Scroll Compressors for Heat Pump Applications

ZH12K4E to ZH11M4E, ZH09KVE to ZH48KVE

About this guideline .................................................................................................. 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................................................................................................................ 3
2.3 Application range .......................................................................................................... 4
2.3.1 Qualified refrigerants and oils ............................................................................. 4
2.3.2 Application limits and operating envelope ........................................................... 4
2.3.3 Dimensions ........................................................................................................ 5
3 Installation ..................................................................................................... 7
3.1 Compressor handling .................................................................................................... 7
3.1.1 Transport and storage ........................................................................................ 7
3.1.2 Positioning and securing .................................................................................... 7
3.1.3 Installation location............................................................................................. 7
3.1.4 Mounting parts ................................................................................................... 8
3.2 Brazing procedure ......................................................................................................... 8
3.3 Accumulators ................................................................................................................ 9
3.4 Screens ...................................................................................................................... 10
3.5 Mufflers ....................................................................................................................... 10
3.6 Sound shell ................................................................................................................. 10
3.7 Reversing valves ......................................................................................................... 10
3.8 Suction line noise and vibration ................................................................................... 11
4 Electrical connection ................................................................................... 12
4.1 General recommendations .......................................................................................... 12
4.2 Electrical installation .................................................................................................... 12
4.2.1 Terminal box .................................................................................................... 14
4.2.2 Motor windings ................................................................................................. 15
4.2.3 Protection devices............................................................................................ 15
4.2.4 Crankcase heaters ........................................................................................... 15
4.3 Pressure safety controls .............................................................................................. 16
4.3.1 High-pressure control ....................................................................................... 16
4.3.2 Low-pressure control........................................................................................ 16
4.4 Discharge temperature protection ................................................................................ 16
4.5 Motor protection .......................................................................................................... 17
4.6 Protector functional check and failure detection ........................................................... 17
4.6.1 Checking the connection .................................................................................. 18
4.6.2 Checking the compressor thermistor chain ....................................................... 18

C6.2.9/1111-1211/E
 4.6.3 Checking the protection module ....................................................................... 18
4.7 High-potential testing................................................................................................... 18
5 Starting up & operation................................................................................ 19
5.1 Strength pressure test ................................................................................................. 19
5.2 Tightness/pressure test ............................................................................................... 19
5.3 Preliminary checks – Pre-starting ................................................................................ 19
5.4 Charging procedure..................................................................................................... 19
5.5 Run-in time ................................................................................................................. 20
5.6 Initial start-up .............................................................................................................. 20
5.7 Rotation direction ........................................................................................................ 20
5.8 Starting sound ............................................................................................................. 20
5.9 Deep vacuum operation .............................................................................................. 21
5.10 Shell temperature ........................................................................................................ 21
5.11 Pump down cycle ........................................................................................................ 21
5.12 Minimum run time........................................................................................................ 21
5.13 Shut-off sound............................................................................................................. 21
5.14 Supply frequency and voltage ..................................................................................... 21
5.15 Oil level ....................................................................................................................... 22
6 Maintenance & repair ................................................................................... 23
6.1 Exchanging the refrigerant .......................................................................................... 23
6.2 Rotalock valves ........................................................................................................... 23
6.3 Replacing a compressor .............................................................................................. 23
6.3.1 Compressor replacement ................................................................................. 23
6.3.2 Start-up of a new or replacement compressor .................................................. 23
6.4 Lubrication and oil removal .......................................................................................... 24
6.5 Oil additives ................................................................................................................ 24
6.6 Unbrazing system components.................................................................................... 25
7 Dismantling & disposal................................................................................ 25
8 References ................................................................................................... 25

C6.2.9/1111-0512/E
About this guideline

instructions
Safety
The purpose of this guideline is to support Emerson ZH Scrolls users applying compressors in
their systems. It intends to answer the questions raised while designing and assembling a
system with these products.
Besides the support it provides, the instructions listed in this document are also critical for the
good and safe functioning of the compressor. Emerson cannot guarantee the performance and
reliability of the product if it is misused in regard of this guideline.

description
Product
1 Safety instructions
Copeland Scroll™ compressors are manufactured 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 EC Machines

Installation
directive. 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 on request.
These instructions should be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.

connection
Electrical
1.1 Icon explanation
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

Starting up &
operation
This icon indicates operations with a This icon indicates instructions to
danger of electric shock. avoid malfunction of the compressor.
Danger of burning or frostbite NOTE This word indicates a recommendation
This icon indicates operations with a for easier operation.
danger of burning or frostbite.
Explosion hazard

Maintenance &
This icon indicates operations with a
danger of explosion.

repair
1.2 Safety statements
 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.
Dismantling &

 Electrical connections must be made by qualified electrical personnel.

disposal

 All valid standards for connecting electrical and refrigeration equipment must be
observed.

