Emerson COPELAND ZH04K1P Instruction Manual

Copeland™Scroll Compressors
for Heat Pump Applications with R410A
ZH04K1P to ZH19K1P
ZHI05K1P to ZHI46K1P
Application Guidelines

AGL_HP_ST_ZHK1P_EN_Rev00
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 Compressor range............................................................................................ 3
2.2 Nomenclature.................................................................................................. 3
2.3 Application range............................................................................................. 4
2.3.1 Qualified refrigerants and oils................................................................... 4
2.3.2 Application limits .................................................................................... 4
2.4 Dimensions..................................................................................................... 6
3Installation.....................................................................................................8
3.1 Compressor handling........................................................................................ 8
3.1.1 Transport and storage............................................................................. 8
3.1.2 Positioning and securing.......................................................................... 8
3.1.3 Installation location................................................................................. 8
3.1.4 Mounting parts....................................................................................... 9
3.2 Brazing procedure............................................................................................ 9
3.3 Pressure safety controls...................................................................................10
3.3.1 High-pressure protection........................................................................10
3.3.2 Low-pressure protection.........................................................................10
3.4 Crankcase heaters ..........................................................................................11
3.5 Soft starters....................................................................................................12
3.6 Discharge gas temperatureprotection................................................................12
3.6.1 Excessive discharge gas temperatures.....................................................14
3.7 Screens.........................................................................................................14
3.8 Mufflers..........................................................................................................14
3.9 Reversing valves.............................................................................................14
3.10Sound and vibration.........................................................................................15
3.11Compressor oil return,oilbalancing and floodback tests........................................15
3.12Suction line accumulator...................................................................................16
4Electrical connection ..................................................................................17
4.1 General recommendations................................................................................17
4.2 Electrical installation........................................................................................17
4.2.1 Wiring diagrams....................................................................................17
4.2.2 Terminal box.........................................................................................19
4.2.3 Motorwinding.......................................................................................21
4.3 Motor insulation...............................................................................................21
4.4 Motorprotection..............................................................................................21

AGL_HP_ST_ZHK1P_EN_Rev00
4.4.1 Internal line break motor protection..........................................................21
4.4.2 External protection with Kriwan................................................................21
4.5 Kriwan protectorfunctional check and failuredetection..........................................22
4.5.1 Checking the connection........................................................................22
4.5.2 Checking the compressor thermistorchain................................................22
4.5.3 Checking the protection module...............................................................22
4.6 High-potential testing .......................................................................................23
5Start-up & operation....................................................................................24
5.1 Strength pressure test......................................................................................24
5.1.1 Compressor strength-pressure test..........................................................24
5.1.2 Systemstrength-pressure test.................................................................24
5.2 Compressor tightness test ................................................................................24
5.3 Preliminarychecks –Pre-starting.......................................................................25
5.4 Charging procedure.........................................................................................25
5.5 Initial start-up..................................................................................................25
5.6 Rotationdirection............................................................................................26
5.7 Starting sound ................................................................................................26
5.8 Deep vacuum operation...................................................................................26
5.9 Shell temperature............................................................................................26
5.10Pumpdowncycle.............................................................................................26
5.11Pump-out cycle...............................................................................................27
5.12Minimum run time............................................................................................27
5.13Shut-off sound ................................................................................................27
5.14Supply frequency and voltage...........................................................................27
5.15Oil level..........................................................................................................28
5.16Oil stub..........................................................................................................28
6Maintenance & repair..................................................................................29
6.1 Exchanging the refrigerant................................................................................29
6.2 Rotalockvalves...............................................................................................29
6.3 Disassembling system components....................................................................29
6.4 Replacing a compressor...................................................................................30
6.4.1 Compressor replacement........................................................................30
6.4.2 Start-up of a new or replacement compressor............................................30
6.5 Lubrication and oil removal ...............................................................................30
6.6 Oil additives....................................................................................................31
7Troubleshooting..........................................................................................32
8Dismantling & disposal...............................................................................35
9References..................................................................................................35
DISCLAIMER...........................................................................................................35

