Emerson Copeland Scroll ZPV066 Manual

© 2017 Emerson Climate Technologies, Inc.
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TABLE OF CONTENTS
Safety
Safety Instructions............................................... 2
Safety Icon Explanation ....................................... 2
Instructions Pertaining to Risk of Electrical
Shock, Fire, or Injury to Persons .......................... 3
Safety Statements................................................ 3
Introduction
Product Description.............................................. 4
Compressor Data................................................. 4
Power Supply ...................................................... 4
Nomenclature...................................................... 4
Agency Approvals................................................ 4
OEM Lab Testing.................................................... 4
Modeling System Performance ............................ 4
Compressor Design Features................................ 4
Compressor Motor............................................... 4
Oil Pump.............................................................. 4
Application Considerations
Compressor Temperature Protection.................... 5
Variable Speed Drive Options
Third Party Drive.................................................. 5
Emerson EVC Drive Features
Oil Boost.................................................... 5
Motor Protection......................................... 5
Missing Phase Protection........................... 5
Short Cycle Protection................................ 5
Resonance Avoidance Feature .................. 5
Discharge Temperature Protection............. 5
Emerson EVC Operating Envelope ............ 5
Emerson EVC Starting and
Stopping Routine ....................................... 5
Other Features........................................... 5
Emerson EVC Drive and Variable Speed
Scroll Set-Up ....................................................... 6
Refrigerant........................................................... 6
Operating Envelope............................................. 6
High Pressure Control.......................................... 6
Low Pressure Control .......................................... 6
Discharge Temperature Protection....................... 6
Motor Overload Protection ................................... 7
Oil Type............................................................... 7
Maximum Tilt Angle ............................................. 7
Contaminant Control............................................ 7
Refrigerant Piping.................................................7
Long Pipe Lengths / High Refrigerant Charge.......7
Discharge Check Valve........................................8
Suction and Discharge Tube Design.....................8
Compressor Mounting..........................................8
Discharge Mufflers ...............................................8
Airborne Sound Control........................................8
Expansion Devices...............................................9
Reversing Valves .................................................9
Accumulators .......................................................9
Off-Cycle Migration Control...................................9
Manifolded Compressors.....................................10
Manifolded Applications.......................................10
Application Tests...................................................11
General Application Tests....................................11
Assembly Line Procedures
Installing the Compressor....................................11
Assembly Line Brazing Procedure.......................11
Pressure Testing.................................................11
Assembly Line System Charging Procedure........11
High Potential Testing .........................................12
Final Run Test.....................................................12
Unbrazing System Components ..........................12
Service Procedures...............................................12
Electrical Troubleshooting ...................................12
Troubleshooting Motor Temperature Trip.............13
Compressor Replacement After a Motor Burn......13
Start-Up of a New or Replacement Compressor ..13
Figures & Tables
Compressor Nomenclature..................................14
EV Nomenclature................................................14
Oil Dilution Chart.................................................15
Scroll Suction Tube Brazing.................................16
How a Scroll Works.............................................17
Discharge Thermistors ........................................18
Cross Sectional View...........................................18
Electrical Nomenclature for Multiples ..................19
Start Up & Shut Down Procedure ........................20
Compressor Accessories & Service Parts............21
Compressor Motor Specifications........................22
Emerson Compressor & Drive Selection..............22
Compressor Refrigerant Charge Limits Table......23
Speed Adjustment Requirements ........................23
AE4-1414
May 2017
ZPV066 & ZPV096 Copeland Scroll™Variable Speed Compressors

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Safety Instructions
Copeland Scroll™ compressors are manufactured according to the latest U.S. and European Safety
Standards. Particular emphasis has 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 3. These
instructions should be retained throughout the lifetime of the compressor. You are strongly advised
to follow these safety instructions.
SafetyIconExplanation
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation
which, 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.
DANGER
WARNING
CAUTION
NOTICE
CAUTION

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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
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 by qualified electrical personnel.
•Failure to follow these warnings could result in serious personal injury.
WARNING
PRESSURIZED SYSTEM HAZARD
•System contains refrigerant and oil under pressure.
•Remove refrigerant from both the high and low compressor side before
removing compressor.
•Never install 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 these warnings could result in serious personal injury.
WARNING
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 these warnings could result in serious personal injury or
property damage.
CAUTION
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 codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.

