Emerson Copeland Scroll ZR18K Series Instruction Manual

Scroll compressors
for air conditioning
pA p i
lcait o i
uG
nden
i
l es
ZR18K* to ZR380K*
ZP23K* to ZP385K*

C6.2.19/0507-0708/E
1 Safety instructions ............................................................................................ 1
1.1 Icon explanation .................................................................................................................1
1.2 Safety statements ..............................................................................................................1
1.3 General instructions ...........................................................................................................2
2 Product description .......................................................................................... 2
2.1 Common information about Copeland Scroll compressors............................................2
2.2 About this guideline............................................................................................................2
2.3 Nomenclature..................................................................................................................... 2
2.4 Application range ...............................................................................................................3
2.4.1 Qualified refrigerants and oils ................................................................................3
2.4.2 Application limits.....................................................................................................3
3 Installation ......................................................................................................... 4
3.1 Compressor handling.........................................................................................................4
3.1.1 Transport and storage ............................................................................................4
3.1.2 Positioning and securing ........................................................................................4
3.1.3 Installation location................................................................................................. 5
3.1.4 Mounting parts........................................................................................................5
3.2 Brazing procedure..............................................................................................................5
3.3 Shut-off valves and adaptors .............................................................................................6
3.4 Accumulators .....................................................................................................................7
3.5 Mufflers ..............................................................................................................................8
3.6 Reversing valves................................................................................................................8
3.7 Suction line noise and vibration .........................................................................................9
4 Electrical connection ...................................................................................... 10
4.1 General recommendations...............................................................................................10
4.2 Electrical installation ........................................................................................................10
4.2.1 Terminal box.........................................................................................................10
4.2.2 Motor winding .......................................................................................................10
4.2.3 Protection devices ................................................................................................ 11
4.2.4 Crankcase heaters ...............................................................................................11
4.3 Pressure safety controls ..................................................................................................11
4.3.1 High-pressure control ...........................................................................................11
4.3.2 Low-pressure control............................................................................................11
4.4 Discharge temperature protection ...................................................................................12
4.5 Motor protection ...............................................................................................................13
4.6 Protector functional check and failure detection..............................................................14
4.7 High-potential testing .......................................................................................................14
5 Starting up & operation................................................................................... 15
5.1 Strength pressure test......................................................................................................15
5.2 Tightness/pressure test....................................................................................................15

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5.3 Preliminary checks – Pre-starting ....................................................................................15
5.4 Charging procedure .........................................................................................................16
5.5 Rotation direction .............................................................................................................16
5.6 Starting............................................................................................................................. 16
5.7 Deep vacuum operation...................................................................................................16
5.8 Shell temperature.............................................................................................................17
5.9 Pump down cycle.............................................................................................................17
5.10 Minimum run time ............................................................................................................ 17
5.11 Shut-off sound..................................................................................................................17
5.12 Excessive liquid flood-back tests .....................................................................................17
6 Maintenance & repair ...................................................................................... 18
6.1 Exchanging the refrigerant...............................................................................................18
6.2 Rotalock valves................................................................................................................18
6.3 Replacing a compressor ..................................................................................................18
6.3.1 Compressor replacement .....................................................................................18
6.3.2 Start-up of a new or replacement compressor .....................................................19
6.4 Lubrication and oil removal..............................................................................................19
6.5 Unbrazing system components .......................................................................................20
7 Dismantling & disposal................................................................................... 20

C6.2.19/0507-0708/E 1
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 EC Machines
directive. 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 on request.
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.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.
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2 C6.2.19/0507-0708/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.
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.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.
2 Product description
2.1 Common information about Copeland Scroll 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.
This application guideline deals with all vertical single Copeland Scroll compressors for
air conditioning and heat pump applications, from ZR18K* to ZR380K* and from ZP23K* to
ZP385K*. These 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.
2.2 About this guideline
This guideline is intended to enable users to ensure the safe installation, starting, operation and
maintenance of the Scroll compressors.
This guideline is not intended to replace the system expertise available from system
manufacturers.
2.3 Nomenclature
The model designation contains the following technical information about the compressor:
ZR 380K C E - TWD - 522
Oil type:
E = POE oil; Blank = Mineral oil
Nominal capacity [BTU/h] @ 60 Hz and ARI conditions
Refrigerant(s):
R = R407C, R134a, R22
P = R410A
Model variation
Compressor family: Z = Scroll
Motor version
Bill of material number