Use personal safety equipment. Safety goggles, gloves,

protective clothing, safety boots and hard hats should be worn
References

where necessary.

C6.2.9/1111-0512/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.

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

CAUTION
Contact with POE! Material damage! POE must be handled carefully and
the proper protective equipment (gloves, eye protection, etc.) must be used
when handling POE lubricant. POE must not come into contact with any
surface or material that might be harmed by POE, including without
limitation, certain polymers (e.g. PVC/CPVC and polycarbonate).

2 C6.2.9/1111-0512/E
2 Product description

instructions
Safety
2.1 Common information about Copeland Scroll™ compressors
The Scroll compressor has been under development at Emerson Climate Technologies since
1979. It is the most efficient and durable compressor Emerson Climate Technologies has ever
developed for air conditioning, refrigeration and heating applications.
This application guideline deals with all vertical single Copeland Scroll™ compressors for

description
dedicated heat pump applications from ZH12K4E to ZH11M4E, and also includes vapour

Product
injection compressors from ZH09KVE to ZH48KVE.
Heating Heating
Compressor capacity Motor Compressor capacity Motor
kW kW

Installation
ZH12K4E 3.68 PFZ
ZH15K4E 4.77 PFJ/TFD
ZH21K4E 6.50 PFJ/TFD/TFR ZH09KVE 8.22 TFD/PFZ
ZH26K4E 8.19 PFJ/TFD/TFR
ZH30K4E 9.45 PFJ/TFD/TFR ZH13KVE 11.85 TFD/PFJ

connection
ZH38K4E 11.65 PFZ/TFD/TFR

Electrical
ZH45K4E 13.95 TFD ZH18KVE 16.7 TFD
ZH56K4E 17.40 TWD/TFR ZH24KVE 21.3 TWD
ZH75K4E 24.20 TWD/TFR ZH33KVE 29.5 TWD
ZH92K4E 30.70 TWD/TFR ZH40KVE 37 TWD
ZH11M4E 37.00 TWD/TFR ZH48KVE 44.7 TWD

Starting up &
operation
Evaporating temperature:-7°C; Condensing temperature: 50°C; Suction gas superheat: 5 K; Liquid sub-cooling: 4 K

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

Maintenance &
The model designation contains the following technical information about the standard and

repair
vapour injection compressors:

Dismantling &
disposal
References

C6.2.9/1111-0512/E 3
2.3 Application range
2.3.1 Qualified refrigerants and oils
IMPORTANT
It is essential that the glide of refrigerant blends (primarily R407C) is carefully
considered when adjusting pressure and superheat controls.

Oil recharge values can be taken from Copeland Scroll™ compressors brochures or Copeland®
brand products Selection Software.

Compressors ZH12K4E – ZH11M4E ZH09KVE – ZH48KVE

Qualified refrigerants R407C, R134a R407C
Copeland® brand
Emkarate RL 32 3MAF
products standard oil
Servicing oils Emkarate RL 32 3MAF, Mobil EAL Arctic 22 CC
Table 1: Qualified refrigerants and oils

2.3.2 Application limits and operating envelope

CAUTION
Inadequate lubrication! Compressor breakdown! Copeland Scroll™
compressors are qualified for operation inside the envelope published by
Emerson Climate Technologies. The envelope is defined according to
Emerson Climate Technologies testing and experience. Operating a
compressor outside the envelope might lead to compressor failure which
would be the heat pump manufacturer’s responsibility. 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. In
the same way, the superheat at the compressor suction must always stay
below a maximum limit specified by Emerson Climate Technologies,
depending on the model and for which the operating envelope is defined.

NOTE: The application envelopes shown below are for R407C only. For other refrigerant
application envelopes, please refer to Copeland® brand products Selection Software
found at www.emersonclimate.eu.
ZH12K4E to ZH45K4E ZH56K4E to ZH11M4E
75 75

70 70

65 65
Condensing Temperature (oC)
Condensing Temperature (oC)

60 60

55 55

50 50

45 R407C 45
R407C
DEW POINT
40 40 DEW POINT

35 35

30 30

25 25

20 20

15 15

10 10
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
Evaporating Temperature (oC) Evaporating Temperature (oC)
10K Suction Superheat
10K Suction Superheat
Limited Operation < 2000 hours

Figure 1: R407C application envelopes for standard compressors ZH12K4E to ZH11M4E