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INTRODUCTION
This bulletin provides instructions on how to apply a
Copeland Scroll™variable speed compressor in a safe
and reliable manner. The Copeland Scroll variable
speed compressor will be referred to throughout this
bulletin as the 'variable speed scroll' or the
'compressor.'
Product Description
ZPV066 and ZPV096 variable speed compressors are
intended for use in commercial air conditioning, chiller,
and heat pump applications. The variable speed scrolls
utilize three-phase brushless permanent magnet
(BPM) motors. The compressors have been qualified
for use with Emerson™EVC Drives which have been
developed and qualified for BPM motor-compressors.
The Emerson drives offer the highest level of
compressor protection through the use of CoreSense™
protection algorithms. If use of a non-Emerson drive is
desired, please work with Application Engineering to
select an appropriate drive for the compressor
application. See Third Party Drive requirements on
the following page.
Compressor Data
Compressor mechanical, electrical, and performance
data are available online in Online Product Information
at Emerson.com/OPI. From this site, compressor
drawings (PDF format) can be downloaded. Other
drawing formats (IGES, DXF, and STP) can be
obtained by contacting your Application Engineer.
Other performance data available to the system
designer includes sound, vibration, and coefficient data
for the polynomial equation used to represent tabular
performance data.
Power Supply
The compressor and drive are an integral and
optimized combination. The drive will convert the input
voltage into a variable frequency and voltage to power
the compressor. For more information on the drive
power input requirements please see the Emerson
EVC Drive user guide.
Ensure correct wiring at both the compressor and drive
connections prior to starting the compressor to avoid a
mis-wire or powered reverse situation. These situations
may cause compressor damage.
The variable speed compressor must be paired
with the appropriate variable speed drive. Do not
connect the power supply directly to the
compressor.
Nomenclature
The model number of the variable speed scroll
includes the approximate displacement in cubic
centimeters per revolution. Figure 1 provides a
complete explanation of all of the alpha and numeric
characters in the compressor model number.
Agency Approval
ZPV066 and ZPV096 compressors are U.L. recognized
in file SA2337, Volume 22. When the compressor is
used with the Emerson EVC, the compressor and drive
are a U.L. listed 508C package. The package is listed
in file SA2337, Volume 22.
OEM LAB TESTING
Application Engineering should be consulted during the
design, development, and production launch of the
variable speed system to help ensure that the variable
speed scroll is applied as intended, in a safe and
reliable manner.
Modeling System Performance
Modeling at any speed range in the approved envelope
is facilitated by 20 coefficient data available from
Application Engineering.
COMPRESSOR DESIGN FEATURES
The variable speed scroll has a number of design
features that improve efficiency and reliability. Figure 7
shows the internal features that are unique to the
variable speed scroll.
Compressor Motor
The brushless permanent magnet (BPM) motor in the
variable speed scroll consists of a three-phase stator
and a rotor embedded with high energy permanent
magnets. The input voltage is a series of pulses of
varying frequency at 120 degree intervals between
phases.
Oil Pump
The variable speed scroll is equipped with an oil pump
to ensure an adequate supply of oil to the bearing
system throughout the operating speed range.

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APPLICATION CONSIDERATIONS
Compressor Temperature Protection
A discharge line thermistor must be used to protect the
compressor. The drive will shut down the compressor
when the thermistor temperature exceeds 275°F
(135°C). Please see the section Troubleshooting
Scroll Temperature Trip for more information on the
discharge line thermistor. Refer to Table 1 for more
information.
Variable Speed Drive Options
Third Party Drive
The customer may use a third party drive. A third
party control system must include: a discharge line
thermistor that will signal the drive to shut down if the
temperature exceeds 275°F (135°C), a soft start and
stopping routine, an oil boost cycle similar to the
Emerson EVC oil boost, and include the operating
envelope. A third party drive must include short cycle
protection similar to the Emerson EVC short cycle
protection. Refer to Table 2 for compressor motor
specifications and Table 5 for speed adjustment
requirements.
Emerson EVC Drive Features
It's recommended that the Emerson variable speed
drive (VSD) be used with the variable speed
compressor. The Emerson VSD has custom built in
features that may improve the longevity of the
compressor and efficiency of the system. Refer to
the Emerson EVC Drive user guide for more
information.
Oil Boost
The Emerson EVC drive includes an oil boost cycle
when the compressor operates at less than 1800
RPM. The oil boost cycle starts once the
compressor operates for two hours at less than
1800 RPM. During the oil boost cycle, the drive
forces the compressor to run for five minutes at
3600 RPM. After operating for five minutes at 3600
RPM, the drive allows the compressor to operate
at less than 1800 RPM. The operating envelope
shows the operating conditions of the oil boost
cycle.
Motor Protection
The Emerson EVC drive includes motor protection
features for the compressor. The drive sets the
maximum current limit, low voltage fold back which
allows the compressor to ride through low voltage
situations, which helps keep the compressor
running to avoid nuisance trips. The drive also
includes lost rotor avoidance and locked rotor
detection. The lost rotor avoidance uses a custom
algorithm to evade a speed error by reducing the
speed by 200 RPM to 're-catch' the rotor.
Missing Phase Protection
The Emerson EVC drive includes compressor
missing phase protection. The drive checks for a
missing phase connection.
Short Cycle Protection
The Emerson EVC drive includes short cycling
protection which checks the duration of the runtime
and quantity of short cycles. The amount of
runtime and the maximum allowable short cycles in
24 hours is adjustable. The default maximum short
cycles in 24 hours is four. The default short cycle
time is five minutes.
Resonance Avoidance Feature
The Emerson EVC drive includes a resonance
avoidance feature which has the ability to skip a
single frequency or a range of frequencies.
Discharge Temperature Protection
The thermistor will signal the drive to shut down if
the temperature exceeds 275°F (135°C).
Emerson EVC Operating Envelope
When using the Emerson EVC drive, the
compressor is designed to operate within the
requirements of the operating envelope.
Emerson EVC Starting and Stopping Routine
The drive controls the starting and stopping routine
of the variable speed scroll. This routine allows soft
starting and controlled stopping, an advantage
over traditional on-off control of fixed capacity
units. Please refer to the Emerson EVC drive user
guide for an exact explanation of the starting and
stopping process.
The variable speed scroll compressor incorporates
a fluid brake design to help mitigate reverse
rotation during shutdown. A momentary reverse
rotation sound may be heard. Refer to Table 5 for
more information.
Other Features
Refer to the Emerson EVC drive user guide for
more features and functions of the drive.

