Emerson Copeland Scroll ZRH49KJE Instruction Manual

Horizontal Scroll compressors
for Transport Air-Conditioning
ZRH49KJE to ZRH72KJE, ZBH30KJE to
ZBH45KJE, ZRHV72KJE and ZBHV45KJE.
Application Guidelines

C6.2.7/0302-1007/E
1Safety instructions.............................................................................................. 1
1.1 Icon explanation ..............................................................................................................1
1.2 Safety statements............................................................................................................1
1.3 General instructions.........................................................................................................2
2Product description............................................................................................ 2
2.1 Common information about Copeland Scroll™ compressors...........................................2
2.2 About this guideline.........................................................................................................2
2.3 Nomenclature..................................................................................................................3
2.4 Application range.............................................................................................................3
2.4.1 Qualified refrigerants and oils...............................................................................3
2.4.2 Application limits ..................................................................................................3
3Installation........................................................................................................... 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............................................................................................................................7
4Electrical connection.......................................................................................... 8
4.1 General recommendations ..............................................................................................8
4.2 Electrical installation........................................................................................................8
4.2.1 Cable connectors.................................................................................................8
4.2.2 Terminal box ........................................................................................................8
4.2.3 Motor winding.......................................................................................................8
4.2.4 Protection devices................................................................................................8
4.3 Inverter operation ............................................................................................................9
4.4 Crankcase heater............................................................................................................9
4.5 Pressure safety controls..................................................................................................9
4.5.1 High-pressure control...........................................................................................9
4.5.2 Low-pressure control..........................................................................................10
4.6 Discharge temperature protection..................................................................................10
4.7 Motor protection.............................................................................................................11
4.8 High potential testing.....................................................................................................11
5Starting up & operation.................................................................................... 12
5.1 Strength pressure test...................................................................................................12
5.2 Tightness/pressure test .................................................................................................12
5.3 Preliminary checks – Pre-starting..................................................................................12

C6.2.7/0302-1007/E
5.4 First start .......................................................................................................................12
5.5 Charging procedure.......................................................................................................13
5.6 Rotation direction...........................................................................................................13
5.7 Minimum run time..........................................................................................................13
5.8 Pump-down cycle..........................................................................................................13
6Maintenance & repair........................................................................................ 14
6.1 Exchanging the refrigerant.............................................................................................14
6.2 Replacing a compressor................................................................................................14
6.2.1 Compressor replacement...................................................................................14
6.2.2 Start-up of a new or replacement compressor....................................................14
6.3 Lubrication.....................................................................................................................14
6.4 Compressor functional check ........................................................................................15
6.5 Unbrazing system components .....................................................................................16
7Dismantling & disposal.................................................................................... 16

C6.2.7/0302-1007/E 1
1 Safety instructions
These compressors are constructed according to the latest European and US Safety Standards.
Particular emphasis has been placed on the user’s safety. Certain residual hazards from the
compressor are not avoidable.
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.
Safety
instructions
Product
description
InstallationElectrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal

2 C6.2.7/0302-1007/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 refrigerant 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 Copeland since 1979. It is the most
efficient and durable compressor Copeland has ever developed for air conditioning and
refrigeration.
This application guideline deals with air-conditioning Copeland Horizontal ScrollTM
compressors, ZRH49KJE to ZRH72KJE, ZBH30KJE to ZBH45KJE, ZRHV72KJE and
ZBHV45KJE.
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.
For additional information, please refer to the “Product Catalogue“ or to the “Copeland Selection
Software” accessible from the Copeland website at www.ecopeland.com.

C6.2.7/0302-1007/E 3
2.3 Nomenclature
The model designation contains the following technical information about the compressor:
Z R H V 72K J E - TFD - 650
Oil type:
None = mineral oil
V= Variable speed
None = Fixedspeed
Application range temperature:
R = air conditionning
B= high/medium with sight glass & schraeder connection
C_T_ZRH_007
Compressor family: Z = Scroll
Model variation
Motor version
Bill of material number
E = POE oil
Nominal capacity[BTU/h] @ 60 Hz andARI conditions
Horizontal orientation
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 brochures or Copeland Selection Software.
Qualified refrigerant R407C and R134a
Copeland standard oil ICI Emkarate RL 32 – 3MAF
Servicing oil ICI Emkarate RL 32 – 3MAF
Mobil EAL Arctic 22 CC
Table 1
2.4.2 Application limits
R407C(mid-point) R134a
Figure 1: ZRH* & ZBH* envelopes with 10K suction superheat
Safety
instructions
Product
description
InstallationElectrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal
80
70
60
50
40
30
Tc
(
°C
)
-20 -15 -10 -5 0 5 10 15
To
(
°C
)
80
70
60
50
40
30
-20 -15 -10 -5 0 5 10 15
To
(
°C
)