4 C6.2.9/1111-0512/E
 ZH09KVE to ZH48KVE

instructions
Safety
description
Product
Installation
Figure 2: R407C application envelope for vapour injection compressors ZH09KVE to ZH48KVE operating with
vapour injection

NOTE: For information regarding vapour injection, as well as the way to handle it, please

connection
Electrical
refer to Technical Information C.7.4.3 “Vapour injection Scroll compressors for heat
pumps”.
2.3.3 Dimensions
ZH12K4E ZH15K4E – ZH26K4E ZH30K4E – ZH45K4E
ZH09KVE ZH13KVE – ZH18KVE

Starting up &
operation
Maintenance &
repair
Dismantling &
disposal
References

C6.2.9/1111-0512/E 5
 ZH56K4E – ZH92K4E ZH11M4E
ZH24KVE – ZH40KVE ZH48KVE

6 C6.2.9/1111-0512/E
3 Installation

instructions
WARNING

Safety
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

description
WARNING

Product
Risk of collapse! Personal injuries! Move compressors only with
appropriate mechanical or handling equipment according to weight. Keep in
the upright position. Stack pallets on top of each other when not exceeding
300 kg. Do not stack single boxes on top of each other. Keep the packaging
dry at all times.

Installation
connection
Electrical
Figure 3

The compressor tilt angle should not be more than 30° during transport and handling. This will
prevent oil from exiting through the suction stub. A tilt angle of maximum 45° is allowed for a
very short time. Tilting the compressor more than 45° might affect its lubrication at start-up.

Starting up &
operation
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.

Maintenance &
The compressor should be kept as vertical as possible during handling. The discharge
connection plug should be removed first before pulling the suction connection plug to allow the

repair
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, e.g., a swaging tool should be inserted deeper
than 51 mm into the suction tube or it might damage the suction screen and motor.
Because oil might spill out of the suction connection located low on the shell, the suction
Dismantling &

connection plug must be left in place until the compressor is set into the unit.
disposal

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
suction tube should be cleaned before brazing
The plugs have to be removed as late as possible before brazing so that the air humidity does
not affect the oil characteristics.
References

3.1.3 Installation location

Ensure the compressors are installed on a solid level base. Scroll compressors are capable of
operating correctly in ambient air temperatures from -40°C to 60°C, ambient humidity from 30%
to 95% and at altitudes up to 1000 meters.
For single compressor application, the compressor tilt angle during operation should not be more
than 15° to allow adequate lubrication. For multiple compressor parallel configurations, the
compressors must be positioned completely vertically on a totally horizontal surface or rail.

C6.2.9/1111-0512/E 7
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, e.g., an M8 screw. The
mounting torque should be 13 ± 1 Nm. It is critically important that the grommet is not
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.
NOTE: For more information please refer to Technical Information C.7.11.2 “Scroll
Mounting Parts”.

Mounting parts ZH12K4E to ZH45K4E & ZH09KVE to ZH18KVE - Soft mountings

Mounting parts ZH56K4E to ZH11M4E & ZH24KVE to ZH48KVE - Soft mountings

Figure 4

3.2 Brazing procedure

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.
Contamination or moisture! Bearing failure! Do not remove the plugs until
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, brazing
procedures may have to be changed from those commonly
used.
Figure 5 shows the proper procedure for brazing the
suction and discharge lines to a Scroll compressor.
Figure 5: Suction tube brazing

8 C6.2.9/1111-0512/E
 The copper-coated steel tubes on Scroll compressors can be brazed in approximately the
same manner as any copper tube.

instructions
 Recommended brazing materials: any Silfos material is recommended, preferably with a

Safety
minimum of 5% silver. However, 0% silver is acceptable.
 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

description
moving the torch around the joint to flow braze material around the circumference.

Product
 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.
To disconnect:
 Heat joint areas 2 and 3 slowly and uniformly until the braze material softens and the tube

Installation
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.

connection
NOTE: Since the discharge stub contains a check valve, care must be taken not to

Electrical
overheat it to prevent brazing material from flowing into it.

3.3 Accumulators
CAUTION
Inadequate lubrication! Bearing and moving parts destruction! Minimise
liquid refrigerant returning to the compressor. Too much refrigerant dilutes

Starting up &
operation
the oil. Liquid refrigerant can wash the oil off the bearings and moving parts
leading to overheating and compressor failure.

