Emerson COPELAND ZH04K1P User manual

Copeland Scroll Compressors
for Heat Pumps with R410A
ZH04K1P to ZH19K1P, ZHI05K1P to ZHI46K1P
TM

C6.2.26/1013-1116/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 Common information about Copeland Scroll™ compressors............................................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 Accumulators ...................................................................................................................10
3.4 Screens............................................................................................................................11
3.5 Mufflers ............................................................................................................................11
3.6 Reversing valves..............................................................................................................11
3.7 Suction line noise and vibration.......................................................................................12
4Electrical connection...................................................................................... 13
4.1 General recommendations...............................................................................................13
4.2 Electrical installation ........................................................................................................13
4.2.1 Wiring diagrams ...................................................................................................13
4.2.2 Terminal box.........................................................................................................15
4.2.3 Motor winding.......................................................................................................16
4.2.4 Protection devices................................................................................................17
4.2.5 Crankcase heaters ...............................................................................................17
4.2.6 Soft starters..........................................................................................................17
4.3 Pressure safety controls ..................................................................................................18
4.3.1 High-pressure protection......................................................................................18
4.3.2 Low-pressure protection.......................................................................................18
4.4 Discharge gas temperature protection.............................................................................18
4.5 Motor protection...............................................................................................................19
4.5.1 Internal line break motor protection......................................................................19
4.5.2 External protection with Kriwan............................................................................19

C6.2.26/1013-1116/E
4.6 Kriwan protector functional check and failure detection ..................................................20
4.6.1 Checking the connection......................................................................................21
4.6.2 Checking the compressor thermistor chain..........................................................21
4.6.3 Checking the protection module...........................................................................21
4.7 High-potential testing .......................................................................................................21
5Starting up & operation................................................................................... 22
5.1 Strength pressure test......................................................................................................22
5.2 Tightness/pressure test....................................................................................................22
5.3 Preliminary checks –Pre-starting....................................................................................22
5.4 Charging procedure .........................................................................................................22
5.5 Initial start-up ...................................................................................................................23
5.6 Rotation direction.............................................................................................................23
5.7 Starting sound..................................................................................................................23
5.8 Deep vacuum operation...................................................................................................23
5.9 Shell temperature.............................................................................................................23
5.10 Pump-down cycle.............................................................................................................24
5.11 Pump-out cycle ................................................................................................................24
5.12 Minimum run time ............................................................................................................24
5.13 Shut-off sound..................................................................................................................24
5.14 Supply frequency and voltage .........................................................................................24
5.15 Oil level ............................................................................................................................25
5.16 Oil stub.............................................................................................................................25
6Maintenance & repair...................................................................................... 26
6.1 Exchanging the refrigerant...............................................................................................26
6.2 Rotalock valves................................................................................................................26
6.3 Replacing a compressor..................................................................................................26
6.3.1 Compressor replacement.....................................................................................26
6.3.2 Start-up of a new or replacement compressor.....................................................26
6.4 Lubrication and oil removal..............................................................................................26
6.5 Oil additives .....................................................................................................................27
6.6 Unbrazing system components .......................................................................................27
7Troubleshooting.............................................................................................. 28
8Dismantling & disposal................................................................................... 32
9References....................................................................................................... 32
DISCLAIMER ............................................................................................................... 32

C6.2.26/1013-1116/E 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 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 only. For mobile applications, please
contact the Application Engineering department at Emerson Climate Technologies 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 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 Manufacturer’s 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.
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.
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Trouble-
shooting
Dismantling &
disposal
References

2 C6.2.26/1013-1116/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
Pressurized system! Serious personal injuries and/or system
breakdown! The system contains refrigerant 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 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.
Only approved refrigerants and refrigeration oils must be used.
Remove refrigerant from both high- and low-pressure sides with a suitable
recovery unit before removing compressor.
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 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.
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.

C6.2.26/1013-1116/E 3
2 Product description
2.1 Common information about Copeland Scroll™compressors
The Scroll compressor has been under development at Emerson Climate Technologies since
1979. It is the most efficient and durable compressor Emerson Climate Technologies has ever
developed for air-conditioning, refrigeration and heating applications.
These application guidelines deal with all vertical single Copeland Scroll compressors for
dedicated heat pump applications from ZH04K1P to ZH19K1P. They also cover vapour
injection compressors from ZHI08K1P to 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; Condensing temperature: 50°C; Suction gas superheat: 5K; Liquid sub-cooling: 4K,
Injection superheat: 5K
These compressors have one Scroll compression set driven by a single or three-phase induction
motor. The Scroll set is mounted at the upper end of the rotor shaft of the motor. The rotor shaft
axis is in the vertical plane.
2.2 Nomenclature
The model designation contains the following technical information about the standard and
vapour injection compressors:
Figure 1: Nomenclature
Safety
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Starting up &
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References