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Emerson EVC Drive and Variable Speed
Scroll Set-Up
A quick start guide is available with the Emerson EVC
drive. Application Engineering is available to assist
during any part of this process.
Refrigerant
ZPV066 and ZPV096 compressors are approved for
use with R-410A only. Use of refrigerants other than R-
410A voids the UL recognition of these compressor
models since the motor overload system could be
adversely affected.
Operating Envelope
The compressor operating envelope at each speed
represents the allowable range of operating
conditions for the compressor at the superheat and
subcooling values defined on the envelope. The most
current and updated operating envelopes can be
accessed in Online Product Information at
Emerson.com/OPI. Contact Application Engineering
if desired to operate at different speeds than
published in the operating envelope.
Operating the compressor at evaporating
temperatures that are higher than those specified in
the envelopes for the given speed will result in a
higher oil circulation rate. A higher oil circulation rate
can reduce heat exchanger efficiency and possibly
result in oil pump-out if the system has long
interconnecting piping. Customers that choose to
operate in these higher evaporating temperature
areas should use a compressor sample with a sight-
tube during system development testing to ensure
that an adequate level of oil is maintained in the
compressor sump. Sight-tubed compressors for
monitoring the oil level are available by contacting
Application Engineering.
The lower right boundary of the operating envelope is
the minimum compression ratio required to keep the
scrolls loaded. Operation below this boundary could
result in the compressor intermittently loading and
unloading and noisy operation.
The upper left boundary of the envelope represents
the maximum compression ratio when operating with
20F° (11°C) suction superheat. If the operating
condition approaches this boundary of the envelope
the compressor discharge temperature will begin to
approach the maximum scroll temperature allowed by
the discharge line thermistor.
If operating the compressor below 1800 RPM, an oil
boost cycle is required. Refer to the note in the
operating envelope.
For applications where the voltage is below the rated
minimum voltage, the drive speed may be limited. The
limitation may also be affected by the ambient
temperature.
High Pressure Control
A high pressure control must be used in all
applications.
A high pressure control must be used with these
compressors since they do not employ an internal
pressure relief valve (IPR). The maximum cut-out
setting must not exceed 650 psig (45 bar). The switch
should be wired in series with the unit contactor to
immediately stop compressor operation if there is a
high pressure event. The high pressure control should
have a manual reset feature for the highest level of
system protection. If an auto reset high pressure
control is used, the compressor should be locked out
after three consecutive trips. If a pressure transducer is
used to protect against high discharge pressure events
the transducer and control logic should comply with
U.L. and/or local safety requirements.
Low Pressure Control
A low pressure control is required to protect against
loss of charge and other system fault conditions that
can lead to compressor overheating. A low pressure
cut-out switch located in the suction line with a cut-out
setting no lower than 20 psig (1.4 bar) is required in all
heat pump applications. For air conditioning units, a
cut-out setting no lower than 55 psig (3.8 bar) will
adequately protect against most low pressure faults. A
higher level of protection for air conditioning units can
be realized if the cut-out setting is increased to 95 psig
(6.6 bar) to prevent evaporator coil icing.
Discharge Temperature Protection
Compressor top cap temperatures can be very hot.
Care must be taken to ensure that wiring or other
materials which could be damaged by these
temperatures do not come into contact with these
potentially hot areas.
ZPV066 and ZPV096 compressors do not have an
internal discharge gas temperature protection. In order
for the variable speed drive to operate properly a
thermistor should be attached to the compressor
discharge line as close as possible and less than 6''
(15cm) from the compressor discharge fitting. The
thermistor is designed for a 7/8" (22 mm) line and

