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

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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

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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

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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

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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)

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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

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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

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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

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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

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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