Copeland Digital Scroll ZRD42KCE Instruction Manual

Digital Scroll Compressors
for Air Conditioning
ZRD42K* to ZRD125K*, ZPD34K* to ZPD182K*
TM
Application Guidelines

C6.2.15/0815/E
About these guidelines ................................................................................................ 1
1Safety instructions............................................................................................ 1
1.1 Icon explanation.................................................................................................................1
1.2 Safety statements..............................................................................................................1
1.3 General instructions...........................................................................................................2
2Product description .......................................................................................... 3
2.1 Common information about Copeland Scroll Digital™compressors.................................3
2.2 Nomenclature.....................................................................................................................3
2.3 Application range ...............................................................................................................4
2.3.1 Qualified refrigerants and oils ................................................................................4
2.3.2 Application limits.....................................................................................................4
2.4 Dimensions ........................................................................................................................6
2.5 Operation, design & performance......................................................................................6
2.6 Mechanical differences in the Digital compressor ranges.................................................8
3Installation......................................................................................................... 9
3.1 Compressor handling.........................................................................................................9
3.1.1 Transport and storage............................................................................................9
3.1.2 Positioning and securing........................................................................................9
3.1.3 Installation location.................................................................................................9
3.1.4 Mounting parts........................................................................................................9
3.2 Solenoid valves................................................................................................................10
3.3 Solenoid valve installation................................................................................................11
3.3.1 General recommendations...................................................................................11
3.3.2 Tubing recommendations.....................................................................................12
3.4 Tandem compressors......................................................................................................12
3.5 Discharge check valve.....................................................................................................14
3.6 Brazing procedure............................................................................................................14
3.7 Shut-off valves and adaptors...........................................................................................15
3.8 Oil separator ....................................................................................................................16
3.9 Accumulators ...................................................................................................................16
3.10 Screens............................................................................................................................17
3.11 Mufflers ............................................................................................................................17
3.12 Reversing valves..............................................................................................................17
3.13 Suction line noise and vibration.......................................................................................18
4Electrical connection ...................................................................................... 19
4.1 General recommendations...............................................................................................19
4.2 Electrical installation ........................................................................................................19
4.2.1 Terminal box.........................................................................................................19
4.2.2 Motor winding.......................................................................................................20
4.2.3 Motor protection ...................................................................................................20

C6.2.15/0815/E
4.2.4 Protection devices................................................................................................20
4.2.5 Crankcase heaters ...............................................................................................20
4.3 Pressure safety controls ..................................................................................................21
4.3.1 IPR valve (Internal Pressure Relief valve) ...........................................................21
4.3.2 High-pressure control...........................................................................................21
4.3.3 Low-pressure control............................................................................................21
4.4 Discharge temperature protection ...................................................................................22
4.5 Low ambient cut-out.........................................................................................................23
4.6 High-potential testing .......................................................................................................23
5Starting up & operation................................................................................... 24
5.1 Strength pressure test......................................................................................................24
5.2 Tightness/pressure test....................................................................................................24
5.3 Preliminary checks –Pre-starting....................................................................................24
5.4 Charging procedure .........................................................................................................24
5.5 Initial start-up ...................................................................................................................25
5.6 Rotation direction.............................................................................................................25
5.7 Pressure fluctuations .......................................................................................................25
5.8 Starting sound..................................................................................................................25
5.9 Deep vacuum operation...................................................................................................26
5.10 Shell temperature.............................................................................................................26
5.11 Minimum run time ............................................................................................................26
5.12 Sound characteristics.......................................................................................................26
5.13 Shut-off sound..................................................................................................................26
5.14 Frequency........................................................................................................................26
5.15 Oil level control ................................................................................................................27
5.16 Digital system control.......................................................................................................27
5.17 Power factor.....................................................................................................................27
6Maintenance & repair...................................................................................... 28
6.1 Exchanging the refrigerant...............................................................................................28
6.2 Rotalock valves................................................................................................................28
6.3 Replacing a compressor..................................................................................................28
6.3.1 Compressor replacement.....................................................................................28
6.3.2 Start-up of a new or replacement compressor.....................................................28
6.4 Lubrication and oil removal..............................................................................................29
6.5 Oil additives .....................................................................................................................29
6.6 Unbrazing system components .......................................................................................30
7Dismantling & disposal................................................................................... 30
DISCLAIMER ............................................................................................................... 30