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should be properly insulated. See Table 6 of AE-1328
for thermistor temperature vs resistance values. Refer
to Table 1 for part numbers of discharge line
thermistors. Figure 6 illustrates the discharge
thermistor.
Motor Overload Protection
The drive will provide motor over current protection in
the event the compressor becomes mechanically
locked or if the load on the compressor motor is
abnormally high. The input power supply to the drive
must be properly fused.
Oil Type
The variable speed scrolls are charged with polyolester
(POE) oil. See the compressor nameplate for the
original oil charge. A complete recharge should be
approximately four fluid ounces (118cc) less than the
nameplate value. Copeland™Ultra 32-3MAF, available
from Emerson Wholesalers, should be used if
additional oil is needed in the field. Mobil Arctic
EAL22CC, Emkarate RL22, Emkarate 32CF and
Emkarate 3MAF are acceptable alternatives.
CAUTION! POE oil must be handled carefully and
the proper protective equipment (gloves, eye
protection, etc.) must be used when handling POE
lubricant. POE must not come into contact with
any surface or material that might be harmed by
POE, and spills should be cleaned up quickly with
paper towels, soap and water.
Maximum Tilt Angle
Applications, such as transportation air conditioning or
mobile radar applications, may require the compressor
to operate at some angle from vertical. Service
personnel may be required to maneuver a unit through
a stairwell or other cramped area that might require
tilting the unit. The maximum allowable tilt angles from
horizontal for individual compressors (not tandem or
trio applications) are summarized below:
Max. tilt angle with compressor running = 15°
Max. tilt angle with compressor not running = 60°
Contaminant Control
Copeland Scroll™compressors leave the factory with a
miniscule amount of contaminants. Manufacturing
processes have been designed to minimize the
introduction of solid or liquid contaminants.
Dehydration and purge processes ensure minimal
moisture levels in the compressor and continuous
auditing of lubricant moisture levels assure that
moisture isn’t inadvertently introduced into the
compressor.
Moisture levels should be maintained below 50 ppm for
optimal performance. A filter-drier is required on all
R-410A and 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 the filter-drier is adequately
sized to accommodate the contaminants from system
manufacturing processes that leave solid or liquid
contaminants in the evaporator coil, condenser coil,
and 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.
Refrigerant Piping
Particular attention must be given to the system
refrigerant pipe size with the variable speed scrolls.
ASHRAE guidelines for pipe sizing should be followed
to ensure that refrigerant velocities are high enough at
low speeds to ensure oil return to the compressor. At
the same time, high refrigerant velocities at high speed
operation can result in excessive pressure drop and
loss of system efficiency. A careful evaluation and
compromise in pipe sizing will likely have to be settled
upon. A compressor sample with a sight-tube for
monitoring the oil level should be used during system
development to ensure an adequate oil level is
maintained at operating conditions and speeds.
If testing shows a gradual, continuous loss of oil in the
compressor sight-tube over long run cycles at low
speed, an oil boost cycle should be incorporated into
the system logic. An oil boost cycle is accomplished by
ramping the compressor speed up to a higher speed to
increase the refrigerant flow rate to flush or sweep oil
back to the compressor. Frequency and duration of a
recovery cycle depends on many variables and would
have to be determined through testing for each system
type and configuration. A default method could be to
initiate a recovery cycle at regular intervals.
Long Pipe Lengths / High Refrigerant Charge
Some system configurations may contain higher-than-
normal refrigerant charges either because of large
internal coil volumes or long line sets. If such a system
also contains an accumulator then the permanent loss
of oil from the compressor may become critical. If the
system contains more than 20 pounds (9 kg) of
refrigerant, it is our recommendation to add one fluid
ounce of oil for every 5 pounds (15 ml/kg) of refrigerant

