Emerson Scroll ZB*KAU Instruction Manual

© 2018 Emerson Climate Technologies, Inc.
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Application Guidelines for ZB*KAU Copeland R-290
Scroll™ Compressors
TABLE OF CONTENTS
Safety........................................................................... 3
Safety Instructions.................................................... 3
Safety Icon Explanation ........................................... 3
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons ........................................ 4
Safety Statements.................................................... 5
1. Introduction .......................................................... 6
1.1. General instructions..................................... 6
2. Product Description.............................................. 7
2.1. Nomenclature............................................... 7
2.2. Application.................................................... 7
2.2.1. Qualified refrigerant and oil.................. 7
2.2.2. Maximum Allowable Operation
Pressures............................................. 7
2.2.3. Application limits .................................. 7
2.2.4. Oil level ................................................ 7
2.2.5. Superheat Requirements..................... 8
3. Installation............................................................ 9
3.1. Transport and storage.................................. 9
3.2. Positioning and securing.............................. 9
3.3. Installation location ...................................... 9
3.4. Compressor mounting parts......................... 9
3.5. Brazing procedure......................................10
3.6. Filter screens..............................................10
3.7. Sound and vibration................................... 11
4. Electrical connection..........................................11
4.1. Units Electrical connection per BOM 634. .11
4.1.1. Assembly of the molded plug cable... 11
4.1.2. Removing the molded plug power cable
...........................................................12
4.2. Electrical installation .................................. 12
4.2.1. US Units.............................................12
4.2.2. European Units .................................. 12
4.2.3. Protection devices.............................. 14
4.2.4. Crankcase heaters.............................14
4.3. Pressure protection devices.......................14
4.3.1. High pressure protection.................... 14
4.3.2. Low-pressure protection ....................14
4.4. Discharge gas temperature protection.......15
4.4.1. Excessive discharge gas temperatures..
............................................................15
4.4.2. Discharge gas temperature protection ...
............................................................15
4.5. Motor protection..........................................17
4.6. High-potential testing..................................17
5. Starting up & operation.......................................17
5.1. Compressor tightness test..........................17
5.2. System evacuation.....................................17
5.3. Charging procedure....................................18
5.4. Preliminary checks –Pre-starting...............18
5.5. Rotation direction........................................18
5.6. Starting sound ............................................18
5.7. Deep vacuum operation .............................18
5.8. Shell temperature.......................................19
5.8.1. Minimum Run Time ............................19
5.8.2. Shut-off sound ....................................19
6. Maintenance & repair .........................................19
6.1. Disassembling system components...........19
6.2. Exchanging the refrigerant .........................20
6.3. Replacing a compressor.............................20
6.3.1. Compressor replacement...................20
6.3.2. Start-up of a new or replacement
compressor.........................................21
6.3.3. Compressor return procedure ............21
6.4. Lubrication and oil removal ........................22
6.5. Oil additives................................................22
7. Troubleshooting..................................................22
8. Dismantling & disposal.......................................23
9. General Guidelines and More Information .........23
Appendix A: Common Scroll problems encountered in
the field.......................................................................25
Appendix B: Oil Filling Test for new applications .......28
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August 2018

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TABLE OF FIGURES
Figure 1 - Extended Medium Temp operating envelope
for ZB*KAU compressors............................................. 8
Figure 2 - Oil filling and minimum acceptable oil level. 8
Figure 3 - Maximum stacking loads for transport and
storage......................................................................... 9
Figure 4 Soft mounting parts for single compressors
ZB07KAU to ZB11KAU..............................................10
Figure 5 - Suction tube connecting areas..................10
Figure 6 - Power cable molded plug IP65, USA........11
Figure 7 - Circle fence with motor terminals, USA..... 11
Figure 8 - Principle of connecting the molded plug power
cable to the connection pins ......................................12
Figure 9 - Connection dimensions in inches.............. 13
Figure 10 - Three-phasecompressors (TF*) with internal
motor protection, USA................................................ 13
Figure 11 - Terminal dome cover and correct electrical
installation, European Electrical................................. 14
Figure 12 - European Electrical connections .............14
Figure 13 –Cover, European.....................................14
Figure 14 - ATEX discharge line thermostat and ATEX
label............................................................................16
Figure 15 - Suction tube connecting areas ................20
Figure 16 - Absorption of moisture in ester oil in
comparison to mineral oil in ppm by weight at 77°F and
50% relative humidity (h=hours).................................22
Figure 17 Dimensions of ZB*KAU compressors, upper
view ............................................................................23
Figure 18 Dimensions of ZB*KAU compressors........24
Figure 19 - ZB*KAU with external oil sight tube.........28
Figure 20 - Markings on the external oil sight tube....28
Figure 21 - Testing points for oil return behavior
investigation................................................................29
TABLES
Table 1 –ZB*KAU available compressors models...... 6
Table 2 -Technical data of the discharge line thermostat
................................................................................... 16
Table 3 - Recommendations for assembling the
discharge line thermostat........................................... 16

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Safety
Safety Instructions
Copeland™compressors are manufactured according to the latest U.S. and European Safety Standards. Particular
emphasis has been placed on the user's safety. Safety icons are explained below and safety instructions applicable
to the products in this bulletin are grouped on Page 3. These instructions should be retained throughout the lifetime
of the compressor. You are strongly advised to follow these safety instructions.