4 C6.2.26/1013-1116/E
2.3 Application range
2.3.1 Qualified refrigerants and oils
Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland™
brand products Select software available at www.emersonclimate.eu.
Compressors
ZH04K1P to ZH19K1P
ZHI05K1P to ZHI46K1P
Qualified refrigerants
R410A
Copeland brand products
standard oil
Emkarate RL 32 3MAF
Servicing oil
Emkarate RL 32 3MAF
Table 1: Qualified refrigerant and oil
2.3.2 Application limits
CAUTION
Inadequate lubrication! Compressor breakdown! Copeland Scroll
compressors are qualified for operation inside the envelope published by
Emerson Climate Technologies. The envelope is defined according to
Emerson Climate Technologies 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 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. In
the same way, the superheat at the compressor suction must always stay
below a maximum limit specified by Emerson Climate Technologies,
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, limited operation <2000 hours on a compressor lifetime
Max 5K suction superheat
Max 5K suction superheat, limited operation <2000 hours on a compressor life time

C6.2.26/1013-1116/E 5
ZHI05K1P to ZHI23K1P ZHI27K1P to ZHI46K1P
Figure 2: Application envelopes with R410A
For air-to-water heat pump applications, an additional envelope extension may be required for
high temperature water production in case of low outdoor temperature. This can be achieved by
the use of wet vapour injection. For further information about wet vapour injection, contact
Application Engineering at Emerson Climate Technologies.
NOTE: For information and design recommendations regarding vapour injection, please
refer to Technical Information C7.4.3 "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
Safety
instructions
Product
description
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Electrical
connection
Starting up &
operation
Maintenance &
repair
Trouble-
shooting
Dismantling &
disposal
References
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 C6.2.26/1013-1116/E
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

C6.2.26/1013-1116/E 7
ZHI46K1P
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description
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connection
Starting up &
operation
Maintenance &
repair
Trouble-
shooting
Dismantling &
disposal
References

8 C6.2.26/1013-1116/E
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. Do not stack single boxes on top of each other. 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
The compressor tilt angle should not be more than 30° during transport and handling. This will
prevent oil from exiting through the suction stub. A tilt angle of maximum 45° is allowed for a
very short time. Tilting the compressor more than 45° might affect its lubrication at start-up.
The suction stub on compressor models ZHI27K1P to ZHI46K1P is located at low level. Oil
might flow through the suction stub and get trapped in the system. To avoid this, Emerson
Climate Technologies 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 kept vertical during handling.
The discharge connection plug should be removed first before pulling the suction connection
plug to allow the dry air pressure inside the compressor to escape. Pulling the plugs in this
sequence prevents oil mist from coating the suction tube making brazing 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
As oil might spill out of the suction connection located low on the shell, the suction connection
plug must be left in place until the compressor is set into the unit.
No object, eg, a swaging tool should be inserted deeper than 51 mm into the suction tube or it
might damage the suction screen and motor.
3.1.3 Installation location
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 be within -40°C to 60°C and the compressor PS and TS have to be
respected at all times during operation and at a standstill.
Ensure the compressors are installed on a solid level base. For single compressor application,
the compressor tilt angle during operation should not be more than 15° to allow adequate

C6.2.26/1013-1116/E 9
lubrication. For multiple compressor parallel configurations, the compressors must be positioned
completely vertically on a totally horizontal surface or rail.
3.1.4 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 the compressor base during operation. The grommets are
supplied with the compressors. 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.
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 these parts
instead of the rubber grommets.
NOTE: For more information, please refer to Technical Information C7.11.2 "Scroll
Mounting Parts".
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 and washer
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.
Safety
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Starting up &
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References

