Copeland 4-1302

® 4-1302

Application Engineering Bulletin

AE-1302-R3
AE-1302-R4 October, 2004
Revised January, 1999

APPLICATION GUIDELINES FOR

"GLACIER™" K4 & KA REFRIGERATION SCROLL COMPRESSORS
7.5-15 HORSEPOWER

Introduction C apillary T ubes For Liquid or Vapor Injection:

C ap T ube
The Glacier™ refrigeration Scroll compressor prod- M odel I.D . Length C opeland
uct offering has expanded into the higher horsepower (inches) (inches) K it
ranges. The scope of this bulletin will cover the applica- num ber
tion parameters unique to the new models. R -22
ZF24K4 0.05 5” 998-1586-00
Nomenclature ZF33K4 0.05 5” 998-1586-00
ZF40K4 0.07 30” 998-1586-05
The Glacier™ Scroll model numbers include the ZF48K4 0.07 10” 998-1586-06
nominal capacity at the standard 60 Hertz “ARI” rating R -404A /R -507
conditions. Please refer to product literature for model ZF24K4E 0.05 30” 998-1586-04
ZF33K4E 0.05 17.5” 998-1586-01
number details.
ZF40K4E 0.07 30” 998-1586-05
ZF48K4E 0.07 30” 998-1586-05
Operating Envelope
Table 2
These Glacier™ models can also be used with a • Solenoid Valve - A solenoid valve with a minimum .109
variety of refrigerants. The following table shows the
inch orifice must be provided in the injection circuit that
selection options:
opens whenever the compressor is operative or cooling
MODEL REFRIGERANT LUBRICANT is required during pumpdown. The solenoid must be
ZB,ZF,ZS R22 MO closed when the compressor is cycled off. Failure to
ZF R-404A, R-507, R-22 POE provide the solenoid valve can result in liquid refrigerant
completely filling the Scroll during an “off” cycle. If power
ZS R404A, R-507 POE
is reapplied in this condition, the hydraulic effect produced
Table 1 could result in pressure high enough to cause permanent
The operating envelopes are depicted in damage to the compressor. Due to this, it is a condition
Figures 1A through 1E. See Oil Type on page 3 for of warranty that the capillary tube and solenoid valve,
recommended lubricants. properly installed, be provided whenever liquid or vapor
injection is used.
Liquid Or Vapor Injection

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

The following Table lists the solid state modules and their specifications:
Copeland P/N 071-0520-07
Mfg.P/N T.I. 30AA201E
Voltage Supply 120V&240V
Frequency 50HZ & 60Hz
Time Delay Reset 30minutes
Relay Output 2.5A,600V
Power Output < 5.5 VA
Phase sensor N/A
Phase monitoring
circuit rating N/A
Table 5
Module and Sensor Functional Check
To check for proper control circuit operation,the
following procedure is recommended:
1. Disconnect power.
2. Disconnect one terminal either S1 or S2 on the
module
3. Reapply power, the compressor should not start.
4. Disconnect power
5. Reconnect the sensor leads to the module
6. Reapply power,the compressor should start.
If the compressor fails to start after this procedure
the sensor circuit and the correct phasing should be
evaluated using the following procedures.
1. Disconnect power
2. Check Verify correct phase lead orientation. Refer
to figure 4
3. Check all electrical terminal connections for pos-
sible loose or broken connections
4. Check the resistance of the sensors at S1 and S2
terminals. The resistance readings should be be-
tween 250 and 1250 ohms at room temperature.
The trip resistance is 10,000 ohms or higher and
reset resistance is 3000 ohms +/- 500 ohms.
5. Reapply power.
CAUTION: Use an Ohmmeter with a maximum of
9 VAC for checking, do not attempt to check continuity
through the sensors with any other type of instrument.
Any external voltage or current applied to the sensors
may cause damage requiring compressor replacement.
The following field trouble shooting procedure can
be used to evaluate the solid state control circuit.
1. If the compressor has been operating and has
tripped on the protector, allow the compressor to
3
Copeland 4-1302
071-0520-05 071-0547-00
Kriwan 69SC-DV Kriwan 69SCY
120V&240V 120V&240V
50HZ & 60Hz 50HZ & 60Hz
30minutes 30minutes
5 A, 300VA 5 A, 300VA
< 3VA < 3VA
N/A 3
3 AC 50/60 Hz
N/A >120 / <632 volts
cool for at least one hour before checking. This
allows time for the motor to cool and the control
circuit to reset.
2. Disconnect control circuit power to de-energize the
module. Connect a jumper across the wires con-
nected to the M1 and M2 terminals on the module.
This will by-pass the module control contacts.
3. Reconnect control circuit power. If the compressor
will not operate with the jumper installed, then the
problem is external to the module. If the compressor
operates with the module bypassed, but will not
operate when the jumper is removed, then the
module is defective.
Oil Type
Polyol ester lubricant (POE) must be provided if the
Glacier™ Scroll is to be used with HFC refrigerants.
Copeland Ultra 22 CC™, Mobil EAL Arctic 22 CC, or ICI
EMKARATE RL 32CF are the only polyol ester oils
approved by Copeland at this time.
ZB**KA model Scrolls, intended for use with R-22,
are supplied with mineral oil. The proper oils are Sontex
200LT, Witco LP-200, or ISO 3GS.
The factory oil charge for all 7.5-15 HP. models is
140 ounces. Field recharge is 135 ounces.
Note: Do not add mineral oil to compressors charged
with POE oil intended for use with HFC refrigerants. Use
only the Copeland approved POE lubricants for these
applications.
Oil Management For Rack Applications
Glacier™ Scrolls may be used on multiple compres-
sor parallel rack applications. This requires the use of an
oil management system to maintain proper oil level in
each compressor crankcase. The sight glass connec-
tion supplied can accommodate the mounting of the oil
control devices.
Unlike Semi-Hermetic compressors, Scrolls do not
have an oil pump with accompanying oil pressure safety