Safety Icon Explanation
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices not related to
personal injury.
FLAMMABLE, Fire hazard!
Sparking in a potentially explosive atmosphere! Explosion hazard!
DANGER
WARNING
CAUTION
NOTICE
CAUTION

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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
ELECTRICAL SHOCK HAZARD
•Disconnect and lock out power before servicing.
•Discharge all capacitors before servicing.
•Use compressor with grounded system only.
•Molded electrical plug must be used when required.
•Refer to original equipment wiring diagrams.
•Electrical connections must be made by qualified electrical personnel.
•Failure to follow these warnings could result in serious personal injury.
PRESSURIZED SYSTEM HAZARD
•System contains refrigerant and oil under pressure.
•Remove refrigerant from both the high and low compressor side before
removing compressor.
•Never install a system and leave it unattended when it has no charge, a
holding charge, or with the service valves closed without electrically locking
out the system.
•Use only approved refrigerants and refrigeration oils.
•Personal safety equipment must be used.
•Failure to follow these warnings could result in serious personal injury.
BURN HAZARD
•Do not touch the compressor until it has cooled down.
•Ensure that materials and wiring do not touch high temperature areas of the
compressor.
•Use caution when brazing system components.
•Personal safety equipment must be used.
•Failure to follow these warnings could result in serious personal injury or
property damage.
CAUTION
COMPRESSOR HANDLING
•Use the appropriate lifting devices to move compressors.
•Personal safety equipment must be used.
•Failure to follow these warnings could result in personal injury or property
damage.
AIR/R290 MIXTURE HANDLING
•Avoid Air/R290 mixture in a potentially explosive atmosphere. R290 mixed
with air can create an explosive atmosphere.
•Fire and smoking are strictly forbidden at all times.
•Continuously check if the ambient atmosphere is non explosive.
•Vibrations! Creation of an explosive atmosphere! Carefully check the system
for vibrations.
•Check for conductor cables in a potentially explosive atmosphere! Fire
hazard!
WARNING
WARNING
WARNING

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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 and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
•The national legislation and regulations must be observed.
•These compressors shall be used only in non-explosive environments. Emerson recommends
to carefully observe relevant information from standard IEC60335-2-89, UL60335-2-34.
•During installation or maintenance procedure of a system never leave it unattended when it has
no charge. A servicing tag must be used for advising to other technician about servicing
procedure running. This will prevent unauthorized personnel from accidentally starting the
equipment and potentially ruining the compressor by operating with no refrigerant
In case of explosive atmosphere:
•do not energize any electrical component in the system;
•no unshielded flame is allowed.
Furthermore, before opening the refrigeration system or working on it:
•continuously check if the ambient atmosphere is non- explosive and ensure proper ventilation of the room;
•if the atmosphere is explosive or reaches a dangerous concentration of flammable gas, avoid any ignition
source and ventilate the room further;
•if parts of the refrigeration system are charged with flammable refrigerant, be sure that all the valves are
tightly closed and that the open pipes after the valves are free of refrigerant and oil.