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over this amount. If the system contains an
accumulator the manufacturer of the accumulator
should be consulted for a pre-charge recommendation.
Other system components such as shell and tube
evaporators can trap significant quantities of oil and
should be considered in overall oil requirements.
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 out of 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 compressor oil
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
production sight-glass that can be used to determine
the oil level in the compressor in the end-use
application. These compressors are 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 is not sustainable in the compressor and the
extra oil will be pumped out into the system
causing a reduction in system efficiency and a
higher-than-normal oil circulation rate.
Discharge Check Valve
ZPV066 and ZPV096 compressors use a shutdown
valve located in the discharge fitting. This check valve
is not a low-leak-back check valve and will leak when
pressure differential across the check valve is low.
Suction and Discharge Tube Design
Proper tube design must be taken into consideration
when designing the tubing connecting the variable
speed scroll to the system. The tubing should provide
enough 'flexibility' to allow normal starting and stopping
of the compressor without exerting excessive stress on
the tube joints.
Because the variable speed scroll has a broad
mechanical running frequency range, it will be almost
impossible to avoid all of the natural frequencies that
may exist in the system piping. The system designer
must carefully evaluate these resonant frequency
conditions and either a) avoid them by not allowing the
compressor speed to align with the resonant
frequency, or b) evaluate the risk and life of the piping
system when the compressor is allowed to run at
frequencies that are coincident with natural frequencies
of the piping system. To do part 'b', strain gauging the
system piping is required. For assistance in evaluating
strain gauging results contact Application Engineering.
In order to properly determine if a design is appropriate
for a given application, samples should be tested and
evaluated for stress under various conditions of use
including frequency, load fluctuations, and shipping
vibration. The guidelines above may be helpful;
however, testing should be performed for each system
designed. For further assistance and analysis of test
results please contact Application Engineering.
Compressor Mounting
ZPV066 and ZPV096 compressors have pierced holes
in the mounting feet so mounting grommets with a
relief are not required. Table 1 lists the recommended
mounting parts. It is extremely important to use the
correct durometer grommet and to have consistent
durometer quality. Wrong or inconsistent durometer of
the mounting grommets can result in sound and
vibration complaints. For additional information on
grommet durometer please consult with Application
Engineering.
Discharge Mufflers
For a variable speed compressor, discharge pulse will
generally decrease as speed increases or if
compression ratio decreases. As speed decreases or if
compression ratio increases the discharge pulse will
increase. Fixed capacity or two-step capacity units
have typically had discharge gas pulsation mufflers
only in heat pump applications. A variable capacity
heat pump and/or air conditioner may both require a
discharge gas pulsation muffler. Discharge pulse
amplitude and frequency and their effects on the piping
system must be taken into account. If testing
determines that a muffler is needed to attenuate
discharge pulse, a hollow shell muffler such as the
Emerson Flow Controls APD164S must be used.
The mufflers should be located a minimum of six
inches (15 cm) to a maximum of 18 inches (46cm) from
the compressor for most effective operation. The
farther 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.
Airborne Sound Control
In addition to structure and gas borne sound
transmission, special consideration needs to be given to
compressor airborne sound. A-weighted, steady-state
sound data is available from Application Engineering.
Sound data is also available at the nominal cooling
condition of 50°F (10°C) evaporating and 115°F (46°C)

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condensing at 5400 RPM. If airborne sound attenuation
is required for the application, Fabricating Services
(www.fabsrv.com) is one manufacturer of custom sound
solutions
Expansion Devices
The expansion device is a crucial component of the
variable capacity system. Fixed-orifice devices, which
are chosen or optimized at one particular operating
condition, will not have the ability to control the
refrigerant flow across a wide range of operating
pressures and flow rates required by the variable
capacity system.
To better control superheat, an electronic expansion
valve (EXV) is recommended. Electronic expansion
valves have the ability to more precisely control
superheat at lower settings over a wider operating
range than a TXV. They also have the capability to be
driven completely closed during the off-cycle,
minimizing off-cycle migration.
Regardless of which expansion device is used, the
manufacturer's recommendations on the application of
the valve should be followed in all cases.
Reversing Valves
A variable speed scroll has a real advantage during the
defrost cycle. By taking advantage of the higher
speeds and flow rates, defrost time will typically be
shorter than a system with a fixed or two-step capacity
compressor. This reduces the time heat is required
during the defrost cycle.
CAUTION Reversing valve sizing must be 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. Conditions that result in low flow rates and
low pressure drop across the valve can result in a
valve not shifting. This can result in a condition
where the compressor appears to be not pumping
(i.e. balanced pressure). It can also 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 operating envelope.
The condition will usually cross the diagonal line
representing the lower right hand corner of the
envelope. The sound that the compressor makes
during this transition period is normal, and the duration
of the sound will depend on the coil volume, outdoor
ambient, and system charge.
The reversing valve solenoid should be wired so that
the valve does not reverse when the system is shut off
by the operating thermostat in the heating or cooling
mode. If the valve is allowed to reverse at the system
shutoff, suction and discharge pressures are reversed
to the compressor. This will result in pressures
equalizing through the compressor which can cause
the compressor to slowly rotate backwards until the
pressures equalize. This condition does not affect the
compressor durability but can cause unexpected sound
after the compressor is turned off.
Accumulators
The use of accumulators is very dependent on the
application. The variable speed scroll has an inherent
ability to handle liquid refrigerant during occasional
operating flood back situations. Systems designed
with EXV or TXV refrigerant control 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 conditions and
to determine if the accumulator or EXV/TXV design is
adequate, please see the Application Tests section.
A large-area protective screen no finer than 30x30
mesh is required to protect this small orifice 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 amount of system refrigerant charge.
System modeling indicates that heat pumps that
operate 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 the beginning and end of the defrost
cycle should be assessed during system
development. This will require special accumulators
and compressors with sight tubes and/or sight
glasses for monitoring refrigerant and oil levels.
Off-Cycle Migration Control
Off-cycle migration control is important for long term
compressor reliability and to minimize nuisance
complaints associated with flooded start conditions.
Off-cycle migration control is recommended when the
system charge exceeds 15.0 lbs (7 kg). Off-cycle
migration control is required when the system charge
exceeds 18 lbs (8 kg). In lieu of using a conventional
wrap-around crankcase heater, the drive has a
programmable feature that will utilize the motor
windings.

