothing,
safety boots and hard hats should be worn where necessary.

1.5 General Instructions
WARNING
System breakdown! Personal injuries! Never install a system in the field and leave it unattended when it has no charge, a holding charge, or with the service valves closed  without electrically locking out the system.
System breakdown! Personal injuries! Only approved refrigerants and refrigeration oils must be used.
WARNING
High shell temperature! Burning! Do not touch the compressor until it has cooled down. Ensure that other materials in the area of the compressor do not get in touch with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without refrigerant charge or without being connected to the system.
CAUTION
Compressors contain oil & refrigerant under pressure. Release pressure from both high & low side of compressor before servicing.
CAUTION
Tube brazing & compressor operation can produce hot surfaces. To avoid burns, allow surfaces to cool.

1.6 Safety Refrigerants/Lubricant
a. Please use correct refrigerant as designed to work in safe operating envelope.
b. Compressor is supplied with an initial oil charge. The standard oil charge for use with HFC refrigerant is polyol ester (POE) lubricant Emkarate RL 32 3MAF.

Nomenclature

Dimensional Drawings & Data

Mechanical Data – 50Hz

Condensing Unit Model| Compressor Model| Receiver
Capacity
(I)| Depth/Width
(D/W) (mm)| Height [H)
(mm)| Suction 0
(SL) (“)| Liquid 0
[LL] n| Water
Inlet FPT
C)| Water
Outlet ODF
(“)| Net
Weight
(Kg)| Gross
Weight
(Kg)
---|---|---|---|---|---|---|---|---|---|---
FDCKA-ZS09-TFM| ZSO9KAE-TFD-600| 4.| 460/618| 495| 5/8| 1/2| 3/8| 5/8| 39| 49
FDCKA-ZS11-TFM| ZS11KAE-TFD-600| 4.| 460/618| 495| 5/8| 1/2| 3/8| 5/8| 39| 49
FDCKA-ZS13-TFM| ZS13KAE-TFD-600| 4.| 460/618| 495| 5/8| 1/2| 3/8| 5/8| 39| 49
FMCKA-ZB15-TFM| ZB15KQE-TFD-559| 4.| 460/610| 471| 3/4| 1/2| 3/8| 5/8| 42| 52
FMCKA-Z1319-TFM| ZB19KQE-TFD-559| 4.| 460/610| 471| 3/4| 1/2| 3/8| 5/8| 44| 54
FMCKA-ZB21-TFM| ZB21 KQE-TFD-559| 4.| 460/610| 494| 3/4| 1/2| 3/8| 5/8| 44| 54
FMCNA-ZB26-TFM| ZB26KQE-TFD-559| 8.| 570/680| 510| 7/8| 1/2| 3/4| 7/8| 62| 77
FMCNA-ZB29-TFM| ZB29KQE-TFD-559| 8.| 570/680| 527| 7/8| 1/2| 3/4| 7/8| 66| 81
FMCNA-Z838-TFM| ZB38KQE-TFD-559| 8.| 570/680| 545| 11/8| 1/2| 3/4| 7/8| 70| 85
FMCNA-ZB45-TFM| ZB45KQE-TFD-559| 8.| 570/680| 545| 11/8| 1/2| 3/4| 7/8| 72| 87
FMCPA-Z848-TFM| ZB48KQE-TFD-559| 8.| 610/725| 559| 1 1/8| 1/2| 3/4| 1 1/8| 76| 91
FLCKA-ZFO6-TFM| ZFO6KQE-TFD-551| 4.| 460/610| 477| 3/4| 1/2| 3/8| 5/8| 42| 52
FLCKA-ZFO9-TFM| ZFO9KQE-TFD-551| 4.| 460/610| 499| 3/4| 1/2| 3/8| 5/8| 44| 54
FLCNA-ZF11-TFM| ZF11KQE-TFD-551| 8.| 570/680| 515| 7/8| 1/2| 3/4| 7/8| 61| 76
FLCNA-ZF13-TFM| ZF13KQE-TFD-551| 8.| 570/680| 545| 7/8| 1/2| 3/4| 7/8| 71| 86
FLCNA-ZF15-TFM| ZF15KQE-TFD-551| 8.| 570/680| 545| 11/8| 1/2| 3/4| 7/8| 72| 87
FLCNA-ZF18-TFM| ZF18KQE-TFD-551| 8.| 570/680| 545| 1 1/8| 1/2| 3/4| 7/8| 74| 89