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1. Introduction
The purpose of these application guidelines is to provide
guidance in the application of Copeland Scroll™
ZB*KAU compressors.
See Table 1 for a summary of mechanical
specifications.
Besides the support they provide, the instructions listed
herein are also critical for the proper and safe
functioning of the compressors. Emerson will not
guarantee the performance and reliability of the product
if it is misused in regard of these guidelines.
ZB*KAU compressors are released only for R290
stationary applications with refrigerant charges below
150 grams (5.29 oz.). For mobile applications, contact
Application Engineering as other considerations may
apply.
1.1. General instructions
During service make sure that:
•the area is well ventilated;
•the materials and equipment used are suitable for
use under explosive conditions;
•only non-sparking tools are used;
•antistatic gloves and clothes are used;
•build-up of electrostatic charges is avoided.
•In case of explosive atmosphere: Immediately stop
the compressor and/or de-energize the power
supply of the compressor and any other electrical
component/equipment
•no unshielded flame is allowed.
Furthermore, before opening the refrigeration system or
working on it with an unshielded flame:
•continuously check if the ambient atmosphere is
non-explosive and ensure proper ventilation of the
room before creating any naked flame; no naked
flame is allowed in an explosive atmosphere;
•if the atmosphere reaches a dangerous
concentration of flammable gas, avoid any ignition
source and ventilate the room further;
If an explosive atmosphere is detected, immediately
stop the compressor and ventilate the room. No open
flame is allowed.
Electrical shock hazard! Serious personal injuries
and/or system breakdown! Allow drive components to
electrically discharge for a minimum of two minutes
before servicing. Use compressor with grounded
system only. Refer to original equipment wiring
diagrams. Electrical connections must be made by
qualified electrical personnel.
System breakdown! Personal injuries! Only
approved refrigerants and refrigeration oils must be
used.
Table 1 –ZB*KAU available compressors models
* ARI Conditions 20°F/120°F/65°F/120°F
WARNING
WARNING
Compressor
Motor
Application
Cooling
Capacity
BTU/hr
Disp./
Rev.
(in³)
CFH
(60 Hz)
ZB07KAU
TFD/TF5
EM*
8060
1.31
158.84
ZB09KAU
TFD/TF5
EM *
9690
1.54
186.91
ZB10KAU
TFD/TF5
EM*
11000
1.77
214.86
ZB11KAU
TF5
EM*
13450
2.076
252.3

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Overheating! Bearing damage! Do not operate
compressor without refrigerant charge or without it being
connected to the system.
Contact with POE!
POE may cause an allergic skin reaction and must
be handled carefully and the proper protective
equipment (gloves, eye protection, etc.) must be
used when handling POE lubricant. POE must not
come into contact with any surface or material that
might be harmed by POE, including without
limitation, certain polymers (e.g. PVC/ CPVC and
polycarbonate). Refer to the Safety Data Sheet
(SDS) for further details.
2. Product Description
These application guidelines deal with vertical single
Copeland Scroll compressor models ZB07KAU,
ZB09KAU, ZB10KAU and ZB11KAU.
2.1. Nomenclature
The model designation contains the following technical
information about the standard compressors:
2.2. Application
2.2.1. Qualified refrigerant and oil
Compressors
ZB07KAU, ZB09KAU,
ZB10KAU
Qualified refrigerant
R-290
Low, Medium Temp Oil
POE68B (Hatcol 4467)
Refer to Emerson Accepted Refrigerant List 93-11
for more options or details.
2.2.2. Maximum Allowable Operation
Pressures
The Maximum Allowable Operation Pressure are the
pressure values at the high- and low-pressure sides up
to which it is safe to operate the compressor. Safety is
established in compliance with the relevant standards
applicable to the given product
Compressor
Maximum Allowable Operation
Pressure
High-pressure
side
Low-pressure
side
ZB07KAU
to ZB11KAU
406 PSIG
(28 bar)
247 PSIG
(17 bar)
2.2.3. Application limits
Inadequate lubrication! Compressor breakdown!