C6.2.15/0815/E 1
About these guidelines
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 Climate Technologies will not guarantee the
performance and reliability of the product if it is misused in regard of these guidelines.
These application guidelines cover stationary applications only. For mobile applications, contact
Application Engineering as other considerations may apply.
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 Machinery Directive
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 the
Manufacturer’s 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.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to
avoid property damage and possible
personal injury.
High voltage
This icon indicates operations with a
danger of electric shock.
IMPORTANT
This icon indicates instructions to
avoid malfunction of the compressor.
Danger of burning or frostbite
This icon indicates operations with a
danger of burning or frostbite.
NOTE
This word indicates a
recommendation for easier operation.
Explosion hazard
This icon indicates operations with a
danger of explosion.
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.
Electrical connections must be made by qualified electrical personnel.
All valid standards for connecting electrical and refrigeration equipment must be
observed.
The national legislation and regulations regarding personnel protection must be
observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

2 C6.2.15/0815/E
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.

C6.2.15/0815/E 3
2 Product description
2.1 Common information about Copeland Scroll Digital™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 and refrigeration.
These application guidelines deal with the following Copeland Scroll Digital™
compressors:
R407C R410A
Compressor
HP
kW(*)
Motor
Compressor
HP
kW(*)
Motor
ZRD42KCE
3.6
9
PFJ/TFD
ZPD34KSE
2.8
8
PFZ/TFM
ZRD48KCE
4
10.2
PFZ/TFD
ZPD42KSE
3.5
9
PFZ/TFM
ZRD61KCE
5
12.5
TFD
ZPD54KSE
4.6
11.8
PFZ/TFM
ZRD72KCE
6
14.8
TFD
ZPD61KCE
5
13.3
PFZ/TFD
ZRD81KCE
6.5
16.7
TFD
ZPD72KCE
6
15.4
TFD
ZRD94KCE
8
19.8
TFD
ZPD83KCE
7
17.7
TFD
ZRD125KCE
10
26
TFD
ZPD91KCE
7.5
19.3
TFD
ZPD103KCE
9
22.4
TFD
ZPD104KCE
9
22.4
TFD
ZPD120KCE
10
26
TFD
ZPD122KCE
10
26
TFD
ZPD137KCE
12
29.3
TFD
ZPD154KCE
13
32.9
TFD
ZPD182KCE
15
39.1
TFD
(*) According to EN 12900
Copeland Scroll Digital 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 compressor:
Safety
instructions
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description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

4 C6.2.15/0815/E
ARI Conditions:
Evaporating temperature ...... 7.2°C Liquid sub-cooling ......................... 8.3K
Condensing temperature .....54.4°C Ambient temperature.....................35°C
Suction gas superheats ...........11K
EN 12900 Conditions:
Evaporating temperature ..........5°C Liquid sub-cooling ............................ 0K
Condensing temperature ........50°C Ambient temperature.....................35°C
Suction gas superheats ...........10K
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 Select software at www.emersonclimate.eu.
Qualified refrigerants
R407C
R410A
Copeland brand
products standard oil
Emkarate RL 32 3MAF
Servicing oil
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Mobil EAL Arctic 22 CC
Table 1: Qualified refrigerants and oils
2.3.2 Application limits
CAUTION
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.
ZRD42K*E to ZRD81K*E ZRD94K*E & ZRD125K*E
Figure 1: Application envelopes with R407C (Dew point)
25
30
35
40
45
50
55
60
65
70
-25 -20 -15 -10 -5 0 5 10 15 20
Condensing Temperature (oC)
Evaporating Temperature (oC)
R407C
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25
Condensing Temperature (oC)
Evaporating Temperature (oC)
R407C
10K Suction superheat
250C Suction gas return

C6.2.15/0815/E 5
ZPD34K*E to ZPD54K*E ZPD61K*E to ZPD91K*E
ZPD103K*E to ZPD137K*E ZPD154K*E & ZPD182K*E
Figure 2: Application envelopes with R410A (Dew point)
25
30
35
40
45
50
55
60
65
70
-25 -20 -15 -10 -5 0 5 10 15
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
25
30
35
40
45
50
55
60
65
70
-25 -20 -15 -10 -5 0 5 10 15
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
25
30
35
40
45
50
55
60
65
70
-25 -20 -15 -10 -5 0 5 10 15
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal
10K Suction superheat
10K Suction superheat