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If off-cycle migration control is required, and no off-
cycle migration testing across the range of expected
indoor/outdoor temperatures is performed, the stator
heater must be powered to at least 100 Watts when
the compressor is 'off'. To use fewer than 100 Watts
or to comply with future DOE requirements for off-
cycle power consumption, off-cycle migration testing
must be performed. A 70 watt crankcase heater may
be used instead of the motor windings to provide heat
to the base.
CAUTION Stator heat for off-cycle migration must
not be energized when the system is in a vacuum
or if there is no refrigerant charge in the system.
The system low pressure cut-out control can be
used as an indicator of the presence of refrigerant
charge.
Manifolded Compressors
Multiple compressor assemblies are available for
purchase from Emerson. In lieu of purchasing the
assembled manifold, the OEM can choose to
purchase the manifold-ready compressor and perform
the assembly in their factory. Drawings of tandem and
trio compressor assemblies are available from
Emerson by contacting your Application Engineer.
NOTICE: Customers who choose to design and
build their own manifolds for tandem and trio
compressor assemblies are ultimately
responsible for the reliability of those manifold
sets.
The suction manifold is close to a symmetrical layout
with the design intent of equal pressure drop to each
compressor. A straight length of pipe is connected to
the suction manifold "T" connection to serve as a flow
straightener to make the flow as uniform as possible.
The discharge manifold is the less critical of the two
manifolds in terms of pressure drop. Low pipe stress
and reliability are its critical design characteristics.
Support for the discharge manifold between the
compressors should be no closer than a straight
distance of 14" (356 mm) from the discharge tee.
For tandem compressor applications, tubing stress
levels should be closely evaluated. If excess stress
levels occur, the Resonance Avoidance Feature in the
Emerson EVC drive may be used.
Manifolded Applications
Manifolded compressors follow the same application
guidelines as single compressors outlined in this
bulletin. The refrigerant charge limit for manifolded
compressors is shown in Table 4. A manifolded
circuit with charge over the limit must have a
crankcase heater or stator heating applied to both
compressors.
Oil levels in the individual sight-glasses will vary,
depending on whether one or more compressors in
the manifolded set are operating and if the manifolded
set is made up of equal or unequal compressor
capacities. Because of the unequal oil levels that can
exist, oil levels should be viewed with the
compressors off to allow the oil level to stabilize
between the compressor sumps. With the
compressors off, oil should be visible in the individual
compressor sight-glasses.
Suction and discharge manifolds are not designed to
support system piping. Support means must be
provided by the system designer to support suction
and discharge lines so that stress is not placed on the
manifolds.
The compressors in a manifolded set can be
started/stopped in any desired sequence. To help
reduce inrush current, starting the compressors
individually is recommended. Should a compressor
fail in the tandem set the complete tandem should be
removed from the unit and replaced with a new
tandem set. Replacing individual compressors is
discouraged because of the care that must be used
when installing the oil equalization tube and the
availability of manifolds to the aftermarket.
Please consult with Application Engineering
during the development of systems with trio
compressor assemblies. Trio compressor
assemblies are sensitive to system operating
conditions and configurations which will affect oil
balancing. Trio compressor assemblies must be
qualified for each application.
Manifolded compressor assemblies are available for
purchase from Emerson. In lieu of purchasing the
assembled tandem, the OEM has the option to
purchase the tandem-ready compressors to assemble
the compressors into a tandem configuration.
Drawings of the tandem manifolds are available by
contacting your application engineer. Manifold ready
compressors are designated with a -4XX bill of
material number at the end of the model number (e.g.
ZPV0662E-4X9-455). Customers that choose to
design and build their own manifolds for tandem
and trio compressors are ultimately responsible
for the reliability of those manifold sets.