Due to Copeland Scrolls inherent ability to handle liquid refrigerant in flooded start and defrost
cycle operation, an accumulator is not required for durability in most systems. However, large
volumes of liquid refrigerant repeatedly flooding back to the compressor during normal off cycles,
or excessive liquid refrigerant flooding back during defrost or varying loads can dilute the oil, no

Maintenance &
matter what the system charge is. As a result, bearings and moving parts will be inadequately
lubricated and wear may occur.

repair
To determine if the accumulator can be removed, dedicated tests must be carried out to ensure
that excessive liquid does not flood back to the compressor during defrost or varying loads. The
defrost test must be done at an outdoor ambient temperature of around 0°C in a high relative
humidity environment. Liquid floodback must be monitored during reversing valve operation,
especially when coming out of defrost. Excessive floodback occurs when the sump temperature
Dismantling &

drops below the safe operation line shown in Figure 6.

disposal
References

Figure 6: Dilution chart for transient operation (tb = bottom shell temp.; te = evaporating dew temp.)

C6.2.9/1111-0512/E 9
If an accumulator must be used, the oil-return orifice should be from 1 to 1.4 mm in diameter for
models ZH12K4E to ZH45K4E and ZH09KVE to ZH18KVE, and 2.0 mm for models ZH56K4E to
ZH11M4E and ZH24KVE to ZH48KVE, depending on compressor size and compressor
floodback results. To protect this small orifice from plugging with system debris a large-area
protective screen no finer than 30 x 30 mesh (0.6 mm openings) is required. Tests have shown
that a small screen with a fine mesh can easily become plugged causing oil starvation to the
compressor bearings.
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. System modelling
indicates that heat pumps that operate down to and below -18°C will require an accumulator that
can hold around 70% to 75% of the system charge.

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

The use of screens finer than 30 x 30 meshes (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.

3.5 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 farther the muffler is placed from the
compressor within these ranges, the more effective. Choose a muffler with a length of
10 to 15 cm.

3.6 Sound shell

The sound power is an important criteria in the development of heating units. The nominal sound
power of each Copeland Scroll™ compressor model is available in the Copeland® brand
products Selection Software for the rating condition.
In order to decrease the sound power of the compressor, Emerson Climate Technologies offers
optional sound covers available for a large range of ZH products.
The crankcase heater (if required by the refrigerant charge) must be placed inside the sound
shell. Using an Emerson qualified crankcase heater within a sound shell has been tested and
approved by Emerson Climate Technologies.
NOTE: For more information please refer to Technical Information C.7.11.4 “Sound shell
installation instructions for Scroll compressors”.

3.7 Reversing valves

Since Copeland Scroll™ compressors have a very high volumetric efficiency their displacements
are lower than those of equivalent capacity reciprocating compressors. As a result, Emerson
Climate Technologies recommends that the capacity rating on reversing valves be no more than
1.5 to 2 times the nominal capacity of the compressor in order to ensure proper operation of the
reversing valve under all operating conditions.

10 C6.2.9/1111-0512/E
The reversing valve solenoid should be wired so that the valve does not reverse when the
system is shut off by the operating thermostat in the heating or cooling mode. If the valve is

instructions
allowed to reverse at system shut off, suction and discharge pressures are reversed to the

Safety
compressor. This results in a condition of system pressures equalising through the compressor
which can cause the compressor to slowly rotate until the pressures equalise. This condition
does not affect compressor durability but can cause unexpected sound after the compressor is
turned off.

3.8 Suction line noise and vibration

description
Product
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

Installation
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
Figure 7: Suction tube design compressors, may result in a low-level "beat" frequency
that can be detected as noise coming along the suction
line into the building under some conditions. Elimination

connection
Electrical
of the beat can be achieved by attenuating all 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.

Starting up &
operation
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
suspension and can be easily avoided by using standard suction line isolation techniques as
described below. The sound phenomena described above are not usually associated with

Maintenance &
reversible heat pump systems because of the isolation and attenuation provided by the reversing
valve and tubing bends.

repair
Recommended configuration
 Tubing configuration: small shock loop
 Service valve: "angled valve" fastened to unit / wall
 Suction muffler: not required
Dismantling &

Alternative configuration
 Tubing configuration:
disposal

small shock loop

 Service valve: "straight through" valve fastened to unit / wall
 Suction muffler: may be required (acts as dampening mass)
References

C6.2.9/1111-0512/E 11
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

Recommended wiring diagrams are shown in figures hereunder.
NOTE: We recommend the use of a contactor K2 for the safety chain in order to comply
with EN 60335.
Single-phase (PF*) compressors:
For the ZH12K4E to ZH38K4E and the ZH09KVE, ZH13KVE ranges of compressors the
following circuit diagrams can be used:
Power circuit Control circuit

Single-phase compressors are connected to the

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

Motor terminal connections

Legend
B1 ........Room thermostat K1, K2 ...Contactors
B3 ........Discharge gas thermostat Q1 .........Main switch
C2........Run capacitor R2 .........Crankcase heater
F1, F6 ..Fuses S1 .........Auxiliary switch
F3 ........HP switch Y5 .........Solenoid valve for injection (if available)
F4 ........LP switch RCD Residual current device

