Transcription
Replacement Guidelinesfor Scroll CompressorsZR90K3*, ZR11M3*. ZR19M3* with ZR94KCE. ZR190KCEZP180KCE with ZP182KCE
1Introduction . 12Nomenclature . 22.1 Previous generation . 22.2 Summit – New generation. 23Ident numbers . 24Technical comparisons. 34.1 Performance & dimensions – Cross-reference tables . 34.1.1R407C refrigerant . 34.1.2R410A refrigerant . 35Drawings . 46Operating envelopes . 87Motor version . 87.1 Motor insulation . 87.2 Motor designation . 98Motor protection . 108.1 Motor code . 108.2 Electronic motor protection device INT69SC – Models ZR90K* to ZR19M* . 109Discharge temperature protection . 1010Terminal box . 1110.1 Protections . 1110.2 Cable connectors . 1110.3 Terminal box dimensions . 1211Tandemization . 1311.1 Replacement of a compressor in an existing Tandem . 1311.2 Replacement of a Tandem. 1411.3 Oil and gas equalization – Two-Phase Tube Line (TPTL) design . 1411.4 Adaptor for TPTL . 1511.5 Oil equalization only . 1512BOM description. 1613Adapters and fittings . 1614Mounting parts . 1714.1 Mounting parts for single operation . 1714.2 Mounting parts for compressors in Tandem/Trio operation . 1714.3 Crankcase heater (optional) . 1715Standard components and accessories – Summit . 1715.1 Standard components . 1715.2 Accessories . 1816Data sheets . 1916.1 Performance data sheet with R407C . 19C5.2.3/1110-1012/E
16.2 Performance data sheet with R410A . 2216.3 Performance data sheet with R134a . 2516.4 Performance data sheet with R22 . 28C5.2.3/1110-1012/E
1IntroductionThe purpose of this Replacement Guideline is to help customers in replacing the existing A/Ccompressor range (ZR90K* to ZR19M*, ZP180K*) with the new A/C SUMMIT compressor range(ZR94K* to ZR190K* and ZP90K* to ZP182K*, from 7.5 to 15 HP). The previous generation willbe phased out by the end of 2010.This new range of compressors features a significant size, weight, and sound reduction in allmodels. These compressors are designed for use with R410A (ZP) and R407C, R22, R134a(ZR) refrigerants. They are built in a uniform platform design, which simplifies engineering andsystem manufacturing for OEMs.SummitPrevious generationShutdown valveLow-leak check valveDischarge temp. probeASTPLine breaKPTC KriwanTeflon bearingsSuction screenDirt trap & magnetSummitC5.2.3/1110-1012/E1
2Nomenclature2.1Previous generationZ R 90K 3 E - TWD - 522Bill of material number (522, 551, 561, 568, 591)Motor versionOil type:E POE oilNone mineral oilModel variationNominal capacity [BTU/h] @ 60 Hz and ARI conditionsCapacity multiplier; K - x 1000, M - x 10000Application range temperature:R high/medium; P 410ACompressor family: Z Scroll2.2Summit – New generationZ R 94K 3 E - TFD - 425Bill of material number (425, 550)Motor versionOil type:E POE oilNone mineral oilModel variationNominal capacity [BTU/h] @ 60 Hz and ARI conditionsCapacity multiplier; K - x 1000Application range temperature:R high/medium; P 410ACompressor family: Z Scroll3Ident numbersPrevious 60415519.222.426.029.333.139.1*R407C Dew (En 12900)R410AZP180KCE**R410A (EN 137KCEZP154KCEZP182KCEC5.2.3/1110-1012/E
4Technical comparisons4.1Performance & dimensions – Cross-reference tablesPreviousSummit4.1.1 R407C "1/41"3/41"1/41"3/41"1/4Sight Glass Ext DiamUNFUNFUNFUNFUNFUNFUNFUNFUNFUNFUNFWeight kg9457965910061611036411966Foot Mounting 220X220 190X190 220X220 190X190 220X220 190X190 190X190 220X220 190X190 220X220 190X190HPkW (En 12900)COPSound LwaABCShell Diameter DSuction Diameter EDischarge Diameter GPreviousSummit4.1.2 R410A 91012131515kW (En 13.23.23.2Sound 20538533519C9414114114115930592Shell Diameter D232232232232232283232Suction Diameter E1"1/81"3/81"3/81"3/81"3/81"5/81"3/8Discharge Diameter G7/8"7/8"7/8"7/8"7/8"1"1/8 UNF7/8"Sight Glass Ext Diam 1"1/4 UNF 1"1/4 UNF 1"1/4 UNF 1"1/4 UNF 1"1/4 UNF 1"3/4 UNF 1"1/4 UNFWeight kg565961616411966Foot Mounting 190 X 190 191 X 190 192 X 190 193 X 190 194 X 190 220 X 220 196 X 190PreviousC5.2.3/1110-1012/ESummit3
