Emerson Copeland Scroll ZRH49K Series Instruction Manual

Copeland Scroll™Horizontal Compressors
for Air-Conditioning Applications
ZRH49K* to ZRH72K*, ZBH30K* to ZBH45K*
ZRHV45K* & ZRHV72K*
Application Guidelines

C6.2.7/1007-0619/E
About these guidelines ...............................................................................................1
1Safety instructions...........................................................................................1
1.1 Icon explanation............................................................................................................... 1
1.2 Safety statements ............................................................................................................ 1
1.3 General instructions......................................................................................................... 2
2Product description .........................................................................................3
2.1 General information about Copeland Scroll™ compressors ........................................... 3
2.2 Nomenclature................................................................................................................... 3
2.3 Application range............................................................................................................. 3
2.3.1 Qualified refrigerants and oils .............................................................................. 3
2.3.2 Application limits................................................................................................... 4
2.3.3 Comparison between ZRH* and ZBH* compressors........................................... 4
2.4 Special requirements for transport applications............................................................... 4
2.5 Dimensions ...................................................................................................................... 5
3Installation........................................................................................................7
3.1 Compressor handling....................................................................................................... 7
3.1.1 Transport and storage.......................................................................................... 7
3.1.2 Positioning and securing...................................................................................... 7
3.1.3Installation location............................................................................................... 7
3.1.4 Mounting parts...................................................................................................... 8
3.2 Brazing procedure............................................................................................................ 8
3.3 Shut-off valves and adaptors........................................................................................... 9
3.4Accumulators ................................................................................................................. 10
3.5 Screens.......................................................................................................................... 10
3.6 Mufflers .......................................................................................................................... 10
4Electrical connection .....................................................................................11
4.1 General recommendations............................................................................................. 11
4.2 Electrical installation ...................................................................................................... 11
4.2.1 Molded plug connection ..................................................................................... 11
4.2.2 Assembly of the molded plug cable ................................................................... 11
4.2.3 Removing the molded plug cable....................................................................... 12
4.2.4 Wiring diagram ................................................................................................... 12
4.2.5 Motor winding..................................................................................................... 12
4.2.6 Protection devices.............................................................................................. 13
4.2.7 Crankcase heater............................................................................................... 13
4.3 Inverter operation........................................................................................................... 13
4.4 Pressure safety controls ................................................................................................ 15
4.4.1High-pressure protection.................................................................................... 15
4.4.2 Low-pressure protection..................................................................................... 15
4.4.3 Internal pressure relief valve.............................................................................. 15

C6.2.7/1007-0619/E
4.5 Discharge gas temperature protection........................................................................... 15
4.6 Motor protection............................................................................................................. 16
4.7 High-potential testing ..................................................................................................... 16
5Start-up & operation.......................................................................................17
5.1 Strength pressure test.................................................................................................... 17
5.2 Tightness/pressure test.................................................................................................. 17
5.3 System evacuation......................................................................................................... 17
5.4 Preliminary checks –Pre-starting.................................................................................. 17
5.5 First start........................................................................................................................ 18
5.6 Charging procedure ....................................................................................................... 18
5.7 Initial start-up ................................................................................................................. 18
5.8 Rotation direction........................................................................................................... 18
5.9 Starting sound................................................................................................................ 19
5.10 Deep vacuum operation................................................................................................. 19
5.11 Refrigerant migration ..................................................................................................... 19
5.12 Pumpdown cycle............................................................................................................ 19
5.13 Shell temperature........................................................................................................... 20
5.14 Minimum run time .......................................................................................................... 20
5.15 Shut-off sound................................................................................................................ 20
5.16 Oil level .......................................................................................................................... 20
6Maintenance & repair.....................................................................................21
6.1 Exchanging the refrigerant............................................................................................. 21
6.2 Replacing a compressor................................................................................................ 21
6.2.1 Compressor replacement................................................................................... 21
6.2.2 Start-up of a new or replacement compressor................................................... 21
6.3 Lubrication and oil removal............................................................................................ 22
6.4 Oil additives ................................................................................................................... 22
6.5 Unbrazing system components ..................................................................................... 22
7Dismantling & disposal..................................................................................23
DISCLAIMER ..............................................................................................................23