The superheat at the compressor suction inlet must
always be sufficient to ensure that no refrigerant
droplets enter the compressor. For a typical
evaporator-expansion valve configuration a
minimum stable superheat of at least 20°F (10 °K) is
required measured 6” (152 mm) from the
compressor suction inlet.
Refer to Figure 1 for application envelopes.
2.2.4. Oil level
ZB*KAU compressors have no oil sight glass which
ensures maximum hermeticity to allow operation with
flammable refrigerant, Consequently, it is difficult to get
an indication of the actual oil level in the compressor
during operation. For new applications, OEM’s are
required to order a sample compressor equipped with
an external site tube for lab testing to confirm operating
oil levels (see Figure 19 and Figure 20). Refer to
Appendix B for details about Oil Filling Test for new
applications.
The factory oil filling for all ZB*KAU compressor models
has been optimized to a value of 16 oz (473 mL). This
is a reduced oil filling which makes the compressor
applicable to run in systems with refrigerant charges
below 150 grams. This reduced oil filling is close to the
minimum oil required, Oil Filling Test of Appendix B is
required for application approval. See Figure 2 for
reference.
CAUTION
WARNING
CAUTION

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2.2.5. Superheat Requirements
To determine if liquid refrigerant is returning to the
compressor is recommended to accurately measure the
temperature difference between the compressor oil
crankcase and the suction line. During continuous
operation we recommend that this difference be a
minimum of 50°F (27°K). This “crankcase differential
temperature” requirement supersedes the minimum
suction superheat requirement in Section 2.2.3. To
measure oil temperature through the compressor shell,
place a thermocouple on the bottom center (not the
side) of the compressor shell and insulate from the
ambient.
During rapid system changes, such as defrost or ice
harvest cycles, this temperature difference may drop
rapidly for a short period of time. When the crankcase
temperature difference falls below the recommended
50°F (27°K), our recommendation is the duration should
not exceed a maximum (continuous) time period of two
minutes and should not go lower than a 25°F (14°K)
difference.
Contact your Emerson Climate Technologies
representative regarding any exceptions to the above
requirements.
Figure 1 - Extended Medium Temp operating envelope for ZB*KAU compressors
Figure 2 - Oil filling and minimum acceptable oil level

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3. Installation
High pressure! Injury to skin and eyes possible!
Compressors are delivered pre-charged with
pressurized dry air. Be careful when opening
connections.
3.1. Transport and storage
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.
NOTE: The compressor is pre-charged with dry air
to avoid any moisture contamination.
3.2. Positioning and securing
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, e.g., a swaging tool should be inserted into
the suction tube or it might damage the suction screen
and motor.
3.3. Installation location
These compressors shall be installed only in a non-
explosive atmosphere.
Scroll compressors are capable of operating correctly in
ambient humidity from 30% to 95% and at altitudes up
to 6562 feet (2000 meters). For correct operation, the
ambient air temperature must range from -31°F to 122°F
(-35°C to 50°C) and the compressor Maximum
Allowable Operation Pressure shall be respected at all
times during operation and at standstill.
Ensure the compressors are installed on a solid level
base. For multiple-compressor parallel configurations,
the compressors must be positioned completely
vertically on a totally horizontal surface or rail.
3.4. Compressor mounting parts
The compressors are designed to be mounted on
vibration absorber grommets. The grommets dampen
the start-up surge of the compressor and minimize
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 0.335 inches (8.5 mm)
to fit, e.g., an M8 screw. The mounting torque should be
CAUTION
CAUTION
CAUTION

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9.588 ± 0.738 ft. lb (13 ± 1 Nm). It is critically important
that the grommet is not compressed.
See Figure 4 for reference.
Figure 4 Soft mounting parts for single
compressors ZB07KAU to ZB11KAU
Note: 3 pieces for compressor are required.
3.5. Brazing procedure
High temperature! Burning! Proceed with caution
when brazing system components. Do not touch the
compressor until it has cooled down. Ensure that other
materials in the area of the compressor do not make
contact
Blockage! Compressor breakdown! Maintain a flow
of oxygen-free nitrogen through the system at very low
pressure during brazing (1.5 to 2 PSI). 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 orifices.