5DrawingsThe following drawings show the position of the suction and discharge plugs as well as the sightglass, the Schrader valve and the terminal 283.0116.5976.6142.322.3 - 01.367.4201.5232.293.64497.34444.3476.328.49 - 28.67ZR94K*194.6ZR90K*C5.2.3/1110-1012/E
35.2194.6ZR108K*, ZR125K*, ZR144K*C5.2.3/1110-1012/EZR11M*, ZR12M*5
2/E109.85219.7141.44219.7283.0179.4722.42
1110-1012/E221.55101.467.413.0194.6318.6ZR190K* & ZP182K*591.85546.1175.7045.75116.59ZR19M* & ZP180K*7
6Operating envelopesOperating envelopes for all qualified refrigerants R407C, R22, R134a & R410A are shown in thediagrams below:7065Condensing Temperature ( C)70ooCondensing Temperature ( C)8060Previousgeneration50Summit40R407C( ZR144)35302520015-35 -30 -25 -20 -15 -10 -50510 15 20 25-35 -30 -25 -20 -15 -10 -5o10 15 20 2570o70Condensing Temperature ( C)75o5Evaporating Temperature ( C)80Condensing Temperature ( C)0oEvaporating Temperature ( 1020-20-15-10-505101520-35 -30 -25 -20 -15 -10 -5oMotor version7.1Motor insulation510 15 20 25oEvaporating Temperature ( C)70Evaporating Temperature ( C)The motor insulation material for scroll compressor models is shown in the table below:CompressorZR94K* to ZR190K*ZP90K* to ZP182K*ZR90K* to ZR19M* and ZP180K*8ClassBHC5.2.3/1110-1012/E
7.2Motor designationScroll refrigerant compressors are available in various motor versions depending upon the sizeof the load. The motor versions differ in operating voltage, type of switching, number of phases,frequency and type of motor protection. A code for the motor is included in the modeldesignation to ensure correct designation because of the many variations available during orderhandling and service. An example for the compressor model designation is given below:T F DT W DMotor TypeT Three-phase motorMotor Protection Device7Motor 3200/2203200/230338033 / 50HzTFDTF5TWCTWDTWE380/420 200/220 200/220 380/420500TWRTW5200/240 200/220F Inherent Internal klixon line breakmotor protectionCDW For three-phase motors, electronicmotor protection with thermistors& release module KRIWAN in theterminal 144ZR160ZR190ZR90ZR11Previous gen. ZR12ZR16ZR19SUMMITPrevious TFE575TF5200/230TF73803 / 60 R125ZR144ZR160ZR190ZR90ZR11Previous gen. ZR12ZR16ZR19SUMMITPrevious 1012/E9
8Motor protection8.1Motor codeThe centre letter of the motor code in the nomenclature of a Copeland Scroll compressorindicates which kind of motor protection device is used. Compressors ZR94K* to ZR144K* andZP90K* to ZP137K* are code TF*. Compressors ZR160K*, ZR190K*, ZP154K* and ZP182K*are code TF* and TW*.The centre letter "F" (eg, TFD) stands for inherent motor protector (Klixon) which is embedded inthe stator head and internally interrupts the power supply of the windings at high current or highmotor winding temperature. After the temperature has dropped down to the reset value thecompressor motor restarts automatically. This protection device is always installed internally andis not accessible.The centre letter "W" in the motor code (eg, TWD) stands for the use of an electronic motorprotection device, which can offer various functions. In general