AGL_HP_ST_ZHK1P_EN_Rev00 1
About these guidelines
The purpose of these guidelines is to provide guidance in the application of Copeland™scroll
compressors in users’ systems. It is intended to answer the questions rais ed while designing,
assembling and operating a system with these products.
Besidesthe support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the compressors. The performance and reliability of the product may be
impacted if the productis not used according to these guidelines oris misused.
These application guidelines cover stationaryapplications only. For mobile applications, please
contactthe Application Engineering department at Emerson as other considerations may apply.
1 Safety instructions
Copeland scroll compressors are manufactured according to the latest European and US safety
standards. Particular emphasis has been placed on the user’s safety.
These compressors are intended for installation in systems in accordance with the European
Machinery Directive MD2006/42/EC. They maybe putto service only if they have been installed in
these systems according to instructions and conformto the corresponding provisions of legislation.
For relevant standardsplease refer to the Manufacturer’s Declaration, available on request.
These instructions should be retained throughoutthe 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
dangerof electricshock.
IMPORTANT
This icon indicates instructions to
avoid malfunction of the compressor.
Danger of burning or frostbite
This icon indicates operations with a
dangerof burning or frostbite.
NOTE
This word indicates a
recommendation for easier operation.
Explosion hazard
This icon indicates operations with a
dangerof explosion.
1.2 Safetystatements
▪Refrigerant compressors must be employed only for their intendeduse.
▪Only qualified andauthorized HVACor refrigeration personnelare 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 AGL_HP_ST_ZHK1P_EN_Rev00
1.3 General instructions
WARNING
System breakdown! Personalinjuries! Never install a systemin the field
and leave it unattended when it has no charge, a holding charge, or with the
service valves closed withoutelectrically locking outthe system.
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils mustbe used.
WARNING
Pressurized system! Serious personal injuries and/or system
breakdown! The systemcontainsrefrigerant and oil under pressure. The
mixture of air and oil at high temperature can lead to an explosion (Diesel
effect).Avoid operating with air.
Never install a systemin 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.
Only approved refrigerants and refrigerationoils must be used.
Remove refrigerant fromboth high- and low-pressure sides with a suitable
recovery unit before removing compressor.
WARNING
High shell temperature! Burning! Do nottouch the compressor until it has
cooled down. Ensure that other materials in the area of thecompressor do
not come into contact with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without
refrigerant charge or withoutbeing connected to the system.
CAUTION
Contact with refrigerant oil! Material damage! POE lubricant must be
handled carefully and the proper protective equipment (gloves, eye
protection, etc.) must be used at all times.POEmust not come into contact
with any surface or material thatit might damage,including without limitation,
certain polymers, eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.

AGL_HP_ST_ZHK1P_EN_Rev00 3
2 Product description
2.1 Compressor range
These application guidelines deal with all vertical single Copeland scrollcompressors for dedicated
heat pump applications fromZH04K1P to ZH19K1P. They also covervapourinjectioncompressors
from ZHI08K1Pto ZHI46K1P.
Compressor
Heating
capacity
kW
Motor
Compressor
Heating
capacity
kW
Motor
ZH04K1P
4.17
PFZ/TFM
ZHI05K1P
5.26
TFM
ZH05K1P
4.98
PFZ/TFM
ZHI08K1P
8.13
PFZ/TFM
ZH06K1P
6.62
PFZ/TFM
ZHI11K1P
10.87
PFZ/TFM
ZH09K1P
8.96
PFZ/TFM
ZHI14K1P
14.03
TFM
ZH12K1P
11.45
PFZ/TFM
ZHI18K1P
19.00
TFM
ZH15K1P
15.05
TFM
ZHI23K1P
23.40
TFM
ZH19K1P
18.70
TFM
ZHI27K1P
26.56
TFD
ZHI32K1P
31.88
TFD
ZHI35K1P
35.80
TFD
ZHI40K1P
39.98
TFD
ZHI46K1P
46.57
TWD
Evaporating temperature: -7 °C; Condensingtemperature: 50 °C; Suction gas superheat: 5 K; Liquid sub-cooling:4 K,
Injection superheat:5 K
Table 1: Compressor models overview
These compressors have one scrollcompression set driven by a single- or three-phase induction
motor.The scroll setis mounted at the upper end of the rotor shaft of the motor. The rotor shaft
axis is in the vertical plane.
2.2 Nomenclature
The model designationcontains the following technical information about the standard and vapour
injection compressors:
Figure 1: Nomenclature