C6.2.7/1007-0619/E 1
About these guidelines
The purpose of these guidelines is to provide guidance in the application of Copeland Scroll™
horizontal 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 cannot guarantee the performance and reliability of
the product if it is misused in regard of these guidelines.
These application guidelines cover stationary applications. For transport or rail applications, other
considerations such as high vibration and shocks, power supply characteristics, high ambient
temperatures, frequent cycling etc. may apply. It is the responsibility of the system designer/planner
to define the individual requirements to qualify the compressor and the complete system for their
specific needs. Please contact the Application Engineering department at Emerson or your local
Emerson representative for additional support.
1 Safety instructions
Copeland Scroll compressors are manufactured according to the latest European safety standards.
Particular emphasis has been placed on the user’s safety.
These compressors are intended for installation in systems according to the EC 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.

2 C6.2.7/1007-0619/E
1.3 General instructions
WARNING
System breakdown! Personal injuries! Never install a system in the field
and leave it unattended when it has no charge, a holding charge, or with the
service valves closed without electrically locking out the system.
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils must be used.
WARNING
High shell temperature! Burning! Do not touch the compressor until it has
cooled down. Ensure that other materials in the area of the compressor do not
come into contact with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without
refrigerant charge or without being connected to the system.
CAUTION
Contact with POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE must not come into contact with any surface
or material that it might damage, including without limitation, certain polymers,
eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.

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2 Product description
2.1 General information about Copeland Scroll™compressors
These application guidelines deal with Copeland Scroll horizontal compressors for air-
conditioning and other applications with HFC refrigerants. This compressor range consists
of models ZRH49KJE to ZRH72KJE and ZBH30KJE to ZBH45KJE fixed speed, and models
ZRHV45KJE and ZBHV72KJE variable speed.
Compressor
Cooling capacity
[kW]
Displacement
[m³/h]
Motor
R407C
R134a
ZBH30KJE
10.0
7.0
11.7
TFD/TF5
ZBH38KJE
12.6
8.6
14.4
TFD/TF5
ZBH45KJE
14.8
10.2
17.1
TFD/TF5
ZBHV45KJE
14.8
10.2
17.1
TFD/TF5
ZRH49KJE
10.2
7.1
11.8
TFD/TF5
ZRH61KJE
13.0
8.9
14.5
TFD/TF5
ZRH72KJE
15.0
10.5
17.1
TFD/TF5
ZRHV72KJE
15.0
10.5
17.1
TFD/TF5
Table 1: Cooling capacity at 5°C/50°C/10K/0K
2.2 Nomenclature
The model designation contains the following technical information about the compressor:
ARI conditions:
Evaporating temperature........7.2°C Liquid sub-cooling...........8.3K
Condensing temperature........54.4°C Ambient temperature.......35°C
Suction gas superheat............11K
2.3 Application range
2.3.1 Qualified refrigerants and oils
IMPORTANT
It is essential that the glide of refrigerant blends (primarily R407C) 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.
Qualified refrigerants
R407C & R134a
Copeland brand
products standard oil
Emkarate RL 32 3MAF
Servicing oils
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Table 2: Qualified refrigerants and oils