6 C6.2.15/0815/E
2.4 Dimensions
Compressor model
A ± 3.0
mm
B
mm
C ± 3.0
mm
D ± 3.0
mm
ZPD34K*E- PFZ/TFM
449.0
380.1
277.1
235.5
ZPD42K*E- PFZ/TFM
449.0
380.1
277.1
235.5
ZPD54K*E- PFZ/TFM
465.4
396.5
293.5
251.9
ZRD42K*E- PFJ/TFD
449.0
380.1
277.1
235.5
ZRD48K*E- PFZ/TFD
465.4
396.5
293.5
251.9
ZPD34K* to ZPD54K* ZPD61K* to ZPD91K* ZPD104K* & ZPD122K*
ZRD42K* & ZRD48K* ZRD61K* to ZRD81K*
ZRD94K*(*) & ZRD125K* ZPD154K* & ZPD182K*
ZPD103K*, ZPD120K* & ZPD137K*
(*) No sight glass
Figure 3: Compressor dimensions
2.5 Operation, design & performance
The Copeland Scroll Digital compressor is capable of modulating its capacity from 10% to 100%.
The compressor is supplied along with an external solenoid valve. This “normally closed” (de-
energized) solenoid valve is a key component for achieving modulation. When the solenoid valve
is in its normally closed position, the compressor operates at full capacity. When the solenoid
valve is energized, the two scroll elements move apart axially. During the unloaded state, the
compressor motor continues running, but since the scrolls are separated, there is no
compression. During the “loaded state”, the compressor delivers 100% capacity and during the
“unloaded state”, the compressor delivers 0% capacity. A cycle consists of a “loaded state” and
an “unloaded state”. By varying the time of “loaded state” and “unloaded state”, an average
capacity is obtained. For instance, in a 20-second cycle, the average capacity is 75%, if the
“loaded time” is 15 seconds and the “unloaded time” is 5 seconds.

C6.2.15/0815/E 7
Full capacity No capacity
Solenoid de-energized Solenoid energized
Figure 4: Modulation of Scroll models ZRD42K* to ZRD81K* and ZPD34K* to ZPD91K*
Figure 5: Example of a cycle
Figure 6: Solenoid opening time depending on the load in a 15-second cycle
Scrolls separated by
approximately 1 mm
Safety
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description
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connection
Starting up &
operation
Maintenance &
repair
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8 C6.2.15/0815/E
ZPD34K*E to ZPD91K*E ZPD103K*E to ZPD182K*E
ZRD42K*E to ZRD81K*E ZRD94K*E & ZRD125K*E
Figure 7: Recommended capacity modulation ranges according to the operating conditions
2.6 Mechanical differences in the Digital compressor ranges
Figure 8: Single Digital Scrolls in the ZRD and ZPD ranges
The internal mechanics of the smaller and the larger models are different but functionally both
approaches to modulation achieve the same results and are to be controlled in exactly the same
way.
Figure 9: Modulation method in larger model ranges
25
30
35
40
45
50
55
60
65
70
-25 -20 -15 -10 -5 0 5 10 15
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
Solenoid valve opens
10-100% recommended application range
50-100% recommended application range
75-100% recommended application range
Unloading floating seal
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-25 -20 -15 -10 -5 0 5 10 15
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A

C6.2.15/0815/E 9
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. 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.
Figure 10
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.
It is recommended that the plugs in the compressor line connections be left in place until the
compressor is set into the unit. This reduces the chance of contaminants and moisture getting
into the compressor especially if the compressor is charged with the more hygroscopic POE oil.
For models ZRD94K*, ZRD125K* and ZPD103K* to ZPD182K*, because oil might spill out of the
suction connection located low on the shell, the suction connection plug must be left in place
until the compressor is set into the unit. 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 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.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

10 C6.2.15/0815/E
Sleeve Rubber spacer
Figure 11: Rubber mounting parts for single models
Hard mounts + washer + bolts Fixation
Figure 12: Rigid mounting parts for Tandem models
Figure 13: Rubber mounting parts rail-to-ground for Tandem models
3.2 Solenoid valves
IMPORTANT
The external solenoid valve is a critical component for proper operation of
this compressor. Only the solenoid valve supplied by Emerson Climate
Technologies must be used.
Care must be taken during the brazing process that no solid parts can enter the control piston
compartment or the solenoid valve tubing. To prevent solid parts from entering the control valve
seat, the solenoid valve kit contains a filter screen, which has to be placed into the horizontal
tube of the valve before brazing the tube connections as shown in Figures 16 & 17.
The solenoid valve has to be fitted in such a way that the sleeve with the stem inside –which
supports the solenoid coil –is fixed and aligned in an upright position.