4 AGL_HP_ST_ZHK1P_EN_Rev00
2.3 Application range
2.3.1 Qualified refrigerants and oils
Oil recharge values can be taken fromCopeland scroll compressors brochuresor Copeland Select
software available at www.climate.emerson.com/en-gb.
Compressors
ZH04K1Pto ZH19K1P
ZHI05K1Pto ZHI46K1P
Qualified refrigerants
R410A
Copeland brand
products standard oil
EmkarateRL 323MAF
Servicing oil
EmkarateRL 323MAF
Table 2: Qualifiedrefrigerant andoil
2.3.2 Application limits
CAUTION
Inadequate lubrication! Compressor breakdown! Copeland scroll
compressors are qualified for operation inside the envelope published by
Emerson. The envelope is defined according to Emerson testing and
experience. Operating a compressor outside the envelope might lead to
compressor failure which would be the heat pump manufacturer’s
responsibility. The superheat at thecompressorsuctioninlet mustalways be
sufficient to ensure that no refrigerantdroplets enter the compressor. For a
typicalevaporator-expansion valveconfiguration a minimumstable superheat
of at least 5K is required.In the same way, the superheatat the compressor
suction must always stay below a maximum limit specified by Emerson,
depending on the model and for which the operating envelope is defined.
NOTE: The application envelopes shown below are for R410A.
ZH04K1P, ZH05K1P (up to S/N 15F) ZH04K1P, ZH05K1P (from S/N 15G onwards)
ZH06K1P to ZH19K1P (all S/N)
10
15
20
25
30
35
40
45
50
55
60
65
70
75
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
10
15
20
25
30
35
40
45
50
55
60
65
70
75
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
Max 10K suction superheat
Max 10K suction superheat, limitedoperation<2000 hours on a compressor lifetime
Max 5K suction superheat
Max 5K suction superheat, limitedoperation <2000hours on a compressorlifetime

AGL_HP_ST_ZHK1P_EN_Rev00 5
ZHI05K1P to ZHI23K1P ZHI27K1P to ZHI46K1P
Figure 2: Applicationenvelopes withR410A
For air-to-water heat pump applications, an additionalenvelope extensionmay be required for high
temperature water production in case of lowoutdoor temperature. This can be achieved by the use
of wet vapourinjection. For furtherinformationabout wet vapourinjection, contact Application
Engineering at Emerson.
NOTE: For information and design recommendations regarding vapour injection, please
refer to Technical InformationC7.4.3 "Vapour injection scroll compressors for heat pumps".
10
15
20
25
30
35
40
45
50
55
60
65
70
75
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
Condensing Temperature (oC)
Evaporating Temperature (oC)
R410A
Vapour injection 5K superheat
+ max 10K suction superheat
Vapour injection 5K superheat
+ max 10K suction superheat
Limited operation <2000 hours
on a compressor lifetime
Vapour injection 5K superheat
+ max 5K suction superheat
Vapour injection 5K superheat
+ max 5K suction superheat
Limited operation <2000 hours
on a compressor lifetime

6 AGL_HP_ST_ZHK1P_EN_Rev00
2.4 Dimensions
ZH04K1P, ZH05K1P ZH06K1P to ZH12K1P ZHI18K1P for tandem
ZHI05K1P ZHI08K1P to ZHI23K1P ZHI23K1P for tandem
ZH15K1P, ZH19K1P ZHI27K1P to ZHI32K1P ZHI35K1P, ZHI40K1P

AGL_HP_ST_ZHK1P_EN_Rev00 7
ZHI46K1P

8 AGL_HP_ST_ZHK1P_EN_Rev00
3 Installation
WARNING
High pressure! Injury to skinand 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.Respectstacking loads according to Figure 3. Check
the tilting stability and if needed take action to ensure the stability of the
stacked loads. Do not stack single boxes on top of each other. Keep the
packaging dry at all times.
Respect the maximumnumberof identicalpackages 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
The compressor tilt angle should not be more than 30° during transport and handling. This will
prevent oil fromexiting through thesuction stub.A tilt angle of maximum45° is allowed for a very
short time.Tilting the compressor more than 45° might affectits lubrication at start-up.
The suction stub on compressor models ZHI27K1P to ZHI46K1P is located at lowlevel. Oil might
flow through the suction stub and gettrapped in the system. To avoid this, Emerson strongly
recommends mounting the suction piping turning vertically upward from the compressor
connection. This will ensure that the oil gets back into the oil sump even when tilting at 30°.
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 compressor should be keptvertical during handling.
The discharge connection plug should be removed first before pulling the suction connection plug
to allow the dryair pressure inside the compressor to escape. Pulling the plugs in this sequence
prevents oil mist from coating the suctiontube making brazing 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 theair humidity does not
affect the oilcharacteristics
As oil might spill outof the suction connection located lowon theshell,the suction connection plug
must be left in place until the compressor is set into the unit.
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
Scroll compressors are capable of operating correctly with compressor ambient humidity within
30 % to 95 % and at altitudes up to 1000 meters. For correct operation the compressor ambient air
temperatures have to bewithin -40 to 60 °C and the compressor PSand TS have to be respected
at all times during operation and at a standstill.
Ensure the compressorsare installed on a solid level base. For single compressor application, the
compressortilt angle during operation should notbe more than 15° to allow adequate lubrication.

