Emerson Copeland Scroll ZB50KCE Instruction Manual

Copeland Scroll™Compressors
for Refrigeration
ZB50KCE to ZB114KCE, ZB66K5E to ZB114K5E
ZF25K5E to ZF54K5E
Application Guidelines

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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 compressors ............................................. 3
2.2 Nomenclature................................................................................................................... 3
2.3 BOM Variation.................................................................................................................. 3
2.4 Application range ............................................................................................................. 4
2.4.1 Qualified refrigerants and oils .............................................................................. 4
2.4.2 Comparison between ZB*KCE and ZB*K5E compressors.................................. 4
2.4.3 Application limits................................................................................................... 4
3Installation........................................................................................................5
3.1 Compressor handling....................................................................................................... 5
3.1.1 Transport and storage.......................................................................................... 5
3.1.2 Positioning and securing...................................................................................... 5
3.1.3 Installation location............................................................................................... 5
3.1.4 Mounting parts...................................................................................................... 5
3.2 Brazing procedure............................................................................................................ 6
3.3 Shut-off valves and adaptors........................................................................................... 7
3.4 Suction accumulators....................................................................................................... 7
3.5 Screens............................................................................................................................ 8
3.6 Mufflers ............................................................................................................................ 8
3.7 Suction line noise and vibration....................................................................................... 8
4ZF*K5E compressors for low temperature applications................................9
4.1 ZF*K5E compressors with liquid injection........................................................................ 9
4.1.1 DTC valve specifications...................................................................................... 9
4.1.2 Valve installation .................................................................................................. 9
4.1.3 Compressor or valve service.............................................................................. 10
4.2 ZF*K5E compressors with vapour injection................................................................... 10
4.2.1 Economized Vapour Injection technology (EVI)................................................. 10
4.2.2 Multiple compressor applications....................................................................... 10
4.3 ZF*K5E compressors with wet vapour injection ............................................................ 11
5Electrical connection .....................................................................................12
5.1 General recommendations............................................................................................. 12
5.2 Electrical installation ...................................................................................................... 12
5.3 Terminal box .................................................................................................................. 13
5.3.1 Motor windings ................................................................................................... 14
5.3.2 Protection devices.............................................................................................. 14

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5.3.3 Crankcase heaters ............................................................................................. 14
5.4 Pressure safety controls ................................................................................................ 14
5.4.1 High pressure control......................................................................................... 14
5.4.2 Low pressure control.......................................................................................... 14
5.5 Discharge temperature protection ................................................................................. 15
5.5.1 ASTP Advanced Scroll Temperature Protection................................................ 15
5.5.2 Discharge line thermostat................................................................................... 15
5.6 Motor protection............................................................................................................. 17
5.7 High-potential testing ..................................................................................................... 17
6Starting up & operation..................................................................................18
6.1 Strength pressure test.................................................................................................... 18
6.2 Tightness/pressure test.................................................................................................. 18
6.3 System evacuation......................................................................................................... 18
6.4 Preliminary checks –Pre-starting.................................................................................. 18
6.5 Charging procedure ....................................................................................................... 19
6.6 Initial start-up ................................................................................................................. 19
6.7 Rotation direction........................................................................................................... 19
6.8 Starting sound................................................................................................................ 20
6.9 Deep vacuum operation................................................................................................. 20
6.10 Shell temperature........................................................................................................... 20
6.11 Pump-down cycle........................................................................................................... 20
6.12 Minimum run time .......................................................................................................... 20
6.13 Shut-off sound................................................................................................................ 21
6.14 Frequency...................................................................................................................... 21
6.15 Oil level .......................................................................................................................... 21
7Maintenance & repair.....................................................................................22
7.1 Exchanging the refrigerant............................................................................................. 22
7.2 Rotalock valves.............................................................................................................. 22
7.3 Replacing a compressor................................................................................................ 22
7.3.1 Compressor replacement................................................................................... 22
7.3.2 Start-up of a new or replacement compressor................................................... 22
7.4 Lubrication and oil removal............................................................................................ 22
7.5 Oil additives ................................................................................................................... 23
7.6 Unbrazing system components ..................................................................................... 23
8Dismantling & disposal..................................................................................24
DISCLAIMER ..............................................................................................................24