it monitors the windingresistances during compressor operation. The electronic motor protector is always installedoutside the shell of the compressor (inside the terminal box) and is exchangeable.8.2Electronic motor protection device INT69SC – Models ZR90K* to ZR19M*This system utilises the temperature dependent resistance of thermistors (also called PTCresistances) to read the winding temperature. A chain of four thermistors connected in series isembedded in the motor windings so that the temperature of the thermistors can follow thewinding temperature with little inertia. An electronic module is required to process the resistancevalues and trip a control relay depending on the thermistor resistance.9Discharge temperature protectionZR94K* to ZR190K* and ZP90K* to ZP182K* Scroll compressors have an Advanced ScrollTemperature Protection (ASTP). Advanced Scroll Temperature Protection is a temperaturesensitive thermo-disc that acts to protect the compressor from discharge gas overheating. Oncethe discharge gas reaches a critical temperature, the ASTP feature will cause the scrolls toseparate and stop pumping although the motor continues to run. After running for some timewithout pumping gas, the motor protector will open.NOTE: Depending upon the heat build-up in the compressor, it may take up to two hoursfor the ASTP and motor protector to reset!A label has been added above the terminal box to identify compressors with Advanced ScrollTemperature Protection.For compressors ZR90K* to ZR19M* and ZP180K*, a thermistor islocated in the discharge port of the fixed scroll. Excessivedischarge temperature will cause the electronic protector moduleto trip. The discharge gas thermistor is wired in series with themotor thermistor chain.10NAT 140 CC5.2.3/1110-1012/E
10Terminal box10.1 ProtectionsThe terminal box is IP21 for all models without electronic motor protection (eg, TF*) and IP54 forall models with electronic motor protection (eg, TW*).Because the electrical characteristics are very close in previous generation and Summit, motorprotections (fuses, contactors) will be the same for both.Summit TF*Summit TW*10.2 Cable connectorsThe following table lists the recommended types of cable connectors to be used for the variouselectrical terminals of the compressors and the motor protection module. “B” and “C” must beselected for diameters of 5 mm.Cable sizes must be selected according to DIN ISO 0100, IEC 364 or national regulations.Ring tongue (B)SUMMITPreviousgenerationSpade (C)ModelZR94K* to ZR190K*ZR90K* to ZR19M*ZP90K* to ZP182K*ZP180K*TF*B/CTW*B/CB/CB/CB/CNOTE: To earth these compressors use a Ring tongue (B) connection.C5.2.3/1110-1012/E11
Fusite connections and recommended wiring diagrams are shown below. Both generations ofcompressors are wired in the same way.Legend1 .Motor2 .Internal inherent motor protection3 .Terminal box4 .Lead connection5 .Earth connectionL1, L2, L3 . LineN . NeutralPE. Protective earthF1, F6, F8 . FusesK1 . ContactorQ1. Main switch10.3 Terminal box dimensionsSummit TFD12Summit TW*Previous generationC5.2.3/1110-1012/E