AGL_HP_ST_ZHK1P_EN_Rev00 9
For multiple compressor parallel configurations, thecompressorsmust be positioned completely
vertically on a totally horizontal surface or rail.
3.2 Mounting parts
The compressors are designed to be mounted on vibration absorber grommets (part of the
standard delivery). The grommets dampen the start-up surge of the compressor and minimise
sound and vibration transmission to thecompressor base during operation. The grommets are
supplied with the compressors. The metal sleeve inside is a guide designed to hold the grommetin
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 notcompressed.
If the compressors are mounted in tandem or used in parallel, then the hard mountings (bolt
M9 5/16") are recommended.The mounting torque should be 27 ± 1 Nm. It is possible to deliver
these hard mounting parts as a kit, or on request to deliver the compressor with theseparts instead
of the rubber grommets.
Mounting parts for single compressor applications:
ZH04K1P, ZH05K1P: 3 pieces per compressor
ZH06K1P to ZH19K1P, ZHI05K1P to ZHI23K1P: 4 pieces per compressor
Mounting parts for single compressor applications:
ZHI27K1P to ZHI46K1P: 4 pieces per compressor
Figure 4: Rubber mounting parts with sleeve andwasher
NOTE: For more information, please refer to TechnicalInformation C7.11.2 "Scroll Mounting
Parts".
3.3 Brazing procedure
CAUTION
Blockage! Compressor breakdown! Maintain a flow of oxygen-free
nitrogen through the systemat very low-pressure during brazing. Nitrogen
displaces the air and prevents the formationof copper oxides in the system.
If allowed to form, the copper oxide materialcan later be sweptthrough the
system and block screenssuch as those protecting capillary tubes, thermal
expansion valves, and accumulator oil return orifices.
Contamination or moisture! Bearing failure! Do not remove the
connectionplugs until the compressor is setinto the unit. This minimisesany
entry of contaminants and moisture.
Copeland scroll compressorshave copper-plated steel
suction,injection and discharge tubes. These tubes are
farmore robust and less prone to leaks than copper
tubes. Dueto the different thermal properties of steel
and copper, brazing procedures may have to be
changed fromthosecommonly used.
Figure 5: Suctiontube connectingareas

10 AGL_HP_ST_ZHK1P_EN_Rev00
Referto Figure 5 above and procedure below for the brazing of the suction and discharge lines to
a scroll compressor.
▪The copper-coated steel tubes on scroll compressors can be brazed in approximatelythe same
manneras any coppertube.
▪Recommended brazing materials: any silfos material is recommended, preferably with a
minimum of 5 % silver. However, 0 % silveris acceptable.
▪Be sure tube fitting inner diameterand tube outer diameter are clean priorto 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 asnecessary to heatthe tube evenly. Add braze material to the joint while
moving the torch around the jointto flow braze materialaround 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 maybe detrimental to the final result.
To disconnect:
▪Heat joint areas 2 and 3 slowly and uniformly until the braze material softensand the tube can
be pulled out ofthe fitting.
To reconnect:
▪Recommended brazing materials: Silfoswith minimum 5 % silver or silver braze used on other
compressors. Due to the different thermal propertiesof steel and copper,brazing procedures
may have to bechanged from those commonly used.
NOTE: Since the dischargestub contains a check valve, care mustbe taken not to overheat
it to prevent brazing material fromflowinginto it.
NOTE: Since the injection tubing design of the ZHI*K1P compressors includes some
O-rings, a wetrag or any other suitable heat protection device mustbe used when brazing
the injection line to the compressor.
3.4 Pressure safetycontrols
3.4.1 High-pressure protection
Applicable regulations and standards,for example EN 378-2, shall be followed to apply appropriate
control and ensure that the pressure never exceeds the maximumlimit.
High-pressure protection is required to stop the compressor operating outside the allowable
pressure limits. The high-pressure control must be installed correctly, which means thatno service
valve is allowed between the compressor and the pressure protection.
The high-pressure cut-outsetting shall be determined according to the applicable standard, the
type of system, the refrigerantand the maximumallowable pressure PS.
3.4.2 Low-pressure protection
CAUTION
Operation outside the application envelope! Compressor breakdown! A
low-pressure protection shall be fitted in the suction line to stop the
compressorwhen it operates outside the envelope limits.
Applicable regulations and standardsshall be followed to apply appropriate control and ensure that
the pressure is always above the required minimum limit.
Low-pressure protection is required to stop the compressor operating outside the allowable
envelope limits. The low-pressure control must be installed correctly into the suction line, which
means that no service valve is allowed between the compressor and the pressure protection.
The minimum cut-outsetting shall be determined according to the refrigerant and the allowed
operation envelope –see Select software at www.climate.emerson.com/en-gb.