10 C6.2.26/1013-1116/E
Copeland Scroll compressors have copper-plated
steel suction, injection 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 5 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 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.
NOTE: Since the injection tubing design of the ZHI*K1P compressors includes some
O-rings, a wet rag or any other suitable heat protection device must be used when
brazing the injection line to the compressor.
3.3 Accumulators
CAUTION
Inadequate lubrication! Bearing and moving parts destruction! Minimise
liquid refrigerant returning to the compressor. Too much refrigerant dilutes
the oil. Liquid refrigerant can wash the oil off the bearings and moving parts
leading to overheating and bearing or compressor failure.
Due to Copeland Scroll compressors inherent ability to handle liquid refrigerant in flooded start
and defrost cycle operation, an accumulator is not required for durability in most systems.
However, large volumes of liquid refrigerant repeatedly flooding back to the compressor during
normal off cycles, or excessive liquid refrigerant flooding back during defrost or varying loads,
can dilute the oil, no matter what the system charge is. As a result, bearings and moving parts
will be inadequately lubricated and wear may occur.
To determine if the accumulator can be removed, dedicated tests must be carried out to ensure
that excessive liquid does not flood back to the compressor during defrost or varying loads. The
defrost test must be done at an outdoor ambient temperature of around 0°C in a high humidity
environment. Liquid floodback must be monitored during reversing valve operation, especially
when coming out of defrost. Excessive floodback occurs when the sump temperature drops
below the safe operation line shown in Figure 6.
If an accumulator has to be used, the oil-return orifice should be from 1 to 1.4 mm in diameter for
models ZH04K1P to ZH19K1P and ZHI05K1P to ZHI23K1P, and 2.0 mm for models ZHI27K1I to
ZHI46K1P, depending on compressor size and compressor floodback results. A large-area
protective screen no finer than 30 x 30 mesh (0.6 mm openings) is required to protect this small
Figure 5: Suction tube connecting areas

C6.2.26/1013-1116/E 11
orifice from plugging with system debris. Tests have shown that a small screen with a fine mesh
can easily become plugged causing oil starvation to the compressor bearings.
The size of the accumulator depends upon the operating range of the system and the amount of
subcooling and subsequent head pressure allowed by the refrigerant control. System modelling
indicates that heat pumps that operate down to and below -18°C will require an accumulator that
can hold around 70% to 75% of the system charge.
Figure 6: Dilution chart for transient operation (tb = bottom shell temperature; te = evaporating temperature)
Note 1: Low load operation may be acceptable in the yellow marked area. Please contact
the Application Engineering department at Emerson Climate Technologies.
3.4 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.
3.5 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 these ranges, the more effective. Choose a muffler with a length of 10 to
15 cm.
3.6 Reversing valves
Since Copeland Scroll compressors have a very high volumetric efficiency their displacements
are lower than those of equivalent capacity reciprocating compressors. As a result, Emerson
Climate Technologies 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 the
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 off by the operating thermostat in the heating or cooling mode. If the valve is
allowed to reverse at system shut off, suction and discharge pressures are reversed to the
Safety
instructions
Product
description
Installation
Electrical
connection
Starting up &
operation
Maintenance &
repair
Trouble-
shooting
Dismantling &
disposal
References

12 C6.2.26/1013-1116/E
Figure 7: Suction tube design
compressor. This results in a condition of system pressures equalising through the compressor
which can cause the compressor to slowly rotate until the pressures equalise. This condition
does not affect compressor durability but can cause unexpected sound after the compressor is
turned off.
3.7 Suction line noise and vibration
Proper pipe design must be taken into consideration when connecting a scroll compressor to the
system. A scroll compressor makes both a rocking and
twisting motion and enough flexibility must be
provided in the pipe-lines to allow starting, 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 compressors using 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 a system is the result of design, quality and application. Scroll compressors
sound power levels generally increase with the compressor model capacity and the condition
pressure ratio.

C6.2.26/1013-1116/E 13
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
4.2.1 Wiring diagrams
The recommended wiring diagrams are shown in figures hereunder.
NOTE: Emerson Climate Technologies recommends using a contactor K2 for the safety
chain in order to comply with EN 60335.
Single-phase (PF*) compressors
For the ZH04K1P to ZH12K1P and ZHI05K1P & ZHI11K1P ranges 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 (if available)
F4 ...............LP switch RCD.......... Residual current device
Figure 8: Wiring diagrams for single-phase compressors
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Three-phase compressors (TF*) with internal motor protection
For the ZH04K1P to ZH19K1P and ZHI05K1P to ZHI40K1P ranges 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
Three-phase compressors are connected to the
T1, T2 and T3 connections
Legend
B1 ...............System controller Q1........... Main switch
B3 ...............Discharge gas thermostat R2........... Crankcase heater
F1, F6, F8...Fuses S1........... Auxiliary switch
F3 ...............HP limiter Y5........... Solenoid valve for injection (if available)
F4 ...............LP switch RCD........ Residual current device
K1, K2.........Contactors
Figure 9: Wiring diagrams for three-phase compressors with internal motor protection