Contamination or moisture! Bearing failure! Do not
remove the connection plugs until the compressor is set
into the unit. This minimizes any entry of contaminants
and moisture
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 material: Any SIL-FOS®
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.
NOTE: Since the discharge stub contains a check
valve, care must be taken not to overheat it to
prevent brazing material from flowing into it.
3.6. Filter screens
Screen blocking! Compressor breakdown! Use filter
screens with at least 0.024” openings.
The use of filter screens finer than 30 x 30 mesh (0.024”
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
WARNING
Figure 5 - Suction tube connecting areas
CAUTION
CAUTION
CAUTION

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normal system debris and block the flow of either oil or
refrigerant to the compressor. Such blockage can result
in compressor failure.
3.7. Sound and vibration
Vibrations during compressor operation can cause
cracks which could lead to refrigerant leakage. This
situation must be avoided by the system
manufacturer/installer. Therefore, proper pipe design
must be taken into consideration when connecting a
scroll compressor to a 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.
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.
4. Electrical connection
4.1. Units Electrical connection per BOM 634.
ZB*KAU compressors for applications in US market are
delivered with electrical pin connections ready for
molded plug connection. Its protection class is IP65.
R290 qualified and dedicated molded plug cables must
be used. The R290 dedicated kit includes a special o-
ring, a grounding connection and a retainer, see figures
below.
Emerson recommends that the electrical installation be
executed considering the recommendations of NEC-
NFPA and/or other standards and national regulations
that may apply.
4.1.1. Assembly of the molded plug cable
•Make sure to apply only R290 qualified and
dedicated molded plug power cables with grounding
and retainer.
•Check, that the o-ring on themolded plug connector
is in place and not damaged.
•Shut off power supply.
•Check, that the circle fence is clean and dry, before
connecting the molded plug power cable.
•Connect the grounding of the molded plug power
cable to the compressor circle fence.
•Install the molded plug connector properly to the
motor terminals. Push the molded plug connector
smoothly as far as possible towards the terminals.
Don`t use any tool to knock on the molded plug
connector, because this could damage the glass
inserts of the Fusite terminal pins.
•Secure the connection with the retainer.
Refer to Figure 6 to Figure 8 for more details.
Figure 6 - Power cable molded plug
IP65, USA
Figure 7 - Circle fence with motor
terminals, USA

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4.1.2. Removing the molded plug power cable
•Shut off power supply.
•Remove the retainer from the connection.
•Remove the molded plug connector from the
connection pins.
•Disconnect the grounding from the compressor
circle fence.
Models with 634 BOM will be single and three phases.
For 3 phase units, pay special attention to appropriate
phase rotation to avoid reverse rotation of the scroll
motor.
4.2. Electrical installation
Conductor cables! Electrical shock! Shut off power
supply before and between each test
The system capacitor may remain charged for a few
minutes after shutdown. Before starting to work on the
electrical installation make sure accidental sparking is
not possible.
Shut off power supply before and between each test.
Continuously check if the ambient atmosphere is non
explosive and ensure proper ventilation before and
when working on the electrical installation.
With flammable or explosive atmosphere no work on the
electrical installation is allowed. If the atmosphere
reaches a dangerous concentration of flammable gas
immediately stop any work on the electrical installation,
avoid any source of ignition and ensure proper
ventilation of the room.
4.2.1. US Units
A motor soft starter can also be used to temporarily
reduce the load, the torque and the electric current
surge of the compressor motor at start-up. For more
information please contact Application Engineering.
Figure 10 shows electrical connections schematic.
NOTE: Emerson recommends the use of a Residual
Current Device (RCD) as an additional safety measure.
NOTE: Emerson recommends the use of a second
contactor K2 for the safety chain of the compressor. This
protection must be considered it in conjunction with the
mentioned RCD.
4.2.2. European Units
4.2.2.1. European Units Electrical connections.
In EU compressors electrical connection is only
available using a terminal dome cover. Due to the IP11
certification of the terminal box, the compressor has to
be protected by a cover, which can only be opened with
a tool.
The compressor terminal box has a wiring diagram on
its cover. Before connecting the compressor, ensure the
supply voltage, the phases and the frequency match the
nameplate data.
When installing these compressors in the system, the
following steps must be taken:
•Add the foam gasket and the plastic terminal cover.