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APPLICATION TESTS
New system designs should be evaluated throughout
the entire expected operating range of the unit to
ensure the system will perform reliably throughout the
life of the product. Test data, taken throughout the
operating range of the unit, should be closely
scrutinized to help identify gross errors in system
design that may produce conditions that could lead to
compressor failure.
General Application Tests
In addition to the tests outlined above, off-cycle
migration tests are recommended if the system
charge amount exceeds 11 pounds (7 kg) and less
than 100 watts of the stator heat option is selected.
The purpose of the off-cycle migration test is to
ensure that stator heat is great enough to minimize
off-cycle migration after long compressor 'off' periods.
System faults, such as low or loss of indoor air-flow,
loss of outdoor air-flow, and low/overcharge
conditions should all be evaluated to ensure the
compressor and service technician are protected
against any adverse condition.
NOTICE The tests outlined above are for common
applications of compressors in this family. Please
consult with Application Engineering on
applications outside of those outlined above for
the appropriate application tests.
ASSEMBLY LINE PROCEDURES
Installing the Compressor
Use care and the appropriate material handling
equipment when lifting and moving compressors.
Personal safety equipment must be used.
Copeland Scroll compressors leave the factory
dehydrated, with a dry air holding charge. If
compressors are stored in a cold ambient (i.e. outside
during the winter), the suction and discharge plugs
should not be removed until the compressor has had
sufficient time to warm up to the plant ambient
temperature. The suggested warm up time is one
hour per 4°F (2°C) difference between outdoor and
indoor temperature. It is suggested that the larger
suction plug be removed first to relieve the internal
pressure. Removing the smaller discharge plug could
result in a spray of oil out of this fitting since some oil
accumulates in the head of the compressor after
Emerson’s run test. The inside of both fittings should
be wiped with a lint free cloth to remove residual oil
prior to brazing. A compressor containing POE oil
should never be left open longer than 20 minutes.
Assembly Line Brazing Procedure
Personal safety equipment must be used during
brazing operation. Heat shields should be used to
prevent overheating or burning nearby
temperature sensitive parts. Fire extinguishing
equipment should be accessible in the event of a
fire.
Figure 4 discusses the proper procedures for brazing
the suction and discharge lines to a scroll
compressor.
NOTICE It is important to flow nitrogen through
the system while brazing all joints during the
system assembly process. Nitrogen displaces the
air and prevents the formation of copper oxides in the
system. If allowed to form, the copper oxide flakes
can later be swept through the system and block
screens such as those protecting capillary tubes,
expansion valves, and accumulator oil return holes.
Any blockage of oil or refrigerant may damage the
compressor resulting in failure.
Pressure Testing
Never pressurize the compressor to more than 475
psig (33 bar) for leak checking purposes. Never
pressurize the compressor from a nitrogen
cylinder or other pressure source without an
appropriately sized pressure regulating and relief
valve.
The pressure used on the line to meet the U.L. burst
pressure requirement must not be higher than 475 psig
(33 bar). Higher pressure may result in permanent
deformation of the compressor shell and possible
misalignment or bottom cover distortion.
Assembly Line System Charging Procedure
Systems should be charged with liquid on the high side
to the extent possible. The majority of the charge
should be pumped in the high side of the system to
prevent low voltage starting difficulties, hipot failures,
and bearing washout during the first-time start on the
assembly line. If additional charge is needed, it should
be added as liquid to the low side of the system with
the compressor operating. Pre-charging on the high
side and adding liquid on the low side of the system
are both meant to protect the compressor from
operating with abnormally low suction pressures during
charging. NOTICE: Do not operate the compressor
without enough system charge to maintain at least
55 psig (3.8 bar) suction pressure. Do not operate