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2.3.2 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.
NOTE: The application envelopes for all horizontal compressor models covered in these
guidelines are available in Copeland brand products Select software at
www.climate.emerson.com/en-gb.
2.3.3 Comparison between ZRH* and ZBH* compressors
ZRH* and ZBH* horizontal compressor models are basically available in two BOM variations:
▪BOM 650 Compressor with brazing stub tubes, electrical box ready for molded plug IP65
▪BOM 651 Compressor with Rotalock connections, electrical box ready for molded plug IP65
Table 2 below describes the differences and similarities between ZRH* and ZBH* models:
Compressor
version
BOM 650
BOM 651
ZRH*
Brazing stub tubes
Electrical connection ready for
molded plug IP65
Without oil sight glass
Without oil service Schraeder valve
Rotalock connections
Electrical connection ready for molded
plug IP65
Without oil sight glass
Without oil service Schraeder valve
ZRHV*
Brazing stub tubes
Electrical connection ready for
molded plug IP65
Without oil sight glass
Without oil service Schraeder valve
Variable speed
Rotalock connections
Electrical connection ready for molded
plug IP65
Without oil sight glass
Without oil service Schraeder valve
Variable speed
ZBH*
Brazing stub tubes
Electrical connection ready for
molded plug IP65
Oil sight glass
Oil service Schraeder valve
Rotalock connections
Electrical connection ready for molded
plug IP65
Oil sight glass
Oil service Schraeder valve
ZBHV*
Brazing stub tubes
Electrical connection ready for
molded plug IP65
Oil sight glass
Oil service Schraeder valve
Variable speed
Rotalock connections
Electrical connection ready for molded
plug IP65
Oil sight glass
Oil service Schraeder valve
Variable speed
Table 3: Differences and similarities between ZRH* and ZBH* horizontal scroll compressors
2.4 Special requirements for transport applications
Transport air-conditioning or refrigeration applications can be particularly sensitive and require
experience and thorough case-by-case analysis. Compared to static applications, additional
demands in terms of applicability to specific norm and standard requirements can arise. The system
designer must pay particular attention to higher demands with regard to shock stress, high vibration
levels, power supply and other installation characteristics.
The qualification for the parts and individual requirements, like system components, piping, piping
layout, fixation, as well as a study about shock, vibration and load requirements must be carried out
by the unit designer for the whole system. Emerson can provide support and assistance with
individual projects.

C6.2.7/1007-0619/E 5
2.5 Dimensions
Figure 1: Dimensions of models ZBH30KJE to ZBH45KJE and ZBHV45KJE

6 C6.2.7/1007-0619/E
Figure 2: Dimensions of models ZRH42KJE to ZRH72KJE and ZRHV72KJE

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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 3. 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 = 1
▪Storage: n = 2
Figure 3: 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.
The lifting tabs are located on the side of the compressor shell end caps.
Figure 4: Handling of a horizontal scroll compressor
NOTE: It is essential to use the lifting tabs to maintain the compressor in the horizontal
position during handling, installation or removal in order to avoid damage to the compressor.
Horizontal scroll compressors have a holding charge and are factory filled with dry air. It is
recommended to remove the discharge connection plug first before pulling the suction connection
plug to allow the dry air pressure inside the compressor to escape.
Care must be taken when removing the plugs from the discharge and suction connections, because
oil mist might come out and coat the suction tube, making the brazing process on the copper-coated
tubes difficult. The copper-coated steel suction tube should be cleaned before brazing.
The plugs must be removed as late as possible before brazing so that the air humidity does not affect
the oil characteristics.
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.

8 C6.2.7/1007-0619/E
3.1.4 Mounting parts
ZRH* and ZBH* horizontal Scroll compressors can be mounted solidly on the chassis using steel
spacers. Alternatively, rubber mounting parts of different hardness can be used. The unit designer
should make a choice after observing the shock/vibration test results.
A kit of soft rubber grommets is supplied in the standard delivery of the horizontal scroll compressor.
Depending on the applications, other or harder mounting parts might be required.
The rubber mounting part kit typically consists of rubber grommets, metal washers and metal
sleeves. The metal sleeve inside is a guide designed to hold the grommet in place. It should not be
used 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, e.g., an M8 screw.
For the soft rubber mounting parts kit, the recommended mounting torque is 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.
The hard rubber mounting parts kit contains two metal washers, which have to be positioned above
the rubber grommet and the metal sleeve. The bolt must be tightened until positive contact occurs
between the bolt head and the washer, ensuring that both are securely clamped together. The
recommended mounting torque is 18 ± 1 Nm.
The metal sleeve inside helps to hold the grommet in place.
Figure 5: Installation of soft rubber mounting parts
NOTE: Use the advised torque below to avoid crushing the sleeve.
NOTE: For an overview of ident numbers, various mounting part alternatives and other
accessories, please refer to the Emerson spare parts software available at
www.climate.emerson.com/en-gb.
Soft rubber mounting parts
Hard rubber mounting parts
Figure 6: Mounting parts with sleeve and washer
NOTE: For more information please refer to Technical Information C7.11.2 "Scroll 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.