Mechanical Data – 60Hz

Condensing unit model| Compressor model| Receiver capacity
(l)| Depth/ width
[D/W] (mm)| Height [H] (mm)| Suction Ø[SL] (″)| Liquid Ø[LL] (″)| Water
inlet FPT
(″)| Water outletODF (″)| Net
weight
(kg)| Gross
weight
(kg)
---|---|---|---|---|---|---|---|---|---|---
FMCKA-ZS 11-TF7| ZS11KAE-TF7-600| 3.9| 460/610| 495| 8-May| 2-Jan| 8-Mar| 8-May| 39| 49
FMCKA-ZB 15-TF7| ZB15KQE-TF7-559| 3.9| 460/610| 471| 4-Mar| 2-Jan| 8-Mar| 8-May| 42| 52
FMCKA-ZB 19-TF7| ZB19KQE-TF7-559| 3.9| 460/610| 471| 8-Jul| 2-Jan| 8-Mar| 8-May| 44| 54
FMCNA-ZB 21-TF7| ZB21KQE-TF7-559| 7.9| 570/680| 496| 8-Jul| 2-Jan| 4-Mar| 8-Jul| 60| 75
FMCNA-ZB 26-TF7| ZB26KQE-TF7-559| 7.9| 570/680| 510| 8-Jul| 2-Jan| 4-Mar| 8-Jul| 62| 77
FMCNA-ZB 29-TF7| ZB29KQE-TF7-559| 7.9| 570/680| 527| 1 1/8| 2-Jan| 4-Mar| 8-Jul| 66| 81
FMCNA-ZB 38-TF7| ZB38KQE-TF7-559| 7.9| 570/680| 545| 1 1/8| 2-Jan| 4-Mar| 8-Jul| 71| 86
FMCPA-ZB 45-TF7| ZB45KQE-TF7-559| 7.9| 610/725| 555| 1 1/8| 2-Jan| 4-Mar| 1/1/2008| 76| 91
FLCKA-ZF 06-CFV| ZF06KQE-PFV-551| 3.9| 460/610| 477| 4-Mar| 2-Jan| 8-Mar| 8-May| 45| 55
FLCNA-ZF 09-CFV| ZF09KQE-PFV-551| 7.9| 570/680| 501| 4-Mar| 2-Jan| 4-Mar| 8-Jul| 62| 77
FLCNA-ZF 11-CFV| ZF11KQE-PFV-551| 7.9| 570/680| 515| 8-Jul| 2-Jan| 4-Mar| 8-Jul| 62| 77
FLCNA-ZF 13-TF7| ZF13KQE-TF7-551| 7.9| 570/680| 546| 8-Jul| 2-Jan| 4-Mar| 8-Jul| 73| 88
FLCNA-ZF 15-TF7| ZF15KQE-TF7-551| 7.9| 570/680| 546| 1 1/8| 2-Jan| 4-Mar| 8-Jul| 73| 88
FLCPA-ZF 18-TF7| ZF18KQE-TF7-551| 7.9| 610/725| 546| 1 1/8| 2-Jan| 4-Mar| 1/1/2008| 76| 91

Envelopes

Electrical Data – 50Hz

Condensing Unit Model| Compressor Model| Compressor Maximum
Operating Current (A)| Compressor Locked
Rotor Current (A)
---|---|---|---
FDCKA-ZS09-TFM| ZSO9KAE-TFD-600 3.0 27.0
FDCKA-ZS11-TFM| ZS11KAE-TFD-600| 3.| 27.0
FDCKA-ZS13-TFM
FMCKA-ZB15-TFM
FMCKA-ZB19-TFM| ZS13KAE-TFD-600 4.0 29.0
ZB15KQE-TFD-559| 5.| 26.0
ZB19KQE-TFD-559 6.5 32.0
FMCKA-ZB21-TFM| ZB21 KQE-TFD-559| 7.| 40.0
FM CNA-ZB26-TFM FM CNA-ZB29-TFM FM CNA-ZB38-TFM FM CNA-ZB45-TFM FM CPA-Z B48-TFM| ZB26KQE-TFD-559 8.9 46.0
ZB29KQE-TFD-559| 10.0| 50.0
ZB38KQE-TFD-559 12.8 65.5
ZB45KQE-TFD-559| 13.| 74.0
ZB48KQE-TFD-559 14.0 101.0
FLCKA-Z F06-TFM| ZFO6KQE-TFD-551| 5.0| 26.0
FLCKA-Z F09-TFM ZFO9KQE-TFD-551 6.0 40.0
FLCNA-Z F11-TFM| ZF11KQE-TFD-551| 7.| 46.0
FLCNA-ZF13-TFM ZF13KQE-TFD-551 8.0 51.5
FLCNA-ZF15-TFM| ZF15KQE-TFD-551| 10.0| 64.0
FLCNA-ZF18-TFM ZF18KQE-TFD-551 12.5 74.0