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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 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 in accordance with the Machinery
Directive MD 2006/42/EC. They may be put to service only if they have been installed in these
systems according to instructions and conform to the corresponding provisions of legislation.
For relevant standards please refer to the Manufacturers Declaration, available at
www.climate.emerson.com/en-gb.
These instructions should be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to
avoid property damage and possible
personal injury.
High voltage
This icon indicates operations with a
danger of electric shock.
IMPORTANT
This icon indicates instructions to
avoid malfunction of the compressor.
Danger of burning or frostbite
This icon indicates operations with a
danger of burning or frostbite.
NOTE
This word indicates a
recommendation for easier operation.
Explosion hazard
This icon indicates operations with a
danger of explosion.
1.2 Safety statements
▪Refrigerant compressors must be employed only for their intended use.
▪Only qualified and authorized HVAC or refrigeration personnel are permitted to install,
commission and maintain this equipment.
▪Electrical connections must be made by qualified electrical personnel.
▪All valid standards for connecting electrical and refrigeration equipment must be
observed.
▪The national legislation and regulations regarding personnel protection must be
observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.

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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.
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 get 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.

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2 Product description
2.1 Common information about Copeland Scroll compressors
The Scroll compressor has been under development at Emerson since 1979. It is the most efficient
and durable compressor Emerson has ever developed for air conditioning, refrigeration and
heating applications.
These application guidelines deal with vertical single Copeland Scroll compressors
ZB50KCE to ZB114KCE & ZB66K5E to ZB114K5E for medium temperature refrigeration
applications, and ZF25K5E to ZF54K5E for low temperature refrigeration applications.
These compressors have one scroll compression set driven by a three-phase induction motor.
The scroll set is mounted at the upper end of the rotor shaft of the motor. The rotor shaft axis is in
the vertical plane.
2.2 Nomenclature
The model designation contains the following technical information about the standard and vapour
injection compressors:
* ARI Conditions high/medium temperature:
Evaporating temperature....... -6.67°C Liquid sub-cooling............................0K
Condensing temperature....... 48.90°C Ambient temperature .......................35°C
Suction gas return ................. 18.33K
** ARI Conditions low temperature:
Evaporating temperature....... -31.67°C Liquid sub-cooling............................0K
Condensing temperature....... 40.56°C Ambient temperature .......................35°C
Suction gas return ................. 18.33K
2.3 BOM Variation
The BOM (bill of material) number at the end of the compressor designation describes the different
compressor layout and details. The following compressor models are available with the BOM
versions:
ZB50KCE to ZB114 KCE:
BOM 551 Rotalock connections, terminal box IP54, oil sight glass, ASTP discharge
temperature control, mounting parts for single operation
BOM 651 Rotalock connections, terminal box ready for molded plug connection IP66, oil sight
glass, mounting parts for single operation
ZB66K5E to ZB114 K5E, ZF25K5E to ZF54 K5E:
BOM 567 Rotalock connections, terminal box IP54, oil sight glass, discharge line thermostat,
mounting parts for single operation

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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)
be 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 available at www.climate.emerson.com/en-gb.
Compressors
ZB*KCE
ZB*K5E
ZF*K5E
50K, 58K, 66K, 76K,
95K, 114K
66K, 76K, 95K, 114K
25K, 34K, 41K, 49K, 54K
Qualified
refrigerants
R404A, R407A, R407F,
R448A, R449A, R134a
R404A, R407A, R407F,
R448A, R449A
R22
R407C
Copeland™brand
products standard
oil
Emkarate RL 32 3MAF
Servicing oils
Emkarate RL 32 3MAF, Mobil EAL Arctic 22 CC
Table 1: Qualified refrigerants and oils
2.4.2 Comparison between ZB*KCE and ZB*K5E compressors
ZB*KC and ZB*K5 models are based on the same compressor platform, but there are slight
differences. Table 2 hereunder explains the differences and similarities between ZB*KCE and
ZB*K5E models:
Equipment
ZB*KCE compressors
ZB*K5E compressors
Suction and discharge
connections
Rotalock
Rotalock,
raised suction fitting
Oil connections
Oil sight glass and Schraeder oil valve
Electrical connection
Traditional (3 screws)
Option = Molded plug
Traditional (3 screws)
Terminal box protection
class
IP21 (standard)
IP66 (with molded plug)
IP54 (standard)
Motor protection
Klixon internal protection
Discharge temperature
protection
ASTP
External thermostat
Table 2: Differences and similarities between ZB*KCE and ZB*K5E models
2.4.3 Application limits
CAUTION
Inadequate lubrication! Compressor breakdown! The superheat at the
compressor suction inlet must always be sufficient to ensure that no refrigerant
droplets enter the compressor. For a typical evaporator-expansion valve
configuration a minimum stable superheat of at least 5K is required.
The application envelopes for the refrigeration Scroll compressors with various refrigerants can
be found in Copeland brand products Select software available at www.climate.emerson.com/en-
gb.

