Application Guidelines

Copeland Scroll™ Compressors

for Refrigeration
ZB15K* to ZB220K*, ZS21K* to ZS11M*
ZF06K* to ZF48K*, ZF13KVE to ZF48KVE
About these guidelines ............................................................................................... 1
1 Safety instructions ........................................................................................... 1
1.1 Icon explanation ............................................................................................................... 1
1.2 Safety statements ............................................................................................................ 1
1.3 General instructions ......................................................................................................... 2
2 Product description ......................................................................................... 3
2.1 Common information about Copeland Scroll™ compressors.......................................... 3
2.2 Nomenclature ................................................................................................................... 4
2.3 Application range ............................................................................................................. 4
2.3.1 Qualified refrigerants and oils .............................................................................. 4
2.3.2 Application limits ................................................................................................... 5
3 Installation ........................................................................................................ 6
3.1 Compressor handling ....................................................................................................... 6
3.1.1 Transport and storage .......................................................................................... 6
3.1.2 Positioning and securing ...................................................................................... 6
3.1.3 Installation location ............................................................................................... 6
3.1.4 Mounting parts ...................................................................................................... 6
3.2 Brazing procedure ............................................................................................................ 7
3.3 Copeland Scroll compressors with liquid injection ........................................................... 8
3.3.1 Liquid injection details for ZF06K4E to ZF18K4E compressors........................... 8
3.3.2 Current sensing relay ........................................................................................... 9
3.3.3 Liquid injection details for ZF24K4E to ZF48K4E compressors........................... 9
3.4 Copeland Scroll compressors with vapour injection ...................................................... 10
3.5 Shut-off valves and adaptors ......................................................................................... 11
3.6 Suction accumulators ..................................................................................................... 11
3.7 Screens .......................................................................................................................... 12
3.8 Mufflers .......................................................................................................................... 12
3.9 Suction line noise and vibration ..................................................................................... 12
4 Electrical connection ..................................................................................... 14
4.1 General recommendations............................................................................................. 14
4.2 Electrical installation ...................................................................................................... 14
4.2.1 Terminal box ....................................................................................................... 17
4.2.2 Motor windings ................................................................................................... 17
4.2.3 Protection devices .............................................................................................. 18
4.2.4 Crankcase heaters ............................................................................................. 18
4.3 Pressure safety controls ................................................................................................ 18
4.3.1 High-pressure control ......................................................................................... 18
4.3.2 Low-pressure control .......................................................................................... 18
4.3.3 Internal pressure relief valve .............................................................................. 18
4.4 Discharge temperature protection ................................................................................. 19

C6.2.20/0716-0617/E
 4.5 Motor protection ............................................................................................................. 20
4.6 Phase protection ............................................................................................................ 21
4.7 Protector functional check and failure detection ............................................................ 21
4.7.1 Checking the connection .................................................................................... 21
4.7.2 Checking the compressor thermistor chain ........................................................ 21
4.7.3 Checking the protection module ......................................................................... 21
4.8 High-potential testing ..................................................................................................... 22
5 Starting up & operation.................................................................................. 23
5.1 Strength pressure test .................................................................................................... 23
5.2 Tightness/pressure test .................................................................................................. 23
5.3 System evacuation ......................................................................................................... 23
5.4 Preliminary checks – Pre-starting .................................................................................. 24
5.5 Charging procedure ....................................................................................................... 24
5.6 Initial start-up ................................................................................................................. 24
5.7 Rotation direction ........................................................................................................... 24
5.8 Starting sound ................................................................................................................ 25
5.9 Deep vacuum operation ................................................................................................. 25
5.10 Shell temperature ........................................................................................................... 25
5.11 Pump-down cycle ........................................................................................................... 25
5.12 Minimum run time .......................................................................................................... 26
5.13 Shut-off sound ................................................................................................................ 26
5.14 Frequency ...................................................................................................................... 26
5.15 Oil level .......................................................................................................................... 26
6 Maintenance & repair ..................................................................................... 27
6.1 Exchanging the refrigerant ............................................................................................. 27
6.2 Rotalock valves .............................................................................................................. 27
6.3 Replacing a compressor ................................................................................................ 27
6.3.1 Compressor replacement ................................................................................... 27
6.3.2 Start-up of a new or replacement compressor ................................................... 27
6.4 Lubrication and oil removal ............................................................................................ 27
6.5 Oil additives ................................................................................................................... 28
6.6 Unbrazing system components ..................................................................................... 28
7 Dismantling & disposal .................................................................................. 29
DISCLAIMER .............................................................................................................. 29

C6.2.20/0716-0617/E
About these guidelines

instructions
Safety
The purpose of these application guidelines is to provide guidance in the application of Copeland
Scroll™ compressors in users’ systems. They are intended to answer the questions raised while
designing, assembling and operating a system with these products.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the compressors. Emerson will not guarantee the performance and reliability
of the product if it is misused in regard of these guidelines.

description
These application guidelines cover stationary applications only. For mobile applications, contact

Product
Application Engineering as other considerations may apply.

1 Safety instructions
Copeland Scroll™ compressors are manufactered according to the latest European and US Safety
Standards. Particular emphasis has been placed on the user’s safety.
These compressors are intended for installation in systems according to the Machinery Directive

Installation
MD 2006/42/EC and to the Pressure Equipment Directive PED 97/23/EC. They may be put to
service only if they have been installed in these systems according to instructions and conform to
the corresponding provisions of legislation. For relevant standards please refer to Manufacturers
Declaration, available at www.emersonclimate.eu.
These instructions should be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.

connection
1.1 Icon explanation

Electrical
WARNING CAUTION
This icon indicates instructions to This icon indicates instructions to
avoid personal injury and material avoid property damage and possible
damage. personal injury.
High voltage IMPORTANT
This icon indicates operations with a This icon indicates instructions to

Starting up &
danger of electric shock. avoid malfunction of the compressor.

operation
Danger of burning or frostbite This word indicates a
This icon indicates operations with a NOTE recommendation for easier operation.
danger of burning or frostbite.
Explosion hazard
This icon indicates operations with a
danger of explosion.
Maintenance &

1.2 Safety statements

repair

 Refrigerant compressors must be employed only for their intended use.

 Only qualified and authorized HVAC or refrigeration personnel are permitted to install,
commission and maintain this equipment.
 Electrical connections must be made by qualified electrical personnel.
 All valid standards for connecting electrical and refrigeration equipment must be
observed.
Dismantling &

 The national legislation and regulations regarding personnel protection must be

disposal

observed.

Use personal safety equipment. Safety goggles, gloves,

protective clothing, safety boots and hard hats should be worn
where necessary.

C6.2.20/0716-0617/E 1
1.3 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
Contact with POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE must not come into contact with any surface
or material that it might damage, including without limitation, certain polymers,
eg, PVC/CPVC and polycarbonate.

IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.