Electrical Data – 60Hz

Condensing unit model| Compressor model| Compressor maximum operating current (A)| Compressor locked
rotor current (A)
---|---|---|---
FM CKA-ZS 11-TF7| ZS11KAE-TF7-600| 3.9| 29
FM CKA-ZB 15-TF7| ZB15KQE-TF7-559| 5.1| 27
FM CKA-ZB 19-TF7| ZB19KQE-TF7-559| 6| 30
FM CNA-ZB 21-TF7| ZB21KQE-TF7-559| 7.2| 39
FM CNA-ZB 26-TF7| ZB26KQE-TF7-559| 8.8| 41
FM CNA-ZB 29-TF7| ZB29KQE-TF7-559| 10| 54
FM CNA-ZB 38-TF7| ZB38KQE-TF7-559| 13| 64
FM CPA-ZB 45-TF7| ZB45KQE-TF7-559| 13.1| 70
FLCKA-ZF 06-CFV| ZF06KQE-PFV-551| 17.1| 61
FLCNA-ZF 09-CFV| ZF09KQE-PFV-551| 20.2| 88
FLCNA-ZF 11-CFV| ZF11KQE-PFV-551| 24.7| 109
FLCNA-ZF 13-TF7| ZF13KQE-TF7-551| 10| 57
FLCNA-ZF 15-TF7| ZF15KQE-TF7-551| 12| 64
FLCPA-ZF 18-TF7| ZF18KQE-TF7-551| 14| 70

Fluid data – 50Hz

Medium temperature

Low temperature

Fluid data – 60Hz
Low temperature

Note: Operating conditions : 20°C suction gas return temperature and 3K subcooling

Features & Benefits

Efficiency
– High efficiency Copeland™ ZB/ZF/ZS compressors for multiple application.
Reliability
– Compressors are supplied with internal thermal protectors that safeguards against motor overheating and high current.
– Dual compliance for better reliability.
Smooth Operation
– Scroll compressor has an inbuilt check valve that isolates high pressure gas, allowing the compressor to start unloaded with low inrush currents.
– Less vibration.
Maintenance
– Optimal layout of components for easy serviceability.

Physical Layout of Condensing Unit

Scope of Supply

• High efficiency scroll compressor
• Co-axial condenser
• Compressor with Oil Sight Glass and Crank Case Heater
• HP/LP switch
• Condenser pressure regulator to be provided by the customer as required.
  The Condenser Pressure Regulator could be selected from below table. This could be provided as additional accessory.

Electrical Connections

Installation, System Processing and Commissioning

Utmost care must be taken while handling the Water-Cooled Scroll condensing unit. Please go through the contents below to ensure proper handling.
a. Inspection
Inspect the condensing unit and any accessories shipped with them for damages or shortages before and during unloading. All items on bill of lading should be accounted for  prior to signing the shipping receipt. Note any shortages or damage on delivery receipt (specify the extent and type of damage found). Unit should be inspected carefully  for concealed damage.
Notify Emerson sales/application personnel of the damage immediately. Do not repair the unit until instructed by Emerson’s representative.
The system is shipped with a holding charge of dry nitrogen. Check to see that pressure is still in the unit upon receipt. Report lack of pressure immediately to the Emerson’s  application/sales representative.
b. Location and Fixing
Generally installed on the top of the cold room to reduce the connection length between the condensing unit and the evaporator. Enough space to be provided around the  unit for easy service. Also ensure easy access to the unit.
c. Refrigeration Piping Installation
All interconnecting pipes should be of refrigeration grade, clean, dehydrated and must remain capped at both ends until installation. Even during installation, if the system is  left for any reasonable period (say two hours), pipes should be re- capped to prevent moisture and contaminants from entering the system.
Do not assume that the service connection sizes on the unit (at the service valves) are the correct size to run your interconnecting refrigeration pipes.
The service valve sizes have been selected for convenience of installation and in some cases (larger units) these may be considered too small. However, for the very short pipe  run within our units, these service connection sizes are adequate.
The pipe should be sized to ensure optimum performance and proper oil return. The sizing must also consider the full capacity range through which this particular unit will  need to operate.