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the compressor with the low pressure cut-out
disabled. Do no operate with a restricted suction or
liquid line. Depending on the discharge pressure,
allowing pressure to drop below 55 psig (3.8 bar) for
more than a few seconds may overheat the scrolls and
cause early drive bearing damage. NOTICE Do not
use the compressor to test the opening set point of
a high pressure cutout. Bearings are susceptible to
damage before they have had several hours of normal
running for proper break in.
'Hipot' (AC High Potential) Testing
Use caution with high voltage and never hipot test
when compressor is in a vacuum.
Copeland Scroll compressors are configured with the
motor down and the pumping components at the top of
the shell. As a result, the motor can be immersed in
refrigerant to a greater extent than hermetic
reciprocating compressors when liquid refrigerant is
present in the shell. In this respect, the scroll is more
like semi-hermetic compressors that have horizontal
motors partially submerged in oil and refrigerant. When
Copeland Scroll compressors are hipot tested with
liquid refrigerant in the shell, they can show higher
levels of leakage current than compressors with the
motor on top. This phenomenon can occur with any
compressor when the motor is immersed in refrigerant.
The level of current leakage does not present any
safety issue. To lower the current leakage reading, the
system should be operated for a brief period of time to
redistribute the refrigerant to a more normal
configuration and the system hipot tested again. See
AE4-1294 for megohm testing recommendations.
Under no circumstances should the hipot test be
performed while the compressor is under a
vacuum.
U.L. sets the requirement for dielectric strength testing
and they should be consulted for the appropriate
voltage and leakage values.
Final Run Test
Customers that use a nitrogen final run test must be
careful to not overheat the compressor. Nitrogen is not
a good medium for removing heat from the
compressor, and the scroll tips can be easily damaged
with high compression ratios and/or long test times.
Copeland Scroll compressors are designed for use
with refrigerant, and testing with nitrogen may result in
a situation where the compressor does not develop a
pressure differential (no pump condition). When testing
with nitrogen, the compressor must be allowed to cool
for several minutes between tests.
Unbrazing System Components
Before attempting to braze, it is important to
recover all refrigerant from both the high and low
side of the system.
If the refrigerant charge is removed from a scroll-
equipped unit by recovering one side only, it is very
possible that either the high or low side of the system
remains pressurized. If a brazing torch is then used to
disconnect tubing, the pressurized refrigerant and oil
mixture could ignite when it escapes and contacts the
brazing flame. Instructions should be provided in
appropriate product literature and assembly (line
repair) areas. If compressor removal is required, the
compressor should be cut out of the system rather than
unbrazed. See Figure 4 for proper compressor
removal procedure.
SERVICE PROCEDURES
The drive offers a two wire 485 interface. This enables
the drive set-up, operation and monitoring to be carrier
out with a PC or controller if required. The drive only
supports Modbus RTU protocol. Refer to the Emerson
EVC drive user guide for more information.
Electrical Troubleshooting
CAUTION The compressor must always have the
green ground wire attached to the ground. The
other end of the green wire must be connected to
the appropriate ground terminal on the drive.
The BPM motors used in the variable speed scrolls are
three-phase. The winding resistance for each
compressor-motor is published in the Online Product
Information. The three windings should always have
line to line continuity because there is no internal
overload at the center of the motor windings to open
and take the motor off-line. If one or more of the
windings shows continuity to ground, the compressor
must be replaced.
CAUTION Energizing a variable speed scroll with a
grounded winding can cause irreversible damage
to the drive.
Measuring the current in the three individual wires
feeding the compressor will provide no useful
information to the service technician, other than to
show that each winding of the compressor is drawing
current. The more appropriate measurement is the

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current input to the drive. Current input to the drive can
be compared to the published values of MCC and RLA.
Compressor Replacement After a Motor Burn
In the case of a motor burn, the majority of
contaminated oil will be removed with the compressor.
The rest of the oil is cleaned with the use of suction
and liquid line filter driers. A 100% activated alumina
suction filter drier is recommended but must be
removed after 72 hours. See AE24-1105 for clean up
procedures and AE11-1297 for liquid line filter-drier
recommendations. NOTICE It is highly
recommended that the suction accumulator be
replaced if the system contains one. This is because
the accumulator oil return orifice or screen may be
plugged with debris or may become plugged shortly
after a compressor failure. This will result in starvation
of oil to the replacement compressor and a second
failure.
Start-Up of a New or Replacement Compressor
It is good service practice, when charging a system
with a scroll compressor, to charge liquid refrigerant
into the high side only. It is not good practice to dump
liquid refrigerant from a refrigerant cylinder into the
crankcase of a stationary compressor. If additional
charge is required, charge liquid into the low side of the
system with the compressor operating. CAUTION Do
not start the compressor while the system is in a
deep vacuum. Internal arcing may occur when any
type of compressor is started in a vacuum. NOTICE
Do not operate the compressor without enough
system charge to maintain at least 55 psig (3.8
bar) suction pressure. Do not operate with a
restricted suction or liquid line. Do not operate
with the low pressure cut-out disabled. Allowing
suction pressure to drop below 55 psig (3.8 bar) for
more than a few seconds may overheat the scrolls
and cause early drive bearing damage. Never install a
system in the field and leave it unattended with no
charge, a holding charge, or with the service valves
closed without securely locking out the system. This
will prevent unauthorized personnel from accidentally
ruining the compressor by operating with no
refrigerant flow.

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Figure 4
Scroll Suction Tube Brazing
New Installations
•The copper-coated steel suction tube 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 suction tube fitting I.D. and suction tube O.D. are clean prior to assembly. If oil film is present wipe with
denatured alcohol, Dichloro-Trifluoroethane or other suitable solvent.
•Using a double-tipped torch apply heat in Area 1. As tube approaches brazing temperature, move torch flame to
Area 2.
•Heat Area 2 until braze temperature is attained, moving torch up and down and rotating around tube as
necessary to heat tube evenly. Add braze material to the joint while moving torch around joint to flow braze
material around circumference.
•After braze material flows around joint, move 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.
Field Service
Remove refrigerant charge from both the low and high side of the compressor before cutting the suction
and discharge lines to remove the compressor. Verify the charge has been completely removed with
manifold gauges.
•To disconnect: Reclaim refrigerant from both the high and low side of the system. Cut tubing near compressor.
•To reconnect:
Recommended brazing materials: Silfos with minimum 5% silver or silver braze material with flux.
Insert tubing stubs into fitting and connect to the system with tubing connectors.
Follow New Installation brazing

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Figure 9
Start Up Procedure
Figure 10
Shut Down Procedure