C6.2.15/0815/E 11
Figure 14: Position of the external solenoid valve Figure 15: Recommended piping
3.3 Solenoid valve installation
3.3.1 General recommendations
Solenoid must be mounted vertically, within ± 15° of vertical. Horizontal mounting is not
permitted.
The valve operation is directional. See Figures 18 & 19 below for inlet and outlet
locations.
Do not restrict the line size coming from or leaving the solenoid. Use 3/8” soft drawn
copper.
Figure 16: Control valve without coil Figure 17: Control valve pipe connection
Safety
instructions
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description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

12 C6.2.15/0815/E
3.3.2 Tubing recommendations
IMPORTANT
This tube has been tested and qualified at 50 and 60 Hz operation for
running stresses and resonance in a single compressor lab environment.
However, in some compressor applications such as racks and transport
applications, the OEM is strongly advised to re-confirm the acceptability of
the tube when the compressor is subject to additional vibration inputs.
The tube from the solenoid to the suction (Figure 17) should be as short as possible (less than
7.5 cm). Dimensions for a typical tube going from the top of the compressor are shown in
Figures 18 & 19.
3.4 Tandem compressors
Copeland Scroll Digital compressors ZRD48K* to ZRD81K* and ZPD54K* to ZPD91K* can be
used in a Tandem arrangement (code 422 in nomenclature), if the single compressor cannot
cover the required capacities and/or there are higher fluctuations in capacity demand. The
fittings for gas equalization and oil equalization must be connected between the two
compressors (see Figure 20).
Figure 18: Tandem configurations for compressor combinations with 3 to 15 hp models (ZR and ZP ranges)
Specific dimensional drawings and technical information documents on system oil balance
control to build qualified Tandem design units are available upon request from Emerson Climate
Technologies.
It needs to have an OEM-system control device providing the signals for common operation,
modulation as well as for single compressor operation. In general the architecture of such a
system controller runs the digital compressor continuously and cycles only the standard
compressor if the capacity demand drops below, eg, 40% of the total capacity.
The standard compressor should join the Digital Scroll compressor operation when the capacity
demand comes to a value of about more than, eg, 60 to 65% and stays on for a defined amount
of time. Any percentage of capacity modulation within the capacity range can be achieved by
switching the cycle time algorithm of the Digital compressor as a reaction to the system
behaviour.
Copeland Scroll Digital compressors ZRD125K* and ZPD103K* to ZPD182K* require some
extra attention for tandemization in terms of oil balance. Emerson Climate Technologies has
worked out a redesign of the Schraeder valve position and qualified an oil balancing system just
via these connections. Models capable for this configuration must have been built from 1st of
October 2009 onwards, serial number 09J…! A combination or a mix of models built before
this date is not released. The common suction return line must have a straight height of at
least 400 mm before joining the T-connector (see Figure 21).

C6.2.15/0815/E 13
Figure 19: No slanted alignment of the oil equalization line! Use models from 09J… onwards only!
Figure 20: Oil equalization line design
Figure 21: Top view of the piping design
Figure 22: Tandem configuration with ZRD125K* and ZPD103K* to ZPD182K*
Digital
Standard
Safety
instructions
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description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
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14 C6.2.15/0815/E
Figure 23: Suction tube brazing areas
Compressor model
Base compressors
Available
voltages
ZPDT21MCE
ZP103KCE + ZPD103KCE
TFD
ZPDT22MCE
ZP104KCE + ZPD104KCE
TFD
ZPDT24MCE
ZP120KCE + ZPD120KCE
TFD
ZPDT25MCE
ZP122KCE + ZPD122KCE
TFD
ZPDT27MCE
ZP137KCE + ZPD137KCE
TFD
ZPDT31MCE
ZP154KCE + ZPD154KCE
TFD
ZPDT36MCE
ZP182KCE + ZPD182KCE
TFD
ZRDT25MCE
ZR125KCE + ZRD125KCE
TFD
Table 2: Tandem configurations with standard models and Digital Scroll compressors
3.5 Discharge check valve
There is no discharge check valve at the discharge port of Copeland Scroll Digital compressors
ZRD42K* to ZRD81K* and ZPD34K* to ZPD91K* since the high-side pressure is needed to
support the operation of the un-loader mechanism.
To avoid bypassing during the unloading process back to suction, a dynamic discharge valve is
fitted internally on the discharge port of the fixed scroll. This discharge valve cannot be used with
recycling pump-down because it is not leak-proof during the off period.
Models ZRD94K*, ZRD125K* and ZPD103K* to ZPD182K* work with an internal un-loader
mechanism (see Figures 5 & 11) and are equipped with a check valve in the discharge fitting
that will prevent backward flow of gas through the scroll when the compressor shuts off.
3.6 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 Digital 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.
Refer to Figure 25 and the procedure below for the
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.
Recommended brazing materials: any Silfos material is recommended, preferably with a
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.

