Emerson Copeland Scroll Digital ZFD13KVE Instruction Manual

Application Guidelines
Digital Scroll™ Compressors for Refrigeration
ZBD21K* to ZBD114K*
ZFD13KVE to ZFD25KVE
ZFD41K5E
Digital

C6.2.24/1014-0215/E
About these guidelines .............................................................................................. 1
1Safety instructions.......................................................................................... 1
1.1 Icon explanation................................................................................................. 1
1.2 Safety statements............................................................................................... 1
1.3 General instructions............................................................................................ 2
2Product description ........................................................................................ 3
2.1 Common information about Copeland Scroll Digital™ compressors............................ 3
2.2 Nomenclature.................................................................................................... 4
2.3 Dimensions ....................................................................................................... 4
2.4 Application range ............................................................................................... 5
2.4.1 Qualified refrigerants and oils..................................................................... 5
2.4.2 Application limits and operating envelopes ................................................... 6
3Installation....................................................................................................... 7
3.1 Compressor handling.......................................................................................... 7
3.1.1 Transport and storage............................................................................... 7
3.1.2 Positioning and securing............................................................................ 7
3.1.3 Installation location................................................................................... 7
3.1.4 Mounting parts......................................................................................... 7
3.2 Solenoid valves for models ZBD21K* to ZBD57K* and ZFD13KVE to ZFD25KVE ........ 8
3.2.1 Securing the filter screen in position............................................................ 8
3.2.2 Solenoid valve installation –General recommendations ................................. 9
3.2.3 Solenoid valve installation –Tubing recommendations................................... 9
3.3 Copeland Scroll Digital compressors ZFD13KVE to ZFD25KVE with vapour injection /
wet vapour injection................................................................................................... 9
3.3.1 Vapour injection (EVI = Economized Vapour Injection) ..................................10
3.3.2 Wet vapour injection (vapour injection + liquid injection) ................................10
3.4 Discharge check valve .......................................................................................11
3.5 Brazing procedure.............................................................................................11
3.6 Shut-off valves and adaptors...............................................................................12
3.7 Oil separator.....................................................................................................13
3.8 Accumulators....................................................................................................13
3.9 Screens ...........................................................................................................13
3.10 Mufflers............................................................................................................14
3.11 Suction line noise and vibration ...........................................................................14
4Electrical connection .................................................................................... 15
4.1 General recommendations..................................................................................15
4.2 Electrical installation ..........................................................................................15
4.2.1 Terminal box...........................................................................................17
4.2.2 Motor winding .........................................................................................17
4.2.3 Motor protection......................................................................................18

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4.2.4 Protection devices ...................................................................................18
4.2.5 Crank case heaters ..................................................................................18
4.3 Pressure safety controls .....................................................................................18
4.3.1 IPR valve (Internal Pressure Relief valve) ...................................................18
4.3.2 High-pressure control...............................................................................18
4.3.3 Low-pressure control ...............................................................................19
4.4 Discharge temperature protection........................................................................19
4.5 High potential testing .........................................................................................20
5Starting up & operation................................................................................. 21
5.1 Strength pressure test........................................................................................21
5.2 Tightness/pressure test ......................................................................................21
5.3 Preliminary checks –Pre-starting.........................................................................21
5.4 Charging procedure...........................................................................................21
5.5 Initial start-up....................................................................................................22
5.6 Rotation direction ..............................................................................................22
5.7 Pressure fluctuations .........................................................................................22
5.8 Starting sound ..................................................................................................22
5.9 Deep vacuum operation .....................................................................................23
5.10 Shell temperature..............................................................................................23
5.11 Minimum run time..............................................................................................23
5.12 Sound characteristics.........................................................................................23
5.13 Shut-off sound ..................................................................................................23
5.14 Frequency........................................................................................................23
5.15 Oil level............................................................................................................24
5.16 Digital system control.........................................................................................24
5.17 Power factor.....................................................................................................24
6Maintenance & repair .................................................................................... 25
6.1 Exchanging the refrigerant..................................................................................25
6.2 Rotalock valves .................................................................................................25
6.3 Replacing a compressor.....................................................................................25
6.3.1 Compressor replacement..........................................................................25
6.3.2 Start-up of a new or replacement compressor..............................................25
6.4Lubrication and oil removal .................................................................................26
6.5 Oil additives......................................................................................................26
6.6 Unbrazing system components............................................................................27
7Dismantling & disposal................................................................................. 27
DISCLAIMER............................................................................................................. 27