•To connect the power leads, use suitable 90°
insulated female crimp connector terminals from
"250 series" suitable for 0.250-inch (6.35 mm) male
tab width. See Figure 9.
•To ensure the wires are properly terminated, the
correct terminal and clamping tool for the selected
wire size must be used.
•The ground wiring must conform to local regulations
and codes of practice (only the provided parts must
be used).
Figure 8 - Principle of connecting the molded
plug power cable to the connection pins
WARNING

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•Add a cable strain relief device.
•Protect cable and wires against sharp edges.
4.2.2.2. Terminal box
Mechanical stress or shock! Terminal box damage!
Mechanical stress and shocks to the terminal box must
be avoided as they might result in tightness failure or
loss of terminal box performance.
Mechanical stress or shock! Terminal Fusite
damage! Mechanical stress and shocks to the Fusite
must be avoided as they could damage the glass and/or
ceramic. This might result in hermetic failure or loss of
terminal performance. Precautions are required to
prevent striking or bending of pins. Bent or damaged
pins may result in loss of hermeticity and/or terminal
performance.
Power Circuit
Control circuit
Motor terminal connections
Three-phase compressors are connected to the TI, T2 and T3 connections.
Legend
B1 System controller
B3 Discharge gas thermostat
F1, F6, F7, F8 Fuses
K1 Contactors
Q1 Main switch
S1 Auxiliary switch
F4 LP limiter
Figure 10 - Three-phase compressors (TF*) with internal motor protection, USA
Figure 9 - Connection dimensions
in inches
CAUTION
CAUTION

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Overheating! Terminal Fusite damage! Ensure
correct connection of cables to the compressor terminal
Fusite to avoid local overheating of Fusite pins which
might lead to refrigerant leaks.
Special attention shall be paid to the electrical
connections owing to possible local overheating.
Figure 11 and Figure 12 show Terminal dome cover
and correct electrical connection. This connection is
only detailed for services propose.
4.2.3. Protection devices
Independently from the internal motor protection, fuses
must be installed before the compressor. The selection
of fuses should be carried out according to UL
standards, RLA and LRA. Failing to install fuses before
the compressor or selecting inappropriate fuses may
result in compressor failure.
4.2.4. Crankcase heaters
Crankcase heaters are not released for ZB*KAU
compressors.
4.3. Pressure protection devices
4.3.1. High pressure protection
For systems conforming to , IEC 60335-2-89, UL 60335-
2-89 and EN 60335-2-89 no high-pressure switch is
required.
4.3.2. Low-pressure protection
Operation under ambient pressure! During operation
under ambient pressure an explosive mixture can form
inside the system. Make sure that the pressure never
falls below atmospheric pressure
Operation outside the application envelope! A low-
pressure protection shall be fitted in the suction line to
stop the compressor when it operates outside the
envelope limits.
Loss of system charge! Loss of lubrication! Bearing
malfunction and compressor breakdown! A low-
pressure limiter protection must be installed and set
above the atmospheric pressure. Do not bridge or by-
pass the low-pressure limiter. Do not operate under
atmospheric pressure.
In some instances, systems must operate at low
evaporating pressure because of the low ambient
temperatures, sometimes combined with a high level of
relative humidity. Proper evaporator sizing and
adequate defrost strategy control will prevent the
CAUTION
Figure 11 - Terminal dome cover and
correct electrical installation, European
Electrical
Figure 12 - European Electrical connections
Figure 13 –Cover, European
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system from operating outside the operating envelope
published by Emerson, whatever the climatic conditions
and the capacity demand.
However, in some extreme cases –such as loss of
system charge, extreme heat transfer restriction at the
evaporator, any defect or blocked flow control
component (expansion valve, screens, etc.) –the
evaporating conditions may be such that the
compressor will operate outside the published operating
envelope limits. These conditions may result in
compressor failure.
Therefore, Emerson requires that all ZB*KAU
compressors without exception be fitted with a low-
pressure protection in the suction line. The mandatory
inclusion of a low-pressure switch will stop the
compressor operating outside the published envelope
limits or below atmospheric pressure.