C6.2.15/0815/E 15
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.
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.
3.7 Shut-off valves and adaptors
CAUTION
Leaking system! System breakdown! It is strongly recommended to
periodically re-torque all pipe and fixing connections to the original setting
after the system has been put into operation.
Figure 24: Adaptors and shut off valves
Braze 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 Table 3 for proper tightening torques:
Connection
Torque [Nm]
M10
45-55
Rotalock ¾"
40-50
Sight glass 1 ¼" Summit
100-110
Rotalock 1 ¾"
170-180
Rotalock 2 ¼"
190-200
Sight glass fitting
30-45
Mounting bolts 5/16”, M9
27 max
2
Table 3
NOTE: More information about adaptors and shut-off valves can be found in the "Spare
parts list".
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16 C6.2.15/0815/E
3.8 Oil separator
During any operating cycle of Copeland Scroll Digital compressors, there is a loaded state during
which the compressor operates at full capacity. The velocity of gas during this loaded state is
sufficient to return oil back to the compressor. Laboratory tests have established that there is no
problem in oil return, even when the length of interconnecting pipe used is
100 metres and the vertical elevation is 30 metres. Based on such performance, Emerson
Climate Technologies does not strictly recommend the use of an oil separator.
3.9 Accumulators
CAUTION
Inadequate lubrication! Bearing destruction! Minimise liquid refrigerant
returning to the compressor. Too much refrigerant dilutes the oil. Liquid
refrigerant can wash the oil off the bearings leading to overheating and
bearing failure.
Due to Copeland Scroll’s 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 which repeatedly flood back to the compressor during normal off
cycles or excessive liquid refrigerant floodback during defrost or varying loads, no matter what
the system charge is, can dilute the oil. As a result, bearings are inadequately lubricated and
wear may occur.
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 humidity
environment. Liquid floodback must be monitored during reversing valve operation, especially
when coming out of defrost.
Excessive floodback occurs when the sump temperature drops below the safe operation line
shown in Figure 27 for more than 10 seconds.
Figure 25: Bottom shell temperature
NOTE: Operation in this refrigerant dilution area is safe in air-to-air heat pump heating
mode. For other applications, such as AC only, review expansion device to raise
superheat. A cold sump may result in high refrigerant migration after shutdown.
If an accumulator has to be used, the oil-return orifice should be from 1 to 1.4 mm in diameter for
models ZRD42K* to ZRD81K* and ZPD34K* to ZPD91K*, depending on compressor size and
compressor floodback results. Models ZRD94K*, ZRD125K* and ZPD103K* to ZPD182K*
should use an orifice diameter of 2.0 mm. A large-area protective screen with mesh no finer than
30 x 30 (0.6 mm openings) is required to protect this small orifice from plugging with system

C6.2.15/0815/E 17
debris. 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. Ideally the suction accumulator should be
connected with a slope to the suction line of the compressor, as shown in Figure 28. A sight
tube fitted to the accumulator makes it easier to check the liquid level inside.
Figure 26: Suction accumulators
3.10 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.
3.11 Mufflers
External mufflers, normally applied to piston compressors in the past, may not be required for
Copeland Scroll compressors.
Tests on individual system 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 45cm
from the compressor for the most effective operation. The farther the muffler is placed from the
compressor within these ranges, the more effective.
3.12 Reversing valves
Since Copeland Digital 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.
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
allowed to reverse at system shut off, suction and discharge pressures are reversed to the
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.
ZRD42K* to ZRD81K*, ZPD34K* to ZPD91K* ZRD94K* & ZRD125K*, ZPD103K* to ZPD182K*
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