C6.2.7/1007-0619/E 9
IMPORTANT
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 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 7 and the 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.
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.
Copeland Scroll horizontal compressors are delivered either with stub or Rotalock connections
depending on the bill of material that has been selected.
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 Table 3 for proper tightening torques:
Connection
Torque [Nm]
Rotalock 1" –14 UNS
70 - 80
Rotalock 1 ¼" –12 UNF
110 - 135
Rotalock 1 ¾" –12 UNF
135 - 160
Table 4
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.
Figure 7: Suction tube brazing

10 C6.2.7/1007-0619/E
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, for example during:
▪normal off cycles;
▪defrost;
▪varying loads.
In such a case an accumulator must be used to reduce floodback to a safe level that the compressor
can handle. The use of accumulators is dependent on the application. If an accumulator must be
used, the oil-return orifice should be from 1 to 1.4 mm in diameter, depending on compressor size
and compressor floodback results.
The size of the accumulator depends upon the operating range of the system and the amount of
subcooling and subsequent head pressure allowed by the refrigerant control. If an accumulator is
used, it is recommended that it be sized to hold from 50% to 70% of the system charge.
Figure 8: Oil dilution chart for operation
Note 1: Low load operation may be acceptable in the yellow marked area. For further
information, please contact the Application Engineering department.
3.5 Screens
CAUTION
Screen blocking! Compressor breakdown! Use screens with at least
0.6 mm openings.
The use of screens finer than 30 x 30 mesh (0.6 mm openings) anywhere in the system should be
avoided with these compressors. Field experience has shown that finer mesh screens used to protect
thermal expansion valves, capillary tubes or accumulators can become temporarily or permanently
plugged with normal system debris and block the flow of either oil or refrigerant to the compressor.
Such blockage can result in compressor failure.
3.6 Mufflers
External mufflers, normally applied to piston compressors in the past, may not be required for
Copeland Scroll compressors. Individual system tests should be performed to verify acceptability of
sound performance. If adequate attenuation is not achieved, use a muffler with a larger cross-
sectional area to inlet area ratio. A ratio of 20:1 to 30:1 is recommended.
A hollow shell muffler will work quite well. Locate the muffler at minimum 15 to maximum 45 cm from
the compressor for the most effective operation. The farther the muffler is placed from the
compressor within this range, the more effective. Choose a muffler with a length of 10 to 15 cm.

C6.2.7/1007-0619/E 11
4 Electrical connection
4.1 General recommendations
The compressor terminal box has a wiring diagram on the inside of its cover. Before connecting the
compressor, ensure the supply voltage, the phases and the frequency match the nameplate data.
4.2 Electrical installation
WARNING
Conductor cables! Electrical shock! Shut off power supply before and
between each test.
4.2.1 Molded plug connection
WARNING
Electric arc! Explosion hazard! Removing the molded plug cable while
under load or electrically energized will create arcing between the connection
pins and the cable connectors. Always shut off power supply before attaching
or removing the molded plug cable from the connection pins.
The molded plug connector must be smoothly pushed by hand towards the
connection pins of the compressor. Never use a tool to knock the molded plug
connector on the terminal pins as this could damage the glass inserts of the
pins.
It is mandatory to secure the molded plug cable on the connection pins with a
retainer.
Any rework on the terminal pins is strictly prohibited.
WARNING
Electrical shock hazard! Serious personal injuries and/or system
breakdown! Use qualified molded plug cables with grounding connection
only. Make sure to connect the grounding first before attaching the molded
plug cable to the connection pins of the compressor. When removing the
molded plug cable from the connection pins, disconnect the grounding last.
ZRH* and ZBH* horizontal Scroll compressors are equipped with electrical connection pins ready for
molded plug connection. This version is compliant with all CE and safety regulations and its
protection class is IP65. The molded plug kit includes an O-ring, a grounding connection and a
retainer (see Figures 9 to 11).
Figure 9: Circle fence Figure 10: Power cable molded plug Figure 11: Connecting the molded plug
with motor terminals (IP65) power cable to the connection pins
4.2.2 Assembly of the molded plug cable
▪Make sure to use only qualified molded plug power cables with grounding connection.
▪Check that the O-ring on the molded plug connector is in place and not damaged.
▪Shut off power supply.
▪Check that the circle fence is clean and dry before connecting the molded plug power cable.
▪For molded plug cables with grounding: connect the grounding of the molded plug power cable
to the compressor circle fence.