2 C6.2.20/0716-0617/E
2 Product description

instructions
2.1 Common information about Copeland Scroll™ compressors

Safety
The Scroll compressor has been under development at Emerson since 1979. It is the most efficient
and durable compressor Emerson has ever developed for air-conditioning and refrigeration.
These application guidelines deal with all vertical single Copeland Scroll compressors for
refrigeration applications from ZB15K* to ZB220K*, ZS21K* to ZS11M* and ZF06K* to
ZF48K*, including vapour injection compressors.

description
Cooling capacity kW

Product
Compressor R448A Motor
R404A R407A R407F R134A R450A R513A
R449A
ZB15KCE 3.32 3.22 3.03 2.07 1.73 1.94 PFJ/TFD
ZB19KCE 4.16 3.95 3.80 1.39 2.04 2.36 PFJ/TFD
ZB21KCE 5.05 4.71 4.61 3.01 2.65 3.05 PFJ/TFD
ZB26KCE 5.85 5.43 5.33 3.48 3.06 3.43 PFJ/TFD

Installation
ZB29KCE 6.97 6.08 3.48 3.89 PFJ/TFD
ZB30KCE 6.87 6.40 6.61 6.67 4.08 3.60 4.03 PFJ/TFD
ZB38KCE 8.53 8.32 8.21 8.34 5.07 4.47 5.03 PFJ/TFD
ZB45KCE 10.05 9.49 9.66 9.76 6.04 5.26 5.92 TFD
ZB48KCE 11.63 10.79 11.22 5.89 6.59 TFD
ZB56KCE 11.75 TWD
ZB57KCE 13.22 12.84 TFD

connection
Electrical
ZB75KCE 17.15 TWD
ZB92KCE 21.20 TWD
ZB11MCE 25.80 TWD
Table 1: Cooling capacity for medium temperature compressors @ -10°C/45°C/20°C/0K

Cooling capacity kW

Starting up &
operation
Compressor R448A Motor
R404A R407A R407F
R449A
ZF06K4E 1.43 1.16 1.22 1.29 TFD
ZF08K4E 1.76 1.44 1.52 1.59 TFD
ZF09K4E 1.94 1.59 1.67 1.75 TFD
ZF11K4E 2.46 2.00 2.10 2.22 TFD Maintenance &
ZF13K4E 2.78 2.23 2.35 2.51 TFD
ZF15K4E 3.42 2.74 2.89 3.08 TFD
repair

ZF18K4E 4.04 3.34 3.52 3.65 TFD

ZF24K4E 5.16 TWD
ZF33K4E 7.09 TWD
ZF40K4E 8.78 TWD
ZF48K4E 10.60 TWD
ZF13KVE 3.96 3.13 3.30 3.18 TFD
Dismantling &

ZF18KVE 6.08 4.92 4.92 4.88 TFD

disposal

ZF24KVE 7.20 TWD

ZF33KVE 9.80 TWD
ZF40KVE 11.90 TWD
ZF48KVE 14.90 TWD
Table 2: Cooling capacity for low temperature compressors @ -35°C/40°C/20°C/0K

C6.2.20/0716-0617/E 3
These compressors have one Scroll compression set driven by a single or three-phase induction
motor. The Scroll set is mounted at the upper end of the rotor shaft of the motor. The rotor shaft
axis is in the vertical plane.

2.2 Nomenclature
The model designation contains the following technical information about the standard and vapour
injection compressors:

2.3 Application range

2.3.1 Qualified refrigerants and oils
WARNING
Use of R450A and R513A refrigerants! Risk of compressor damage!
Refrigerant migration of R450A or R513A into the compressor crankcase
could cause low oil viscosity, which could lead to compressor damage. When
using R450A and R513A it is critical to meet the following requirements:
 maintain adequate superheat settings with a minimum superheat of 8-10K;
 no liquid refrigerant migration into the compressor at any time, especially
during standstill, during or after defrost, or after reverse mode for example
in heat pumps;
 pumpdown is recommended;
 the use of a crankcase heater is mandatory;
 retrofit to R450A and R513A is only allowed for compressors which are
approved for these refrigerants.
Contact Application Engineering for any further information.

IMPORTANT
It is essential that the glide of refrigerant blends (primarily R407C and R407F)
be carefully considered when adjusting pressure and superheat controls.

4 C6.2.20/0716-0617/E
Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland™
brand products Select software available at www.emersonclimate.eu.

instructions
Safety
Compressors ZB ZS, ZF ZF*KVE
R404A,
R404A, R407C,
R407A, R407F, R404A,
R407A, R407F,
Qualified refrigerants1) R448A, R449A, R407A, R407F
R448A, R449A,
R450A, R513A, R448A, R449A
R134a, R22
R134a, R22

description
Copeland™ brand
Emkarate RL 32 3MAF

Product
products standard oil
Servicing oils Emkarate RL 32 3MAF, Mobil EAL Arctic 22 CC
1) ZB/ZS/ZF compressors in the TW* version are not qualified for R407A, R407F, R448A, R449A
Table 3: Qualified refrigerants and oils

2.3.2 Application limits

CAUTION

Installation
Inadequate lubrication! Compressor breakdown! The superheat at the
compressor suction inlet must always be sufficient to ensure that no refrigerant
droplets enter the compressor. For a typical evaporator-expansion valve
configuration a minimum stable superheat of at least 5K is required.

Application envelopes for the various refrigerants can be found in Select software, available at
www.emersonclimate.eu.

connection
Electrical
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

C6.2.20/0716-0617/E 5
3 Installation
WARNING
High pressure! Injury to skin and eyes possible! Be careful when opening
connections on a pressurized item.

3.1 Compressor handling

3.1.1 Transport and storage
WARNING
Risk of collapse! Personal injuries! Move compressors only with
appropriate mechanical or handling equipment according to weight. Keep in
the upright position. Respect stacking loads according to Figure 1. Check the
tilting stability and if needed take action to ensure the stability of the stacked
loads. Keep the packaging dry at all times.

Respect the maximum number of identical packages which may be stacked on one
another, where "n" is the limiting number:
 Transport: n = 1
 Storage: n = 2

Figure 1: Maximum stacking loads for transport and storage

3.1.2 Positioning and securing

IMPORTANT
Handling damage! Compressor malfunction! Only use the lifting eyes
whenever the compressor requires positioning. Using discharge or suction
connections for lifting may cause damage or leaks.

If possible, the compressor should be kept vertical during handling.

The discharge connection plug should be removed first before pulling the suction connection plug
to allow the dry air pressure inside the compressor to escape. Pulling the plugs in this sequence
prevents oil mist from coating the suction tube making brazing difficult. The copper-coated steel
suction tube should be cleaned before brazing.
No object, eg, a swaging tool should be inserted deeper than 51 mm into the suction tube or it
might damage the suction screen and motor.
3.1.3 Installation location
Ensure the compressors are installed on a solid level base.
3.1.4 Mounting parts
Four vibration absorber grommets are supplied with each compressor. They dampen the start-up
surge of the compressor and minimise sound and vibration transmission to the compressor base
during operation. The metal sleeve inside is a guide designed to hold the grommet in place. It is
not designed as a load-bearing member, and application of excessive torque to the bolts can crush
the sleeve. Its inner diameter is approximately 8.5 mm to fit, eg, an M8 screw. The mounting torque
should be 13 ± 1 Nm. It is critically important for the grommet not to be compressed.
If the compressors are mounted in tandem or used in parallel, then the hard mountings (bolt M9
5/16") are recommended. The mounting torque should be 27 ± 1 Nm. It is possible to deliver these
hard mounting parts as a kit, or on request to deliver the compressor with these parts instead of
the rubber grommets.

6 C6.2.20/0716-0617/E
 Mounting parts: ZB15K* to ZB48K* & ZB57K*, ZS21K* to ZS45K*, ZF06K* to ZF18K* -
Soft mountings

instructions
Safety
Mounting parts: ZB56K* to ZB11M*, ZS56K* to ZS11M*, ZF24K* to ZF48K* -
Soft mountings

description
Product
Mounting parts: ZB220K* - Soft mountings

Installation
Figure 2: Mounting parts

3.2 Brazing procedure

connection
Electrical
IMPORTANT
Blockage! Compressor breakdown! Maintain a flow of oxygen-free nitrogen
through the system at very low pressure during brazing. Nitrogen displaces
the air and prevents the formation of copper oxides in the system. If 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.

