Copeland F-Series Scroll Condensing Units

Disclaimer and Safety Information

Thank you for purchasing the Copeland scroll F-series indoor condensing unit. We hope that this product meets your refrigeration needs efficiently and effectively.

Please read through this User Manual thoroughly to familiarize yourself with the installation and commissioning process of this product and how to use it optimally. Please do read the following information in this page before proceeding with the rest of the manual.

The Copeland F-series 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.

These instructions are general in nature for this family of products and due to our policy of continuous improvement, some of the details may not apply to the unit you are installing. If in doubt, 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.

Important

The information contained in this manual is critical to the correct operation and maintenance of the condensing unit and should be read by all persons responsible for the installation, commissioning, and maintenance of this unit.

Safety

The equipment has been designed and manufactured to meet international safety standards but, like any mechanical/ electrical equipment, care must be taken if you are to obtain the best results.

General instructions

Rapid release of pressurised gas! Personal injuries! Units are factory charged with pressurised dry air to between 1.5 and 2 bar to ensure no ingress of air or moisture during transit. Pressure must be safely reduced prior to fully opening connections or removing blanking components.

System breakdown! Personal injuries! Systems without a full charge or with the service valves closed should be electrically locked/tagged if left unattended. Only approved refrigerants and refrigeration oils must be used. Never block the condenser fins, ensure continual airflow through the condenser.

High pressure! Injury to skin and eyes possible! Be careful when opening up a pressurized component or system.

High pressure! Personal injuries! Use of safety relief valves according to EN 378 is mandatory. Consider personal safety requirements and refer to test pressures prior to test.

Rotating machinery! Personal injuries! When the unit is running, do not put your hand inside the unit or remove the fan guard, protective covers etc. Electrically isolate the unit removing fuses before working on the unit.

Receiving your unit

All units are shipped with a holding charge of Inert Gas inside at a low but positive pressure. Suitable labeling is prominently displayed on both the unit and the packaging. Service connectors are provided on the CDU service valve for the convenient checking of the integrity of the holding charge.

Nomenclature

F-series scroll condensing unit was designed based on key features demanded by industry users:

• Wide operating envelope
• Low applied cost - factory built
• Compact design
• Optimal layout of components for easy serviceability
• Energy efficient silent fans
• Condenser coils options available for both moderate and high ambient conditions
• Liquid receiver, HP/LP switch as standard feature
• Local availability
• Pre-wired electrical junction box
• Copeland scroll compressor
• Proven reliability
• Lower sound levels and pulsations
• Dual compliance for superior efficiency and better liquid handling

Nomenclature Breakdown

Example: FMC8A-ZS09-PFZ-0

• Family series: F series
• Code: M (Medium temperature), L (Low temperature)
• Condenser model: Revision no.
• Application range: Medium temperature, Low temperature
• Refrigerant: R-404A/134a, R-404A
• Compressor model reference: Code (PFZ, TFM)
• Unit voltage code: Voltage supply-phase (230 V ±10% - 1~ - 50Hz, 400 V ±10% - 3~ - 50Hz)
• Bill of material: 0 - Base supply

Scope of supply

• HP/LP switch
• Crankcase heater
• Liquid receiver

Scroll Compressor Features

Dual compliance

Compliance means sealing between the orbiting and fixed scroll involutes. Dual compliance means the sealing is on both the axial and radial directions. This prevents refrigerant leak back across successive scroll pressure pockets. Compliance design also allows the scroll involutes to separate in both the radial and axial directions. This allows debris or liquid refrigerant to pass through the scroll involutes without damaging the compressor. Benefits of dual compliance are:

• Increased efficiency
• Better liquid handling capability
• Better handling of debris

Scroll wear-in

The scroll involutes of Copeland scroll compressor wear-in, rather than wear-out. So unlike in other compressor technologies among similar categories, there is no constant degradation of performance with time due to wear-out.

Lower sound, vibration and pulsation

The compression process in a scroll set is symmetrical and continuous. This inherently reduces the sound, vibration and pulsation. This eliminates the need for use of vibration absorbers and suction or discharge mufflers in most of the applications. Further, ZB scroll compressors are engineered to produce smooth sound spectrum which improves the quality of sound.

Unloaded start

The scroll sets separate at the instant of compressor shutdown. This allows the scroll set internal pressures to equalize on compressor stops. In addition to this, the scroll sets are not engaged at the instant of starting. Scroll sets engage only after few milliseconds of startup. This allows easier startup of ZB scroll compressors. Due to this design feature, typically a start assist kit is not required even on single phase compressors.