12 C6.2.7/1007-0619/E
▪Attach the molded plug connector to the compressor connection pins. Smoothly push the
molded plug connector by hand as far as possible towards the pins. Never use a tool to knock
the molded plug as this could damage the glass inserts of the pins.
▪For molded plug cables with retainer: secure the connection with the retainer.
4.2.3 Removing the molded plug cable
▪Shut off power supply.
▪For molded plug cables with retainer: remove the retainer from the connection.
▪Remove the molded plug connector from the connection pins.
▪For molded plug cables with grounding: disconnect the grounding from the compressor circle
fence.
NOTE: To select the appropriate molded plug power cables, please refer to the Emerson spare
parts software available at www.climate.emerson.com/en-gb.
4.2.4 Wiring diagram
Three-phase compressors (TF*) with internal motor protection:
Power circuit Control circuit
L1
K1
K2
S1
P>
P<
F3
F4
B3
K2
R2
N1 2 3
B1
K1
B1
F1
Motor terminal connections
Three-phase compressors are connected to the
T1, T2 and T3 connections
Legend
B1 ...............Room thermostat K1, K2.........Contactors
B3 ...............Discharge gas thermostat Q1...............Main switch
F1, F6, F8...Fuses R2...............Crankcase heater
F3 ...............HP switch S1...............Auxiliary switch
F4 ...............LP switch
Figure 12: Wiring diagrams for three-phase compressors with internal motor protection
4.2.5 Motor winding
ZRH* and ZBH* horizontal Scroll compressors have a three-phase induction motor. All three-phase
motors are connected in star.
The motor insulation material is class "B" according to IEC 34-1 or DIN 57530.

C6.2.7/1007-0619/E 13
4.2.6 Protection devices
Independently from the internal motor protection, fuses must be installed before the compressor.
The selection of fuses has to be done according to VDE 0635, DIN 57635, IEC 269-1 or
EN 60-269-1.
4.2.7 Crankcase heater
IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours
before starting the compressor.
A crankcase heater is required with ZRH* and ZBH* horizontal Scroll compressors if the system
configuration enables large amounts of refrigerant to condense in the compressor and to be
absorbed by the oil during standstill periods. A crankcase heater is always required when the system
charge exceeds 4.5 kg.
The crankcase heater must be turned on a minimum of 12 hours prior to starting the
compressor. This will prevent oil dilution and bearing stress on initial start-up.
The crankcase heater should be positioned on the right-hand side of the compressor, a few
centimetres away from the position of the electrical connection.
Caution: Crankcase heaters must be properly grounded!
4.3 Inverter operation
Copeland Scroll horizontal compressors ZRH49K* to ZRH72K* and ZBH30K* to ZBH45K* are limited
to fixed speed operation at either 50 or 60 Hz.
Compressor models ZRHV72K* and ZBHV45K* can be operated on inverter-derived power over the
range of 35 to 75 Hz. The inverter drives used to power these compressors must comply with the
provisions of technical specification IEC 600034-17. In particular, the motor input voltage must be
limited to 1.35 kV/microsecond line-to-line impulse voltage. These provisions are required to avoid
motor insulation breakdown, to limit motor heating, and to extend motor lifetime.
The compressor operating voltage must vary with frequency according to the diagram shown in
Figure 13. The value of the voltage should be 7.67 multiplied by the operating frequency over the
range of 35 to 60 Hz. From 60 to 75 Hz, the voltage should be a constant 460 volts. Matching voltage
to frequency according to these guidelines will prevent motor saturation and overheating.
Figure 13: Voltage versus operating frequency ZRHV72KJE-TFD and ZBHV45KJE-TFD
Operating compressor models ZRH49K* to ZRH72K* and ZBH30K* to ZBH45K* over a defined
frequency range will result in different application envelopes (see Figures 14 & 15). These envelopes
are more restricted at lower operating speeds. This is to prevent overloading and overheating of the
compressor motor during low-speed operation.