Starting up &
Contamination or moisture! Bearing failure! Do not remove the plugs until

operation
the compressor is set into the unit. This minimises any entry of contaminants
and moisture.

Copeland Scroll compressors have copper-plated steel

suction and discharge tubes. These tubes are far more
robust and less prone to leaks than copper tubes. Due to
the different thermal properties of steel and copper, Maintenance &
brazing procedures may have to be changed from those
commonly used.
repair

Refer to Figure 3 and the procedure below for the

Figure 3: Suction tube brazing areas brazing of the suction and discharge lines to a scroll
compressor.
 The copper-coated steel tubes on Scroll compressors can be brazed in approximately the
same manner as any copper tube.

Dismantling &

Recommended brazing materials: any silfos material is recommended, preferably with a

minimum of 5% silver. However, 0% silver is acceptable.
disposal

 Be sure tube fitting inner diameter and tube outer diameter are clean prior to assembly.
 Using a double-tipped torch, apply heat in area 1.
 As the tube approaches brazing temperature, move the torch flame to area 2.
 Heat area 2 until braze temperature is attained, moving the torch up and down and rotating
around the tube as necessary to heat the tube evenly. Add braze material to the joint while
moving the torch around the joint to flow braze material around the circumference.
 After the braze material flows around the joint, move the torch to heat area 3. This will draw
the braze material down into the joint. The time spent heating area 3 should be minimal.
 As with any brazed joint, overheating may be detrimental to the final result.
C6.2.20/0716-0617/E 7
To disconnect:
 Heat joint areas 2 and 3 slowly and uniformly until the braze material softens and the tube can
be pulled out of the fitting.
To reconnect:
 Recommended brazing materials: Silfos with minimum 5% silver or silver braze used on other
compressors. Due to the different thermal properties of steel and copper, brazing procedures
may have to be changed from those commonly used.
NOTE: Since the discharge stub contains a check valve, care must be taken not to overheat
it to prevent brazing material from flowing into it.

3.3 Copeland Scroll compressors with liquid injection

The installation of liquid injection is mandatory for all ZF* compressors used in low temperature
applications. Liquid injection will keep discharge gas temperatures within safe limits. The
corresponding operating envelopes in the technical documentation of these compressors are
based on the use of liquid injection.
3.3.1 Liquid injection details for ZF06K4E to ZF18K4E compressors
Liquid injection is achieved by means of a Discharge Temperature Control (DTC) valve. The same
DTC valve can be used for all compressors and approved refrigerants.
NOTE: For the selection of adequate liquid injection parts such as DTC valve and discharge
thermostat, refer to the Emerson spare parts software at www.emersonclimate.eu.

Figure 4: Liquid injection with DTC valve

ZF* compressors include a well in the top cap combined with a valve cap. The Copeland DTC
valve is equipped with a custom bulb profile, which must be installed in the top well of the
compressor sensing the temperature closest to the discharge port. The bulb/bellows combination
injects only when cooling is needed and in the required amounts. The connection to the liquid line
is a 3/8" braze.

Figure 5: DTC valve assembly

8 C6.2.20/0716-0617/E
To prevent a partial or full blockage at the injection port caused through shavings, foreign bodies
etc a filter should be installed in the liquid line prior to the DTC valve inlet.

instructions
3.3.2 Current sensing relay

Safety
It is mandatory to install the current sensing relay on compressors ZF06K* to ZF18K* with liquid
injection and ZF13KVE to ZF18KVE with vapour injection using capillary tubes for injection.
Compressors using a DTC valve for liquid injection are not concerned.
Power to the injection solenoid must be cut if the internal motor protector trips and the danger of
flooding the compressor arises. For models mentioned above a current sensing relay, eg,
KRIWAN INT215, Type K35 can be supplied.

description
Product
The relay must be installed in a way that it senses the same phase as the control circuit it is hooked
up to. "L1" in Figure 6 serves only as an example. It has to be wired in such a way that marking
"L" faces the compressor and "K" the contactor.

Installation
connection
Electrical
Figure 6: Current sensing relay

3.3.3 Liquid injection details for ZF24K4E to ZF48K4E compressors

The compressor is supplied with a 1/4" diameter injection stub to accept a capillary tube. Liquid

Starting up &
injection takes place directly with the capillary tube as shown in Figure 7. Injection takes place

operation
into two distinct pockets of the spirals which has no impact on the suction process. Injection
increases the mass flow through the condenser.

Maintenance &
repair
Dismantling &
disposal

Figure 7: Liqui injection

The capillary tube is needed to meter the correct amount of liquid refrigerant into the compressor.
For liquid injection it consists of a wrapped capillary tube inside a shell. It is supplied with a clamp
to support the assembly at the injection port. In case this assembly is not wanted but an own
device has to be built, please take the specifications out of Table 4.
C6.2.20/0716-0617/E 9
 R404A/R507 R22
Model I.D. Length I.D. Length
(inch) (inch) (inch) (inch)
ZF24K4E 0.050" 30" 0.050" 5"
ZF33K4E 0.050" 17.5" 0.050" 5"
ZF40K4E 0.070" 30" 0.070" 30"
ZF48K4E 0.070" 30" 0.070" 10"
Table 4: Capillary tube details

A standard On/Off solenoid valve such as Alco 110 RB 2T2 should be used. The valve should
have a port diameter of at least 1.4 mm and should be wired to open when the compressor is
running and to close:
 when the compressor shuts off;
 during a hot gas defrost;
 during a pump down cycle.
A filter drier such as Alco ADKPlus 036MMS or ADKPlus 032S should be installed before the
solenoid valve to avoid blocking the valve and the injection device. If the internal motor protector
trips power to the injection solenoid must be shut-off.

3.4 Copeland Scroll compressors with vapour injection

The installation of vapour injection is mandatory for all ZF* compressors used in low temperature
applications. All corresponding operating envelopes are based on the use of vapour injection or
wet injection.
Copeland Scroll compressors with vapour injection are equipped with a vapour injection
connection for Economizer Operation. Economizing can be accomplished by using a subcooling
circuit similar to the circuit shown in Figure 8. This increases the refrigeration capacity and the
system efficiency.
The line diagram shows a system configuration for the economizer cycle. A heat exchanger is
used to provide additional subcooling to the refrigerant before it enters the evaporator. This
subcooling process provides the increased capacity gain measured in the system.
The refrigerant evaporated through the heat exchanger is injected into the compressors and
provides additional cooling at higher compression ratios.

Figure 8: Vapour injection line diagram

NOTE: For further information on vapour injection refer to Technical Information C7.19.1
"Vapour Injection Scroll Compressors for Refrigeration" and C7.19.2 "ZF* Refrigeration
Copeland Scroll™ Compressors Using R407A and R407F in Low Temperature
Applications".