4.4. Discharge gas temperature protection
Inadequate lubrication! Scroll set damage! All
ZB*KAU compressors must be equipped with an
external discharge gas temperature protection.
A good system control shall prevent the system from
operating outside the published operating envelope and
acceptable superheat range, whatever the climatic
conditions and the capacity demand. However, under
some extreme operating conditions (such as loss of
charge or improper control operation), the internal
discharge gas temperature reached can cause
compressor damage.
To guarantee positive compressor protection, it’s
required that discharge gas temperature protection be
used for any application with Copeland brand
compressors. This protection must not be used as an
operating envelope controller. If not used, the warranty
of the compressor will be lost.
The maximum discharge gas temperature is 275°F
(135°C) for Internal limitation. The external DLT is set
1
The ATEX directive consists of two EU directives describing what
equipment and work space is allowed in an environment with an
explosive atmosphere.
for 250°F (121°C) for all ZB*KAU models. These
compressors have no internal discharge gas
temperature protection. Therefore, an external protector
is required. See Section 4.4.2 for more details.
4.4.1. Excessive discharge gas temperatures
A few of the possible consequences are listed below:
•Since the oil circulates in the system with the
refrigerant, it is subjected to high discharge gas
temperatures. If the discharge gas temperature
becomes too high, the so-called "coking" 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 listed under the first 2 points
frequently occur simultaneously, particularly since
the chemical reaction time approximately doubles at
every 20°F (10°C) temperature rise. This directly
leads to chemical reactions of the oil with the
refrigerant and the compounds extracted from
sealants and insulation material. Therefore,
contaminants of various types, among them acids,
will form inside the system.
4.4.2. Discharge gas temperature protection
Discharge gas temperature protection is the "fall-back"
for failure of the system control. It is essential that proper
control of the evaporating and condensing pressures
and the superheat is maintained and has the ability to
cope with all likely conditions and high loads. Reliance
on protectors will cause inadequate system
performance and short cycling. Emerson offers a
discharge line thermostat, which complies with the
ATEX
1
requirements. This thermostat is marked with a
special ATEX label, see Figure 14.
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Figure 14 - ATEX discharge line thermostat and
ATEX label
NOTE: Please make sure to select a discharge line
thermostat that complies with the ATEX requirements.
Other discharge thermostat devices might not comply
with the ATEX requirements and could be a potential
ignition source, and therefore they could only be
installed in a non-explosive atmosphere.
NOTE: For correct discharge line thermostat (DLT)
selection, please refer to the Emerson.com/OPI.
To be ATEX compliant, the cable ends of the thermostat
must be connected with suitable cable glands and
electrical enclosure to achieve a minimum protection
degree of IP54 according to UL471 SB5 (IEC60079-15,
clause 6.3).
When connecting the cable ends, a creepage distance
of minimum 0.16 inches (4 mm) and a clearance
distance of 0.1 inches (2.5 mm) between the conductive
parts at different potentials must be maintained.
Maximal Voltage and Amps values for the thermostat
and a protection against electrical shock must be
respected during the installation.
Additionally, the ATEX compliance requires a protection
of the thermostat body against mechanical damage,
according to UL471 SB5 (IEC 60079-0, clause 26.4.2,
table 13). There is no need for an additional housing
around the thermostat body. Protection against
mechanical damage to the thermostat can be achieved
with an overall cover or box placed around the
compressor or refrigerant system.
See Table 2 for Technical data of the discharge line
thermostat.
For installation, please follow recommendations
detailed on Table 3 .
Table 2 -Technical data of the discharge line thermostat
Ident number / Part number
971-0034-00
Voltage
230V (± 10%)
Maximum amperage
5A/240V
Operating temperatures
Open
273°F (± 7°F); 134°C (± 4K)
Close
222°F (±14°F); 106°C (± 8K)
Wire insulation maximum temperature
302°F (150°C)
Clips for tube
Ø 0.5 inch (12.7 mm)
Table 3 - Recommendations for assembling the discharge line thermostat
Install the discharge line thermostat on the discharge tube 5” (127
mm) from top cap.
Snap the retainer clip over the tube and onto the thermostat. The
thermostat should be placed on the discharge tube so that its body
is in upward position on a horizontal tube installation. Ensure that
the thermostat is not tilted.