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*ARI-Conditions:
Evaporating temperature 7.2°C Liquid sub-cooling 8.3 K
Condensing temperature 54.4°C Ambient temperature 35°C
Suction gas superheat 11 K
2.4 Application range
2.4.1 Qualified refrigerants and oils
IMPORTANT
It is essential that the glide of refrigerant blends (primarily R407C) is
carefully considered when adjusting pressure and superheat controls.
Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland®
Brand Products Selection Software.
Qualified Refrigerants R22 R407C, R134a, R22 R410A
Copeland Standard Oil White oil / Suniso 3
GS ICI Emkarate RL 32 3MAF
ICI Emkarate RL 32 3MAF
Servicing Oil Suniso 3 GS
White oil Mobil EAL Arctic 22 CC
Table 1
2.4.2 Application limits
ZR18K* to ZR81K* ZR94K* to ZR190K* ZR250K* to ZR380K*
25
30
35
40
45
50
55
60
65
70
-25 -20 -15 -10 -5 0 5 10 15 20
Evaporating Temperature to (oC)
Condensing Temperature tc (
o
C)
R407C
Dew point
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25
Evaporating Temperature to (oC)
Condensing Temperature tc (
o
C)
R407C
Dew point
ZR144
20
25
30
35
40
45
50
55
60
65
70
75
-30 -25 -20 -15 -10 -5 0 5 10 15 20
Evaporating Temperature to (oC)
Condensing Temperature tc (
o
C)
R407C
Dew point
10K Suction Superheat
25
o
C Suction Gas Return
Figure 1: Application envelopes for compressors ZR18K* to ZR380K* with R407C
ZP23K* to ZP83K* ZP90K* to ZP137K*
20
25
30
35
40
45
50
55
60
65
70
-30 -25 -20 -15 -10 -5 0 5 10 15 20
Evaporating Temperature to (oC)
Condensing Temperature tc (
o
C)
R410A
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25
Evaporating Temperature to (oC)
Condensing Temperature tc (
o
C)
R410A
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4 C6.2.19/0507-0708/E
ZP154K* to ZP182K* ZP235K* to ZP385K*
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25
Evaporating Temperature to (oC)
Condensing Temperature tc (
o
C)
R410A
ZP154
20
25
30
35
40
45
50
55
60
65
70
-30 -25 -20 -15 -10 -5 0 5 10 15 20
Evaporating Temperature to (oC)
Condensing Temperature tc (
o
C)
R410A
10K Suction Superheat
25
o
C Suction Gas Return
Figure 2: Application envelopes for compressors ZP23K* to ZP385K* with R410A
NOTE: For application envelopes with R134a and R22, please refer to Copeland®Brand
Products Selection Software.
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 3
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.
For models ZR94K* to ZR380K* and ZP90K* to ZP385K*, 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

C6.2.19/0507-0708/E 5
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
Figure 4
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. A clearance space of approximately 2 mm between the bottom of the washer and
the top of the grommet spacer is recommended.
If the compressors are mounted in tandem or used in parallel, then the hard mountings (bolt M 9
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.
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.
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Mounting Parts ZR250K* to ZR380K* and ZP235K* to ZP385K* - Soft Mountings
Mounting Clearance 2 mm
Mounting Parts ZR18K* to ZR190K* and ZP23K* to ZP182K* - Soft Mountings

6 C6.2.19/0507-0708/E
Figure 5: Suction tube brazing
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.
Since the discharge stub contains a check valve,
care must be taken not to overheat it to prevent
brazing material to flow into it.
Figure 5 shows the proper procedures 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.
Since the discharge stub contains a check valve, care must be taken not to overheat it to
prevent brazing material to flow into it.
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 6

C6.2.19/0507-0708/E 7
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 or just make brazing connections.
Braze connections can be converted to Rotalock by means of adaptors. Rotalock shut-off valves
are available for the suction as well as discharge sides. Using either straight or angled adaptors
provides a way to convert a Rotalock into a brazing connection.
Refer to the following table for proper tightening torques:
NOTE: More information concerning
adaptors and shut-off valves can be
found in the "Spare parts list".
Table 2
3.4 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
The use of accumulators is very dependent on the application. Copeland Scrolls inherent ability
to handle liquid refrigerant during occasional operating flood back situations makes the use of an
accumulator unnecessary in standard designs such as condensing units. Applications such as
heat pumps with orifice refrigerant control, that allow large volumes of liquid refrigerant to flood
back to the compressor during normal steady operation can dilute the oil to such an extent that
bearings are inadequately lubricated, and wear will occur. In such a case an accumulator must
be used to reduce flood back to a safe level that the compressor can handle. Heat pumps
designed with a TXV to control refrigerant during heating may not require an accumulator if
testing assures the developer that there will be no flood back throughout the operating range.
The accumulator oil-return orifice should be from 1 to 1.4 mm in diameter for models ZR18K* to
ZR81K* and ZP23K* to ZP83K*, depending on compressor size and compressor flood back
results. Models ZR94K* to ZR380K* and ZP90K* to ZP385K* should use an orifice diameter of
2.0 mm.
CAUTION
Screen blocking! Compressor breakdown! Use screens with at least 0.6
mm openings (30 x 30 meshes per inch). Screens with a finer mesh can
easily become plugged causing oil starvation to the compressor bearings. A
compressor breakdown may be the consequence.
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. System modelling
indicates that heat pumps that operate down to and below -18°C will require an accumulator that
can hold around 70% to 75% of the system charge.
Charge compensators
Charge compensators are devices that store excess refrigerant during the heating operation of a
heat pump with a TXV refrigerant control. Unlike an orifice, a TXV will not allow excess
refrigerant to flood back to the compressor. This means that the excess system refrigerant will
Torque [Nm]
Rotalock 3/4"16UNF 40-50
Rotalock 1”-14UNS 70-80
Rotalock 1"1/4-12UNF 110-135
Rotalock 1"3/4-12UNF 135-160
Rotalock 2"1/4-12UNF 165-190
C_T_SCA_002
Safety
instructions
Product
description
InstallationElectrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal