Copeland Scroll ZR KC Series User manual

© 2023 Copeland LP
1
TABLE OF CONTENTS
Safety Instructions................................................3
Safety IconExplanation.........................................3
Instructions Pertaining to Risk of Electrical Shock, Fire,
or Injury to Persons...............................................4
Safety Statements ................................................4
1. Introduction............................................5
1.1. Nomenclature.........................................5
2. Application Considerations.......................5
2.1. Operating Envelope & Superheat Control ...5
2.2. Internal Pressure Relief (IPR)Valve...........6
2.3. Advanced Scroll Temperature Protection....6
2.4. Discharge Line Thermostat.......................6
2.5. High Pressure Control .............................6
2.6. LowPressure Control..............................6
2.7. ShutDown Device..................................6
2.8. Discharge Check Valve............................7
2.9. Discharge Mufflers..................................7
2.10. Compressor Cycling................................7
2.11. Long Pipe / High Refrigerant Charge..........7
2.12. Suction & Discharge Noise and Vibration....7
2.13. Suction and Discharge Fittings..................8
2.14. System Tubing Stress..............................8
2.15. Accumulators.........................................8
2.16. Crankcase Heat......................................8
2.17. Pump Down Cycle..................................9
2.18. Reversing Valves....................................9
2.19. SystemScreens & Strainers.....................9
2.20. Contaminant Control...............................9
2.21. Oil Type& Removal..............................10
2.22. Three PhaseElectrical Phasing...............10
2.23. Power Factor Correction........................10
2.24. Deep Vacuum Operation........................10
2.25. Manifolded Compressors .......................11
2.26. Manifolded Applications......................... 11
2.27. MotorOverload Protection..................... 12
2.27.1. Models with Electrical Code TF............... 12
2.27.2. Models with Electrical Code TW* or TE*... 12
3. APPLICATION TESTS.......................... 12
3.1. Application Test Summary ..................... 12
3.2. Continuous Floodback Test.................... 12
3.3. Field Application Test............................ 13
4. ASSEMBLY LINEPROCEDURES .......... 13
4.1. Compressor Handling............................ 13
4.2. Mounting............................................. 13
4.3. Suction and Discharge Fittings ............... 14
4.4. Assembly Line Brazing Procedure........... 14
4.5. Unbrazing System Components.............. 14
4.6. Pressure Testing.................................. 14
4.7. Assembly Line System Charging............. 14
4.8. Electrical Connections........................... 15
4.9. “Hipot” (AC High Potential) Testing)......... 15
4.10. Tandem Assembly................................ 15
5. SERVICE PROCEDURES..................... 16
5.1. Field Replacement................................ 16
5.1.1. Mounting............................................. 16
5.1.2. Removing Oil....................................... 16
5.1.3. Electrical............................................. 16
5.1.4. Module................................................ 16
5.2. Compressor Replacement MotorBurn..... 16
5.3. Manifolded Compressor Replacement ..... 16
5.4. Start-up Newor Replacement ................ 17
5.5. Trouble Shooting the Kriwan Module....... 17
5.6. Troubleshooting CoreSense Module........ 18
5.7. CompressorFunctional Check................ 18
5.8. Refrigerant Retrofits.............................. 19
6. General Guidelines and More Information. 19
APPENDIXES
APPENDIX A: Kriwan to CoreSense™
Communications Retrofit Instructions for ZR160-
190KC & ZP154-182KC Compressors
AE4-1303 R17
January 2024
7 to 15 Ton ZR*KC, ZH*KC and ZP*KC Copeland Scroll™Compressors

© 2023 Copeland LP.
2
AE4-1303 R17
FIGURES
Figure 1 - How a Scroll Works ..............................20
Figure 2- ZR Operating Envelope.........................21
Figure 3 –ZP Operating Envelope........................21
Figure 4- ZH Operating Envelope.........................22
Figure 5 –ASTP Label........................................23
Figure 6 –Crankcase Heater Location................... 24
Figure 7 –Suction Tube Brazing........................... 25
Figure 8 –Tandem Oil Balancing.......................... 26
Figure 9 –Tilted Tandem..................................... 26
TABLES
Table 1 - ZR*KC, ZH*KCand ZP*KC Features..........5
Table 2 - Field Application Test.............................27
Table 3 - Design Configurations............................27
Table 4 - Compressor Accessories &Service Parts..28
Table 5 - Refrigerant Charge Limits....................... 29
Table 6 - Torque Values...................................... 29
Revision Tracking R17
Added ZH Compressors & Superheat Requirements

© 2023 Copeland LP.
3
AE4-1303 R17
Safety
Safety Instructions
Copeland Scroll™compressors are manufactured according to the latest U.S. and European Safety Standards.
Particular emphasishas been placed on the user's safety.Safety icons are explained below and safety instructions
applicable to the products in this bulletin are grouped on Page 4. These instructions should be retained throughout
the lifetime of the compressor. You are strongly advised to follow these safety instructions.
Safety Icon Explanation
DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorserious
injury.
WARNING indicatesa hazardous situationwhich, if not avoided, could result in death or
serious injury.
CAUTION, used with the safetyalert symbol, indicatesa hazardous situationwhich, if not
avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices not related to
personal injury.
FLAMMABLE, Fire hazard! Sparking in a potentially explosive atmosphere! Explosion
hazard!
WARNING
CAUTION
NOTICE
DANGER
CAUTION

© 2023 Copeland LP.
4
AE4-1303 R17
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
ELECTRICAL SHOCK HAZARD
•Disconnect and lock out power before servicing.
•Discharge all capacitors before servicing.
•Use compressor with grounded system only.
•Molded electrical plug must be used when required.
•Refer to original equipment wiring diagrams.
•Electrical connections must be made byqualified electrical personnel.
•Failure to follow these warnings could result in serious personal injury.
PRESSURIZED SYSTEM HAZARD
•System contains refrigerant andoil under pressure.
•Remove refrigerantfromboth the high and low compressorsidebefore
removing compressor.
•Neverinstall a system and leave it unattended when it has no charge, a
holding charge, or with the service valves closed without electrically
locking out the system.
•Use only approved refrigerants and refrigeration oils.
•Personal safety equipment must be used.
•Failure to follow thesewarningscould resultin seriouspersonalinjury.
BURN HAZARD
•Do not touch the compressor until it has cooled down.
•Ensure that materials and wiring do not touch high temperature areas
of the compressor.
•Use caution when brazing system components.
•Personal safety equipment must be used.
•Failure to follow thesewarnings could resultin serious personal injury
or property damage.
COMPRESSOR HANDLING
•Use the appropriate lifting devices to move compressors.
•Personal safety equipment must be used.
•Failure to follow these warnings could result in personal injury or
property damage.
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 and codesfor installing, servicing, and maintaining electrical and refrigeration equipment
must be observed.
CAUTION
WARNING
WARNING
WARNING