Figure 8

12 C6.2.9/1111-0512/E
Three-phase compressors (TF*) with internal motor protection:

instructions
For the ZH15K4E to ZH45K4E and the ZH09KVE to ZH18KVE ranges of compressors the
following circuit diagrams can be used:

Safety
Power circuit Control circuit

description
Product
Installation
connection
Electrical
Starting up &
operation
Three-phase compressors are connected to the
T1, T2 and T3 connections

Maintenance &
repair
Motor terminal connections

Legend
B1 .............. Room thermostat Q1...........Main switch
B3 .............. Discharge gas thermostat R2 ...........Crankcase heater
Dismantling &

F1, F6, F8 .. Fuses S1 ...........Auxiliary switch

disposal

F3 .............. HP switch Y5 ...........Solenoid valve for injection (if available)

F4 .............. LP switch RCD........Residual current device
K1, K2........ Contactors

Figure 9
References

C6.2.9/1111-0512/E 13
Three-phase compressors (TW*) with external motor protection INT69SC2:
For the ZH56K4E to ZH11M4E and the ZH24KVE to ZH48KVE ranges of compressors the
following circuit diagrams can be used:
Power circuit Control circuit

Three-phase compressors are connected to the

T1, T2 and T3 connections

Motor terminal connections

Legend
A1 .............. Motor protection module Q1...........Main switch
B1 .............. Room thermostat R2 ...........Crankcase heater
F1, F6, F8 .. Fuses S1 ...........Auxiliary switch
F3 .............. HP switch Y5 ...........Solenoid valve for injection (if available)
F4 .............. LP switch RCD........Residual current device
K1, K2........ Contactors

Figure 10

4.2.1 Terminal box

The terminal box is IP21 for all models without electronic motor protection (eg, TF*/PF*) and
IP54 for all models with electronic motor protection (eg, TW*).
Maximum thickness of cable connectors for terminal box should be 1 mm for ZH30K4E to
ZH45K4E and ZH13KVE to ZH18KVE compressors and 2 mm for ZH56K4E to ZH11M4E and
ZH24KVE to ZH48KVE compressors (see Figure 11).

14 C6.2.9/1111-0512/E
 instructions
Safety
description
Product
Figure 11

4.2.2 Motor windings

The ZH Scroll compressors are offered with either a single-phase or a three-phase induction

Installation
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" (PF* and TF*) or "H" (TW*) for compressor models
covered in this guideline (maximum allowable operating temperatures 130°C (class B), 180°C
(class H) according to IEC 34-1 or DIN 57530).

connection
4.2.3 Protection devices

Electrical
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

Starting up &
operation
Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours
before starting the compressor.

A crankcase heater is required when the system charge exceeds the compressor charge limits
listed in Table 2.

Model Refrigerant charge limit

Maintenance &
ZH12K4E 2.7 kg

repair
ZH15K4E to ZH26K4E / ZH09KVE 3.6 kg
ZH30K4E to ZH45K4E / ZH13KVE to ZH18KVE 4.5 kg
ZH56K4E to ZH11M4E / ZH24KVE to ZH48KVE 7.5 kg
Table 2 Dismantling &
disposal

The crankcase heater must be mounted tight to the shell

40 mm above foot plate (see Figure 12).

Figure 12: Crankcase heater location

References

NOTE: The crankcase heater must be turned on a minimum of 12 hours prior to starting
the compressor and must remain energised during compressor off cycles.

C6.2.9/1111-0512/E 15
4.3 Pressure safety controls
4.3.1 High-pressure control
A high-pressure limiter should be installed according to EN 378.
4.3.2 Low-pressure control
IMPORTANT!
Loss of system charge and loss of lubrication! Bearing malfunction
and compressor breakdown! A low-pressure control is highly
recommended. Do not bridge or by-pass the low-pressure limiter.

Heat pumps in some geographical areas have to operate at low evaporating pressure because
of the low ambient temperatures, sometimes combined with a high level of relative humidity.
Good evaporator sizing and adequate defrost strategy control should prevent the system from
operating outside the Emerson Climate Technologies published operating envelope, whatever
the climatic conditions and the heating demand.
However, in some extreme cases – such as loss of system charge, extreme heat transfer
restriction at the evaporator, any defect or blocked flow control component (expansion valve,
screens, etc.) – the evaporating conditions may be such that the compressor tends to operate
outside the Emerson Climate Technologies operating envelope limits. All those conditions may
result in compressor failure.
Therefore, Emerson Climate Technologies strongly recommends the installation of a low
pressure limiter in the suction line to stop the compressor when it operates outside the published
envelope limits.