14 C6.2.7/1007-0619/E
Figure 14: Operating envelope for variable speed ZRHV72KJE and ZBHV45KJE with R407C
Figure 15: Operating envelope for variable speed ZRHV72KJE and ZBHV45KJE with R134a
25
30
35
40
45
50
55
60
65
70
-25 -20 -15 -10 -5 0 5 10 15
Condensing Temperature (oC)
Evaporating Temperature (oC)
R407C
45-75Hz
35-75Hz
15
20
25
30
35
40
45
50
55
60
65
70
75
-20 -15 -10 -5 0 5 10 15 20
Condensing Temperature (oC)
Evaporating Temperature (oC)
R134a
35-75Hz
45-75Hz

C6.2.7/1007-0619/E 15
4.4 Pressure safety controls
4.4.1 High-pressure protection
The cut-out setting for the high-pressure control shall be determined according to regional standards,
usually EN 378, part 2 in Europe.
The maximum pressure value for the individual compressor type, PS high side, is printed on the
nameplate of the compressor.
The high-pressure cut-out should have a manual reset feature for the highest level of system
protection.
4.4.2 Low-pressure protection
IMPORTANT
Loss of system charge and lubrication! Bearing malfunction!
Compressor breakdown! A low-pressure control is highly recommended. Do
not bridge or by-pass the low-pressure cut out.
The minimum cut-out setting shall be determined according to the refrigerant and to the allowed
operation envelope –see technical data in Select software at www.climate.emerson.com/en-gb. For
example, a minimum cut-out setting of 1.0 bar(g) is required for ZRH* and ZBH* compressors using
R407C.
The low-pressure cut-out should have a manual reset feature for the highest level of system
protection.
4.4.3 Internal pressure relief valve
ZRH(V)* and ZBH(V)* horizontal compressors do NOT have any internal pressure relief valve. To
ensure safe operation, a high-pressure control must be used in all applications.
4.5 Discharge gas temperature protection
IMPORTANT
Inadequate lubrication! Scroll set damage! All ZRH* and ZBH* horizontal
Scroll compressors must be equipped with an external discharge gas
temperature protection.
Internal discharge temperatures can reach unacceptable values under some extreme operating
conditions (such as loss of refrigerant injection charge or extremely high compression ratio). This
could cause compressor damage.
The discharge thermostat dedicated to ZRH* and ZBH* horizontal Scroll compressors has a cut-out
setting of 105°C ± 4K with closing at 88°C ± 8K. It should be installed approximately 120 mm from
the discharge valve outlet (see assembly instructions below).
To ensure proper functioning and to avoid false readings, the discharge line thermostat must be
installed and insulated according to the procedure and recommendations hereunder.
Assembly of the discharge line thermostat
▪Install the discharge line thermostat on the
discharge tube 120 mm from top cap.
▪Snap the retainer clip over the tube and onto
the thermostat.
▪The thermostat should be placed on the
discharge tube so that its body is in upward
position on a horizontal tube installation.
▪Ensure that the thermostat is not tilted.