© 2023 Copeland LP.
5
AE4-1303 R17
1. Introduction
The 7 to 15 ton ZR*KC, ZH*KCand ZP*KC Copeland
Scroll™compressors are designed fora wide variety of
light commercial air-conditioning,heat pump,andchiller
applications. This bulletin describes the operating
characteristics, design features, and application
requirements for these compressors.
For additional information, please refer to Copeland
Mobile. Operating principles of the Copeland Scroll
compressorare described in Figure 1 of this bulletin.
The ZR*KC, ZH*KC and ZP*KC scrolls outlined in this
bulletin range in size from 84,000 to 190,000 Btu/hr
(24.6 to 55.7 kW) and 90,000 to 182,000 Btu/hr (26.4 to
53.3 kW)respectively. These models includeall of the
standard 50 and 60 Hertz three phase voltages.
Compressors in this size range include a number of
features outlined in Table 1 below.
1.1. Nomenclature
The ZR*KCand ZP*KCmodelnumbersoftheCopeland
Scroll compressors include the approximate nominal 60
Hz capacity at standard operating conditions. An
example would be the ZP90KCE-TFD, which has
90,500 But/hr (26.5kW) cooling capacity at the AHRI
high temperature air conditioning rating point when
operated at 60 Hz. Note that the same compressor will
have approximately5/6 ofthiscapacity or74,500Btu/hr
(21.8kW) when operated at 50 Hz.
2. Application Considerations
The following application guidelines should be
considered in the design of a system using ZR*KC,
ZH*KC and ZP*KC scroll compressors. Some of this
informationis recommended,whereas otherguidelines
must be followed. The Application Engineering
department will always welcome suggestions that will
help improve these types of documents.
2.1. Operating Envelope & Superheat Control
To assure that liquid refrigerant does not return to the
compressor during the running cycle, attention mustbe
given to maintaining proper superheat at the
compressor suction inlet. A minimum of 9°F (5°K)
superheat is required. It’s recommended to control the
superheat to a higher value to ensure the superheat
doesn’t drop below 9°F (5°K). Superheat is measured
on the suction line 6 inches (152mm) from the suction
fitting on the compressor. Proper superheat control to
avoid liquid refrigerant while running is importantforall
compressors. The ZH compressors with the R513A
refrigerant are very sensitive to liquid floodback and
measures mustbe taken to prevent this fromoccurring.
It is essential that the glide of R-407C is carefully
considered when adjusting pressure and superheat
controls.
Figure 2, Figure 3 and Figure 4illustrate the operating
envelopes for the ZR*KC, ZH*KC and ZP*KC
compressors. The operating envelopes represent
operating conditions with 20F° (11K) superheat in the
return gas. The steady-state operating condition of the
compressor must remain inside the prescribed
operating envelope. Excursionsoutside ofthe envelope
should be brief and infrequent. Use of refrigerants other
than the approved refrigerantforthe compressor voids
the compressor UL recognition.
Table 1 - ZR*KC, ZH*KC and ZP*KC scrolls models outlined in this bulletin
Model
Application
IPR
Valve
Discharge
Temperature
Protection
(ASTP)
Quite
Shutdown
Discharge
Check
Valve
Motor
Protection
Electrical
Connections1
A/C
Heat
Pump
ZR84-144KCE-TF*2,
ZH40-50KCE- TF*2
Yes
Yes
No
Yes
Yes
Yes
Internal
MP, TB
ZR160-190KCE-TE/W2,
ZH64-76KCE-TE*2
Yes
Yes
No
Yes
Yes
Yes
Module
TB
ZP90,103,120,137KCE-TF2
Yes
Yes
No
Yes
Yes
Yes
Internal
MP, TB
ZP154-182KCE-TE/W2
Yes
Yes
No
Yes
Yes
Yes
Module
TB
1
MP = Molded Plug, TB = Terminal Block & Ring Terminals
2
Last character in voltage code (5 = 200/230-3-60, 200/220-3-50; D = 460-3-60, 380/420-3-50; E = 575-3-60; 7 =
380-3-60)

© 2023 Copeland LP.
6
AE4-1303 R17
2.2. Internal Pressure Relief (IPR) Valve
A high pressure control must be used in all
applications.
These models of CopelandScroll compressorsdo not
have internal pressure relief valves. To ensure safe
operation, a high pressure control must be used in all
applications.
2.3. Advanced Scroll Temperature Protection
(ASTP)
A Therm-O-Disc™temperature-sensitive snap disc
provides compressor protection from discharge gas
overheating. Events such aslossof charge, evaporator
blower failure, or low side charging with inadequate
pressure will cause the discharge gas to quickly rise
above a critical temperature. Once this critical
temperature is reached,the ASTP feature willcause the
scrollstoseparateandstoppumpingbutallowthemotor
to continue to run. After the compressor runs for some
time without pumping gas,the motor overload protector
will open. Depending on the heat buildup in the
compressor, it maytake up to two hours for the ASTP to
reset. The addition of the Advanced Scroll Temperature
Protection makes it possible to eliminate the discharge
line thermostat previously required in heat pump
applications.Compressors in this size range that have
ASTP are identified with the ASTP label shown below.
Scan this code to see a
short video clip about
ASTP.
2.4. Discharge Line Thermostat
A discharge temperature thermostat is not an
application requirement because of the built-in ASTP
featurethatprotectsthecompressoragainstabnormally
high discharge temperatures. If the system designer
wants to prevent ASTP trips and limit the maximum
compressor discharge temperature to a lower
temperature, a discharge temperature switch should be
used. Table 4 lists available discharge line thermostats
that strap on to the discharge line ofthe compressor for
the highest level of compressor reliability.
2.5. High Pressure Control
A high pressure cut-out control must be used in all
applications.The maximum cut out settingis 425 psig
(30 bar)forR-22, R-407C, R513A and R-134aand 650
psig (45 bar) for R-410A. The high pressure control
should have a manual reset feature for the highest level
of system protection.
2.6. Low Pressure Control
A low pressure control is highlyrecommended forloss
of charge protection and othersystemfault conditions
that may result in very low evaporating temperatures.
Even though these compressors have internal
discharge temperature protection, loss of system
charge will result in overheating and recycling of the
motor overload protector. Prolonged operation in this
manner could result in oil pump out and eventual
bearing failure.
The low pressure cut-out setting will depend on the
application type and minimum expected evaporating
temperature. The low pressure cut-out should be
selected to prevent compressoroverheatingand other
system failure modes such as coil icing in air
conditioning systems and frozen heat exchangers in
chiller systems.
The minimum, recommended low pressure cut-out
switch settings are:
Air conditioning and chiller:
55 psig/3.8 bar (R-410A)
25 psig/1.7 bar (R-22 & R-407C)
10 psig/0.7 bar (R-134a & R513A)
Heat pumps:
20 psig/1.4 bar (R-410A)
10 psig/0.7 bar (R-22, R-407C, R513A & R-134a)
2.7. Shut Down Device
All scrolls in this size range have floating valve
technologyto mitigateshutdownnoise.SinceCopeland
Scroll™compressorsare also excellent gas expanders,
they may spin backwards for a brief period after
shutdown as the internal pressures equalize.
WARNING

© 2023 Copeland LP.
7
AE4-1303 R17
2.8. Discharge Check Valve
A low mass, disk-type check valve in the discharge
fitting of the compressor prevents the high side, high
pressure discharge gas from flowing rapidly back
through the compressor after shutdown. This check
valve was not designed to be used with recycling pump
down because it is not entirely leak-proof.
2.9. Discharge Mufflers
Flow through Copeland Scroll compressors is semi-
continuous with relatively low pulsation. External
mufflers, where they are normally applied to piston
compressors today,may not be required forCopeland
Scroll compressors. Because of variability between
systems, however, individual system tests should be
performed to verify acceptability of sound performance.
When no testing is performed, mufflers are
recommended in heat pumps. The muffler should be
located a minimumof six inches (15 cm) to a maximum
of 18 inches (46 cm) fromthe compressor for the most
effective operation. The further the muffler is placed
from the compressor within these ranges the more
effective it may be. If adequate attenuation is not
achieved, use a muffler with a larger cross-sectional
area to inlet-area ratio. The ratio should be a minimum
of 20:1 with a 30:1 ratio recommended. The muffler
should be from four to six inches (10 -15 cm) long.
2.10.Compressor Cycling
There is no set answerto howoftenscroll compressors
can be started and stopped in an hour, since it is highly
dependent on system configuration. There is no
minimum off time because Copeland Scroll
compressors start unloaded, even if the system has
unbalanced pressures. The most critical consideration
is the minimum run time required to return oil to the
compressor after startup. To establish the minimum run
time, obtain a sample compressorequipped with a sight
tube (available from Copeland) 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 startup to return
to the compressor sump and restore a minimal oillevel
that will assure oil pick up through the crankshaft. The
minimum oil level required in thecompressor is1.5" (40
mm) below the center of the compressor sight-glass.
Cycling thecompressorforashorterperiodthanthis,for
instance to maintainvery tight temperature control, will
result in progressive loss of oil and damage to the
compressor. See AE17-1262 for more information on
preventing compressor short cycling.
2.11.Long Pipe Lengths / High Refrigerant
Charge
Some systems may contain higher than normal
refrigerantcharges.Systemswithlargereheatcoils,low
ambient condenser flooding, or systems with multiple
heat exchangers are among some system
configurationsthatmay require additional lubricant. For
compressors with sight-glasses foroillevel viewing,the
oil level should always be checked during OEM
assembly,field commissioning, and fieldservicing. An
estimationoftheamountof additionallubricantto addto
the compressor(s) when the circuit charge exceeds 20
pounds of refrigerant is as follows:
Single compressor application:0.5 fluid ounce of oil per
pound of refrigerant over initial 20 pounds.
Compressor Multiple arrangements: Refer to AE4-
1430.
Other system components such as shell and tube
evaporators can trap significant quantities of oil and
should beconsideredinoverall oilrequirements.Reheat
coils and circuits that are inactive during part of the
normal cycle can trap significant quantities of oil if
system piping allows the oil to fall outof the refrigerant
flow into the inactive circuit. The oil level must be
carefully monitored during system development, and
corrective action should be taken if the compressoroil
level falls more than 1.5" (40 mm) below the center of
the sight-glass. The compressor oil level should be
checked with the compressor "off" to avoid the sump
turbulence when the compressor is running.
These compressors are available to the OEM with a
productionsight-glassthatcanbeusedtodeterminethe
oil level in the compressor in the end-use application.
These compressorsare also available to the OEM with
an oil Schrader fitting on the side of the compressor to
add additional oil if needed because of long lengths of
piping or high refrigerant charge.No attempt should be
made to increase the oil level in the sight-glass above
the 3/4 full level. A high oil level isnot sustainable in the
compressor and the extra oil will be pumped outinto the
system causing a reduction in system efficiency and a
higher-than-normal oil circulation rate.
2.12.Suction & Discharge Line Noise and
Vibration
Copeland Scroll™compressors inherently have low
sound and vibrationcharacteristics. However,thesound
and vibration characteristics differ in some respects
from those of reciprocating compressors. In rare
instances, these could result in unexpected sound
complaints.
One difference is that the vibration characteristicsofthe
scroll compressor, although low,include two very close
frequencies,one of which is normally isolated from the