C6.2.24/0215-0515/E 1
About these guidelines
The purpose of these application guidelines is to provide guidance in the application of Copeland
Scroll™ compressors in users’ systems. They are intended to answer the questions raised while
designing, assembling and operating a system with these products.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the compressors. Emerson Climate Technologies will not guarantee the
performance and reliability of the product if it is misused in regard of these guidelines.
These application guidelines cover stationary applications only. For mobile applications, contact
Application Engineering as other considerations may apply.
1 Safety instructions
Copeland Scroll compressors are manufactured according to the latest European and US Safety
Standards. Particular emphasis has been placed on the user’s safety.
These compressors are intended for installation in systems according to the Machinery Directive
MD 2006/42/EC and to the Pressure Equipment Directive PED 97/23/EC. They may be put to
service only if they have been installed in these systems according to instructions and conform
to the corresponding provisions of legislation. For relevant standards please refer to
Manufacturers Declaration, available at www.emersonclimate.eu.
These instructions should be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to
avoid property damage and possible
personal injury.
High voltage
This icon indicates operations with a
danger of electric shock.
IMPORTANT
This icon indicates instructions to
avoid malfunction of the compressor.
Danger of burning or frostbite
This icon indicates operations with a
danger of burning or frostbite.
NOTE
This word indicates a
recommendation for easier operation.
Explosion hazard
This icon indicates operations with a
danger of explosion.
1.2 Safety statements
Refrigerant compressors must be employed only for their intended use.
Only qualified and authorized HVAC or refrigeration personnel are permitted to install,
commission and maintain this equipment.
Electrical connections must be made by qualified electrical personnel.
All valid standards for connecting electrical and refrige ration equipment must be
observed.
The national legislation and regulations regarding personnel protection must be
observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

2 C6.2.24/1014-0215/E
1.3 General instructions
WARNING
System breakdown! Personal injuries! Never install a system in the field
and leave it unattended when it has no charge, a holding charge, or with the
service valves closed without electrically locking out the system.
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils must be used.
WARNING
High shell temperature! Burning! Do not touch the compressor until it has
cooled down. Ensure that other materials in the area of the compressor do
not get in touch with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without
refrigerant charge or without being connected to the system.
CAUTION
Contact with POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE must not come into contact with any surface
or material that it might damage, including without limitation, certain
polymers, eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.