Deep Vacuum Operation
WARNING: Do not run a Glacier™ compressor in
a deep vacuum. Failure to heed this advice can result in
arcing of the Fusite pins and permanent damage to the
compressor.
A low pressure control is required for protection
against deep vacuum operation. See Pressure Control
section for proper set points.
Scroll compressors (as with any refrigerant com-
pressor) should never be used to evacuate a refrigera-
tion or air conditioning system. See Application Engi-
neering Bulletin AE 24-1105 for proper system evacua-
tion procedures.
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 as it
escapes and contacts the brazing flame. It is important
to check both the high and low sides with manifold
gauges before unbrazing or in the case of assembly line
repair, remove refrigerant from both the high and low
sides. Instructions should be provided in appropriate
product literature and assembly (line repair) areas.
HiPot Testing
Compliant Scroll compressors are configured with
the motor in the bottom of the shell. Unlike most other
hermetic compressors, the Scroll motor can be im-
mersed in refrigerant when liquid is present in the shell.
In this respect, the Scroll is more like the semi-hermetic
compressors that have horizontal motors partially sub-
merged in oil and refrigerant. HiPot test with liquid
refrigerant in the shell can show higher levels of current
leakage due to higher electrical conductivity of liquid
refrigerant vs. refrigerant vapor and oil. This phenom-
enon can occur with any compressor when the motor is
5
Copeland 4-1302
immersed in refrigerant and does not present any safety
issue. To lower the current leakage reading operate the
system for a brief period of time, redistributing the
refrigerant to a more normal configuration and test
again.
Note: The solid state electronic module compo-
nents and internal sensors are delicate and can be
damaged by exposure to high voltage. Under no circum-
stances should a high potential test be made at the
sensor terminals or sensor leads connected to the
module. Damage to the sensors or module may result.
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 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 com-
pressor is functioning properly.
1. Verify proper unit voltage.
2. Normal motor winding continuity and short to ground
checks can be used to determine proper motor
resistance or if an internal short to ground has
developed.
3. With service gauges connected to the 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. If the suction pressure does not drop and the
discharge pressure does not rise, reverse any two
of the compressor power leads and reapply power
to verify the compressor was not wired to run in the
reverse direction.
The operational compressor current draw should be
compared to published performance curves at the oper-
ating conditions (pressures and voltages). Significant
deviation (± 15%) from published values may indicate a
faulty compressor.
Copeland 4-1302

ZB**KA Envelope (R-22)

Conditions: 65°F Return Gas; 0°F Subcooling; 95°F Ambient
°C °F
65 150
60 140
Condensing Temperature

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

ZF**K4 Envelope (R-22)

Conditions: 65°F Return Gas; 0°F Subcooling; 95°F Ambient
°C °F
65 150
Liquid
60 140
Injection
Condensing Temperature

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

-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 °C

Evaporating Temperature

Figure 1B

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 Copeland 4-1302

ZF**K4E Envelope (R-404A/R-507)

Conditions: 65°F Return Gas; 0°F Subcooling; 95°F Ambient
°C °F
65 150
Liquid
60 140 Injection
55 130
Condensing Temperature

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

-45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 °C

Evaporating Temperature
Figure 1C

ZS**K4E Envelope (R-404A/R-507)

Conditions: 65°F Return Gas; 0°F Subcooling; 95°F Ambient
°C °F
65 150
60 140
55 130
Condensing Temperature

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

-45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 °C

Evaporating Temperature
Figure 1D

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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

-35 -30 -25 -20 -15 -10 -5 0 5 10 °C

Evaporating Temperature

Figure 1E

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 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

* See catalog 1.401 for part information.

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Copeland 4-1302
Scroll Wiring Schematic

Oil Control

Compressor
Contactor
Coil

L1 L2 L3
Black

White
Red

(To Motor Overload Sensors)

(To Compressor Terminal Block) Figure 4

7.5 - 15 HP Glacier™ Rack Mounting

102-0119-00
WASHER

027-0115-00
RUBBER PAD

KIT #527-0158-00

027-0280-00
STEEL SPACER

Figure 5A

7.5 - 15 HP Glacier™ Condensing Unit Mounting

030-0142-00
SLEEVE

102-0008-21 027-0137-00
WASHER RUBBER SPACER

KIT #527-0159-00

027-0268-00 COMPRESSOR
RUBBER GROMMET MOUNTING

Figure 5B

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 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.

(3) If a run over 30” is required, intermediate clamps may be necessary.

(4) Do not hang weights on tubing (e.g. filter drier on suction tubing) except after clamps or close to the header.

(5) Tube runs of less than 12” are not recommended.

(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