Pipe runs should be kept as short as possible, using the minimum number of directional changes. Use large radius bends and avoid trapping of oil and refrigerant. This is  particularly important for the suction line. The suction line should ideally slope gently towards the unit. Recommendation slope is 1/200~1/250. P traps, double risers and  reduced pipe diameters may be required for suction lines where long vertical risers cannot be avoided. All pipes should be adequately supported to prevent sagging which can  create oil traps.

The recommended pipe clamp support distance is shown in the table.

d. Refrigerant line insulation
– Insulate suction lines from the evaporators to the condensing unit with minimum of 1” thickness closed-cell type insulation.
– Long liquid lines run in areas exposed to high temperatures should be fully insulated with minimum 1/2” insulation.
– Suction and liquid lines should never be taped or soldered together.
e. Electrical
– All electrical work must be done in accordance with the National Electrical Code and existing local codes.
– Power supply must be the same as specified on the unit’s name plate.
– Voltage fluctuations in excess of 10 percent must be corrected.
– Before starting the unit, ensure that all protective devices are in place and that all wiring is secure.
f. Brazing Recommendation
Maintain a flow of oxygen-free nitrogen through the system at a very low pressure during brazing. Nitrogen displaces the air and prevents the formation of copper oxides in  the system. If copper oxidization is allowed to form, the copper oxide material can later be swept through the system and block screens such as those protecting capillary  tubes, thermal expansion valves, and accumulator oil return holes. This minimizes any entry of contaminants and moisture.

• Remove the liquid line connection cap.
• Then remove the suction connection cap.
• Open both valves midway.
• Care should be taken to avoid the holding charge from releasing too quickly.
• Be sure tube fitting inner diameter and tube outer diameter are clean prior to assembly.
• Recommended brazing materials: a copper / phosphorous or copper /phosphorous / silver alloy rod should be used for joining copper to copper whereas to join  dissimilar or ferric metals, use a silver alloy rod, either flux coated or with a separate.
• Use a double tip torch.
  

g. Start-up & Operation

Initial pressure test (by vacuum and nitrogen)

Step-by-step

• Use a 4-port gauge manifold with 3/8” hose and connections to the vacuum pump. The vacuum gauge does not have to be connected for this part of the process.
• Connect the gauges to service ports provided on receiver valve and suction tube. In order to remove any non-condensable that may have entered the system during installation, follow these steps:
• Start the vacuum pump. The evaporator fan should be running and the compressor crankcase heater is energized at this point. This will involve powering up the unit so  it is important to disconnect the live feed wire to the compressor contactor (so the compressor cannot run and the crank case heater can be energized).
• Open both valves on the manifold and then open the main vacuum valve on the pump. Run the system until the vacuum level of -0.85 bar (as read on manifold gauge) is  achieved.
• Shut off the main vacuum pump valve. Check for vacuum rise using the manifold compound gauge. A rise would indicate a large leak.
• If vacuum holds for 10 minutes, break vacuum with Nitrogen. Check the name plate of the unit / compressor for allowable leak test pressure. Ensure that pressure  regulators are installed on the Nitrogen cylinders.
  Check for leaks and repair leakage.

Leak Check
The success of all the subsequent commissioning depends on a leak free system, free of contaminants, free of oxides, free of non-condensable’ s, that has been evacuated to a  low vacuum and charged with the prescribed refrigerant.
Leak test is particularly important for field-connected systems. Typically, field systems lose as much as 20%–30% of their refrigeration charge annually. This is not only an  unnecessary expense but also damages the environment. Compressor oil can be lost at the same time as refrigerant and eventually lead to compressor failure. (Time spent on  leak test will eventually reduce the time spent on the evacuation process).
Ensure that all service valves are open during the leak test process. It is important to recheck all joints within the unit as well as the external joints.
a. The unit is shipped with a holding charge of dry nitrogen and should be leak free.
b. Ensure that the test pressure do not exceed the system design pressures.
c. Do not expose system pressure control LP to test pressures above the design pressure. This can damage the pressure controls.
d. Using an approved, calibrated electronic gas leak detector, leak test the entire system paying attention to all joints (you might have to charge small quantity of refrigerant before charging the Nitrogen to enable this procedure).
e. Periodically check functionality of the electronic leak detector during this process.
f. To further check system integrity, spray a soapy water solution over joins then visually inspect for bubbles.
g. Leave the system under pressure for a designated period (24 Hours).
h. Check and record the ambient temperatures and the system pressure with calibrated approved instruments. This process is to be carried out every 8-12 hours during the pressure testing process.
i. If the test pressures cannot be maintained, repeat the leak testing process employing the isolation of sections of the system to determine the source of leaks. Repair the leak  and repeat the leak testing process until system can be signed off as leak free and approved by authorized personnel.
j. Record findings and confirm pressure testing process completion.
Evacuation
a. After the system is leak checked, connect approved dual stage vacuum pump sized to application with preferably fresh oil to evacuate the system.
b. Ensure all inline system shut-off valves and solenoid valves are fully open.
c. Evacuate the system to 300 microns.
d. A triple evacuation is recommended in case of using analog gauges as we might not know the exact vacuum level being achieved