C6.2.24/0215-0515/E 3
2 Product description
2.1 Common information about Copeland Scroll Digital™compressors
The Scroll compressor has been under development at Emerson Climate Technologies since
1979. It is the most efficient and durable compressor Emerson Climate Technologies has ever
developed for air conditioning and refrigeration.
These application guidelines deal with Copeland Scroll Digital™compressors for
refrigeration from ZBD21K* to ZBD114K*, ZFD13K* to ZFD41K*. These compressors
include a wide range of capacities, electrical options and features.
Compressor
Cooling Capacity kW
Motor
R404A
R407A
R407F
R448A
R449A
R134a
R450A
R513A*
ZBD21KCE
5.09
4.88
4.67
3.14
2.67
3.00
PFJ/TFD
ZBD29KCE
6.83
6.35
6.77
3.97
TFD
ZBD30KCE
6.98
6.78
6.84
6.67
4.25
3.63
4.09
TFD
ZBD38KCE
8.59
8.46
8.37
8.33
5.29
4.48
5.04
TFD
ZBD45KCE
10.25
9.39
10.00
9.76
6.04
5.38
6.03
TFD
ZBD57KCE
13.22
12.86
12.84
7.63
TFD
ZBD58KCE
13.45
12.00
12.84
TFD
ZBD76KCE
17.85
15.95
17.24
10.20
TFD
ZBD76K5E
18.38
17.08
18.40
TFD
ZBD114K5E
26.19
24.10
24.09
TFD
Table 1: Cooling capacity for medium temperature compressors @EN 12900 Medium temp.
Compressor
COP
Motor
R404A
R407A
R407F
R448A
R449A
R134a
R450A
R513A*
ZBD21KCE
2.23
2.28
2.01
2.15
2.24
2.14
PFJ/TFD
ZBD29KCE
2.20
2.14
2.09
2.07
TFD
ZBD30KCE
2.22
2.16
2.22
2.15
2.21
2.24
2.12
TFD
ZBD38KCE
2.23
2.20
2.22
2.15
2.23
2.25
2.14
TFD
ZBD45KCE
2.24
2.17
2.23
2.22
2.20
2.27
2.14
TFD
ZBD57KCE
2.26
2.17
2.17
2.36
1.99
TFD
ZBD58KCE
2.12
2.02
2.08
TFD
ZBD76KCE
2.16
2.08
2.16
2.18
2.08
TFD
ZBD76K5E
2.14
2.11
2.19
TFD
ZBD114K5E
2.07
2.08
2.08
TFD
Table 2: Coefficient of performance (COP) for medium temperature compressors @EN 12900 Medium temp.
Compressor
R404A
R407A
R407F
R448A, R449A
Motor
kW
COP
kW
COP
kW
COP
kW
COP
kW
ZFD13KVE
3.96
1.35
3.15
1.16
3.31
1.16
3.27
1.45
TFD
ZFD18KVE
5.91
1.49
4.92
1.44
4.92
1.29
4.83
1.43
TFD
ZFD25KVE
7.68
1.62
6.12
1.43
6.43
1.43
6.16
1.58
TFD
ZFD41K5E
8.56
1.35
7.32
1.18
7.32
1.18
TFD
ZFD41K5E EVI
12.46
1.58
10.02
1.55
10.02
1.55
TFD
Table 3: Cooling capacity in kW and COP for low temperature compressors @EN 12900 Low temp
EN 12900 MT: Evaporating: -10°C, Condensing: 45°C, Suction gas: 20°C, Sub-cooling: 0K
Except for R513A*, Suction Superheat = 10K
EN 12900 LT: Evaporating: -10°C, Condensing: 45°C, Suction gas: 20°C, Sub-cooling: 0K
Copeland Scroll Digital compressors have one Scroll compression set driven by a single or
three-phase induction motor. The Scroll set is mounted at the upper end of the rotor shaft of the
motor. The rotor shaft axis is in the vertical plane.
Safety
instructions
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description
Installation
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connection
Starting up &
operation
Maintenance &
repair
Dismantling &
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4 C6.2.24/1014-0215/E
2.2 Nomenclature
The model designation contains the following technical information about the compressor:
2.3 Dimensions
A
B
C
D
E
ZBD21KCE
432.4
414.3
363.6
261.6
218.9
ZBD29KCE
463.2
445.2
394.3
291.3
249.7
Figure 1: Dimensions ZBD21KCE & ZBD29KCE Figure 2: Dimensions ZBD30K* to ZBD57K*
& ZFD13KVE to ZFD25KVE

C6.2.24/0215-0515/E 5
A
mm
B
mm
C
mm
D
mm
E
mm
H
mm
ZBD58KCE
476.3
444.3
211.7
93.6
201.5
74.3
ZBD76KCE
533.2
501.2
253
122.1
242.8
92.3
ZBD76K5E
533.6
501.8
253.7
277.3
245.7
93
ZBD114K5E
881.5
519.5
271.3
295
263.3
93
Figure 3: Dimensions ZBD58KCE & ZBD76KCE Figure 4: Dimensions ZBD76K5E & ZBD114K5E
2.4 Application range
2.4.1 Qualified refrigerants and oils
IMPORTANT
It is essential that the glide of refrigerant blends (primarily R407A and
R407F) is carefully considered when adjusting pressure and superheat
controls.
Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland™
brand products Select software at www.emersonclimate.eu.
Compressor
ZBD21K* to ZBD114K*
ZFD13K* to ZFD41K*
Qualified refrigerants
R404A, R407A, R407F, R448A,
R449A, R134a, R450A, R513A, R507;
R22 for ZBD30K* & ZBD45K* only
R404A, R407A, R407F,
R448A, R449A, R507
Copeland brand products
standard oil
Emkarate RL 32 3MAF
Servicing oils
Emkarate RL 32 3MAF / Mobil EAL Arctic 22 CC
Table 4: Qualified refrigerants and oils
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