© 2023 Copeland LP.
8
AE4-1303 R17
shell by the suspension of an internally suspended
compressor.Thesefrequencies,whicharepresentinall
compressors, may result in a low level “beat” frequency
that may be detected asnoise coming along the suction
line into the building under some conditions. Elimination
of the “beat” can be achieved by attenuating either of the
contributing frequencies. The most important
frequencies to avoid are 50 and 60 Hz power supply
line. This is easily done by using one of the common
combinationsofdesignconfigurationdescribedinTable
3. The scroll compressor makes both a rocking and
torsionalmotion,and enoughflexibilitymust beprovided
intheline to preventvibrationtransmissionintoanylines
attached to the unit. In a split systemthe most important
goal is to ensure minimal vibration is all directionsat the
service valve to avoid transmitting vibrations to the
structure to which the lines are fastened
A second difference of the Copeland Scroll compressor
is that under some conditions the normal rotational
starting motion of the compressor can transmit an
“impact” noise along the suction line. 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 in Table 3.
The sound phenomena described above are not usually
associated with heat pump systems because of the
isolationandattenuationprovidedbythereversingvalve
and tubing bends.
2.13.Suction and Discharge Fittings
Copeland Scroll compressorshave copper plated steel
suction and discharge fittings. These fittings are far
moreruggedand lesspronetoleaksthancopperfittings
used on othercompressors.Due to the differentthermal
properties ofsteel and copper, brazing procedures may
have to be changed from those commonly used. See
Figure 7 for assembly line and field brazing
recommendations.
2.14.System Tubing Stress
System tubing should be designed to keep tubing
stresses below 9.5 ksi (62 MPa), the endurance limit of
copper tubing. Start, stop and running (resonance)
cases should be evaluated.
2.15.Accumulators
The use of accumulators is very dependent on the
application. The Copeland Scroll™compressor’s
inherent ability to handle liquid refrigerant during
occasionaloperatingfloodbacksituationsmaketheuse
of an accumulator unnecessary in standard designs
such as condensing units. Applications such as heat
pumps with orifice refrigerant control that allow large
volumes of liquid refrigerant to flood back to the
compressor during normal steady operation can dilute
the oil to such an extentthat bearings are inadequately
lubricated, and wear will occur. In such a case an
accumulatormustbeusedtoreducefloodbacktoasafe
level that the compressor can handle. Heat pumps
designedwithaTXVtocontrolrefrigerantduringheating
may not require an accumulator if testing assures the
system designer that there will be no flood back
throughout the operating range. To test for flood back
conditionsand to determine if the accumulator or TXV
design is adequate, please see the section entitled
Application Tests.
Alarge-areaprotectivescreenno finerthan30x30mesh
(0.6mmopenings)isrequiredtoprotectthissmallorifice
from plugging. 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 amountof sub cooling and subsequent
head pressure allowed by the refrigerant control.
Systemmodelingindicatesthatheatpumpsthatoperate
down to and below 0°F (-18°C) will require an
accumulator that can hold around 70% to 75% of the
system charge. Behavior of the accumulator and its
ability to prevent liquid slugging and subsequent oil
pump-out at thebeginningand end of the defrost cycle
should be assessed during system development. This
will require specialaccumulators and compressors with
sight tubes and/or sight glasses for monitoring
refrigerant and oil levels.
2.16.Crankcase Heat
A90 wattcrankcaseheateris requiredwhenthesystem
charge exceeds the values listed in Table 5. This
requirement is independent of system type and
configuration.Table4listsCopelandcrankcaseheaters
by partnumberand voltage.SeeFigure6fortheproper
heater location on the compressor shell. The crankcase
heater must remain energized during compressor off
cycles.
The initial start-up in the field is a very critical period for
any compressor because all load-bearing surfaces are
new and require a short break-in period to carry high
loads under adverse conditions.The crankcase heater
must be turned on a minimum of 12 hours prior to
starting thecompressor.This willpreventoildilutionand
bearing stress on initial start up.
To properly install the crankcase heater, the heater
should be installed in the location illustrated in Figure 6.
Tighten the clamp screw carefully, ensuring that the
heater is uniformly tensioned along its entire length and

© 2023 Copeland LP.
9
AE4-1303 R17
that the circumference of the heater element is in
complete contact with the compressor shell. It's
importantthat the clamp screw is torqued to the range
of 20-25 in-lb (2.3-8 N-m) to ensure adequatecontact
and to preventheaterburnout.Neverapplypowerto the
heater in free air or before the heateris installed on the
compressor to prevent overheating and burnout.
Crankcase heaters must be properly grounded.
2.17.Pump Down Cycle
A pump down cycle for control ofrefrigerantmigration is
not recommendedforscroll compressorsof this size.If
a pump down cycle is used, a separate discharge line
check valve must be added. The scroll compressor’s
discharge check valve is designed to stop extended
reverse rotation and to preventhigh-pressure gas from
leaking rapidly into the lowside aftershutoff. The check
valve will in some cases leak more than reciprocating
compressor dischargereeds, normallyused 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
hasto bereviewed sincearelativelylargevolumeofgas
will re-expand fromthe high side of the compressor into
the low side aftershut down. Pressure control setting:
Never set the low pressure control to shut offoutside of
theoperatingenvelope.Thelowpressurecontrolshould
be set to open no lower than 5 to 10F° (3-6K) equivalent
suctionpressurebelowthelowestexpectedevaporating
temperature.
2.18.Reversing Valves
Since Copeland Scroll compressors have very high
volumetricefficiency,theirdisplacementsarelowerthan
those of comparable capacity reciprocating
compressors.
Reversing valve sizing mustbe within the guidelines of
the valve manufacturer. Required pressure drop to
ensure valve shifting must be measured throughout the
operating range of the unit and compared to the valve
manufacturer's data. Low ambient heating conditions
with low flow rates and low pressure drop across the
valve can resultin a valve not shifting. This can result in
a condition where the compressor appears to be not
pumping(i.e. balanced pressures). It canalso result in
elevated compressor sound levels.
During a defrost cycle, when the reversing valve
abruptly changes the refrigerant flow direction, the
suction and discharge pressures will go outside of the
normal operating envelope. The sound that the
compressor makes during this transition period is
normal,and thedurationofthesoundwilldependonthe
coil volume,outdoorambient, and systemcharge level.
The preferred method of mitigating defrost sound is to
shut down the compressor for20 to 30 seconds when
the reversing valve changes position going into and
coming out of the defrost cycle.This technique allows
the system pressures to reach equilibrium without the
compressor running. The additionalstart-stop cycles do
not exceed the compressor design limits, but suction
and discharge tubing design should be evaluated.
The reversing valvesolenoidshouldbewired sothat the
valve does notreverse when the system is shut off by
the operating thermostat in the heating orcooling mode.
If the valve is allowed to reverse at system shutoff,
suction and discharge pressures are reversed to the
compressor. This results in pressures equalizing
through the compressor which can cause the
compressor to slowly rotate backwards until the
pressures equalize. This condition does not affect
compressor durability but can cause unexpected sound
after the compressor is turned off.
2.19.System Screens & Strainers
Screens finer than 30x30 mesh (0.6mm openings)
should not be used anywhere in the system. 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 blockthe flow of
either oil or refrigerant to the compressor. Such
blockage can result in compressor failure.
2.20.Contaminant Control
Copeland Scroll™compressorsleave the factory with a
miniscule amount of contaminants. Manufacturing
processes have been designed to minimize the
introduction ofsolid or liquid contaminants.Dehydration
and purge processes ensure minimal moisture levels in
the compressor, and continuous auditing of lubricant
moisture levels ensures that moisture isn’t inadvertently
introduced into the compressor.
It is generally accepted that system moisture levels
should be maintained below 50 ppm. A filter-drier is
required on all POE lubricant systems to prevent solid
particulate contamination, oil dielectric strength
degradation, ice formation, oil hydrolysis, and metal
corrosion. It is the system designer’s responsibility to
make sure that the filter-drier is adequately sized to
accommodate the contaminants from system
manufacturing processes which leave solid or liquid
contaminants in theevaporator coil,condenser coil,and
WARNING
CAUTION