4.4 Discharge temperature protection

IMPORTANT!
Inadequate lubrication! Scroll set damage! Compressors ZH12K4E to
ZH45K4E and ZH09KVE to ZH18KVE must be equipped with an external
discharge temperature protection.

For ZH12K4E to ZH45K4E and ZH09KVE to ZH18KVE Scroll compressors, internal discharge
temperatures reached under some extreme operating conditions (such as loss of charge or
extremely high compression ratio) can cause compressor damage. In order to guarantee positive
compressor protection, the compressor must be equipped with an external discharge
temperature protection. This protection must not be used as an operating envelope limitation.
For compressors ZH12K4E to ZH45K4E the maximum discharge temperature is 140°C while for
ZH09KVE to ZH18KVE compressors it is 130°C.
For compressors ZH56K4E to ZH11M4E and ZH24KVE to ZH48KVE, 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 13: Internal discharge temperature sensor position for models ZH56K4E to ZH11M4E and ZH24KVE to
ZH48KVE

16 C6.2.9/1111-0512/E
4.5 Motor protection

instructions
For the ZH12K4E to ZH45K4E and the ZH09KVE to ZH18KVE ranges of compressors,

Safety
conventional inherent internal line break motor protection is provided.
The electronic motor protection system used in all ZH56K4E to ZH11M4E and ZH24KVE to
ZH48KVE 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

description
with little inertia. An electronic module INT69SC2 is required to process the resistance values

Product
and trip a control depending on the thermistor resistance.
Protection module specifications
Type: ........................................... Kriwan INT69SC2
Voltage: ....................................... 115/120 V AC; 230/240 V AC – 50/60 Hz
Normal PTC resistance: ............... <1.8 kΩ

Installation
Trip resistance: ........................... >4.50 kΩ ± 20%
Reset resistance: ......................... <2.75 kΩ ± 20%
Module time out: .......................... 30 min ± 5 min for ZH56K4E to ZH92K4E & ZH24KVE
to ZH40KVE
60 min ± 5 min for ZH11M4E & ZH48KVE

connection
Electrical
Reset of running time: .................. Power interruption / mains failure approx. 5 seconds
Phase monitor: ............................. No
Ambient temperature range: ......... -30°C…+70°C
Module
For protection in case of blocked rotor one

Starting up &
thermistor for each phase is embedded in the

operation
winding heads on the upper (suction gas) side of the
compressor motor. A fourth thermistor is located in a
winding head at the lower end of the motor. A fifth
sensor is located in the discharge port of the fixed
scroll to control discharge-gas superheat. The entire
chain is internally led to the fusite from where it is

Maintenance &
connected to the module connections S1 and S2.
When any resistance of the thermistor chain

repair
T1/L1 Neutral connection reaches the tripping value, the module interrupts the
T2/L2 Line voltage connection control line and causes the compressor to switch off.
S1, S2 Thermistor chain connection After the thermistor has cooled sufficiently, its
M1, M2 Control resistance drops to the reset value but the module
Figure14: Wiring of the motor protection
itself resets after module time out then restarts the
compressor.
Dismantling &

module
disposal

4.6 Protector functional check and failure detection

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:
References

 Disconnect one terminal either S1 or S2 of the protection module. If the compressor is now
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:

C6.2.9/1111-0512/E 17
4.6.1 Checking the connection
 Check the connection of the thermistor leads in the terminal box and at the protection
module 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.
4.6.2 Checking the compressor thermistor chain
Caution: Use maximum measuring voltage of 3V!
The thermistor leads at terminals S1 and S2 of the module shall be disconnected and the
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.
If no defect is detected in the thermistor chain the module must be checked.
4.6.3 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
then off again after a short period; connection established then interrupted between
terminals M1 and M2.
 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.

4.7 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 Climate Technologies 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, e.g., motor protection module, fan speed control, etc prior to testing.

18 C6.2.9/1111-0512/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.

description
Product
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.

Installation
5.2 Tightness/pressure test
WARNING
High pressure! Personal injuries! Consider personal safety requirements
and refer to test pressures prior to test.

WARNING

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

CAUTION
System contamination! Bearing malfunction! Use only dry nitrogen or
dried air for pressure testing.

Starting up &
operation
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 Preliminary checks – Pre-starting

Discuss details of the installation with the installer. If possible, obtain drawings, wiring diagrams,
etc.