C6.2.26/1013-1116/E 15
Three-phase compressors (TWD) with external motor protection INT69SU2
For ZHI46K1P compressors the following circuit diagrams can be used:
Power circuit Control circuit
L1
K1
K2
S1
P>
P<
F3
F4
K2
R2
N1 3 4
B1
K1
B1
F1
A1
T1/L
T2/N
S1 S2 M1
M2
2
Motor terminal connections
Three-phase compressors are connected to the
T1, T2 and T3 connections
Legend
A1 ...............Motor protection module INT69SU2 K1, K2.........Contactors
B1 ...............Room thermostat Q1...............Main switch
F1, F6, F8...Fuses R2...............Crankcase heater
F3 ...............HP limiter S1...............Auxiliary switch
F4 ...............LP switch
Figure 10: Wiring diagrams for three-phase compressors with external motor protection
4.2.2 Terminal box
The terminal box is IP21 for ZH04K1P to ZH19K1P and ZHI08K1P to ZHI14K1P models, ie,
TF*/PF*.
For compressor ZHI18K1P single BOM 526 the terminal box is IP21 and for compressor
ZHI18K1P tandem ready BOM 476 the terminal box is IP54.
For ZHI27K1P to ZHI40K1P models, the terminal box is IP54, enclosure class according to IEC
60034-5.
Respect the torques for the screw connections at the terminals according to Table 2 hereunder:
Compressor model
Grounding screw
torques
Terminals screw
torques
Maximum thickness
of cable shoe
according to Fig. 11
ZH04K1P to ZH09K1P
ZHI05K1P to ZHI08K1P
2.4 - 2.6 Nm
Fast-on cable shoes
ZH12K1P to ZH19K1P
ZHI11K1P to ZHI23K1P
2.4 - 2.6 Nm
2.4 - 2.6 Nm
1 mm
ZHI27K1P to ZHI46K1P
2.4 - 2.6 Nm
1.5 - 2.1 Nm
2 mm
Table 2: Torques of screws for electrical connection
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16 C6.2.26/1013-1116/E
Figure 11: Maximum thickness of cable shoe connectors
Cable glands have an influence on the protection class of the terminal box. It is strongly
recommended to use appropriate cable glands in order to reach the rated protection class.
Emerson Climate Technologies advises installers/service providers to pay attention to this
aspect every time they install or replace a Copeland Scroll compressor and to use cable glands
according to EN 50262 or any other relevant standard of application in their country/region.
Examples of correct electrical installations are shown in Figures 12 & 13 below.
Figure 12: Correct electrical installation with cable glands for IP21 T-box, eg, model ZH04K1P
Figure 13: Correct electrical installation with cable glands for IP54 T-box (model ZHI46K1P)
4.2.3 Motor winding
The ZH Scroll compressors are offered with either a single-phase or a three-phase induction
motor, depending on the size. All three-phase motors are connected in star; single-phase motors
need a run capacitor.

C6.2.26/1013-1116/E 17
The motor insulation material is class "B" (PF* and TF*) or "H" (TW*) for compressor models
covered in these guidelines.
4.2.4 Protection devices
Independently from the internal motor protection, fuses must be installed before the compressor.
The selection of fuses has to be carried out according to VDE 0635, DIN 57635, IEC 269-1 or
EN 60-269-1.
4.2.5 Crankcase heaters
IMPORTANT
Oil dilution! Bearing malfunction! Turn the crankcase heater on 12 hours
before starting the compressor.
A crankcase heater is required when the system charge exceeds the compressor charge limit,
listed in Table 3.
Compressor model
Refrigerant charge limit
Single compressor
systems
Refrigerant charge limit
Even Tandem systems
ZH04K1P & ZH05K1P
3.6 kg
5.0 kg
ZH06K1P to ZH12K1P
ZHI05K1P to ZHI14K1P
4.5 kg
6.3 kg
ZH15K1P & ZH19K1P
ZHI18K1P & ZHI23K1P
4.5 kg
6.3 kg
ZHI27K1P to ZHI46K1P
7 kg
10.9 kg
Table 3: Refrigerant charge limit
For compressor models ZH04K1P to ZH19K1P
and ZHI05K1P to ZHI23K1P, the crankcase
heater must be mounted 10 to 40 mm above
compressor legs (see Figure 14).
Figure 14: Crankcase heater location, models ZH04K1P to ZH19K1P and ZHI05K1P to ZHI23K1P
For compressor models ZHI27K1P to
ZHI46K1P, the crankcase heater must be
mounted below the oil removal valve located on
the bottom shell for tandem versions (see
Figure 15).
Figure 15: Crankcase heater location, models ZHI27K1P to ZHI46K1P
NOTE: The crankcase heater must be turned on a minimum of 12 hours prior to starting
the compressor and must remain energised during compressor off cycles.
4.2.6 Soft starters
Soft starters can be used with the 20 to 40 hp Copeland Scroll compressors to reduce inrush
current. Soft starters should be selected in accordance with the soft starter manufacturer's
recommendations, taking into consideration ambient temperature, number of starts per hour, and
compressor amps. The maximum ramp-up time should not exceed 3 seconds.
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