© 2023 Copeland LP.
10
AE4-1303 R17
interconnecting tubing plus any contaminants
introduced during the field installation process.
Molecular sieve and activated alumina are two filter-
drier materials designed to remove moisture and
mitigate acid formation. A 100% molecular sieve filter
can be used for maximum moisture capacity. A more
conservative mix, such as 75% molecular sieve and
25% activated alumina, should be used for service
applications.
2.21.Oil Type & Removal
Mineral oil is used in the ZR*KC compressorsforR22
applications. Polyolester (POE) oil is used in the
ZR*KCE, ZH*KCE and ZP*KCE compressors for -
22/R407C/R134a, R513A and R410A applications
respectively. See the compressor nameplate for the
original oil charge. A complete recharge should be
approximately four fluid ounces (118 ml) less than the
nameplate value.
If additional oil is needed in the field for POE
applications, Copeland™Ultra 32-3MAF, Lubrizol
Emkarate RL32-3MAF, Parker Emkarate RL32-3MAF/
(Virginia) LE32-3MAF, or Nu Calgon 4314-66
(Emkarate RL32-3MAF) should be used. Copeland™
Ultra 22 CC, HatcolEAL 22CC, and Mobil EAL Arctic 22
CC are acceptable alternatives.
If additional oil is needed in the field for mineral oil
applications, Sonneborn Suniso 3GS or Chevron
Texaco Capella WF32 should be used.
When a compressor is exchanged in the field it is
possible that a major portion of the oil fromthe replaced
compressor may still be in the system. While this may
not affect thereliabilityof thereplacementcompressor,
the extra oil will add to rotor drag and increase power
usage. To remove this excess oil an access valve port
has been added to the lower shell of the service
compressor. After running the replacementcompressor
foraminimumof10minutes,shutdownthecompressor
and drain excess oilfromthe Schrader valve until the oil
level is at one-half of thesight-glass level.This should
be repeated twice to make sure the proper oil level has
been achieved.
POE may cause an allergic skin reaction and must
be handled carefully and the proper protective
equipment (gloves, eye protection, etc.) must be
used when handling POE lubricant. POE mustnot
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). Refer to the Safety Data Sheet
(SDS) for further details.
2.22.Three Phase Scroll Compressor Electrical
Phasing
Compressorsthat employ CoreSensetechnologyhave
phaseprotectionandwillbelockedoutafteronereverse
phase event.
Copeland Scroll compressors,like several othertypes
of compressors, will only compress in one rotational
direction. Three phase compressors will rotate in either
direction depending upon phasing of the power. Since
there is a 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 locationson the equipment to ensure that
proper rotation direction is achieved when the system is
installed and operated. Verification of proper rotation
direction is made by observing that suction pressure
drops and discharge pressure rises when the
compressor is energized. Reverse rotation will result in
no pressure differentialas compared to normalvalues.
A compressor running in reverse will sometimes make
an abnormal sound.
There is no negative impact on durability caused by
operating three phase Copeland Scroll™compressors
in thereversed directionforashortperiodoftime(under
one hour). After several minutes of reverse operation,
the compressor’s internal overload protector will trip
shutting off the compressor. If allowed to repeatedly
restart and run in reverse without correcting the
situation,the compressor bearingswill be permanently
damaged because of oil loss to the system. All three-
phase scroll compressors are wired identically
internally. As a result, once the correct phasing is
determined for a specific system or installation,
connecting properly phased power leads to the
identified compressor electrical (Fusite™)terminalswill
maintain the proper rotational direction. It should be
noted that all three-phasescrolls will continue to run in
reverseuntiltheinternaloverloadprotectoropensorthe
phasing is corrected.
2.23.Power Factor Correction
If power factor correction is necessary in the end-use
application,please see AE9-1249 for more information
on this topic.
2.24.Deep Vacuum Operation
Copeland Scroll compressors incorporate internal low
vacuum protection and will stop pumping (unload) when
WARNING
NOTICE

© 2023 Copeland LP.
11
AE4-1303 R17
the pressure ratio exceedsapproximately 10:1.There is
an audible increase in sound when the scrolls start
unloading.
Copeland Scroll compressors (as with any refrigerant
compressor) should never be used to evacuate a
refrigeration or air conditioning system. The scroll
compressor can be used to pump down refrigerant in a
unitaslong asthepressuresremainwithintheoperating
envelope shown in Figure 2, Figure 3 and Figure 4.
Prolonged operation at lowsuction pressures will result
in overheating of the scrolls and permanent damage to
the scroll tips, drive bearing and internal seal. See
AE24-1105 for propersystemevacuation procedures.
2.25.Manifolded Compressors
Tandem compressor assemblies are available for
purchase from Copeland. In lieu of purchasing the
assembled tandem,the OEM can choose to purchase
the manifold-ready compressor and perform the
assembly in their factory. All of the ZP*KC and ZR*KC
compressors are available for manifolding with another
compressor in this compressor family. Manifold-ready
compressors are designated with a -4XXbill of material
number at the end of the model number (e.g.
ZP120KCE-TFD-422). Drawings of tandem and trio
compressor assemblies are available from Copeland by
contacting your Application Engineer.
Customers who choose to design and build their own
manifolds for tandem and trio compressor assemblies
are ultimately responsible for the reliability of those
manifold sets.
The suction manifold is close to a symmetrical layout
with the design intent of equal pressure drop to each
compressor.Astraightlengthofpipeisconnectedtothe
suction manifold "T" connection to serve as a flow
straightener to make the flow as uniform as possible.
The discharge manifold is the less critical of the two
manifolds in terms of pressure drop. Low pipe stress
and reliability are its critical design characteristics.
Two different oil balancing techniques are used with
tandems in this family of compressors - two-phase
tandem line (TPTL) and oil equalization line (OEL). For
trio assemblies, only the TPTL design has been
qualified. The TPTL design is a larger diameter pipe
connecting the oil sumps of the individual compressors
allowing both gas and oil to flow between the
compressors at thesame time. To install theTPTL, the
individual sight-glasses on each compressor must be
removed to allow the TPTL to screw on to the sight-
glass fitting on the compressors. A sight-glass is
installed on the TPTL to view the presence of oil as
shown in Figure 8.
The OEL design is a 3/8" (10mm) copper tube
connecting the oil sumps of the individual compressors
allowing the flow of oil between the compressor sumps.
To install the OEL, the oil drain Schrader fitting oneach
compressor must be removed to expose the stub tube
fitting for a brazed connection (see Tandem Assembly
section).The OEL has an oil drain Schraderfitting on
the 3/8" OEL tube for adding/removing oil as shown in
Figure8.The OELdesignallowstheindividualoillevels
in each compressorto be viewed, which isn't possible
with the TPTL.
2.26.Manifolded Applications
Manifolded compressor designs employ a passive oil
managementsystem.Allsystemdesignsmustbetested
by the OEM to ensure that the passive design will
provide adequate oil balancing between the
compressors in the manifolded set under all operating
conditions. If inadequate oil balancing can't be
demonstrated,anactiveoilmanagementsystemshould
be considered.
Manifolded compressors follow the same application
guidelines as single compressors outlined in this
bulletin. The refrigerant charge limit for tandem
compressors isshown in Table 5. A tandemcircuitwith
a charge over this limit must have crankcase heaters
applied to both compressors.
Oil levels in the individual sight-glasses will vary,
depending on whetherone or more compressorsin the
manifolded set are operating and if the manifolded set
is made up of equal orunequal compressorcapacities.
Because of the unequal oil levels that can exist, oil
levels should be viewed with the compressors off to
allow the oil level to stabilize between the compressor
sumps.Withthecompressorsoff,oilshouldbevisiblein
the individual compressor sight-glasses when the OEL
is used, or in the sight-glasson the TPTL. If oil is not
visible,additional oil should be added to the system.
Suction and discharge tandem manifolds are not
designedtosupportsystempiping.Supportmeansmust
be provided by the systemdesignerto support suction
and discharge lines so that stress is not placed on the
manifolds.
The compressors in a manifolded set can be started/
stoppedinanydesiredsequence.To help reduceinrush
CAUTION
NOTICE
NOTICE