Maintenance &
It is ideal to use a check-list but always check the following:

repair
 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
Dismantling &

 All valves in the correct running position


disposal

Pressure and compound gauges fitted

 Correctly charged with refrigerant
 Compressor electrical isolator location & position

5.4 Charging procedure

CAUTION
Low suction pressure operation! Compressor damage! Do not operate
References

with a restricted suction. Do not operate with the low-pressure limiter

bridged. Do not operate compressor at pressures that are not allowed by the
operating envelope. Allowing the suction pressure to drop below the
envelope limit for more than a few seconds may overheat scrolls and cause
early drive bearing and moving parts 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
R407C is a blend and scrolls have discharge check valves, systems should be liquid-charged on

C6.2.9/1111-0512/E 19
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.

5.5 Run-in time

Scroll compressors exhibit a slight decrease in input power during the initial running period.
Published performance ratings are based on calorimeter testing which is carried out after run-in.
Therefore users should be aware that before the performance specified by EN 12900 is
achieved the compressor needs to be run-in. Typical run-in times required for ZH compressors
to attain the published performance are 16 hours at the saturation dew evaporating and
condensing temperatures condition -7/50°C with a superheat of 10K.

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 limit. Bearings and
moving parts 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. 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 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 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 rotation if the tubing is routed at least 15 cm above the compressor. After several
minutes of operation in reverse, the compressor protection system will trip due to high motor
temperature. The operator will notice a lack of cooling or heating. 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.

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. Due to the design of the Copeland Scroll™ compressors, the internal
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.

20 C6.2.9/1111-0512/E
5.9 Deep vacuum operation

instructions
CAUTION

Safety
Vacuum operation! Compressor damage! Copeland Scroll™ compressors
should never be used to evacuate refrigeration or air-conditioning systems.

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 and moving parts.

description
5.10 Shell temperature

Product
System component failure may cause the top shell and discharge line to briefly reach
temperatures above 140°C. Wiring or other materials, which could be damaged by these
temperatures, should not come in contact with the shell.

Installation
5.11 Pump down cycle
A pump down cycle for control of refrigerant migration may be used in conjunction with a
crankcase heater when the compressor is located so that cold air blowing over the compressor
makes the crankcase heater ineffective.
If a pump down cycle is used, a separate external check valve must be added. The scroll

connection
discharge check valve is designed to stop extended reverse rotation and prevent high-pressure

Electrical
gas from leaking rapidly into the low side after shut-off. The check valve will in some cases leak
more than reciprocating compressor discharge reeds, normally used with pump down, causing
the scroll compressor to recycle more frequently. Repeated short-cycling of this nature can result
in a low oil situation and consequent damage to the compressor. The low-pressure control
differential has to be reviewed since a relatively large volume of gas will re-expand from the high
side of the compressor into the low side after shutdown.

Starting up &
operation
Pressure control setting: Never set the low-pressure control to shut off outside of the
operating envelope. To prevent the compressor from running into problems during such
faults as loss of charge or partial blockage, the control should not be set lower than the
minimum suction pressure allowed by the operating envelope.

5.12 Minimum run time

Maintenance &
Emerson Climate Technologies recommends a maximum of 10 starts per hour. There is no
minimum off time because scroll compressors start unloaded, even if the system has

repair
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 Climate Technologies) 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
Dismantling &

crankshaft. Cycling the compressor for a shorter period than this, for instance to maintain very
disposal

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.
References

5.14 Supply frequency and voltage

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.
The last digit of the model motor code indicates which frequency and voltage must be applied
(see section 2.3 “Nomenclature”).

C6.2.9/1111-0512/E 21
 50 Hz 60 Hz Code
380-420-3 ph 460-3 ph D
220-240-1 ph 265-1 ph J
380-420-3 ph ---- M
220-240-3 ph ---- R
220-240-1 ph ---- Z
200-220-3 ph 200-230-3 ph 5
Table 3: Typical ZH models electrical codes

For models allowing operation at 50 or 60 Hz (codes D, J and 5), only frequencies from 50 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

Compressor models ZH56K4E to ZH11M4E and ZH24KVE to ZH48KVE are equipped with an oil
sight glass. In these models the oil level should be maintained at mid-point of the sight glass. If
an oil regulator is used the level should be set within the top half of the sight glass.
During the heat pump development, adequate oil return in any operation should be checked,
whatever the compressor model. For this purpose, compressor samples with sight tube can be
ordered from Emerson Climate Technologies. Oil return check test recommendations are also
available on demand from Application Engineering.

22 C6.2.9/1111-0512/E
6 Maintenance & repair

instructions
Safety
6.1 Exchanging the refrigerant
Qualified refrigerants and oils are given in section 2.4.1.
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

description
down by comparing the refrigerant temperature and pressure using precision measurements at a

Product
location in the system where liquid and vapour phases are present and when the temperatures
have stabilised.
In the event that the refrigerant needs replacing, the charge should be recovered using a
suitable recovery unit.