4 C6.2.7/0302-1007/E
R407C (mid point) R134a
Figure 2: ZRHV72* & ZBHV45* envelopes with 10K suction superheat
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.
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.
Positioned on the topside of the compressor shell end caps are lifting tabs. It is very
important to utilize these lifting devices to maintain the compressor in the horizontal
position during the installation and removal. Otherwise, damage to the compressor could
occur.
Figure 3
80
70
60
50
40
30
Tc
(
°C
)
-20 -15 -10 -5 0 5 10
To
(
°C
)
35-75 Hz
45-75 Hz
80
70
60
50
40
30
Tc
(
°C
)
-20 -15 -10 -5 0 5 10 15
To
(
°C
)
45-75 Hz
35-75 Hz

C6.2.7/0302-1007/E 5
NOTE: Keep the compressor upright during installation and removal; otherwise oil could spill out
of the suction tube.
3.1.3 Installation location
Ensure the compressors are installed on a solid level base.
3.1.4 Mounting parts
Four vibration absorber grommets are supplied with each compressor. they dampen the start-up
surge of the compressor and minimise sound and vibration transmission to the compressor base
during operation. The metal sleeve inside is a guide designed to hold the grommet in place. It is
not designed as a load-bearing member, and application of excessive torque to the bolts can
crush the sleeve. Its inner diameter is approximately 8.5 mm to fit, eg, an M8 screw. The
mounting torque should be 13 ± 1 Nm. It is critically important that the grommet is not
compressed. A clearance space of approximately 2 mm between the bottom of the washer and
the top of the grommet spacer is recommended.
NOTE: Use the advised torque below to prevent from crushing the sleeve.
Table 2
The metal sleeve inside helps to hold the grommet in place.
Figure 4
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, especially if the compressor is charged with POE oil that is
very hygroscopic.
Copeland ScrollTM 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.
Fig. 5 shows the proper procedure for brazing the suction and discharge lines to a scroll
compressor.
Bolt M 8
Mounting torque
13 ±1 Nm.
Safety
instructions
Product
description
InstallationElectrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal
321
Z.8.14.00
Figure 5: Suction tube brazing

6 C6.2.7/0302-1007/E
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.
Copeland Horizontal ScrollTM compressors are provided either with stub or Rotalock connections
depending on the bill of material selected.
Rotalock shut-off valves are available for the suction as well as discharge side. Using either
straight or angled adaptors provides a way to convert a Rotalock into a brazing connection.
Refer to the following table for proper tightening torques:
Table 3
NOTE: More information concerning adaptors and shut-off valves can be found in the "Spare
parts list".

C6.2.7/0302-1007/E 7
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.
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.
Irrespective of system charge, oil dilution may occur when large amounts of liquid refrigerant
repeatedly flood back to the compressor during:
normal off cycles
defrost
varying loads
To determine if an accumulator is required, refer to Technical Information "Excessive Liquid
Floodback Tests".
If an accumulator must be used, an oil return orifice size in the range of 1.4 mm in diameter is
recommended.
If an accumulator is used it is recommended that it be sized to hold from 50% to 70% of the
system charge.
If an accumulator is fitted, and there is no crankcase heater, it should be piped to allow free
liquid drainage during the off cycle.
A large area protective screen no finer than 30 x 30 mesh (0.6 mm openings) is required to
protect this small orifice from plugging with system debris.
SCROLL
ANW.4.05.00
Figure 6: Suction accumulator installation
Tests have shown that a small screen with a fine mesh can easily become plugged causing oil
starvation to the compressor bearings. Such blockage can result in compressor failure.
3.5 Mufflers
External mufflers, normally applied to piston compressors in the past, may not be required for
Copeland ScrollTM 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 these ranges, the more effective it is. Choose a muffler with a length of 4 to
10-15 cm.
Safety
instructions
Product
description
InstallationElectrical
connection
Starting up &
operation
Maintenance &
repair
Dismantling &
disposal