© 2023 Copeland LP.
12
AE4-1303 R17
current, starting the compressors individually is
recommended.
Please consultwith Application Engineering during the
development of systems with trio compressor
assemblies. Trio compressorassemblies are sensitive
to systemoperatingconditionsand configurationswhich
will affect oil balancing. Trio compressor assemblies
must be qualified for each application.
2.27.Motor Overload Protection
2.27.1.Models with Electrical Code TF
Models with an "F" in the electrical code (i.e.
ZP120KCE-TFD), have an internal line break motor
overload located in the center of the Y of the motor
windings.This overload disconnects allthree legs of the
motor from power in case of an over-current or over-
temperature condition. The overload reacts to a
combination of motor current and motor winding
temperature. The internal overload protects against
single phasing.Time must be allowed for the motor to
cool down before the overload will reset. If current
monitoring to the compressor is available, the system
controllercantakeadvantageofthecompressorinternal
overload operation. The controller can lock out the
compressor if current draw is not coincident with
contactor energizing, implying that the compressor has
shut off on its internal overload. This will prevent
unnecessary compressor cycling on a fault condition
until corrective action can be taken.
2.27.2.Models with Electrical Code TW* or TE*
The electronic motor protection module is a U.L.
recognized safety device and must be used with all
compressors that have TW* electrical codes and TE*
electrical codes respectively.
Models with a "W" or "E" in the electrical code (i.e.
ZP182KCE-TWD) have a motor overload system that
consists of an external electronic control module
connected to a chain of four thermistors embedded in
the motor windings. The module will trip and remain off
fora minimum of 30minutes if the motortemperature
exceeds a preset point.
Note: Turning off power to the module will reset it
immediately.
The module has a 30 minute time delay to allow the
scrolls to cool down after the motor temperature limit
has been reached.
Restarting the compressor sooner may cause a
destructive temperature build up in the scrolls.For this
reason, module powermust neverbe switchedoff with
the control circuit voltage.
Since the compressor is dependent upon the contactor
to disconnect it from power in case of a fault, the
contactor must be selected in accordance with AE10-
1244. The contactor must meet both the Rated Load
Amps (RLA) and Locked Rotor Amps (LRA) specified
for the compressor.
3. APPLICATION TESTS
3.1. Application Test Summary
There are a minimal number of tests the system
designerwill want to run to ensure the system operates
as designed. These tests should be performed during
system development and are dependenton the system
type and amount of refrigerant charge. These
application tests are to help identify gross errors in
system designthat may produce conditionsthat could
lead to compressorfailure.The ContinuousFloodback
Test and Field ApplicationTest,bothoutlinedbelow,are
two tests to runto help verify thedesign. Whento run
these tests can be summarized as follows.
For manifolded compressor assemblies, oil balancing
tests must be performed to demonstrate oil balancing
between the compressors. Compressors with sight-
tubesforviewingawiderangeofoillevelsisappropriate
forthis typeof testing. Theleast amount of testing will
evaluate the minimum and maximum flow conditions at
which the compressorswill be required to operate,with
min and max suction superheat.
Continuous Floodback:
Required for all air-source heatpumps.
Field Application Test:
Required for any unit where both the design
system charge is higher than the compressor
refrigerant charge limit listed in Table 5; and a
capillary tube, fixed orifice,or bleed-type TXV is
used on either the indoor or the outdoor coil of
the unit.
3.2. Continuous Floodback Test
No floodback is acceptable for use with the ZH
compressorswhenusingR513Aduetothesensitivityto
liquid refrigerant.
It is expected that the design would not flood during
standard air conditioning operation. Flooding during
defrost cycles should be minimal and the flow control
device must regain control of the refrigerant flow after
WARNING
CAUTION

© 2023 Copeland LP.
13
AE4-1303 R17
the defrost cycle to ensure suction gas superheat. The
use of a TXV in heating does not guaranteeoperation
without flood back in the lower end of the unit/TXV
operating range.
To test forexcessivecontinuous liquidrefrigerant flood
back, itisnecessarytooperatethesysteminatestroom
at conditionswhere steady stateflood backmay occur
(lowambientheatingoperation).Thermocouplesshould
be attached with glue or solder to the center of the
bottom shell and to the suction and discharge lines
approximately 6 inches (15 cm) from the shell. These
thermocouplesshould be insulated from the ambient air
with Permagum™or otherthermal insulation to be able
to record true shell and line temperatures. If the system
isdesignedtobefieldcharged,itshouldbeovercharged
by 15% in this test to simulate overcharging often found
in field installations.
The system should be operated at an indoor
temperature of 70°F (21°C) and outdoor temperature
extremes of 10°F (-12°C) or lower in heating to produce
flood back conditions. The compressor suction and
discharge pressures and temperatures as well as the
sump temperature should be recorded. The system
should beallowedtofrost upforseveralhours (disabling
the defrost control and spraying water on the outdoor
coil may be necessary) to cause the saturated suction
temperature to fall below 0°F (-18°C). The suction
superheatmustremainpositiveordesignchangesmust
be made to increase suction superheat and reduce
flooding. Increasing indoor coil volume, increasing
outdoorairflow,reducingrefrigerantcharge,decreasing
capillary or orifice diameter, and adding a charge
compensator can also be used to reduce excessive
continuous liquid refrigerant flood back.
3.3. Field Application Test
To test for repeated, excessive liquid flood backduring
normal system off-cycles, perform the Field Application
Test that is outlined in Table 2. Obtain a sample
compressor with a sight-tube to measure the liquid level
in the compressor when it is off.
Note: The sight-tube is not a good liquid level indicator
when the compressor is running because the top of the
sight-tube is at a lower pressure than the bottom
causing a higher apparent oil level.
Set the systemup in a configuration with the indoor unit
elevated several feet above the outdoor unit with a
minimum of 25 feet (8 meters) ofconnecting tubing with
no traps between the indoor and outdoor units. If the
system is designed to be field charged, the system
should be overchargedby 15% in this test to simulate
field overcharging. Operate the system in the cooling
mode at the outdoor ambient, on/off cycle times, and
numberof cyclesspecifiedinTable2.Recordtheheight
of theliquid in the compressorat the start of each on
cycle, any compressor overload trips, or any
compressor abnormal starting sounds during each test.
Review the results with Application Engineering to
determineif an accumulatororothermeansof off cycle
migration control are required. This test does not
eliminate the requirement for a crankcase heater if the
system charge level exceeds the values in Table 5.The
criteria forpass/failis whether the liquid level reaches
the bottomof the terminal box.Liquid levels higher than
this can allowrefrigerant/oil to be ingested bythe scrolls
and pumped out of the compressor after start-up.
The tests outlinedaboveareforcommonapplications of
compressors in this family.Many otherapplicationsof
the compressor exist,and tests to insure those designs
can’t possibly be covered in this bulletin. Please consult
with Application Engineering on applicationsoutside of
those outlined above for the appropriate application
tests.
4. ASSEMBLY LINE PROCEDURES
4.1. Compressor Handling
Use care and the appropriate material handling
equipment when lifting and moving compressors.
Personal safety equipment must be used.
Because oil might spill out of the suction connection
located low on the shell, the suction connection plug
must be left in place untilthe compressor is setinto the
unit. If possible,the compressorshould be kept vertical
during handling.The discharge connection plug should
be removed firstbefore pulling the suction connection
plug to allow the dry air pressure insidethe compressor
to escape. Pulling the plugs in this sequence prevents
oil mist from coating the suction tube making brazing
difficult. The coppercoated steel suctiontube should be
cleaned before brazing (see Figure 7). No object (e.g.
a swaging tool) should be inserted deeper than two
inches(51mm)into thesuctiontube,oritmightdamage
the suction screen and motor.
4.2. Mounting
The tested rubber mounting grommetand sleeve kit is
listed inTable4.Thisdrawingcanbefoundat Copeland
Mobile. For applications such as tandems or mobile
applications,the compressor should be hard mounted
directly to the rails or base to relieve stress on the
tubing. An additionalbellyband brace must be used with
mobile applicationsto keep compressor movement to a
minimum and relieve stress on both the feet and the
WARNING