10 C6.2.20/0716-0617/E
3.5 Shut-off valves and adaptors
CAUTION

instructions
Leaking system! System breakdown! It is strongly recommended to

Safety
periodically re-torque all pipe and fixing connections to the original setting after
the system has been put into operation.

description
Product
Installation
Figure 9

Copeland Scroll compressors are delivered with a discharge check valve fitted inside the
discharge port and rubber plugs fitted to the suction and discharge ports as standard. There are

connection
Electrical
options to fit either Rotalock valves, or Rotalock adaptors or just make brazing connections.
Brazing connections can be converted to Rotalock by means of adaptors. Rotalock shut-off valves
are available for the suction as well as discharge sides. Using either straight or angled adaptors
provides a way to convert a Rotalock into a brazing connection.
Refer to the following table for proper tightening torques:

Torque [Nm]

Starting up &
operation
Rotalock ¾" – 16UNF 40-50
Rotalock 1" – 14UNS 70-80
Rotalock 1 ¼" – 12UNF 110-135
Rotalock 1 ¾" – 12UNF 135-160
Rotalock 2 ¼" – 12UNF 165-190
Table 5
Maintenance &

NOTE: More information about adaptors and shut-off valves can be found in the spare parts
repair

software at www.emersonclimate.eu.

3.6 Suction accumulators

CAUTION
Inadequate lubrication! Bearing destruction! Minimise liquid refrigerant
returning to the compressor. Too much refrigerant dilutes the oil. Liquid
Dismantling &

refrigerant can wash the oil off the bearings leading to overheating and bearing
disposal

failure. For R450A and R513A refrigerants Emerson recommends to use

suction accumulators, unless it has been qualified that an accumulator is not
needed – see below.

Irrespective of system charge, oil dilution may occur if large amounts of liquid refrigerant
repeatedly flood back to the compressor during:
 normal off cycles;
 defrost;
 varying loads.

C6.2.20/0716-0617/E 11
In such a case an accumulator must be used to reduce flood-back to a safe level that the
compressor can handle. The use of accumulators is dependent on the application. If an
accumulator must be used, the oil-return orifice should be from 1 to 1.4 mm in diameter for models
ZB15K* to ZB48K*, ZB57K*, ZS19K* to ZS45K*, ZF06K* to ZF18K* and 2.0 mm for models
ZB56K* to ZB11M*, ZS56K* to ZS11M*, ZF24K* to ZF48K* depending on compressor size and
compressor flood-back results.
The size of the accumulator depends upon the operating range of the system and the amount of
subcooling and subsequent head pressure allowed by the refrigerant control.

3.7 Screens
CAUTION
Screen blocking! Compressor breakdown! Use screens with at least
0.6 mm openings.

The use of screens finer than 30 x 30 mesh (0.6 mm openings) anywhere in the system should be
avoided with these compressors. Field experience has shown that finer mesh screens used to
protect thermal expansion valves, capillary tubes, or accumulators can become temporarily or
permanently plugged with normal system debris and block the flow of either oil or refrigerant to
the compressor. Such blockage can result in compressor failure.

3.8 Mufflers
External mufflers, normally applied to piston compressors in the past, may not be required for
Copeland Scroll compressors.
Individual system tests should be performed to verify acceptability of sound performance. If
adequate attenuation is not achieved, use a muffler with a larger cross-sectional area to inlet area
ratio. A ratio of 20:1 to 30:1 is recommended.
A hollow shell muffler will work quite well. Locate the muffler at minimum 15 to maximum 45 cm
from the compressor for the most effective operation. The further the muffler is placed from the
compressor within these ranges, the more effective. Choose a muffler with a length of 10 to
15 cm.

3.9 Suction line noise and vibration

Copeland Scroll compressors inherently have low
sound and vibration characteristics. However in
some respects the sound and vibration
characteristics differ from reciprocating compressors
and in rare instances could result in unexpected
sound generation. One difference is that the vibration
characteristic of the scroll compressor, although low,
includes two very close frequencies, one of which is
normally isolated from the shell by the suspension of
an internally-suspended compressor. These
frequencies, which are present in all compressors,
may result in a low-level "beat" frequency that can be
detected as noise coming along the suction line into
Figure 10: Suction tube design
the building under some conditions. Elimination of
the beat can be achieved by attenuating either of the
contributing frequencies. This is easily done by using
one of the common combinations of recommended design configurations. The scroll compressor
makes both a rocking and twisting motion and enough flexibility must be provided in the line to
prevent vibration transmission into any lines attached to the unit. In a split system, the most
important goal is to ensure minimal vibration in all directions at the service valve to avoid
transmitting vibrations to the structure to which the lines are fastened.
A second difference of the Copeland Scroll is that under some conditions the normal rotational
starting motion of the compressor can transmit an "impact" noise along the suction line. This may
be particularly pronounced in three-phase models due to their inherently higher starting torque.
This phenomenon, like the one described previously, also results from the lack of internal

12 C6.2.20/0716-0617/E
suspension and can be easily avoided by using standard suction line isolation techniques as
described below.

instructions
Recommended configuration

Safety
 Tubing configuration: ...........small shock loop
 Service valve: ....................."angled” valve fastened to unit / wall
 Suction muffler: ....................not required
Alternative configuration
 Tubing configuration: ...........small shock loop
 Service valve: ......................."straight through" valve fastened to unit / wall

description
 Suction muffler: ....................may be required (acts as dampening mass)

Product
Installation
connection
Electrical
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

C6.2.20/0716-0617/E 13
4 Electrical connection

4.1 General recommendations

The compressor terminal box has a wiring diagram on the inside of its cover. Before connecting
the compressor, ensure the supply voltage, the phases and the frequency match the nameplate
data.

4.2 Electrical installation

Single-phase (PF*) compressors:
Power circuit Control circuit

Motor terminal connections

Single-phase compressors are connected to the

Common (C), Start (S) and Run (R) connections

Legend
B1 ....... Room thermostat K1 ........ Contactor
B3 ....... Discharge gas thermostat K35 ...... Current relay (ZF06-ZF18)
C2 ....... Run capacitor R2 ........ Crankcase heater
F1 ....... Fuse S1 ........ Auxiliary switch
F3 ....... HP switch Y5 ........ Solenoid valve for refrigeration injection
F4 ....... LP switch

Figure 11

14 C6.2.20/0716-0617/E
Three-phase compressors (TF*) with internal motor protection:
For the ZB15K* to ZB48K*, ZB57K*, ZS19K* to ZS45K*, ZF06K* to ZF18K* TF* range of

instructions
compressors the following circuit diagrams can be used:

Safety
Power circuit Control circuit

description
Product
Installation
Motor terminal connections

connection
Electrical
Three-phase compressors are connected to the T1,
T2 and T3 connections

Starting up &
operation
Legend
B1 ....... Room thermostat K1 ........ Contactor
B3 ....... Discharge gas thermostat K35 ...... Current relay (ZF06-ZF18)
F1 ....... Fuse R2 ........ Crankcase heater
F3 ....... HP switch S1 ........ Auxiliary switch
F4 ....... LP switch Y5 ........ Solenoid valve for refrigeration injection
Maintenance &
Figure 12 repair
Dismantling &
disposal

C6.2.20/0716-0617/E 15
Three-phase compressors (TW*) with external motor protection INT69SCY2:
For the ZB56K* to ZB220K*, ZS56K* to ZS11M*, ZF24K* to ZF48K* TW* range of compressors
the following circuit diagrams can be used:
Power circuit Control circuit

Motor terminal connections

Three-phase compressors are connected to the T1, T2

and T3 connections

Legend
A ......... Motor protection module INT69SCY2 K1 ........ Contactor
B1 ....... Room thermostat R2 ........ Crankcase heater
B3 ....... Discharge gas thermostat S1 ........ Auxiliary switch
F1 ....... Fuse Y5 ........ Solenoid valve for refrigeration injection
F3 ....... HP switch
F4 ....... LP switch

Figure 13

16 C6.2.20/0716-0617/E
4.2.1 Terminal box
The standard terminal box is IP21 for most of the compressor models with internal motor protection

instructions
(TF*/PF*). For some models a version with IP54 is available. The standard protection class for all

Safety
models with external motor protection (TW*) is IP54, enclosure class according to IEC 60034-5.
Cable glands have an influence on the protection class of the terminal box. Emerson strongly
recommends to use appropriate cable glands in order to reach the rated protection class.
Installers/service providers are advised to pay attention to this aspect every time they install or
replace a Copeland Scroll compressor and to use cable glands according to EN 50262 or any
other relevant standard of application in their country/region. Examples of correct electrical

description
installations are shown in Figures 14 & 15 below.