DU bearings

A space age bearing material comprising of porous bronze with PTFE-lead overlay. These bearings are used in ZB scroll compressors in the scroll drive and main bearings. DU bearings work with exceptionally low friction between the load bearing surfaces. In addition, DU bearings can operate safely for a short time with loss of lubrication. This situations could happen on compressor applications due to oil pump out during a flooded start or heavy oil dilution after a defrost cycle.

Physical Layout of the Unit

The unit consists of the following key components:

• 1. Service valves for customer connection
• 2. Liquid receiver
• 3. Scroll compressor
• 4. HP/LP cutout
• 5. Junction box

Transport and storage

Move F-series unit only with appropriate mechanical or handling equipment according to weight. Keep in the upright position. Do not stack single boxes on top of each other without pallet in any case. Keep the packaging dry at all times.

Unit lifting

If the unit is dropped, it should immediately be checked for damage.

Pre-Installation Guideline

The installation position should be selected with the following points in mind:

• Leveling should be +/- 5 mm.
• Pipework and electrical connections are readily accessible.
• Ensure there are no obstructions in front of the condenser inlet.
• It is recommended to have a clearance of at least 500mm between the condenser face and adjacent wall or unit.

Where multiple units are to be installed in the same location, the contractor needs to consider each individual case carefully. Due care should be taken to avoid the discharge air from each unit adversely affecting other units in the vicinity. There can be many variations of unit quantities and available space and this manual does not cover all such possible options. In general terms, air recirculation and local heat build up should be avoided at all times.

Mechanical Data – 50Hz

Medium temperature

Low temperature

Mechanical Data – 60Hz

Medium temperature

Low temperature

Installation, System Processing and Commissioning

Utmost care must be taken while handling the scroll condensing unit. Please go through the contents below to ensure proper handling.

Leak test, evacuation and charging

The following assumes the condensing unit to be leak-free on arrival. That is an important step before proceeding with the following.

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.

Initial pressure test (by vacuum and nitrogen)

Step-by-step

1. 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.
2. 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 crankcase 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 and pressurize to 20 bar. Check for leaks and repair leakage.

Leak test (by nitrogen pressure)

Release nitrogen from system. Start vacuum pump and open main pump valve.

Evacuation

Note that the following procedure is based upon achieving an actual system vacuum standard and it is NOT TIME-DEPENDENT!

Step-by-step:

1. Check suction capability of the vacuum pump with a gauge before commencing evacuation process. The vacuum pump must be rated to achieve a vacuum level of at least 100 µmHg (microns) or 13 Pa.
2. Connect the vacuum gauge to the system.
3. It is recommended to carry out the evacuation process three times as detailed below: Start the vacuum pump and then open the main valve. It is assumed that the crank case heater is still energized and the compressor cannot start.

4. Step 1 Evacuation: Evacuate to 1500 µmHg (microns) or 200 Pa and break vacuum to 0.1 bar with Nitrogen
5. Step 2 Evacuation: Same as in step 1
6. Step 3 Evacuation: Leave the pump running while checking the vacuum regularly. The target system vacuum is 500 µmHg (microns) or 67 Pa.

Once the target vacuum level is reached, the quality of the vacuum within the system must be tested. This is achieved by shutting off the main pump valve, allowing the internal system pressure to rise, and recording the time taken for the vacuum to rise by no more than 300 µmHg (microns) or 40 Pa within 30 minutes. (i.e. to 100 µmHg (microns) or 13.3 Pa). Evacuation is only complete once the vacuum quality is achieved. Close the manifold valves tightly. Close the pump main valve, switch off, and remove the vacuum pump.

Charging and commissioning

Step-by-step:

1. Ensure that there is no power supply to the unit. Hence, it is acceptable to leave the crankcase heater off.
2. Connect the refrigerant cylinder to main service hose and purge line at the manifold end.
3. Invert the refrigerant cylinder if necessary to ensure only liquid refrigerant can be charged into the system. This will be charged through the high pressure side of the manifold and liquid service valve.
4. The refrigerant cylinder should be weighed at this point to be able to record the final refrigerant charge. Refer to the table below for the approximate holding capacity of receiver is at 32°C when it is 80% full. Now, open the liquid service valve (off the back seat). In warm ambients, with a good vacuum in the system and the refrigerant cylinder inverted, it may not be necessary to run the compressor.
5. In cooler ambients, it may be necessary to run the compressor in order to complete charging.

IMPORTANT! TO BE CLEARLY UNDERSTOOD PRIOR TO RUNNING ANY SCROLL COMPRESSOR

Scroll compressor systems should be charged as quickly as possible by bleeding liquid refrigerant into the suction line with the compressor running. DO NOT VAPOR CHARGE SCROLL CONDENSING UNIT SYSTEM!