© 2023 Copeland LP.
14
AE4-1303 R17
tubing.Thesteelspacerdevelopedforsuchapplications
is the 027-0385-00.
Many OEM customersbuy themounting parts directly
from the supplier,but Copeland'sgrommet design and
durometer recommendations should be followed for
best vibration reduction through the mounting feet.
4.3. Suction and Discharge Fittings
These compressors are available with stub tube or
Rotalock connections. The stub tube version has
copper-plated steel suction and discharge fittings.
These fittingsare farmorerugged thancopperfittings
used on othercompressors.Due to the differentthermal
properties ofsteel and copper, brazing procedures may
have to be changed from those commonly used. See
Figure 7 for assembly line and field brazing procedures
and Table 6 for Rotalock torque values.
4.4. Assembly Line Brazing Procedure
Personal safety equipmentmustbe used during brazing
operation. Heat shields should be used to prevent
overheating or burning nearby temperature sensitive
parts. Fire extinguishing equipment should be
accessible in the event of a fire.
Figure 7 discusses the proper procedures for brazing
the suctionand dischargelines to a scroll compressor.
It is importantto flow nitrogen through the systemwhile
brazing all joints during the systemassembly process.
Nitrogen displaces the air and prevents the formation of
copper oxides in the system. If allowed to form, the
copper oxide flakes can later be swept through the
system and block screens such as those protecting
capillary tubes, thermal expansion valves, and
accumulator oil return holes. The blockage- whether it is
of oil or refrigerant - is capable of doing damage
resulting in compressor failure.
4.5. Unbrazing System Components
Before attempting to braze, it is importantto recover all
refrigerant from both the high and low side of the
system.
If the refrigerant charge is removed from a scroll-
equipped unit by evacuating the high side only, it is
possible for the scrolls to seal, preventing pressure
equalization through the compressor. This may leave
the low side shell and suction line tubing pressurized.If
a brazing torch is then applied to the low side while the
low side shell and suction line contain pressure, the
pressurized refrigerantandoilmixturecouldignitewhen
it escapes and contacts the brazing flame.
It is importantto check both the high pressure and low
pressure sides with manifold gaugesbefore unbrazing.
Instructions should be provided in appropriate product
literature and assembly (line repair) areas. If
compressor removal is required,the compressor should
becutoutofsystemratherthanunbrazed.SeePage25
for the proper compressor removal procedure.
4.6. Pressure Testing
Never pressurize the compressor to more than 400 psig
(27.6 bar) for ZR*KCE and 475 psig (32.8 bar) for
ZP*KCE compressors. Never pressurize the
compressor from a nitrogen cylinderor other pressure
source without an appropriately sized pressure
regulating and relief valve.
Higherpressuremayresultinpermanentdeformationof
the compressor shell and possiblycause misalignment
or bottom cover distortion.
4.7. Assembly Line System Charging
Procedure
Systemsshould be charged with liquid on the high side
to theextentpossible.Themajorityof thechargeshould
be pumped in the high side ofthe system to prevent low
voltage starting difficulties, hipot failures, and bearing
washout during the first-time start on the assembly line.
If additional charge is needed, it should be added as
liquid to the lowside of thesystem with the compressor
operating. Pre-charging on the high side and adding
liquid on the low side of the system are both meant to
protect the compressor fromoperating with abnormally
low suction pressures during charging.
Do not operate the compressor withoutenough system
charge to maintain at least 55 psig (3.8 bar) suction
pressure for R-410A and 20 psig (1.4 bar) for R-22 & R-
407C. Do not operate the compressor with the low
pressure cut-out disabled. Do not operate with a
restricted suction or liquid line. Do not use the
compressor to test the opening set point of a high
pressure cutout. Bearings are susceptible to damage
before they have had several hours of normal running
for proper break in.
WARNING
NOTICE
WARNING
CAUTION
WARNING
NOTICE

© 2023 Copeland LP.
15
AE4-1303 R17
4.8. Electrical Connections
The orientation of the electrical connections on the
wiring diagram inside the terminal box cover. The T-
block screwterminals used on this compressor should
be fastened with a torque of 21 to 25 in-lb (2.37 to 2.82
Nm).
A molded plug electrical option is available for
compressors with internal overload protection (TF
electrical code) and is noted by a 1XX series bill of
material (i.e. ZP120KCE-TFD-130). Theterminal cover
must be installed after the molded plug is installed to
help keep the plug in place.
The molded electrical plug should be installed by hand
to properly seat the plug onthe electrical terminals. The
plug should not be struck with a hammer or any other
device.
The terminalboxesusedoncompressorswithTW*/TE*
electrical codes are larger because of the motor
overload module that is housed inside of the terminal
box. These terminal boxesalso have a higher ingress
protection (IP) rating. Every effort should be made to
keep the terminal box completely sealed. Oversized
conduits,poorconduitconnectionsto the terminalbox,
an incorrectly installed terminal box cover or a missing
terminalboxcovergasketareafewpossibleairleakage
paths.
Moisture from warm,moist air that is permitted to freely
enter the terminal box can condense into droplets of
water inside the cooler terminal box of the compressor.
To alleviate this problem,thewarm, moist air must be
prevented from entering the terminal box. Sealing
conduits and eliminating other air leakage paths must
be taken. DowCorning 3165 RTV is ideally suited for
sealing around wires in a conduit at the compressor
terminal box.Drilling a holein the bottomof the terminal
box to allow the moisture to escape isnot acceptable.
4.9. “Hipot” (AC High Potential) Testing)
Use caution with high voltage and never hipot when
compressor is in a vacuum.
Copeland Scroll compressors are configured with the
motor down and the pumping components at the top of
the shell. As a result, the motor can be immersed in
refrigerant to a greater extent than hermetic
reciprocating compressors when liquid refrigerant is
presentintheshell.Inthisrespect,thescrollismorelike
semi-hermetic compressors which can have horizontal
motorspartially submerged in oil and refrigerant. When
Copeland Scrollcompressorsarehipottestedwithliquid
refrigerant in the shell, they can show higher levels of
leakagecurrentthancompressorswiththemotorontop.
This phenomenon can occur with anycompressor when
themotorisimmersedinrefrigerant.Thelevelofcurrent
leakage doesnot presentany safetyissue. To lowerthe
current leakage reading, the system should be operated
for a brief period of time to redistribute the refrigerantto
a morenormalconfigurationand thesystemhipottested
again. See AE4-1294 for Megohm testing
recommendations. Underno circumstancesshould the
hipot testbe performed while the compressor is under a
vacuum.
4.10.Tandem Assembly
The first step in the tandem assembly process is to
securely mountboth compressors to the rails using the
appropriatemountinghardware.Afterbothcompressors
are mounted to the rails, the suction and discharge
manifoldscan be brazed to the appropriate stub tubes
on each compressor using standard brazing practices
with a nitrogen purge.See Figure 8 for a picture of a
typicaltandem assembly. Specialconsideration needs
to be given to the oil line that connects the oilsumpsof
the two compressors. For even tandems (two
compressors with equal capacities) there are two
options for connecting the compressor oil sumps--oil
equalization line (OEL)or two-phase tube line (TPTL).
For uneven tandems (two compressors with unequal
capacities) only the TPTL option is qualified.
After the compressorsare mounted to the compressor
rails the entire assembly should be tilted back a
minimum of 12 degrees from horizontal (Figure 9) to
move the oil level away from the Schrader fittings and
sight-glasses. If the compressor sumps are to be
connected with the TPTL the compressor sight-glasses
can now be removed for installation of the TPTL. The
TPTL Rotalock fitting should be torqued to the value
listed in Table 6. If the compressor sumps are to be
connected with the OEL option the Schrader fittings can
now be removed by unscrewing them. Removing the
Schrader fittings exposes the stub that is used to braze
the OEL to each compressor. The oil equalization stubs
of both compressorsshould be wiped clean with a lint
free towel to remove any oil residue before brazing.
For a detailed instruction list of how to assemble a trio
of compressors, please contact Application
Engineering.
CAUTION
CAUTION
CAUTION