6 C6.2.24/1014-0215/E
2.4.2 Application limits and operating envelopes
CAUTION
Inadequate lubrication! Compressor breakdown! The superheat at the
compressor suction inlet must always be sufficient to ensure that no
refrigerant droplets enter the compressor. For a typical evaporator-expansion
valve configuration a minimum stable superheat of at least 5K is required.
The application envelopes for Digital refrigeration Scroll compressors are for various refrigerants,
you can find them in the Copeland brand products Select software, which can be downloaded for
free on our website www.emersonclimate.eu.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

C6.2.24/0215-0515/E 7
3 Installation
WARNING
High pressure! Injury to skin and eyes possible! Be careful when
opening connections on a pressurized item.
3.1 Compressor handling
3.1.1 Transport and storage
WARNING
Risk of collapse! Personal injuries! Move compressors only with
appropriate mechanical or handling equipment according to weight. Keep in
the upright position. Stack pallets on top of each other when not exceeding
300 kg. Do not stack single boxes on top of each other. Keep the packaging
dry at all times.
Figure 5
3.1.2 Positioning and securing
IMPORTANT
Handling damage! Compressor malfunction! Only use the lifting eyes
whenever the compressor requires positioning. If the compressor has two
lifting tabs, both must be used for lifting. Using discharge or suction
connections for lifting may cause damage or leaks.
For models ZBD58K* to ZBD114K* and ZFD41K5E, because oil might spill out of the suction
connection located low on the shell, the suction connection plug must be left in place until the
compressor is set into the unit. If possible, the compressor should be kept vertical during
handling. The discharge connection plug should be removed first before pulling the suction
connection plug to allow the dry air pressure inside the compressor to escape. Pulling the plugs
in this sequence prevents oil mist from coating the suction tube making brazing difficult. The
copper-coated steel suction tube should be cleaned before brazing. No object, eg, a swaging
tool should be inserted deeper than 51 mm into the suction tube or it might damage the suction
screen and motor.
3.1.3 Installation location
Ensure the compressors are installed on a solid level base.
3.1.4 Mounting parts
Four vibration absorber grommets are supplied with each compressor. They dampen the start-up
surge of the compressor and minimise sound and vibration transmission to the compressor base
during operation. The metal sleeve inside is a guide designed to hold the grommet in place. It is
not designed as a load-bearing member, and application of excessive torque to the bolts can
crush the sleeve. Its inner diameter is approximately 8.5 mm to fit, eg, an M8 screw. The
mounting torque should be 13 ± 1 Nm. It is critically important that the grommet is not
compressed.
If the compressors are mountedin tandem or used in parallel, then the hard mountings (bolt M9
5/16”) are recommended. The mounting torque should be 27 ± 1 Nm. It is possible to deliver
these hard mounting parts as a kit, or on request to deliver the compressor with these parts
instead of the rubber grommets.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