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

6.3 Replacing a compressor

CAUTION
Inadequate lubrication! Bearing destruction! Exchange the accumulator

connection
Electrical
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

Starting up &
In the case of a motor burnout, the majority of contaminated oil will be removed with the

operation
compressor. The rest of the oil is cleaned through the use of suction and liquid line filter driers. A
100% activated alumna 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

Maintenance &
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

repair
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, if the flanks of the compressor happen to be in a sealed position, rapid pressurisation of the
Dismantling &

low side without opposing high-side pressure can cause the scrolls to seal axially. As a result,
disposal

until the 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 specified in the published operating envelope must be maintained
during charging. Allowing the suction pressure to drop below that value may overheat the scrolls
and cause early drive bearing and moving parts damage. Never install a system in the field and
References

leave it unattended when it has no charge, 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 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.

C6.2.9/1111-0512/E 23
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.

The compressor is supplied with an initial oil charge. The standard oil charge for use with
refrigerants R407C / R134a 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 0.1litre less.
One disadvantage of POE is that it is far more hygroscopic than mineral oil (see Figure 15).
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 Climate Technologies 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 moisture content no higher than
50 ppm.

Figure 15: 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 contents 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 Climate Technologies 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.

24 C6.2.9/1111-0512/E
6.6 Unbrazing system components

instructions
WARNING

Safety
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

description
compressor. This may leave the low side shell and suction line tubing pressurized. If a brazing

Product
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 assembly (line repair) areas. If compressor removal is required, the compressor
should be cut out of system rather than unbrazed.

Installation
7 Dismantling & disposal
Removing oil and refrigerant:
Do not disperse in the environment.
Use the correct equipment and method of removal.

connection
Dispose of oil and refrigerant properly.

Electrical
Dispose of compressor properly.

8 References
 C7.11.2 “Mounting parts for Copeland Scroll™ compressors”
 C7.11.4 “Sound Shell Installation Instructions for for Copeland Scroll™ compressors”

Starting up &
 C7.4.3 “Vapour injection Scroll compressors for heat pumps”

operation
 C7.17.3 “Paralleling of ZH Copeland Scroll™ compressors for heat pump
applications”

ADDENDUM

Maintenance &
1. The contents of this publication are presented for informational purposes only and are not to

repair
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, Inc. and/or its affiliates (collectively "Emerson"), as
applicable, reserve the right to modify the design or specifications of such products at any
time without notice.
3. Emerson does not assume responsibility for the selection, use or maintenance of any
Dismantling &

product. Responsibility for proper selection, use and maintenance of any Emerson product
disposal

remains solely with the purchaser or end user.

References

C6.2.9/1111-0512/E 25
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8, Allée du Moulin Berger Pascalstr. 65
FR-69130 Ecully Cédex DE-52076 Aachen
Tel. +33 4 78 66 85 70 Tel. +49 2408 929 0 Tel. +40 - 364 - 73 11 72
Fax +33 4 78 66 85 71 Fax +49 2408 929 525 Fax. +40 - 364 - 73 12 98
[email protected] [email protected] [email protected]

ITALY POLAND MIDDLE EAST & AFRICA

Via Ramazzotti, 26 Szturmowa 2 PO Box 26382
IT-21047 Saronno (VA) PL-02678 Warsaw Jebel Ali Free Zone - South, Dubai - UAE
Tel. +39 02 96 17 81 Tel. +48 22 458 92 05 Tel. +971 4 811 81 00
Fax +39 02 96 17 88 88 Fax +48 22 458 92 55 Fax +971 4 886 54 65
[email protected] [email protected] [email protected]

SPAIN & PORTUGAL RUSSIA & CIS

C/ LLull, 321 (Edifici CINC) Letnikovskaya 10, Bld. 2, fl oor 5
ES-08019 Barcelona RU-115114 Moscow
Tel. +34 93 412 37 52 Tel. +7 495 981 98 11
Fax +34 93 412 42 15 Fax +7 495 981 98 16
[email protected] [email protected]
C6.2.9/1111-0512/E

For more details, see www.emersonclimate.eu

Emerson Climate Technologies - European Headquarters - Pascalstrasse 65 - 52076 Aachen, Germany

Phone: +49 (0) 2408 929 0 - Fax: +49 (0) 2408 929 570 - Internet: www.emersonclimate.eu
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Information contained in this brochure is subject to change without notifi cation.

© 2011 Emerson Climate Technologies, Inc.