Product
Installation
connection
Electrical
Starting up &
Figure 14: Correct electrical installation with cable glands for IP21 T-box (models ZB15K* to ZB45K*)

operation
Maintenance &
repair
Dismantling &
disposal

Figure 15: Correct electrical installation with cable glands for IP54 T-box (models TW*)

4.2.2 Motor windings

These Scroll compressors are offered with either a single-phase or a three-phase induction motor,
depending on the size. All three-phase motors are connected in star; single-phase motors need a
run capacitor.
The motor insulation material is class "B" (TF*) or "H" (TW*) for compressor models covered in
these guidelines.
C6.2.20/0716-0617/E 17
4.2.3 Protection devices
Independently from the internal motor protection, fuses must be installed before the compressor.
The selection of fuses has to be carried out according to VDE 0635, DIN 57635, IEC 269-1 or
EN 60-269-1.
4.2.4 Crankcase heaters
IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours
before starting the compressor.

A crankcase heater is used to prevent refrigerant migrating into the shell during standstill periods.
Due to the Copeland scroll’s inherent ability to handle liquid refrigerant in flooded conditions a
crankcase heater is not required when the system charge does not exceed the charge limits
indicated in Table 6.
Compresseur model Refrigerant
Medium temperature Low temperature charge limit
ZB15K* to ZB29K* / ZS21K* to ZS26K* ZF06K* to ZF11K* 3.6 kg
ZB30K* to ZB48K* / ZB57K* /
ZF13K* & ZF18K* 4.5 kg
ZS30K* to ZS45K*
ZB56K* to ZB11M* / ZS56K* to ZS11M* ZF24K* to ZF48K* 7.5 kg
ZB220K* 11.3 kg
Table 6

If a crankcase heater is fitted it is recommended that

the heater be turned on for a minimum of 12 hours
prior to starting the compressor. This will prevent oil
dilution and bearing stress on initial start up. The
crankcase heater must remain energised during
compressor off cycles.
The crankcase heater must be mounted below the oil
schraeder valve located on the bottom shell (see
Figure 16).
Figure 16: Crankcase heater location

4.3 Pressure safety controls

4.3.1 High-pressure control
The cut-out setting for the high-pressure control shall be determined according to regional
standards, usually EN 378, part 2 in Europe.
The maximum pressure value for the individual compressor type, PS high side, is printed on the
nameplate of the compressor.
The high-pressure cut-out should have a manual reset feature for the highest level of system
protection.
4.3.2 Low-pressure control
The minimum cut-out setting shall be determined according to the refrigerant and to the allowed
operation envelope (see technical data in Select software at www.emersonclimate.eu). For
example, a minimum cut-out setting of 0.3 bar(g) is required for ZF compressors using R404A.
The low-pressure cut-out should have a manual reset feature for the highest level of system
protection.
4.3.3 Internal pressure relief valve
There is an internal pressure relief valve on all ZB15K* to ZB48K*, ZB57K*, ZF06K* to ZF18K*
and ZS21K* to ZS45K* refrigeration scroll compressors, which opens at a differential pressure of
28 bar ± 3 bar between high- and low-pressure sides. A high-pressure cut-out may be required
according to national regulations and is strongly recommended due to the capabilities of pumping
to high pressures once the discharge is obstructed. The IPR valve is a safety device, not an HP

18 C6.2.20/0716-0617/E
switch. It is not designed for repeated operation and there is no guarantee that it will reset correctly
if it does have repeated operation.

instructions
Safety
4.4 Discharge temperature protection
The use of an external discharge thermostat is required for compressor models ZF06K* to ZF18K*,
ZF13KVE to ZF18KVE, ZS21K* to ZS45K* and ZB57K*.
A discharge thermostat can be used but is not mandatory for compressor models ZB15K* to
ZB48K* because these models have an internal thermodisc which is positioned next to the
discharge port of the scroll set. When the thermodisc opens, a small gas by-pass occurs which

description
trips the Klixon motor protector. The internal thermodisc opens at 146°C ± 4K and closes at

Product
91°C ± 7K.
Internal discharge temperatures can reach unacceptable values under some extreme operating
conditions (such as loss of refrigerant injection charge or extremely high compression ratio). This
could cause compressor damage.
The discharge thermostat dedicated to R404A, R407A, R407F, R448A, R449A has a cut-out
setting of 130°C ± 4K with closing at 101°C ± 8K and should be installed approximately 120 mm

Installation
from the discharge valve outlet (see assembly instructions below).
To ensure proper functioning and to avoid false readings, the discharge line thermostat must be
installed and insulated according to the procedure and recommendations hereunder.
Assembly of the discharge line thermostat
 Install the discharge line thermostat on the
discharge tube 120 mm from top cap.

connection
Electrical
 Snap the retainer clip over the tube and onto

Starting up &
the thermostat.

operation
 The thermostat should be placed on the
discharge tube so that its body is in upward
position on a horizontal tube installation.
 Ensure that the thermostat is not tilted.

 The wire must not be in contact with the top

Maintenance &
cap of the compressor or the discharge tube.
Care should be taken to route wires so that
repair

they do not come into contact with sharp

objects.

 To avoid any impact on tripping temperature

by the ambient, the discharge line thermostat
must be insulated.
Dismantling &

 Wrap thermal insulation around the pipe left

disposal

and right of the thermostat and secure it with

plastic straps.
 Wrap a second layer of insulation around the
first one and around the thermostat, and
secure it with plastic straps.

C6.2.20/0716-0617/E 19
For compressors ZB56K* to ZB11M*; ZS56K* to ZS11M*; ZF24K* to ZF48K* and ZB220K*, a
thermistor is located in the discharge port of the fixed scroll. Excessive discharge temperature will
cause the electronic protector module to trip. The discharge gas thermistor is wired in series with
the motor thermistor chain.