8 C6.2.24/1014-0215/E
Mounting parts ZBD21K* to ZBD114K* & ZFD13K* to ZFD41K* - Soft mountings
Figure 6
3.2 Solenoid valves for models ZBD21K* to ZBD57K* and ZFD13KVE to
ZFD25KVE
IMPORTANT
The external solenoid valve is a critical component for proper function of this
compressor. Only the Copeland brand solenoid valve supplied as a
requested accessory must be used.
Care must be taken during the brazing process that no solid parts can enter the control piston
compartment or the solenoid valve tubing. To prevent solid parts from entering the control valve
seat, the solenoid valve kit contains a filter screen, which has to be placed into the horizontal
tube of the valve before brazing the tube connections as shown in Figure 10 below.
The solenoid valve has to be fitted in such a way that the sleeve with the stem inside –which
supports the solenoid coil –is fixed and aligned in the upright position.
3.2.1 Securing the filter screen in position
The filter screen should be placed into the small tube running
at 90° to the solenoid valve stem. A narrow washer fixed on
the filter screen will sit on the end of the tube preventing it
falling inside (see photos). The tube running from the top
centre of the compressor down to the previous tube needs to
be swaged at the solenoid valve end so that it covers the filter screen/tube and is
then brazed into position.
Filter screen with washer
To solenoid valve end From top o From compressor
Swaged tube
Swaged tube
Figure 7
Figure 8: Position of external solenoid v alv e Figure 9: Recommended piping

C6.2.24/0215-0515/E 9
3.2.2 Solenoid valve installation –General recommendations
The solenoid must be mounted vertically, within ± 15° of vertical. Horizontal mounting is not
permitted.
If a suction rotalock fitting is used, the threaded shipping plug in the rotalock fitting must be
removed prior to brazing in the vertical solenoid line.
The valve operation is directional. See Figures 13 & 14 below for inlet and outlet locations.
Do not restrict the line size coming from or leaving the solenoid. Use 3/8” soft drawn
copper.
Figure 10: Control v alv e w ithout coil Figure 11: Control v alv e pipe connection
3.2.3 Solenoid valve installation –Tubing recommendations
IMPORTANT
This tube has been tested and qualified at 50 and 60 Hz operation for
running stresses and resonance in a single compressor lab environment.
However, in some compressor applications such as racks and transport
applications, the OEM is strongly advised to re-confirm the acceptability of
the tube when the compressor is subject to additional vibration inputs.
The tube from the solenoid to the suction, marked “A” (see Figure 12), should be as short as
possible (less than 7.5 cm). Dimensions for a typical tube going from the top of the compressor
are shown in Figures 13 & 14.
3.3 Copeland Scroll Digital compressors ZFD13KVE to ZFD25KVE with vapour
injection / wet vapour injection
The following injection systems can be used:
Compressor family
Liquid injection
Vapour injection
Wet vapour injection
(vapour + liquid injection)
ZFD13KVE to ZFD25KVE
X
X
ZFD41KE
X
X
X
Table 5
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

10 C6.2.24/1014-0215/E
Copeland Scroll compressors ZFD13KVE to ZFD25KVE are vapour injection only. Liquid
injection alone is not possible. For compressor model ZFD41K5E both liquid injection and
vapour injection are possible.
Dedicated discharge temperature thermostats (DLT) shall be used for R407A, R407F, R448A
and R449A applications and can also be used for R404A. The R407A/R407F/R448A/R449A
dedicated discharge thermostat has a cut-out setting of 130°C ± 4K with closing at 101°C ± 8K.
It should be installed approximately 120 mm from the discharge valve outlet.
3.3.1 Vapour injection (EVI = Economized Vapour Injection)
Compressor models ZFD13KVE to ZFD25KVE and ZFD41K5E can be used with R404A,
R407A, R407F, R448A and R449A refrigerants and vapour injection.
These compressors are equipped with a vapour injection connection for economizer operation.
Economizing can be achieved by using a subcooling circuit similar to the circuit shown in
Figure 15. This increases the refrigeration capacity and the system efficiency.
The line diagram shows a system configuration for the economizer cycle. A heat exchanger is
used to provide additional subcooling to the refrigerant before it enters the evaporator. This
subcooling process provides the increased capacity gain measured in the system.
The evaporated refrigerant through the heat exchanger (economizer) is injected into the
compressors and provides additional cooling at higher compression ratios.
Figure 12: Vapour inj ection line dia gram
The application envelopes for the use of R407A and R407F refrigerants with vapour injection are
significantly limited, because of possible high discharge temperatures. Special attention should
be paid to the maximum suction gas temperature / superheat values.
NOTE: For further information on vapour injection see Technical Information C7.19.2
"ZF* Refrigeration Copeland Scroll™ Compressors Using R407A and R407F in Low
Temperature Applications".
3.3.2 Wet vapour injection (vapour injection + liquid injection)
Compressor models ZFD13KVE to ZFD25KVE and ZFD41K5E can be used with R407A and
R407F refrigerants and wet vapour injection.
The operating envelopes for R407A and R407F low temperature applications can be enlarged
thanks to the use of wet vapour injection, ie, a combination of vapour injection and liquid
injection (DTC valve) (see Figures 6 & 7in Chapter 2.4.2).
The wet vapour injection cycle showing the main components is shown in Figure 16 next page:

