AE-1345 R2

AE4-1345 R2

March 2013

Application Guidelines for Copeland Scroll Horizontal Cryogenic Compressors ZCH22/48/68/72 ™

TABLE OF CONTENTS Section

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Section

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 Nomenclature ............................................................ 4 Oil Management......................................................... 4 Oil Separation......................................................... 4 Oil Flow Rate........................................................... 4 Reverse Oil Flow..................................................... 4 Oil Type and Removal............................................. 4 Oil Charge............................................................... 4 Compressor Operating Temperature.......................... 4 Shell Temperature ..................................................... 5 Discharge Line Thermostat ....................................... 5 Motor Protection......................................................... 5 Mounting..................................................................... 5 Compressor Orientation............................................. 5 High Pressure Control................................................ 5 Low Pressure Control Valve ...................................... 5 Discharge Check Valve ............................................. 5 Internal Pressure Relief.............................................. 6 Cycle Times................................................................ 6

© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

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Shutoff Sound............................................................. 6 Rotation Direction....................................................... 6 Brief Power Interruptions............................................ 6 Electrical Connections................................................ 6 Deep Vacuum Operation............................................ 6 Suction and Discharge Fittings................................... 7 Brazing Procedure...................................................... 7 Removing System Components................................. 7 Screens...................................................................... 7 Scroll Functional Check.............................................. 7 System Clean Up....................................................... 8 Figures & Tables Port Locations........................................................... 9 Oil Management Diagram......................................... 9 Horizontal CryoScroll Operating Map....................... 10 Scroll Suction Tube Brazing..................................... 11 Bracket Compressor Mounting ZCH22.................... 12 Bracket Compressor Mounting ZCH72.................... 13 Minimum Oil Flow..................................................... 14 Mounting Specifications........................................... 14 Valve Requirements................................................. 14 Cryogenic Scroll Specifications................................ 15

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AE-1345 R2 Safety Instructions ™ Copeland Scroll Scroll™ compressors are are manufactured manufactured according according to to the the latest latest U.S. U.S. and and European European Safety Safety Standards. Copeland compressors Particular emphasis has been placed on the user's safety. Safey icons are explained below and Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained safety below instructions applicable to the products this bulletin arebulletin grouped ongrouped Page 3.on These and safety instructions applicable to theinproducts in this are Pageinstructions 3. These should be retained throughout the lifetime of the compressor. strongly advised to follow advised these safety instructions should be retained throughout the lifetime You of theare compessor. You are strongly instructions. to follow these safety instructions.

Safety Icon Explanation

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE CAUTION

© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.

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AE-1345 R2 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.

CAUTION

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.

© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.

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AE-1345 R2 Introduction

system. Too large an orifice will result in a high to low leak, while too small an orifice will result in oil carryover.

The information given below is intended to provide guidance to those intending to use the Copeland Scroll™ Cryogenic compressors in their cryogenic systems. These guidelines provide necessary requirements for a successful application of the compressor and components but do not guarantee satisfactory results for user performance or regulatory agency approval.

Oil Flow Rate Rate of oil flow returning to the compressor for all operating conditions is essential to ensure proper lubrication and cooling of the compressor running hardware. For example, Table 1 (at the end of this bulletin) indicates for ZCH22 models the rate of oil flow returning to the compressor shall be no less than 0.8 GPM (3 Liters/Min.) and for the ZCH72 models returning oil flow rate shall be no less than 1.8 GPM (6.8 Liters/Min.) The original equipment manufacturer (OEM) is to specify the orifice size and design to maintain a discharge line temperature below 200°F (93°C) 6” (150mm) from the outlet of the compressor.

Nomenclature The Copeland Scroll Cryogenic compressor model number includes the mass flow (SCFM) pumping rate of the compressor. SCFM is Standard Cubic Feet/ Min calculated based upon helium properties at 1 Atm pressure and 70°F (21°C). The SCFM is indicated by the fourth and fifth digits, (e.g. ZCH22C1G moves 23.5 SCFM (34.5Nm³/hr)). The mass flow in the model number is taken at the Copeland Cryo rating point (CCRP) of 85psig (5.9 bar) suction pressure and 285psig (19.7 bar) discharge pressure. For actual compressor performance information, please visit Online Product Information at www.emersonclimate.com. Please refer to the product literature for model number details.

Reverse Oil Flow Oil inside the compressor must be prevented from flowing backward from the compressor to the low side of the system during shutdown and during the off cycle. This can be accomplished by using the auxiliary suction port of the compressor and by installing a lowleak check valve in the suction line of the compressor. With the compressor discharge port pointing straight down, the auxiliary suction port will be located at the upper portion of the compressor, see Figure 1.

Oil Management Oil Separation A primary oil separator is necessary to separate and return oil to the compressor for proper cooling and lubrication of compressor running hardware.

Oil Type and Removal Copeland Scroll Cryogenic compressors are designed to operate with PAG oil, UCON LB300X or equivalent, with a kinematic viscosity between 30 and 70 centistoke @ 104°F (40°C). Any other oil must be approved by Emerson Climate Technologies, Inc.

A secondary oil separator, located downstream of the primary oil separator, is required to limit oil circulation through the system to