AGL_HP_ST_ZHK1P_EN_Rev00 11
3.5 Crankcase heaters
CAUTION
Overheating and burnout! Compressor damage! Never apply power to
the crankcase heater in free air, before the crankcase heater isinstalled on
the compressor or when it is not in complete contact with the compressor
shell.
IMPORTANT
Oil dilution! Bearingmalfunction! Turn the crankcase heater on 12 hours
before starting the compressor.
A crankcase heater is used to prevent refrigerant from migrating into the shell during standstill
periods. The installation of a crankcase heater is required when the system charge exceeds the
compressorcharge limits indicated in Table 3. This requirement isindependent fromsystem type
and configuration.
Compressormodel
Refrigerantchargelimit
Single compressorsystems
Refrigerantchargelimit
Even Tandem systems
ZH04K1P& ZH05K1P
3.6 kg
5.0 kg
ZH06K1Pto ZH12K1P
ZHI05K1Pto ZHI14K1P
4.5 kg
6.3 kg
ZH15K1P& ZH19K1P
ZHI18K1P& ZHI23K1P
4.5 kg
6.3 kg
ZHI27K1Pto ZHI46K1P
7 kg
10.9kg
Table 3: Refrigerantcharge limit
For compressor models ZH04K1Pto ZH19K1P and
ZHI05K1P to ZHI23K1P, the crankcaseheater must
be mounted 10 to 40 mm above compressor legs –
see Figure 6.
Figure 6: Crankcase heater location, models ZH04K1P toZH19K1P andZHI05K1P toZHI23K1P
For compressor models ZHI27K1Pto ZHI46K1P, the
crankcase heater must be mounted below the oil
removal valve located on the bottom shell for tandem
versions –see Figure 7.
Figure 7: Crankcase heater location, models ZHI27K1P toZHI46K1P
The initial start-up in the field is a very critical period for any compressor because all load-bearing
surfacesare newand require a short break-in period to carry high loadsunder adverse conditions.
The crankcase heater must be turned on a minimum of 12 hours prior to starting the
compressor. This will prevent oil dilution and bearing stresson initial start -up. The crankcase
heater must remain energizedduringcompressor off cycles.
NOTE: Please refer to the Spare Parts list available at www.climate.emerson.com/en-
gb/tools-resources to select the correct crankcase heater model.
Caution: Crankcase heaters must be properly grounded!
For installation, the manufacturer/installer shallfollowthe recommendations mentioned below.
Assembly instructions
▪Choose the appropriate model according to compressor size and required wattage.
▪Check the compressor application guidelines for crankcase heater connection and operation.
▪Positionthe crankcase heaterbetween the lowercover and the lower bearing weld projection
(Fig. 8).