C6.2.24/0215-0515/E 11
Figure 13: Wet v apour injection cycle for R407A & R407F low temperature applications
NOTE: For Digital compressors ZFD13KVE and ZFD25KVE, the DTC valve bulb must
replace the existing NTC sensor located at the side of the compressor top cap. The
previous NTC sensor has to be removed and the controller, eg, ALCO EC3-D*, has to be
modified (disable discharge sensor input). A new thermostat must be installed on the
discharge line. DO NOT use the previous solution NTC sensor + controller as a discharge
temperature protection since its rating is not suitable for R407A and R407F.
3.4 Discharge check valve
There is no discharge check valve at the discharge port of Copeland Scroll Digital compressors
ZBD21K* to ZBD57K* and ZFD13KVE to ZFD25KVE since the high-side pressure is needed to
support the operation of the unloader mechanism.
To avoid by-passing during the unloading process back to suction, a dynamic discharge valve is
fitted internally on the discharge port of the fixed scroll. This discharge valve cannot be used with
recycling pump down because it is not leak-proof during the off period.
Models ZBD58K* to ZBD114K* work with an internal unloader mechanism and are equipped
with a check valve in the discharge fitting that will prevent backward flow of gas through the
scroll when the compressor shuts off.
3.5 Brazing procedure
IMPORTANT
Blockage! Compressor breakdown! Maintain a flow of oxygen-free
nitrogen through the system at very low pressure during brazing. Nitrogen
displaces the air and prevents the formation of copper oxides in the system.
If allowed to form, the copper oxide material can later be swept through the
system and block screens such as those protecting capillary tubes, thermal
expansion valves, and accumulator oil return holes.
Contamination or moisture! Bearing failure! Do not remove the plugs
until the compressor is set into the unit. This minimises any entry of
contaminants and moisture.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

12 C6.2.24/1014-0215/E
Copeland Scroll compressors have copper-plated
steel suction and discharge tubes. These tubes are
far more robust and less prone to leaks than copper
tubes. Due to the different thermal properties of
steel and copper, brazing procedures may have to
be changed from those commonly used.
Figure 17 shows the proper procedure for brazing
the suction and discharge lines to a scroll
compressor.
The copper-coated steel tubes on scroll compressors can be brazed in approximately the
same manner as any copper tube.
Recommended brazing materials: any silfos material is recommended, preferably with a
minimum of 5% silver. However, 0% silver is acceptable.
Be sure tube fitting inner diameter and tube outer diameter are clean prior to assembly.
Using a double-tipped torch, apply heat in area 1.
As the tube approaches brazing temperature, move the torch flame to area 2.
Heat area 2 until braze temperature is attained, moving the torch up and down and rotating
around the tube as necessary to heat the tube evenly. Add braze material to the joint while
moving the torch around the joint to flow braze material around the circumference.
After the braze material flows around the joint, move the torch to heat area 3. This will draw
the braze material down into the joint. The time spent heating area 3 should be minimal.
As with any brazed joint, overheating may be detrimental to the final result.
To disconnect:
Heat joint areas 2 and 3 slowly and uniformly until the braze material softens and the tube
can be pulled out of the fitting.
To reconnect:
Recommended brazing materials: Silfos with minimum 5% silver or silver braze used on
other compressors. Due to the different thermal properties of steel and copper, brazing
procedures may have to be changed from those commonly used.
NOTE: Since the discharge stub contains a check valve, care must be taken not to
overheat it to prevent brazing material from flowing into it.
3.6 Shut-off valves and adaptors
CAUTION
Leaking system! System breakdown! It is strongly recommended to
periodically re-torque all pipe and fixing connections to the original setting
after the system has been put into operation.
Copeland Scroll compressor models ZBD58K* to ZBD114K* and ZFD41K5E are delivered with a
discharge check valve fitted inside the discharge port and rubber plugs fitted to the suction and
discharge port as standard. There are options to fit either Rotalock valves or Rotalock adaptors,
or just make brazing connections.
Figure 15
Figure 14: Suction tube brazing