11TandemizationThe following table shows the Tandem Summit-Summit configurations approved by EmersonClimate Technologies:ZP Tandem SUMMIT CompressorsHPZPT180K*E 2 x ZP90K*EZPT206K*E 2 x ZP103K*EZPU223K*E ZP103K*E ZP120K*EZPT240K*E 2 x ZP120K*EZPU240K*E ZP103K*E ZP137K*EZPU257K*E ZP120K*E ZP137K*EZPU272K*E ZP90K*E ZP182K*EZPT274K*E 2 x ZP137K*EZPU274K*E ZP120K*E ZP154K*EZPU285K*E ZP103K*E ZP182K*EZPU302K*E ZP182K*E ZP120K*EZPT308K*E 2 x ZP154K*EZPU319K*E ZP137K*E ZP182K*EZPU336K*E ZP182K*E ZP154K*EZPT364K*E 2 x ZP182K*E161819202122232423242526272830ZR Tandem SUMMIT CompressorsZRT188K*E 2 x ZR94K*EZRT216K*E 2 x ZR108K*EZRT250K*E 2 x ZR125K*EZRT285K*E ZR160K*E ZR125K*EZRT288K*E 2 x ZR144K*EZRU315K*E ZR190K*E ZR125K*EZRT320K*E 2 x ZR160K*EZRU334K*E ZR190K*E ZR144K*EZRU350K*E ZR190K*E ZR160K*EZRT380K*E 2 x ZR190K*E11.1 Replacement of a compressor in an existing TandemA compressor in an existing Tandem with previous generation compressors cannot be replacedwith a new Summit compressor because the positions of the suction, discharge and sight glassports are different. The distances between holes on the mounting feet are different too.Therefore a previous generation compressor will be needed for replacement on a Tandem.Previous generationC5.2.3/1110-1012/ESUMMIT13
11.2 Replacement of a TandemA new Summit Tandem can replace a previous generation Tandem.Previous generationSUMMITSummit Tandems are approximately 100 mm shorter in length and 80 mm shorter in width thanprevious generation Tandems. For replacement see table below:ZR previous generationZRT180K3* ZR90K3* ZR90K3*ZRT220K3* ZR11M3* ZR11M3*ZRT240K3* ZR12M3* ZR12M3*ZRT280K3* ZR12M3* ZR16M3*ZRU310K3* ZR19M3* ZR12M3*ZRT320K3* ZR16M3* ZR16M3*ZRU350K3* ZR16M3* ZR19M3*ZRT380K3* ZR19M3* ZR19M3*HP1518202325262830ZR SUMMITZRT188K*E 2 x ZR94K*EZRT216K*E 2 x ZR108K*EZRT250K*E 2 x ZR125K*EZRT285K*E ZR160K*E ZR125K*EZRU315K*E ZR190K*E ZR125K*EZRT320K*E 2 x ZR160K*EZRU350K*E ZR190K*E ZR160K*EZRT380K*E 2 x ZR190K*E11.3 Oil and gas equalization – Two-Phase Tube Line (TPTL) designConnection for both oil and gas equalization is made via the sight glass of each compressoreven when the compressors are of different tonnage (ZRU/ZPU). The so-called Two-PhaseTube Line (TPTL) for oil and gas equalization balances the pressure between the shells therebymaintaining the same oil level in each compressor.The Two-Phase Tube Line (TPTL) allows for oil and gas equalization between compressors.TPTL is not a requirement for even Tandem combinations, but is a requirement for all unevenTandems. An even Tandem is defined as any Tandem assembly where the compressors are ofequal capacity. An uneven Tandem includes compressors of different capacities.Previous generation14C5.2.3/1110-1012/E
424 mm753 mmNew generation SUMMIT11.4 Adaptor for TPTLEven or uneven Tandems: 1”1/4 Rotalock sight glassTube 1”1/8 for TPTLAdapter kit 1”1/4 1”1/8# 8602955 (with seal)11.5 Oil equalization onlyFor even Tandems an oil equalization line is an adequate and much more cost-effective option.Even Tandem only: 3/8” Oil tube throughout Schrader stub(Schrader removed)C5.2.3/1110-1012/E15
12BOM descriptionModelBOMZR90K toZR19MPreviousgenerationZP180KSummit13ZR and tion /DischargeConnectionsBraze RotXXXXXXXXXXXXXXXOilsightglass EGasOil24V120-240 V 24V ACRot Braze RotXXXXXXXXXXXXXXXXXXXXXProtectionXXAdapters and fittingsBecause new Summit compressors have only brazed connections and many systems withprevious generation compressors have Rotalock connections, the customer will need adaptors ifhe wants to keep Rotalock valve connections. For adapters and fittings please refer to tableshereunder:Diamcomp1 1/8"Kit to transform braze into RotalockDischargeSuction k851516884006481 90ZP90ZP103ZP120ZP137ZP154ZP1821 3/4"SuctionModelZ
2 Nomenclature 2.1 Previous generation 2.2 Summit – New generation 3 Ident numbers Previous generation SUMMIT R407C TWD-551 TWD-522 kW* TFD-425 TFD-550 kW* ZR90K3E 8508586 8514256 18.7 ZR