© 2023 Copeland LP.
16
AE4-1303 R17
5. SERVICE PROCEDURES
POE may cause an allergic skin reaction and must
be handled carefully and the proper protective
equipment (gloves, eye protection, etc.) must be
used when handling POE lubricant. POE mustnot
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). Refer to the Safety Data Sheet
(SDS) for further details.
5.1. Field Replacement
Use care and the appropriate material handling
equipment when lifting and moving compressors.
Personal safety equipment must be used.
5.1.1. Mounting
There is an older7 to 15 ton scroll family(ZR*K3)as
well as a reciprocating compressor family (BR)thatcan
be replaced by this scroll compressor family. The
mounting dimensions of the older scroll and the
reciprocating compressor are 8.65" X 8.65" (220mm X
220mm) to the center of the mounting holes. The newer
scroll has a mounting dimension of 7.5" X 7.5"(190mm
X 190mm). To help adapt to this new dimension use
mountingkit922-0001-00thatcontainsanadaptorplate
and mounting bolts. It will bolt in place of the old
compressor mounts and has a 7.5" (190mm) square
mounting bolt hole pattern for the new compressor.
5.1.2. Removing Oil
If the oil level is higherthan the oil Schraderfitting on
the sump of the compressor oil can be drained fromthis
fittinguntil theoil level reaches thelevel of theSchrader
fitting.To remove oil fromthe compressor when the oil
level is below the oil Schrader fitting one of two different
procedures can be used. The first procedure is to
remove the compressor fromthe systemand drain the
oil from the compressor suction connection. This
method ensures complete removal of the oil from the
compressor. The second procedure is to remove the
compressor sight-glass and insert a hose into the sump
of the compressor and drawthe oil outwith a hand-held
pump (Yellow Jacket Pump UPC#77930).
5.1.3. Electrical
When replacing a compressor, especially one that has
been in the field fora numberof years, it is always a
good idea to replace the contactor.
Note: See the locked rotor on the nameplate of the new
compressor and make sure the contactor exceeds this
locked rotor rating.
5.1.4. Module
If the compressor to be replaced hasa motorprotection
module (i.e. ZR*K3) butthe newcompressor doesnot,
the following modifications must be made.
1. Entirely remove the wiring leads originally run to
(T1-T2) on the solid state module fromthe line
or transformer.
2. Either tie together the leads originally attached to
the control terminals (M1-M2) on the solid state
moduleorremovetheleadsto M1-M2andrerunthe
control wiring directly from the control to the
contactor coil.
3. The only wiring connectionsto the newcompressor
will be the three high-power leads.
5.2. Compressor Replacement after Motor
Burn
In thecaseof amotorburn,themajorityofcontaminated
oil will be removed with the compressor. The rest of the
oil is cleaned through use of suction and liquid line filter
dryers. A 100% activated alumina suction filter drier is
recommendedbutmustberemovedafter72hours.See
AE24-1105 for clean up proceduresand AE11-1297 for
liquid line filter-drier recommendations.
It is highly recommended that the suction accumulator
be replaced if the systemcontainsone.This is because
the accumulator oil return orifice or screen may be
plugged with debris or may become plugged shortly
aftera compressorfailure.This will result in starvation
of oil to the replacement compressor and a second
failure.
5.3. Manifolded Compressor Replacement
When lifing manifolded compressor assemblies, all
compressors must be lifted by their respective lifting
rings. Use care and exercise extreme caution when
lifting and moving compressors. Personal safety
equipment must be used.
Should a compressor fail in a manifolded set, only the
failed compressor should be replaced and not both
compressors. The oil from the failed compressor will
stay mostly in the failed compressor.Anycontaminated
oil that doesenter the tandem circuit will be cleaned by
WARNING
WARNING
NOTICE
WARNING

© 2023 Copeland LP.
17
AE4-1303 R17
the liquid line filter drier,and when used, the suction line
filter drier.
The suction and discharge manifolds can be reused if
the failed compressor is carefully removed and the
manifoldsarecutinsuchawaythatacouplingand short
piece of copper can reconnectthe new compressor.A
new oil equalization line can be field fabricated using
3/8" (10mm) OD AC&R tubing, if one is needed. The
replacement oil equalization line should be formed to
exactly the same outline and dimensionsas the line that
is being replaced.To reconnect the oilequalization line
to the compressor, theoil in one or both compressors
will have to be lowered below the oil fitting on the
compressor. To do this, oil should either be removed
from the compressors or the compressors should be
tilted back a minimum of 12 degreesfromhorizontal to
move the oil away from the fitting (see Figure 9).
5.4. Start-up of a New or Replacement
Compressor
It is good service practice,when charging a system with
a scroll compressor, to charge liquid refrigerantinto the
high side only. It is not good practice to dump liquid
refrigerant froma refrigerant cylinder into the crankcase
of a stationary compressor. If additional charge is
required, charge liquid into the low side of the system
with the compressor operating.
Do not start the compressor while the system is in a
deep vacuum. Internal arcing mayoccur when any type
of compressor is started in a vacuum.
Do not operate the compressor withoutenough system
charge to maintain at least 55 psig (3.8 bar) suction
pressure for R-410A and 20 psig (1.4 bar) for R-22 & R-
407C. Do not operate with a restricted suction or liquid
line. Do not operate with the low pressure cut-out
disabled.Never install a system in the field and leave it
unattended withnocharge,aholdingcharge,orwiththe
service valves closed without securely locking out the
system.This will prevent unauthorized personnelfrom
accidentallyruining thecompressorby operatingwithno
refrigerant flow.
As mentioned in the Manifolded Applications section,
attention must be given to compressor oil levelswhen
commissioning a newsystem and servicing an existing
system. Oil levels should be checked with the
compressor"off"and aftertheoil has had a chance to
equalize between the compressors (for manifolded
applications). If oilcan't be seen in the sight-glassof the
compressor, add oil until the sight-glass is
approximately half full.
5.5. Field TroubleShooting theKriwan Module
Follow the steps listed below to trouble shoot the
module in the field. See wiring diagramin terminal box
cover.
1. De-energize control circuit and module power.
Remove the control circuit wires from the module
(Terminals M1 & M2). Connect a jumper across
these “control circuit” wires. This will bypass the
“control contact” of the module.
The motor protection systemwithin the compressor
is now bypassed. Use this configuration to
temporarily test module only.
Re-energize the control circuit and module power. If
the compressor will not operate with the jumper
installed, then the problem is external to the solid
state protection system.
If the compressor operates with the module
bypassed but will not operate when the module is
reconnected, then the control circuit relay in the
module is open. The thermistor protection chain
now needs to be tested to determine if the module’s
controlcircuitrelayisopenduetoexcessiveinternal
temperatures or a faulty component.
2. Check the thermistor protection chain located in the
compressor as follows:
De-energize control circuit and module power.
Remove the sensor leads from the module(S1 &
S2). Measure the resistance of the thermistor
protection chain through these sensor leadswith an
ohmmeter.
Use an Ohmmeter with a maximum of 9 volts to
check the sensor chain. The sensor chain is
sensitiveandeasilydamaged;noattemptshouldbe
made to check continuity through it with anything
other than an ohmmeter. The application of any
external voltage to the sensor chain may cause
damage requiring the replacement of the
compressor.
The diagnosis of this resistance reading is as
follows:
•200 to 2250ohms -Normaloperatingrange
•2750 ohms or greater - Compressor
WARNING
NOTICE
CAUTION
NOTICE