C6.2.24/0215-0515/E 13
Braze connections can be converted to Rotalock by means of adaptors. Rotalock shut-off valves
are available for the suction as well as discharge side. Using either straight or angled adaptors
provides a way to convert a Rotalock into a brazing connection.
Refer to Table 6 for proper tightening torques:
Torque [Nm]
Rotalock 3/4" –16UNF
40-50
Rotalock 1" –14UNS
70-80
Rotalock 1 ¼" –12UNF
110-135
Rotalock 1 ¾" –12 UNF
135-160
Table 6
NOTE: More information about adaptors and shut-off valves can be found in the "Spare
parts list".
3.7 Oil separator
During any operating cycle of Copeland Digital Scroll compressors, there is a loaded state during
which the compressor operates at full capacity. The velocity of gas during this loaded state is
sufficient to return oil back to the compressor. Laboratory tests have established that there is no
problem in oil return, even when the length of interconnecting pipe used is
100 metres and the vertical elevation is 30 metres. Based on such performance, we do not
strictly recommend the use of an oil separator.
3.8 Accumulators
CAUTION
Inadequate lubrication! Bearing destruction! Minimise liquid refrigerant
returning to the compressor. Too much refrigerant dilutes the oil. Liquid
refrigerant can wash the oil off the bearings leading to overheating and
bearing failure.
Irrespective of system charge, oil dilution may occur if large amounts of liquid refrigerant
repeatedly flood back to the compressor during:
normal off cycles;
defrost;
varying loads.
In such a case an accumulator must be used to reduce flood-back to a safe level that the
compressor can handle. The use of accumulators is dependent on the application. If an
accumulator must be used, the oil-return orifice should be from 1 to 1.4 mm in diameter for
models ZBD21K* to ZBD57K* and ZFD13KVE to ZFD25KVE and 2.0 mm for models ZBD58K*
to ZBD114K* and ZFD41K5E, depending on compressor size and compressor flood-back
results.
The size of the accumulator depends upon the operating range of the system and the amount of
subcooling and subsequent head pressure allowed by the refrigerant control.
3.9 Screens
CAUTION
Screen blocking! Compressor breakdown! Use screens with at least
0.6 mm openings.
The use of screens finer than 30 x 30 mesh (0.6 mm openings) anywhere in the system should
be avoided with these compressors. Field experience has shown that finer mesh screens used
to protect thermal expansion valves, capillary tubes, or accumulators can become temporarily or
permanently plugged with normal system debris and block the flow of either oil or refrigerant to
the compressor. Such blockage can result in compressor failure.
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14 C6.2.24/1014-0215/E
Figure 16: Suction tube design
3.10 Mufflers
External mufflers, normally applied to piston compressors in the past, may not be required for
Copeland Scroll compressors.
Individual system tests should be performed to verify acceptability of sound performance. If
adequate attenuation is not achieved, use a muffler with a larger cross-sectional area to inlet
area ratio. A ratio of 20:1 to 30:1 is recommended.
A hollow shell muffler such as the Alco APD-1 will work quite well. Locate the muffler at minimum
15 cm to maximum 45 cm from the compressor for the most effective operation. The farther the
muffler is placed from the compressor within these ranges, the more effective. Choose a muffler
with a length of 10 to 15 cm.
3.11 Suction line noise and vibration
Copeland Scroll compressors inherently have low sound
and vibration characteristics. However in some respects
the sound and vibration characteristics differ from
reciprocating compressors and in rare instances could
result in unexpected sound generation. One difference is
that the vibration characteristic of the scroll compressor,
although low, includes two very close frequencies, one of
which is normally isolated from the shell by the
suspension of an internally-suspended compressor.
These frequencies, which are present in all compressors,
may result in a low-level "beat" frequency that can be
detected as noise coming along the suction line into the
building under some conditions. Elimination of the beat
can be achieved by attenuating either of the contributing
frequencies. This is easily done by using one of the
common combinations of recommended design
configurations. The scroll compressor makes both a rocking and twisting motion and enough
flexibility must be provided in the line to prevent vibration transmission into any lines attached to
the unit. In a split system, the most important goal is to ensure minimal vibration in all directions
at the service valve to avoid transmitting vibrations to the structure t o 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 may be particularly pronounced in three-phase models due to their inherently higher
starting torque. This phenomenon, like the one described previously , also results from the lack of
internal suspension and can be easily avoided by using standard suction line isolation
techniques as described below. The sound phenomena described above are not usually
associated with reversible air conditioning / heat pump systems because of the isolation and
attenuation provided by the reversing valve and tubing bends.
Recommended configuration
Tubing configuration: ...... small shock loop
Service valve: ................ "angled valve" fastened to unit / wall
Suction muffler: ............. not required
Alternative configuration
Tubing configuration: ...... small shock loop
Service valve: ................ "straight through" valve fastened to unit / wall
Suction muffler: ............. may be required (acts as dampening mass)