NAT = 140°C

Figure 17: Internal discharge temperature sensor position

4.5 Motor protection

For the ZB15K* to ZB48K*, ZB57K*, ZS21K* to ZS45K*, ZF06K* to ZF18K* range of compressors,
conventional inherent internal line break motor protection is provided.
The electronic motor protection system used in all ZB56K* to ZB220K*, ZS56K* to ZS11M*,
ZF24K* to ZF48K* models is identified by a "W" as the centre letter in the motor code. This system
utilizes the temperature-dependent resistance of the thermistors (also called PTC-resistance) to
read the winding temperature. A chain of four thermistors connected in series is embedded in the
motor windings so that the temperature of the thermistors can follow the winding temperature with
little inertia. An electronic module INT69SCY2 is required to process the resistance values and
trip a control depending on the thermistor resistance.
Protection module specifications
Type: .............................................. Kriwan INT69SCY2
Dual voltage:.................................. 115 – 230V/120 – 240V AC 50/60 Hz , -15%...+10%, 3VA
Normal PTC resistance: ................ <1.8 kΩ
Trip resistance: ............................. 4.50 kΩ ± 20%
Reset resistance: ........................... 2.75 kΩ ± 20%
Reset time delay: ........................... 30 minutes ± 5 minutes
Reset of running time………………Power interruption / mains failure approx. 5s
Phase monitor: .............................. Yes
Ambient temperature range……….-30°C…+70°C
Module
The INT69SCY2 hermetic motor protection
module complies with IEC/EN 60335.
The module features mean that the
refrigeration system would still be in a safe
condition even if two faults were to occur.
Backup is provided if the first fault protection
should fail. An additional control contactor
should be fitted to the system.
For protection in case of blocked rotor one
thermistor for each phase is embedded in the
winding heads on the upper (suction gas)
side of the compressor motor. A fourth
T1/T2 Power supply thermistor is located in a winding head at the
L1/L2/L3 Phase control lower end of the motor. A fifth sensor is
S1/S2 Thermistor chain located in the discharge port of the fixed scroll
M1/M2 Relay control circuit to control discharge-gas superheat. The
Figure 18: Wiring of the motor protection module
entire chain is internally led to the fusite from
where it is connected to the module
connections S1 and S2. When any resistance
of the thermistor chain reaches the tripping value, the module interrupts the control line and causes
the compressor to switch off. After the thermistor has cooled sufficiently, its resistance drops to
the reset value but the module itself resets after a time delay of 30 minutes and restarts the
compressor.
20 C6.2.20/0716-0617/E
4.6 Phase protection
The phase protection capabilities of the INT69SCY2 module will sense the correct phase

instructions
sequence of L1, L2, and L3 incoming power. Three-phase power must be wired in the correct

Safety
phase sequence that will ensure the compressor will start and operate in the correct rotation. When
the INT69SCY2 trips on phase loss a delay of 5 minutes is activated. If all three phases are present
then the compressor will continue to run, if not the module will lock out.
After 10 attempts to restart the compressor, the module will lock out, which could be reset by re-
establishing incoming power to the module.

description
4.7 Protector functional check and failure detection

Product
WARNING
Conductor cables! Electrical shock! Shut off power supply before and
between each test.

Prior to start-up of the fully connected compressor a functional check shall be carried out:
 Disconnect one terminal either S1 or S2 of the protection module. If the compressor is now

Installation
switched on, the motor should not start (simulation of an open thermistor chain).
 Reconnect the disconnected thermistor line. If the compressor is now switched on, the motor
must start.
If the motor does not start up during the functional check, this indicates a disturbance in operation.
The following steps should be followed:
4.7.1 Checking the connection


connection
Check the connection of the thermistor leads in the terminal box and at the protection module

Electrical
for possible loose connections or cable breakage.
If there is neither loose connection nor cable breakage the resistance of the thermistor chain must
be checked.
4.7.2 Checking the compressor thermistor chain
Caution: Use maximum measuring voltage of 3V!

Starting up &
The thermistor leads at terminals S1 and S2 of the module shall be disconnected and the

operation
resistance measured between the leads. The resistance must be between 150 Ω and 1250 Ω.
 If the thermistor chain has a higher resistance (2750 Ω or higher), the motor temperature is
still too high and it must be allowed to cool. Then measure again.
 If the resistance is below 30 Ω, the compressor has to be exchanged due to shorted sensor
circuit.
 An infinite value indicates an open sensor circuit and the compressor has to be replaced.
Maintenance &

If no defect is detected in the thermistor chain the module must be checked.

repair

4.7.3 Checking the protection module

The control connections at M1 and M2 have to be removed and the switching conditions must be
checked by an ohmmeter or signal buzzer:
 Simulation of a short circuit in the thermistor chain (0 Ω): Bridge the already disconnected
thermistor terminals S1 and S2 and switch on the voltage supply; the relay must switch on
Dismantling &

then off again after a short period; connection established then interrupted between terminals
M1 and M2.
disposal

 Simulation of an open thermistor chain (∞ Ω): Remove the jumper used for the short-circuit
simulation and switch on the voltage supply; the relay remains switched off; no connection
between terminals M1 and M2.
If one of the above conditions is not met, the module is defective and has to be exchanged.
NOTE: The function of the module should be tested each time the fuse in the control circuit
breaks the power supply. This ensures the contacts did not stick.

C6.2.20/0716-0617/E 21
4.8 High-potential testing
WARNING
Conductor cables! Electrical shock! Shut off power supply before high-
potential testing.

CAUTION
Internal arcing! Motor destruction! Do not carry out high-voltage or
insulation tests if the compressor housing is under vacuum.

Emerson subjects all Scroll compressors to a high-voltage test after final assembly. Each motor
phase winding is tested, according to EN 0530 or VDE 0530 part 1, at a differential voltage of
1000V plus twice the nominal voltage. Since high-voltage tests lead to premature ageing of the
winding insulation further additional tests of that nature are not recommended.
If it has to be done for any reason, a lower voltage must be used. Disconnect all electronic devices,
eg, motor protection module, fan speed control, etc prior to testing.

22 C6.2.20/0716-0617/E
5 Starting up & operation

instructions
WARNING

Safety
Diesel effect! Compressor destruction! The mixture of air and oil at high
temperature can lead to an explosion. Avoid operating with air.

IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours
before starting the compressor.

5.1 Strength pressure test

The compressor has been strength-tested in the factory. It is not necessary for the customer to
strength- or leak-test the compressor again although the compressor will normally be exposed to
the testing made as part of system testing.

5.2 Tightness/pressure test

WARNING

description
High pressure! Personal injuries! Consider personal safety requirements

Product
and refer to test pressures prior to test.

WARNING
System explosion! Personal injuries! DO NOT USE other industrial gases.

CAUTION
System contamination! Bearing malfunction! Use only dry nitrogen or dried

Installation
air for pressure testing.

If using dry air do not include the compressor in the pressure test – isolate it first. Never add
refrigerant to the test gas (as leak indicator).

5.3 System evacuation

Before the installation is put into commission, it has to be evacuated with a vacuum pump. Proper

connection
evacuation reduces residual moisture to 50 ppm. During the initial procedure, suction and

Electrical
discharge shutoff valves on the compressor remain closed. The installation of adequately sized
access valves at the furthest point from the compressor in the suction and liquid lines is advisable.
Pressure must be measured using a vacuum pressure (Torr) gauge on the access valves and not
on the vacuum pump; this serves to avoid incorrect measurements resulting from the pressure
gradient along the connecting lines to the pump.
Evacuating the system only on the suction side of a Scroll compressor can occasionally result in
a temporary no start condition for the compressor. The reason for this is that the floating seal could
Starting up &
operation
axially seal with the scroll set, with the higher pressure on the floating seal. Consequently, until
the pressures equalise, the floating seal and scroll set can be held tightly together. The installation
should be evacuated down to 0.3 mbar / 0.22 Torr.
Subsequently, the factory holding charge of dry air in the compressor is released to the ambient.
The shut-off valves are opened and the installation, including the compressor, are once more
evacuated as described after the system has been recharged with dry nitrogen. Highest demands
are placed on the leak proof design of the installation and on leak testing methods (please refer
Maintenance &

to EN 378).
repair
Dismantling &
disposal

C6.2.20/0716-0617/E 23
5.4 Preliminary checks – Pre-starting
Discuss details of the installation with the installer. If possible, obtain drawings, wiring diagrams,
etc.
It is ideal to use a check-list but always check the following:
 Visual check of the electrics, wiring, fuses etc
 Visual check of the plant for leaks, loose fittings such as TXV bulbs etc
 Compressor oil level
 Calibration of HP & LP switches and any pressure actuated valves
 Check setting and operation of all safety features and protection devices
 All valves in the correct running position
 Pressure and compound gauges fitted
 Correctly charged with refrigerant
 Compressor electrical isolator location & position

5.5 Charging procedure

CAUTION
Low suction pressure operation! Compressor Damage! Do not operate
with a restricted suction. Do not operate with the low-pressure cut-out bridged.
Do not operate compressor without enough system charge to maintain at least
0.3 bar suction pressure. Allowing pressure to drop below 0.3 bar for more
than a few seconds may overheat scrolls and cause early drive bearing
damage.