12 AGL_HP_ST_ZHK1P_EN_Rev00
▪Fit the heater horizontally around the crankcase, ensuring that it is in close contact with the
compressorhousing along theentire length.
▪Avoid having the heating portion of the heaterin contactwith any weld projection (Fig. 9 & 10).
▪Avoid having the assembly heater inclined (Fig.11).
▪Close the lock and tighten the screw,torque: 2-3 Nm.
▪The excess clamp bracketmaybe trimmed. Sharp edges must not come into contact with wires.
▪The presence of the heater shallbe made evident by the posting of caution signs ormarkings at
appropriate locations.
Figure 8 Figure 9 Figure 10 Figure 11
Electrical connection
▪Connect the crankcase heater according to the compressor application guidelines.
▪The crankcase heater mustbe connected only to its rated voltage.
▪The metal braid of the heater mustbe connected to a suitableearthing terminal.
▪Check the resistance according to the technical data.
▪Performan insulation test before start-up.
▪Electrical security and safety measures are to be provided on site.
3.6 Soft starters
Softstarters can be used with the 20 to 40 hp Copeland scroll compressors to reduce inrush
current. Soft starters should be selected according to the soft starter manufacturer's
recommendations, taking into consideration ambient temperature,number of starts per hour, and
compressoramps. The maximumramp-up time should not exceed 3 seconds.
Due to the inherent design of the Copeland scroll, the internal compression components start
unloaded, evenif systempressures are notbalanced. Since the compressor internal pressuresare
balanced at start-up, low voltage starting characteristics are excellent, and starting components are
normally notrequired.
However, for extremeelectricalconditionssuch as weakpower supplies, single-phase soft starters
can be supplied on request by Emerson, while three-phase soft starters are available on the
market.
3.7 Discharge gas temperature protection
CAUTION
Inadequate lubrication! Scroll set damage! Compressors ZH04K1P to
ZH19K1P and ZHI05K1P to ZHI46K1P mustbe equipped with a discharge
gas temperature protection.
A good system control shall preventthe systemfromoperating outside the published operating
envelope and acceptable superheat range, whatever the climatic conditions and the capacity
demand. However, under some extreme operating conditionssuch as loss of charge or improper
control operation, the internal discharge gas temperature reached can cause compressor damage.
In order to ensure positive compressor protection, discharge gas temperature protection is required
for any applicationwith Copeland compressors.
For compressors ZH04K1P to ZH19K1Pthe maximumdischarge gastemperature is 140 °C. For
compressors ZHI18K1P and ZHI23K1Psingle BOM526 and ZHI05K1Pto ZHI14K1Pit is 135 °C.
These compressors mustbe equipped with an external discharge gas temperature protection –see
Figure 12. The protection shall be installed 120 mm fromthe compressor shell, along the straight
or bended pipe.

AGL_HP_ST_ZHK1P_EN_Rev00 13
Figure 12: Sketch ofdischarge gas temperature protectionfor compressors withexternal sensor
For compressors ZHI18K1P and ZHI23K1P tandem-ready BOM 477 and for compressors
ZHI27K1P to ZHI46K1P, the maximum discharge gas temperature is 135°C. These compressors
are equipped with a NTC-temperature sensor in the top cap –see Figure 13. This sensor
measures the discharge gastemperature in the top cap and mustbe connected to the controller,
eg, EXD TEVI (contact Emerson formore information). The controller has to stop the compressor
when the maximum discharge gas temperature is exceeded.
Figure 13: NTC sensor in top cap and resistance values for compressors ZHI18K1P and ZHI23K1P tandem ready
BOM 477 and ZHI27K1P to ZHI46K1P
In case the NTC top cap sensor shown in Figure 13 has to be replaced please refer to the Spare
parts catalogue available at www.climate.emerson.com/en-gb for the replacement kit with all
needed parts.
Please followinstructions hereunder:
▪Remove the existing thermally conductive compound
from the thermal well.
▪Dispense 0.75-1 cm3of thermally conductive compound
into the bottom of the thermal well.
▪Clean any debris, grease or dirt from the upper cap
surface outside the thermistor tubeopening along with the inside
tube surface. If the areas shown are not clean, the silicone
sealant will not adhere to the compressor.
▪Apply a 5 mm bead of silicone sealant (Copeland ident
nr 8413046) on the thermistor in areas indicated.
▪After installation, the thermistor must be flushed with the
top cap on, and the sealmust be watertight.
Figure 14: Replacementofthe NTC top cap sensor
Discharge gas temperature protection is the "fall-back" for failure of the system control. It is
essential that proper control of both the evaporating and condensing pressures and the superheat
is maintained and has theability to cope with all likely conditions and high loads. Reliance on
protectors willcause inadequate system performance and short cycling.
Temperature
in °C
Resistance
in KΩ
Temperature
in °C
Resistance
in KΩ
-40 2889.60 80 10.79
-30 1522.20 90 7.87
-20 834.72 100 5.85
-10 475.74 110 4.45
0 280.82 120 3.35
10 171.17 130 2.58
20 107.44 140 2.02
25 86.00 150 1.59
30 69.28 160 1.25
40 45.81 170 1.01
50 30.99 180 0.83
60 21.40 190 0.68
70 15.07 - -
Spring coil