16 C6.2.7/1007-0619/E
▪The wire must not be in contact with the top
cap of the compressor or the discharge tube.
Care should be taken to route wires so that
they do not come into contact with sharp
objects.
▪To avoid any impact on tripping temperature
by the ambient, the discharge line thermostat
must be insulated.
▪Wrap thermal insulation around the pipe left
and right of the thermostat and secure it with
plastic straps.
▪Wrap a second layer of insulation around the
first one and around the thermostat, and
secure it with plastic straps.
4.6 Motor protection
Conventional inherent internal line break motor protection Klixon is provided with all compressor
models covered in these guidelines.
The protector reacts to a combination of motor current and motor winding temperature. The internal
protector protects against single phasing. Time must be allowed for the motor to cool down before
the protector will reset.
4.7 High-potential testing
WARNING
Conductor cables! Electrical shock! Shut off power supply before high-
potential testing.
CAUTION
Internal arcing! Motor destruction! Do not carry out high-voltage or
insulation tests if the compressor housing is under vacuum.
Emerson subjects all Scroll compressors to a high-voltage test after final assembly. Each motor
phase winding is tested, according to EN 0530 or VDE 0530 part 1, at a differential voltage of 1000V
plus twice the nominal voltage. Since high-voltage tests lead to premature ageing of the winding
insulation additional tests of that nature are not recommended.
If it has to be done for any reason, a lower voltage must be used. Disconnect all electronic devices,
eg, motor protection module, fan speed control, etc prior to testing.

C6.2.7/1007-0619/E 17
5 Start-up & operation
WARNING
Diesel effect! Compressor destruction! The mixture of air and oil at high
temperature can lead to an explosion. Avoid operating with air.
IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours
before starting the compressor.
5.1 Strength pressure test
The compressor has been strength-tested in the factory. It is not necessary for the customer to
strength- or leak-test the compressor again although the compressor will normally be exposed to the
testing made as part of system testing.
5.2 Tightness/pressure test
WARNING
High pressure! Personal injuries! Consider personal safety requirements
and refer to test pressures prior to test.
WARNING
System explosion! Personal injuries! DO NOT USE other industrial
gases.
CAUTION
System contamination! Bearing malfunction! Use only dry nitrogen or dried
air for pressure testing.
If using dry air do not include the compressor in the pressure test –isolate it first. Never add
refrigerant to the test gas (as leak indicator).
5.3 System evacuation
Before the installation is put into commission, it has to be evacuated with a vacuum pump. Proper
evacuation reduces residual moisture to 50 ppm. During the initial procedure, suction and discharge
shut-off valves on the compressor remain closed. The installation of adequately sized access valves
at the furthest point from the compressor in the suction and liquid lines is advisable. Pressure must
be measured using a vacuum pressure (Torr) gauge on the access valves and not on the vacuum
pump; this serves to avoid incorrect measurements resulting from the pressure gradient along the
connecting lines to the pump.
Evacuating the system only on the suction side of a Scroll compressor can occasionally result in a
temporary no-start condition for the compressor. The reason for this is that the floating seal could
axially seal with the scroll set, with the higher pressure on the floating seal. Consequently, until the
pressures equalise, the floating seal and scroll set can be held tightly together. The installation should
be evacuated down to 0.3 mbar.
Subsequently, the factory holding charge of dry air in the compressor is released to the ambient. The
shut-off valves are opened and the installation, including the compressor, are once more evacuated
as described after the system has been recharged with dry nitrogen. The highest demands are placed
on the leak-proof design of the installation and on leak-testing methods –please refer to EN 378.
5.4 Preliminary checks –Pre-starting
Discuss details of the installation with the installer. If possible, obtain drawings, wiring diagrams, etc.
It is ideal to use a check-list but always check the following:
▪Visual check of the electrics, wiring, fuses etc.
▪Visual check of the plant for leaks, loose fittings such as TXV bulbs etc.
▪Compressor oil level
▪Calibration of HP & LP switches and any pressure actuated valves
▪Check setting and operation of all safety features and protection devices
▪All valves in the correct running position
▪Pressure and compound gauges fitted
▪Correctly charged with refrigerant
▪Compressor electrical isolator location & position