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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. Respect stacking loads according to Figure 1. Check the
tilting stability and if needed take action to ensure the stability of the stacked
loads. Keep the packaging dry at all times.
Respect the maximum number of identical packages which may be stacked on one
another, where "n" is the limiting number:
▪Transport: n = 2
▪Storage: n = 3
Figure 1: Maximum stacking loads for transport and storage
3.1.2 Positioning and securing
IMPORTANT
Handling damage! Compressor malfunction! Only use the lifting eyes
whenever the compressor requires positioning. Using discharge or suction
connections for lifting may cause damage or leaks.
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.
For all models the suction connection plug must be left in place until the compressor is set into the
unit otherwise oil might spill out of the suction connection located low on the shell.
The compressor plugs must be removed as late as possible before brazing so that the air humidity
does not affect the oil characteristics.
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 as 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 for the grommet not to be compressed.
If the compressors are mounted in tandem or used in parallel, then the hard mountings (bolt
M9 5/16") are recommended. The mounting torque should be 27 ± 1 Nm. It is possible to deliver
these hard-mounting parts as a kit. See Emerson spare parts software for reference.

6 C6.2.27/0716-0219/E
Mounting parts ZB50K* to ZB114K* and ZF25K* to ZF54K* - Soft mountings
Figure 2: Mounting parts
3.2 Brazing procedure
IMPORTANT
Blockage! Compressor breakdown! Maintain a flow of oxygen-free nitrogen
through the system at very low pressure during brazing. Nitrogen displaces the
air and prevents the formation of copper oxides in the system. If allowed to
form, the copper oxide material can later be swept through the system and
block screens such as those protecting capillary tubes, thermal expansion
valves, and accumulator oil return holes.
Contamination or moisture! Bearing failure! Do not remove the plugs until
the compressor is set into the unit. This minimises any entry of contaminants
and moisture.
Copeland Scroll compressors have copper-plated steel
suction, injection and discharge tubes. These tubes are far
more robust and less prone to leaks than copper tubes. Due
to the different thermal properties of steel and copper,
brazing procedures may have to be changed from those
commonly used.
Refer to Figure 3 and procedure below for the brazing of the
suction and discharge lines to a scroll compressor.
▪The copper-coated steel tubes on scroll compressors can be brazed in approximately the
same manner as any copper tube.
▪Recommended brazing materials: any Silfos material is recommended, preferably with a
minimum of 5% silver. However, 0% silver is acceptable.
▪Be sure tube fitting inner diameter and tube outer diameter are clean prior to assembly.
▪Using a double-tipped torch, apply heat in area 1.
▪As the tube approaches brazing temperature, move the torch flame to area 2.
▪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.
Figure 3: Suction tube brazing areas

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3.3 Shut-off valves and adaptors
CAUTION
Leaking system! System breakdown! It is strongly recommended to
periodically re-torque all pipe and fixing connections to the original setting after
the system has been put into operation.
Figure 4
Copeland Scroll compressors are delivered with a discharge check valve fitted inside the
discharge port and rubber plugs fitted to the suction and discharge ports as standard. There are
options to fit either Rotalock valves, or Rotalock adaptors. Using either straight or angled adaptors
provides a way to convert a Rotalock into a brazing connection.
Refer to Table 4 hereunder for proper tightening torques:
Torque [Nm]
Rotalock 1 ¼" –12 UNF
100 –110
Rotalock 1 ¾" –12 UNF
170 - 180
Table 3
NOTE: More information about adaptors and shut-off valves can be found in the "Spare
parts list" available at www.climate.emerson.com/en-gb.
3.4 Suction 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 an accumulator is dependent on the application. If an
accumulator must be used, the oil-return orifice should be 2.0 mm in diameter for all models.
The size of the accumulator depends upon the operating range of the system and the amount of
sub-cooling and subsequent head pressure allowed by the refrigerant control.