14 AGL_HP_ST_ZHK1P_EN_Rev00
NOTE:The maximum discharge gas temperatures indicated in this chapter are valid for safe
operation within the approvedapplication envelope.The discharge line thermostat has the
function of a compressor protection device; it is not designed to control the operating
envelope. For compressor envelope control, an additional control device or regulation must
be used.
3.7.1 Excessive discharge gas temperatures
A few of the possible consequences of excessive discharge gas temperatures are listed below:
▪Since the oil circulates in the systemwith the refrigerant, it is subjected to high discharge gas
temperatures.If the discharge gas temperature becomes too high,the so-called "cooking"effect
will occur(heating of oil under exclusion of air). Carbon deposits can form at points of high
temperature, for example on the valves, oil channels, oil filters, etc. The oil lubricity will be
reduced and a progressive wear process will occur which will prematurely damage the
compressor.
▪The stability of the refrigerant can also be affected, particularly if traces of contaminant are
present.
The problems described above frequently occur simultaneously, particularly since the chemical
reaction speed approximatelydoubles with every10 °C temperature rise. This directly leads to
chemical reactions of the oil with the refrigerant and the compounds extracted from sealants and
insulation material.As a consequence,contaminants of various types,among themacids, will form
inside the system.
NOTE: For more information, please refer to Technical Information C7.8.6 "Discharge Gas
Temperature Protection for Copeland™Heat Pump compressors".
3.8 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 withthese compressors. Field experience has shown that finer mesh screens used to
protectthermalexpansionvalves,capillary tubes oraccumulators can become temporarily or
permanently plugged with normal systemdebris and block the flowof either oil orrefrigerant to the
compressor. Such blockage can result in compressor failure.
3.9 Mufflers
External mufflers, normally applied to pistoncompressors 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 attenuationis not achieved, use a mufflerwith a larger cross-sectional area to inlet area
ratio. A ratio of 20:1 to 30:1 is recommended.
A hollow shellmuffler will work quite well. Locate the muffler at minimum 15 to maximum 45 cm
from the compressor forthe most effective operation. The fartherthe muffler is placed from the
compressorwithin these ranges, the more effective.Choose a muffler with a length of 10 to 15 cm.
3.10 Reversing valves
Since Copeland scroll compressorshavea very high volumetric efficiencytheir displacements are
lower than those of equivalent capacity reciprocating compressors. As a result, Emerson
recommends that the capacity rating on reversing valves be no more than 1.5 to 2 times the
nominal capacity of the compressor in order to ensure proper operation of t he reversing valve
under all operating conditions.
The reversing valve solenoid should be wired so that the valve does not reverse when the system
is shut offby the operating thermostatin the heating or cooling mode. If the valve is allowed to
reverse at system shut off, suction and discharge pressuresare reversed to the compressor. This
results in a condition of system pressures equalising through the compressor which can cause the
compressorto slowly rotate until the pressures equalise.This condition does not affectcompressor
durability but can cause unexpected sound after the compressor is turned off.

AGL_HP_ST_ZHK1P_EN_Rev00 15
Figure 15: Suctiontube design
3.11 Sound and vibration
Vibrations during compressor operation can cause cracks which could lead to refrigerantleakage.
This situation must be avoided by the systemmanufacturer/installer. To this end, the pipework
must be carefully designed when connecting a scroll compressor to a system.
A scroll compressormakesboth a rocking and twisting
motion and enough flexibility mustbe provided in the
pipe-lines to allowstarting,stopping and steady state
running of the compressor without transmitting
excessive stress into any line attached to the unit.In a
split system, the most important goal is to ensure
minimal vibration in all directions to avoid transmitting
vibrations to the structure to which the lines are
fastened.
Under some conditions, the Copeland scroll has a
normal starting rotational motion that can transmit a
transient noise along the lines. This may be
particularly pronounced in compressorsusing a three-
phase motor due to their inherently higher starting
torque. This phenomenon, like the one described
previously, can easily be avoided by using standard
line isolation techniques.
The sound level of asystem isthe resultof design, quality and application. Scroll compressors
sound powerlevels generally increase with thecompressor model capacity and the condition
pressure ratio.
3.12 Compressoroil return, oil balancingandfloodback tests
CAUTION
Inadequate lubrication! Bearing andmovingparts destruction! Ensure
adequate oil return from the system into the compressor at any time. No
liquid refrigerant return to the compressor. Liquid refrigerant dilutes the oil,
could wash the oil off the bearings and moving parts and could lead to
overheating and compressor failure.
The system piping mustbe carefully designed to ensure sufficient refrigerantgas velocity, so that
oil returns to the compressor at all times and conditions.Individual piping diameter calculation
depends on the refrigerant properties, pressure level, mass flow,and density.
Once a new system design is set and assembled, a functional testis required. The functional test
includes a qualification for the general systemoil return and a refrigerantfloodback test. Systems
with multiple compressor applications (two, three, or more) require additional oil balancing
qualification between the parallelcompressors.
A sample compressor equipped withan external oil sight tubecan beordered from Emerson for lab
testing.
Records ofthe evaporating temperature and the bottom shell temperature shall be taken with a
high sampling rate during the entire oil return or oil balance testing and under all tested conditions.
The liquid levelin the sight tube has to be observed and recorded too. Testing conditions shall
include defrostand varying loads.If thesystem is reversible,the tests should be conducted in both
operation modes.
System engineersshould reviewthe system design and operation to identify the critical conditions
and to check oil return,oilbalancing and liquid floodback. Typically, the following situations should
be considered:
▪In single compressor systems: to check oil return, testing conditions shall be at minimum
mass flow and minimumdensity of suction gas in continuousand frequent start-stop-cycling.
▪In multiple compressor systems: to check oil return and oil balancing in the tandem or trio,
testing conditions shall be at the corner points of the systemapplication envelope in continuous
and frequentstart-stop-cycling.
▪In all systems: to test liquid floodback, all possible transient operation conditions in the system
should be checked, eg, compressorfrequent start/stop,compressorstart afterlong off time with
migration, defrost, switching between the operation modes in reversible systems, load changes,