6. The system needs to be operated down to its set point before you can be sure that 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.
7. If the system is still short of the refrigerant, bleed liquid refrigerant into the suction side with the compressor running.
8. Check the oil level and add oil if necessary.

User Operation

Unit operation

Before starting the unit, ensure the following:

• All the electrical connections are correct and as per the recommended wiring diagrams
• All low side tubings are properly insulated
• Leak check is done and unit is pre-charged with refrigerant through high side
• Check for superheat setting on the expansion valve (TXV) appropriate or not

Adding refrigerant on a cold weather results to an overcharged unit, which may then trip out on high pressure limit during warm weather. Suction Superheat should be 10-15 K for reliable operation.

Remember that the refrigerant is under pressure. Always wear protective equipment, i.e. safety glasses or goggles and gloves when working with refrigerant, and guard against refrigerant spraying into the face or skin. Line pressures on an operating conditioning unit will vary with outdoor temperatures. As outdoor temperatures rise, pressures will also rise.

Application tips for scroll compressors

• Do not use compressor to pull vacuum
• Never use the compressor to suck oil into the system
• Do not test compressor by closing suction valve
• Do not set low pressure switch below 0 bar
• Do not bypass LP controls
• Do not pump down below 0 bar

Reverse Rotation

• Incorrect rotation can be identified by: Low current, noise, balanced suction, and discharge pressure;
• Correct by interchanging any two phases
• Short-term reverse rotation will not damage the compressor

Approved compressor oil

POE-32: Polyolester oil (Copeland Ultra 32-3MAF, Lubrizol Emkarate RL32-3MAF, Everest 32-3MAF, National NL PE32-3MAF, Parker EMKARATE RL32-3MAF/ (Virginia) LE323MAF, Nu Calgon 4314-66/EMKARATE RL32-3MAF, Everest 22 CC, Copeland Ultra 22 CC, Mobil Arctic 22 CC). Last three are approved for 'top off' only, 32-3MAF preferred.

High and low pressure control settings

Maintenance

Condenser fins

Condenser fins become dirty over time as ambient air is induced to the condenser. Dirty coil surfaces result in high condensing temperatures and poor unit performance. Regular cleaning is recommended with frequency depending on the installation and the surrounding environment. As a general guide, it is advisable to do this at least once every two months. Fins should be cleaned with liquid detergent diluted with clean water. Before washing, a light brush downward (in the direction of the fins) should be done to remove heavy deposits. Electrical Connections Check tightness of electrical connections occasionally.

Routine leak test

All joints should be checked for leaks during site visits. All joints should be leak tested once a year. Condenser Fan(s) and Motor(s) An annual inspection of these items is recommended. Fastenings may loosen, bearings may wear, and fans may require cleaning of solid deposits which can cause imbalance.

Wiring Diagrams

The document includes wiring diagrams for the F Series Condensing Unit TFM and CFZ models. These diagrams detail the typical control circuits and component connections for various voltage and frequency configurations (e.g., 230V/50Hz, 230V/60Hz, 400V/50Hz, 380V/60Hz).

Key components identified in the diagrams include:

• Terminal Box Compressor (A5)
• Terminal Box Condensing Unit (A7)
• Room Thermostat (B1)
• Run Capacitors (C1, C2)
• Start Capacitor (C3)
• Pressure Control Switch (F3)
• Internal Over-Current Thermal Protector (F11)
• Discharge Gas Thermostat (F13)
• Signal Lamp (H4)
• Contactors (K1, K51, K52)
• Relay Unit Alarm (K6)
• Compressor Motor (M1)
• Fan Motors (M21, M22)
• Speed Control Fan (N1)
• Crankcase Heater (R2)
• Terminal Blocks (X1, X2)

Cable color codes are provided for identification, including:

• WH = White
• BU = Blue
• GY = Grey
• RD = Red
• BK = Black
• YE = Yellow
• BN = Brown
• LGY = Light Grey
• CGY = Charcoal Grey
• G/Y = Green/Yellow

About Copeland

Copeland is a global leader in sustainable heating, cooling, refrigeration and industrial solutions. We help commercial, industrial, refrigeration and residential customers reduce their carbon emissions and improve energy efficiency. We address issues like climate change, growing populations, electricity demands and complex global supply chains with innovations that advance the energy transition, accelerate the adoption of climate friendly low GWP (Global Warming Potential) and natural refrigerants, and safeguard the world's most critical goods through an efficient and sustainable cold chain. We have over 18,000 employees, with feet on the ground in 50 countries - a global presence that makes it possible to serve customers wherever they are in the world and meet challenges with scale and speed. Our industry-leading brands and diversified portfolio deliver innovation and technology proven in over 200 million installations worldwide. Together, we create sustainable solutions that improve lives and protect the planet today and for future generations. For more information, visit copeland.com.

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