The system should be liquid-charged through the liquid-receiver shut-off valve or through a valve
in the liquid line. The use of a filter drier in the charging line is highly recommended. Because
scrolls have discharge check valves, systems should be liquid-charged on both the high and low
sides simultaneously to ensure a positive refrigerant pressure is present in the compressor before
it runs. The majority of the charge should be placed in the high side of the system to prevent
bearing washout during first-time start on the assembly line.

5.6 Initial start-up

CAUTION
Oil dilution! Bearing malfunction! It is important to ensure that new
compressors are not subjected to liquid abuse. Turn the crankcase heater on
12 hours before starting the compressor.

CAUTION
High discharge pressure operation! Compressor damage! Do not use
compressor to test opening set point of high-pressure cut-out. Bearings are
susceptible to damage before they have had several hours of normal running
in.

Liquid and high pressure loads could be detrimental to new bearings. It is therefore important to
ensure that new compressors are not subjected to liquid abuse and high-pressure run tests. It is
not good practice to use the compressor to test the high-pressure switch function on the production
line. Switch function can be tested with nitrogen prior to installation and wiring can be checked by
disconnecting the high-pressure switch during the run test.

5.7 Rotation direction

Scroll compressors, like several other types of compressors, will only compress in one rotational
direction. Direction of rotation is not an issue with single-phase compressors since they will always
start and run in the proper direction. Three-phase compressors will rotate in either direction
depending upon phasing of the power to L1, L2 and L3. Since there is a 50/50 chance of
connecting power in such a way as to cause rotation in the reverse direction, it is important to
include notices and instructions in appropriate locations on the equipment to ensure
proper rotation direction is achieved when the system is installed and operated.
Observing that suction pressure drops and discharge pressure rises when the compressor is
energized allows verification of proper rotation direction. There is no negative impact on durability

24 C6.2.20/0716-0617/E
caused by operating three-phase Copeland Scroll compressors in the reversed direction for a
short period of time (under one hour) but oil may be lost. Oil loss can be prevented during reverse

instructions
rotation if the tubing is routed at least 15 cm above the compressor. After several minutes of

Safety
operation in reverse, the compressor protection system will trip due to high motor temperature.
The operator will notice a lack of cooling. However, if allowed to repeatedly restart and run in
reverse without correcting the situation, the compressor will be permanently damaged.
All three-phase Scroll compressors are identically wired internally. Therefore, once the correct
phasing is determined for a specific system or installation, connecting properly phased power
leads to the identified compressor terminals will ensure proper rotation direction.

description
Compressors ZB56K* to ZB220K*, ZS56K* to ZS11M* and ZF24K* to ZF48K* have an electronic

Product
protection unit (INT69SCY2) that will not let the compressor operate if the phasing of the wires is
incorrect.

5.8 Starting sound

During the very brief start-up, a clicking sound is audible, resulting from initial contacting of the
spirals and is normal. No start assist devices are required for single-phase compressors, even if
a system uses non-bleed expansion valves. Due to the design of the Copeland Scroll, the internal

Installation
compression components always start unloaded even if system pressures are not balanced. In
addition, since internal compressor pressures are always balanced at start-up, low-voltage starting
characteristics are excellent for Copeland Scroll compressors. Moreover, if low voltage conditions
exist at start up, protector trips could result.

5.9 Deep vacuum operation

CAUTION

connection
Vacuum operation! Compressor damage! Scroll compressors should never

Electrical
be used to evacuate a refrigeration or air-conditioning system.

The Scroll compressor can be used to pump down refrigerant in a unit as long as the pressures
remain within the operating envelope. Low suction pressures will result in overheating of the scrolls
and permanent damage to the compressor drive bearing. Scroll compressors incorporate internal
low vacuum protection; the floating seal unloads when the pressure ratio exceeds approximately
20:1 for ZS and ZF compressors, and 10:1 for ZB compressors.

Starting up &
operation
5.10 Shell temperature
The top shell and discharge line can briefly but repeatedly reach temperatures above 177°C if the
compressor cycles on its internal protection devices. This only happens under rare circumstances
and can be caused by the failure of system components such as the condenser or evaporator fan
or loss of charge and depends upon the type of expansion control. Care must be taken to ensure
that wiring or other materials that could be damaged by these temperatures do not come in contact Maintenance &
with the shell. repair

5.11 Pump-down cycle

To control refrigerant migration a pump-down system should be used. The discharge check valve
with a refrigeration scroll compressor is designed for low leak back and will allow the use of a
pump-down without the addition of an external check valve.
If the compressor is stationary for prolonged periods, refrigerant could migrate into the compressor
and therefore a crankcase heater must be installed.
Dismantling &
disposal

If cold air is constantly drawn over the compressor this could make the crankcase heater
ineffective and therefore a pump-down system is recommended.
For ZB models care should be taken because the scroll sets will unload at a pressure ratio of
approximately 10:1. If the unit fails to pump down the pump-down pressure should be reset to a
higher value. The low-pressure control differential for all models needs to be reviewed since a
relatively lower volume of gas will reexpand from the discharge plenum of the compressor into the
low side on shutdown.

C6.2.20/0716-0617/E 25
5.12 Minimum run time
Emerson recommends a maximum of 10 starts per hour. There is no minimum off time because
Scroll compressors start unloaded even if the system has unbalanced pressures. The most critical
consideration is the minimum run time required to return oil to the compressor after start-up. To
establish the minimum run time obtain a sample compressor equipped with a sight tube (available
from Emerson) and install it in a system with the longest connecting lines that are approved for
the system. The minimum on time becomes the time required for oil lost during compressor start-
up to return to the compressor sump and restore a minimal oil level that will ensure oil pick-up
through the crankshaft. Cycling the compressor for a shorter period than this, for instance to
maintain very tight temperature control, will result in progressive loss of oil and damage to the
compressor.

5.13 Shut-off sound

Scroll compressors incorporate a device that minimizes reverse rotation. The residual momentary
reversal of the scrolls at shut off will cause a clicking sound, but it is entirely normal and has no
effect on compressor durability.

5.14 Frequency
There is no general release of standard Copeland Scroll compressors for use with variable speed
AC drives. There are numerous issues that must be considered when applying Scroll compressors
with variable speed, including system design, inverter selection, and operating envelopes at
various conditions. Only frequencies from 50 Hz to 60 Hz are acceptable. Operation outside this
frequency range is possible but should not be done without specific Application Engineering
review. The voltage must vary proportionally to the frequency.
If the inverter can only deliver a maximum voltage of 400V, the amps will increase when the speed
is above 50 Hz, and this may give rise to nuisance tripping if operation is near the maximum power
limit and/or compressor discharge temperature limit.