16 AGL_HP_ST_ZHK1P_EN_Rev00
fans or pumpscycling at low load and more. To evaluate the risk of liquid floodback, please
refer to the oildilution chart in Figure 16.Liquid level andsuperheat at compressor inlet have to
be checked.
The bottom shell temperature together with the evaporating temperature gives an indication
whetherliquid refrigerant is returning ordiluted in the compressor oil sump.The compressor sump
temperature must remain in the (green) safe area, as shown in the oil dilution chart in Figure 16
below. In case of operation in the (red) unsafe area, adjustments are required in order to modify the
system design,refrigerant charge or superheat setting of the expansion device(s).The bottomshell
temperature should be measured accurately. The thermo-probe must be positioned on the opposite
side of the sight glass or at an angle of 90° clockwise from the suction inletwith viewon the top.
Figure 16: Oil dilution chart (tb = bottom shell temperature;te = evaporatingtemperature)and oil temperature
3.13 Suction line accumulator
Due to Copeland scroll’s inherent ability to handle liquid refrigerant, for example in f looded start
and defrost cycleoperation, an accumulator is not requiredin most systems.
To determine if a suction line accumulator is required, the system designer must check this with an
appropriate test scenario. See section 3.11 "Compressor oil return, oil balancing and
floodback tests".
If an accumulatoris used, the oil-return orifice should be from1 to 1.4 mm in diameter for all ZH(I)*
modelsdepending on compressor size and compressor floodbackresults. To protect this small
orifice from plugging with systemdebris a large-area protective screen no finer than 30 x 30 mesh
(0.6 mm openings)is required. Tests have shown thata small screen with a fine mesh can easily
becomeplugged causing oil starvation to the compressor bearings. The size of the accumulator
depends upon the operating range of the systemand the amountof sub-cooling and subsequent
head pressure allowed bythe refrigerant control.For the correct selection and size of the suction
line accumulator, ref er to the manufacturer’s specifications.

AGL_HP_ST_ZHK1P_EN_Rev00 17
4 Electrical connection
4.1 General recommendations
The compressor terminal boxhas a wiring diagram on the inside of its cover. Before connecting the
compressor, ensure the supply voltage, the phasesand the frequency match the nameplate data.
4.2 Electrical installation
4.2.1 Wiring diagrams
The recommended wiring diagrams are shown in figureshereunder.
NOTE: Emerson recommends using a contactor K2 for the safety chain in order to comply
with EN60335.
Single-phase (PF*) compressors
For the ZH04K1P to ZH12K1P and ZHI05K1P& ZHI11K1Pranges of compressors the following
circuit diagrams can be used:
Power circuit Control circuit
L1
K1
K2
K1
K2
S1
P>
P<
F3
F4
B3
K2
R2
N1 2 3 4
Y5
B1
K1
B1
F1
Motor terminal connections
Single-phase compressors are connected to the
Common (C), Start (S) and Run (R) connections
Legend
B1...........System controller K1, K2......Contactors
B3...........Discharge gas thermostat Q1 ...........Main switch
C2...........Run capacitor R2............Crankcase heater
F1, F6......Fuses S1............Auxiliary switch
F3...........HP limiter Y5............Solenoid valve for injection (ifavailable)
F4...........LP switch RCD.........Residual current device
Figure 17: Wiringdiagrams forsingle-phase compressors