© 2023 Copeland LP.
18
AE4-1303 R17
overheated - Allow time to cool
•zero resistance - Shorted sensor circuit -
Replace the compressor
•infinite resistance - Open sensor circuit -
Replace the compressor
If the resistance reading is abnormal, remove the
sensor connector plug from the compressor and
measure the resistance at the sensor fusite pins.
This will determine if the abnormal reading was due
to a faulty connector.
On initial start-up, and after any module trip, the
resistance of the sensor chain must be below the
module reset point before the module circuit will
close. Reset values are 2250-3000 ohms.
3. If the sensor chain has a resistance that is below
2250 ohms, and the compressor will run with the
control circuit bypassed, but will not run when
connected properly, the solid state module is
defective and should be replaced.The replacement
module must have the same supply voltage rating
as the original module.
NOTE: The Kriwan INT69 SU2 has been phased out of
production by Kriwan. Kriwan modules that require
replacement in the field should be replaced with the
CoreSense Communicationsmodule listed in Table 4.
Kriwanto CoreSenseretrofitinstructionsarelistedatthe
end of this bulletin.
5.6. Field Troubleshooting CoreSense
Communications Module
A solid green LED indicates the module is powered and
operation is normal. A solid red LED indicates an
internal problem with the module.If a solid red LED is
encountered,power down the module (interrupt the T1-
T2power)for30secondstorebootthemodule.If asolid
red LED is persistent, change the CoreSense module.
CoreSense communicates Warning codesvia a green
flashingLED. Warning codesdo not result in a trip or
lockout condition. Alert codes arecommunicatedvia a
red flashing LED. Alert codes will result in a trip
condition and possibly a lockout condition. For more
informationon CoreSense please refer to AE8-1408.
5.7. Copeland Scroll Compressor Functional
Check
A functional compressor test with the suction service
valve closed to check how low the compressor will pull
suction pressure is not a good indication of how well a
compressor is performing. Such a test may damage a
scroll compressor. The following diagnostic procedure
should be used to evaluate whethera Copeland Scroll
compressor is working properly.
1. Proper voltage to the unit should be verified.
2. The normal checks of motor winding continuity and
short to ground should be made to determine if the
inherent overload motorprotectorhas opened or if
an internal motor short or ground fault has
developed. If the protector has opened, the
compressormust be allowed to coolsufficientlyto
allow it to reset.
3. Proper indoor and outdoor blower/fan operation
should be verified.
4. With service gauges connected to suction and
discharge pressure fittings, turn on thecompressor.
If suction pressure falls below normal levels, the
system is either low on charge or there is a flow
blockage in the system.
5. If suction pressure does not drop and discharge
pressure doesnotrise to normal levels, reverse any
two of the compressor power leads and reapply
powerto make sure compressorwas not wired to
run in reverse direction. If pressures still do not
move to normalvalues,either the reversing valve (if
so equipped)orthecompressoris faulty.Reconnect
the compressorleads as originally configured and
use normal diagnostic procedures to check
operation of the reversing valve.
6. To test if the compressoris pumping properly, the
compressor current draw must be compared to
published compressor performance curves using
the operating pressuresand voltage of the system.
If themeasuredaveragecurrentdeviatesmorethan
±15% from published values, a faulty compressor
may be indicated. A current imbalance exceeding
15% of the average on the three phasesshould be
investigatedfurther.Amorecomprehensivetrouble-
shooting sequence for compressors and systems
canbefoundinSectionHoftheCopelandElectrical
Handbook, Form No. 6400.
7. Before replacing or returning a compressor: Be
certain that the compressoris actually inoperable.
As aminimum, recheckacompressorreturned from
the field in the shop or depot for Hipot, winding
resistance,and ability tostartbeforereturning.More
thanone-third ofcompressorsreturned toCopeland
for warranty analysis are determined to have
nothing found wrong. They were misdiagnosed in
the field as being inoperable. Replacing working
compressors unnecessarily costs everyone.

© 2023 Copeland LP.
19
AE4-1303 R17
5.8. Refrigerant Retrofits
ZR compressors are UL recognized for use with R-22,
R-407C, or R-134a only. Use of any other refrigerants
will void the compressor UL recognition.
Only thosesystemsthat are in need of service should
be considered for a refrigerant retrofit if R-22 is not
available. Systems that are operating without issue
should be maintained and not be considered for a
refrigerant retrofit. Inmostif notall cases, theretrofitted
system will not be as energy efficient as the R-22
system.
Only those refrigerants approved by Copeland and the
OEM should be considered. For a list of Copeland
approved refrigerants please refer to Form 93-11,
Refrigerants and Lubricants Approved for Use in
Copeland Compressors. Please consult with the OEM
to obtain their input and approval on refrigerant
retrofitting.
If the compressor lubricant is mineral oil, it must be
changed to POE for a successful retrofit. See the
section Removing Oil forinstructionson how to remove
the oil charge from the compressor.
POE oil should be added to the compressor through the
oil charging connection on the sump of the compressor.
The compressor should be filled to 1/2 sight-glass.
For detailed R-407Cretrofit instructions please refer to
Form 95-14, Refrigerant ChangeoverGuidelinesforR-
22 to R-407C. For otherretrofit guidelinesplease refer
to the equipment OEM.
6. General Guidelines and More Information
Forgeneral Copeland™compressor information please
refer to Copeland Mobile., refer to the Application
Engineering bulletins listed below, or contact your
Application Engineer.
AE8-1408
CoreSense™Communications for 13
to 15 Ton Copeland Scroll™Air
Conditioning Compressors
AE4-1365
5 to 12 Ton ZP*K3, ZP*KC, and
ZP*KW R-410A Copeland Scroll™
Compressors for Air Conditioning
AE17-1262
Compressor Short Cycling - An
Unrecognized Problem
AE9-1249
Power Factor Correction
AE24-1105
Principles of Cleaning Refrigeration
Systems
AE10-1244
RecommendedContactorSelectionfor
Three Phase Motor Control
AE4-1294
Megohm Values of Copeland®
Compressors
AE4-1430
Copeland Scroll™Compressor
Multiples for Air Conditioning
AE11-1297
LIQUID LINE FILTER-DRIERS
NOTICE

© 2023 Copeland LP.
20
AE4-1303 R17
Compression in the scroll is
created by the interaction of an
orbiting spiral and a stationary
spiral. Gas enters the outer
openings as one of the spirals
orbits.
The open passages are sealed off
as gas is drawn into the spiral.
As the spiral continues to orbit,the
gas is compressed into two
increasing smaller pockets.
By the time the gas arrives at the
center port, discharge pressure
has been reached.
Actually, during operation, all six
passages are in various stages of
compression at all times, resulting
in nearly continuous suction and
discharge.
How a Scroll Works
The scroll is a simple compression concept first
patented in 1905. A scroll is an involute spiral which,
when matched with a mating scroll form as shown
above, generates a series of crescent-shaped gas
pockets between the two members. During
compression,onescrollremains stationary(fixed scroll)
while the other form (orbiting scroll) is allowed to orbit
(bot not rotate) around the first form. As this motion
ocurrs, the pockets between the two forms are slowly
pushed to the center of the two scroll while
simultaneously being reduced in volume. When the
pocket reaches the center of the scroll form, the gas,
which is nowathigh pressure,is discharged outofa port
located at the center. During compression, several
pockets arebeing compressedsimultaneusly, resultingin
a very smooth process. Both the suction process (outer
portion of the scroll members) and thedischargeprocess
(inner portion) are continuous.
Scan this code to see a
short video clip about how
Scroll Works.
Figure 1 - How a Scroll Works