5.15 Oil level

The oil level should be maintained at mid-point of the sight glass. If an oil regulator is being used
the level should be set within the top half of the sight glass.

26 C6.2.20/0716-0617/E
6 Maintenance & repair

instructions
6.1 Exchanging the refrigerant

Safety
Qualified refrigerants and oils are given in section 2.3.1.
It is not necessary to replace the refrigerant with new unless contamination due to an error such
as topping up the system with an incorrect refrigerant is suspected. To verify correct refrigerant
composition, a sample can be taken for chemical analysis. A check can be made during shut down
by comparing the refrigerant temperature and pressure using precision measurements at a
location in the system where liquid and vapour phases are present and when the temperatures

description
have stabilised.

Product
In the event that the refrigerant needs replacing, the charge should be recovered using a suitable
recovery unit.

6.2 Rotalock valves

Rotalock valves should be periodically re-torqued to ensure that leak tightness is maintained.

Installation
6.3 Replacing a compressor
CAUTION
Inadequate lubrication! Bearing destruction! Exchange the accumulator
after replacing a compressor with a burned out motor. The accumulator oil
return orifice or screen may be plugged with debris or may become plugged.
This will result in starvation of oil to the new compressor and a second failure.
6.3.1 Compressor replacement

connection
Electrical
In the case of a motor burnout, the majority of contaminated oil will be removed with the
compressor. The rest of the oil is cleaned through the use of suction and liquid line filter driers. A
100% activated alumina suction line filter drier is recommended but must be removed after
72 hours. It is highly recommended that the suction accumulator be replaced if the system
contains one. This is because the accumulator oil return orifice or screen may be plugged with
debris or may become plugged shortly after a compressor failure. This will result in starvation of
oil to the replacement compressor and a second failure. When a single compressor or tandem is

Starting up &
operation
exchanged in the field, it is possible that a major portion of the oil may still be in the system. While
this may not affect the reliability of the replacement compressor, the extra oil will add to rotor drag
and increase power usage.
6.3.2 Start-up of a new or replacement compressor
Rapid charging only on the suction side of a scroll-equipped system or condensing unit can
occasionally result in a temporary no start condition for the compressor. The reason for this is that, Maintenance &
if the flanks of the compressor happen to be in a sealed position, rapid pressurisation of the low
side without opposing high-side pressure can cause the scrolls to seal axially. As a result, until the
repair

pressures eventually equalise, the scrolls can be held tightly together preventing rotation. The best
way to avoid this situation is to charge on both the high and low sides simultaneously at a rate
which does not result in axial loading of the scrolls.
A minimum suction pressure of 1.75 bar must be maintained during charging. Allowing pressure
to drop below 0.3 bar for more than a few seconds may overheat scrolls and cause early drive
bearing damage. Never install a system in the field and leave it unattended when it has no charge,
Dismantling &

a holding charge, or with the service valves closed without securely electrically locking out the
system. This will prevent unauthorised personnel from accidentally operating the system and
disposal

potentially ruining the compressor by operating with no refrigerant flow. Do not start the
compressor while the system is in a deep vacuum. Internal arcing may occur when a Scroll
compressor is started in a vacuum causing burnout of the internal lead connections.

6.4 Lubrication and oil removal

CAUTION
Chemical reaction! Compressor destruction! Do not mix up ester oils with
mineral oil and/or alkyl benzene when used with chlorine-free (HFC)
refrigerants.

C6.2.20/0716-0617/E 27
The compressor is supplied with an initial oil charge. The standard oil charge for use with
refrigerants R404A / R407A / R407F / R448A / R449A / R407C / R134a / R450A / R513A / R22 is
a polyolester (POE) lubricant Emkarate RL 32 3MAF. In the field the oil level could be topped up
with Mobil EAL Arctic 22 CC if 3MAF is not available. See nameplate for original oil charge shown
in litres. A field recharge is from 0.05 to 0.1 litre less.
One disadvantage of POE is that it is far more hygroscopic than mineral oil (see Figure 19). Only
brief exposure to ambient air is needed for POE to absorb sufficient moisture to make it
unacceptable for use in a refrigeration system. Since POE holds moisture more readily than
mineral oil it is more difficult to remove it through the use of vacuum. Compressors supplied by
Emerson contain oil with low moisture content, and it may rise during the system assembling
process. Therefore it is recommended that a properly sized filter-drier is installed in all POE
systems. This will maintain the moisture level in the oil to less than 50 ppm. If oil is charged into a
system, it is recommended to use POE with a moisture content no higher than 50 ppm.

Figure 19: Absorption of moisture in ester oil in comparison to mineral oil in ppm by weight at 25°C and 50%
relative humidity (h=hours)

If the moisture content of the oil in a refrigeration system reaches unacceptably high levels,
corrosion and copper plating may occur. The system should be evacuated down to 0.3 mbar or
lower. If there is uncertainty as to the moisture content in the system, an oil sample should be
taken and tested for moisture. Sight glass/moisture indicators currently available can be used with
the HFC refrigerants and lubricants; however, the moisture indicator will just show the moisture
content of the refrigerant. The actual moisture level of POE would be higher than the sight glass
indicates. This is due to the high hygroscopicity of the POE oil. To determine the actual moisture
content of the lubricant, samples have to be taken from the system and analysed.

6.5 Oil additives

Although Emerson cannot comment on any specific product, from our own testing and past
experience, we do not recommend the use of any additives to reduce compressor bearing losses
or for any other purpose. Furthermore, the long term chemical stability of any additive in the
presence of refrigerant, low and high temperatures, and materials commonly found in refrigeration
systems is complex and difficult to evaluate without rigorously controlled chemical laboratory
testing. The use of additives without adequate testing may result in malfunction or premature
failure of components in the system and, in specific cases, in voiding the warranty on the
component.

6.6 Unbrazing system components

WARNING
Explosive flame! Burning! Oil-refrigerant mixtures are highly flammable.
Remove all refrigerant before opening the system. Avoid working with an
unshielded flame in a refrigerant charged system.

Before opening up a system it is important to remove all refrigerant from both the high and low
sides of the system. If the refrigerant charge is removed from a scroll equipped unit from the high
side only, it is 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 while the low side shell and suction line contain pressure, the
pressurized refrigerant and oil mixture could ignite when it escapes and contacts the brazing flame.
To prevent this occurrence, it is important to check both the high and low sides with manifold
gauges before unbrazing. Instructions should be provided in appropriate product literature and

28 C6.2.20/0716-0617/E
assembly (line repair) areas. If compressor removal is required, the compressor should be cut out
of system rather than unbrazed.

instructions
Safety
7 Dismantling & disposal
Removing oil and refrigerant:
 Do not disperse in the environment.
 Use the correct equipment and method of removal.
 Dispose of oil and refrigerant according to national legislation and
regulations.
 Dispose of compressor according to national legislation and regulations.

description
Product
DISCLAIMER
1. The contents of this publication are presented for informational purposes only and are not to
be construed as warranties or guarantees, express or implied, regarding the products or
services described herein or their use or applicability.
2. Emerson Climate Technologies GmbH and/or its affiliates (collectively "Emerson"), as
applicable, reserve the right to modify the design or specifications of such products at any time

Installation
without notice.
3. Emerson does not assume responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use and maintenance of any Emerson product remains
solely with the purchaser or end user.
4. Emerson does not assume responsibility for possible typographic errors contained in this
publication.

connection
Electrical
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

C6.2.20/0716-0617/E 29
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