Charging and commissioning

Reminder

• The scroll compressor design requires system charging with liquid refrigerant into the liquid line.
• Do not vapor charge the Water Cooled Scroll unit. After ensuring all valves are opened and system is evacuated properly, only then start the refrigerant charging process.  Also ensure that LP cutout is not by-passed during the charging process.

Step-by-step:

1. Ensure that there is no power supply to the Water Cooled Scroll unit.
   The liquid line solenoid needs to be kept open for the charging process and this may require a temporary power feed to it.

2. Connect the refrigerant cylinder to main service hose and purge line at the manifold end.

3. Ensure correct orientation of the refrigerant cylinder. Follow cylinder labeling/instructions so that liquid refrigerant can be charged into the system. This will be charged  through the high-pressure side of the manifold and Water Cooled Scroll unit liquid service valve. Ensure that at least 70-80% of the required refrigerant charging is done  by this method.

4. The compressor can then be started, and the unit continued to be charged (with the controlled liquid refrigerant through the suction service valve). The quantity of  charge should always be measured. See note.

5. The system needs to be operated down to its design evaporating temperature before you can be sure the charge is correct. It is at this point that the normal refrigeration  operational checks can be carried out – such as checking the liquid line sight glass for bubbles and the operating pressures.
   Refrigerant charging is regarded full/complete when the operating tempera-ture of the system has been stable for some time and the liquid line sight glass is clear.

h. Maintenance
Water Quality
Ensure that the water quality is maintained to reduce the amount of scaling inside the condenser
Electrical Connections
Check tightness of electrical connections periodically
Routine Leak Test
All joints should be checked for leaks during site visits. All joints should be leak tested once a year.
TURN OFF OR DISCONNECT THE ELECTRICAL POWER SOURCE BEFORE CLEANING THE CONDENSER COIL OR DOING MAINTENANCE.

System Start-Up and Operational Check Sheet

Details
---|---
Pipe Length (approx.) :|
OAT @ Start-Up/Check :|
PSI Leak Test :| PSIG
Duration :| Hours
System is Leak Tight :| Y I N
Triple Evacuation :| Y I N
Micron Gauge Reading :| microns
Total Evacuation :| PSIG @ # of Hrs
Refrigerant :|
Total Charge :| Kg.
Sight Glass Clear :| Y I N
Evap Fans Running :| Y I N
Liquid Line Insulation :| Y I N
Sound and Vibration|
|
System Operation
COMP Voltage :| V
COMP Current :| A
Suction Pressure :| PSIGIBar
Liquid Line Pressure :| PSIGIBar
COMP Suction Temp :| °C
COMP Disch Temp :| °C
Liquid Line Temp :| °C
Compressor SH :| K
Subcooling :| K
Adjustable LP Setpoint :| PSIG
Design/Operating Temp:| °C
Actual Room/Case Temp :| °C
Condenser Fins :|

Disclaimer
Technical data given was correct at the time of printing. Products, specifications and data in this literature are subject to change without prior notice. Updates will be done periodically. Should you need clarification of a specific data, value or information, kindly contact Emerson representative.

Contact list

United Arab Emirates
Jebel Ali Free Zone
P.O. Box 26382, Dubai
United Arab Emirates
Toll Free: 8000 441 3428
Tel: +971 4 8118100
Fax: +971 4 8865465| Saudi Arabia
P.O. Box 34332 – 3620
2nd Industrial City, 67 St.
Dammam, Saudi Arabia
Toll Free: 8008 443 426
Tel: +966 3 8147560
Fax: +966 3 8147570
---|---
South Africa
11 Quark Crescent
Linbro Business Park
Sandton 2065, South Africa
Toll Free: 0800 980 3711
Tel: +27 11 451 3700
Fax: +27 11 451 3800| Egypt
P.O.Box 11799
11 Mustafa Refaat Street
Sheraton, Heliopolis
Cairo, Egypt
Tel: +20 2 226 5854

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