C6.2.24/0215-0515/E 15
4 Electrical connection
4.1 General recommendations
The compressor terminal box has a wiring diagram on the inside of its cover. Before connecting
the compressor, ensure the supply voltage, the phases and the frequency match the nameplate
data.
4.2 Electrical installation
Single-phase (PF*) compressors:
Pow er circuit Control circuit
Motor terminal connections
Single-phase compressors are connected to the
Common (C), Start (S) and Run (R) connections
Legend
B1....Room thermostat F4.... LP switch
B3....Discharge gas thermostat K1.... Contactor
C2 ....Run capacitor R2.... Crankcase heater
F1 ....Fuse S1.... Auxiliary switch
F3 ....HP switch
Figure 17
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16 C6.2.24/1014-0215/E
Three-phase compressors (TF*) with internal motor protection:
Power circuit Control circuit
Motor terminal connections
Three-phase compressors are connected to the T1,
T2 and T3 connections
Legend
B1....Room thermostat K1.... Contactor
B3....Discharge gas thermostat R2.... Crankcase heater
F1 ....Fuse S1.... Auxiliary switch
F3 ....HP switch Y5.... Solenoid valve for refrigerant injection
F4 ....LP switch
Figure 18

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4.2.1 Terminal box
The standard terminal box is IP21 for all models with internal motor protection (TF*/PF*),
enclosure class according to IEC 60034-5.
Cable glands have an influence on the protection class of the terminal box. It is strongly
recommended to use appropriate cable glands in order to reach the rated protection class. We
advise installers/service providers to pay attention to this aspect every time they install or
replace a Copeland Scroll compressor and to use cable glands according to EN 50262 or any
other relevant standard of application in their country/region. Examples of correct electrical
installations are shown in Figures 22 & 23 below.
Figure 19: Correct electrical installation w ith cable glands for IP21 T-box (compressors ZBD21K* & ZBD29K*)
Figure 20: Correct electrical installation w ith cable glands for IP21 T-box (compressors ZBD30K* to ZBD114K*,
ZFD13KVE to ZFD25KVE & ZFD41K5E)
4.2.2 Motor winding
Compressor model ZBD21K* is available in single-phase (PF*). ZBD and ZFD compressors are
offered with three-phase (TF*) induction motors. Single-phase motors need a run capacitor while
all three-phase motors are connected in star.
The motor insulation material is class "B" for compressor models covered in these guidelines.
This is according to VDE 0530, IEC 34-18-1 or DIN 57530.
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