The wire must not be in contact with the top cap of the compressor
or the discharge tube. Care should be taken to route wires so that
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4.5. Motor protection
Conventional inherent internal line break motor
protection is provided for the ZB*KAU range of
compressors.
4.6. High-potential testing
High potential testing on R290 compressor! Special
attention should be paid when performing high-potential
testing.
Conductor cables! Electrical shock! Shut off power
supply before high-potential testing.
Internal arcing! Motor destruction! Do not carry out
high-voltage or insulation tests if the compressor
housing is under vacuum.
Emerson subjects all Scroll compressors to a high-
voltage test after final assembly. Each motor phase
winding is tested according to EN60335-2-34, IEC
60335-2-34 and UL 60335-2-34 at a differential voltage
of 1000V plus twice the nominal voltage.
Since high-voltage tests lead to premature ageing of the
winding insulation, further additional tests of this nature
are not recommended. However, if it must be done for
any reason, a lower voltage must be used. Disconnect
all electronic devices, e.g., motor protection module, fan
speed control, etc. prior to testing.
The high-potential and/or Megohm resistance
testing must not be done with the compressor
charged with R-290. These tests can induce an
electrical arc and cause a potential fire/explosion
hazard.
For the same reason, compressors removed from an
R290 system will need to have the oil drained and a
nitrogen purge introduced to flush any remaining
refrigerant from the compressor prior to high-potential
testing and Megohm resistance reading.
5. Starting up & operation
5.1. Compressor tightness test
High pressure! Personal injuries! Consider personal
safety requirements and refer to test pressures prior to
test.
System explosion! Personal injuries! Use only dry
nitrogen for leak testing. DO NOT USE other industrial
gases.
System contamination! Bearing malfunction! Use
only dry nitrogen for leak testing. DO NOT USE other
industrial gases.
The compressor has been leak-pressure tested in the
Emerson factory according to standards EN 14276-1,
EN 60335-2-34, IEC 60335-2-34 and UL60335-2-34.
Therefore, it is not necessary for the system
manufacturer/installer to leak-pressure test the
compressor on the assembly/system.
Never add refrigerant to the test gas (as leak indicator).
Leak checking at a pressure not to exceed 175 PSIG
should be Ok to verify connections.
5.2. System evacuation
Before the installation is put into commission, it must be
evacuated with a vacuum pump. The vacuum pumpand
all tools must be approved for R290/air mixture. The
installation should be evacuated down to 225 microns.
Proper evacuation reduces residual moisture to 50 ppm.
Evacuating the system only on the suction side of a
Scroll compressor can occasionally result in a
temporary no-start condition for the compressor. The
reason for this is that the floating seal could axially seal
with the scroll set, with the higher pressure on the
floating seal. Consequently, until the pressures
equalize, the floating seal and scroll set can be held
tightly together.
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5.3. Charging procedure
In any case avoid air/R290 mixture in the refrigeration
system. Make sure that the system is filled with pure
R290.
Low suction pressure operation! Compressor
damage! Do not operate compressor with a restricted
suction. Do not operate with the low-pressure limiter
bridged. Do not operate at pressures that are not
allowed by the operating envelope. Allowing the suction
pressure to drop below the envelope limit for more than
a few seconds may overheat scrolls and cause early
drive bearing and moving parts damage.
For this dedicated system with refrigerant charges
below 150 grams, the entire refrigerant quantity can be
charged from the bottle by means of pressure
difference. The charging point is typically on high
pressure side, in the proximity of the filter drier.
5.4. Preliminary checks –Pre-starting
•Visual check of the electrics, wiring, fuses etc.
•Cable glands in good state, all electrical
connections well connected and terminal dome
cover closed to ensure corresponding IP protection
for European units and compressor molded plug
fully seated and clipped in place for US units.
•Visual check of the plant for leaks, loose component
parts such as TXV bulbs or solenoid valve coil,
loose wires in electrical installation, etc.
•Functional test of LP switch
•Check setting and operation of all safety features
and protection devices
•All valves in the correct running position
•Correctly charged with refrigerant
•Compressor electrical auxiliary switch location and
position
5.5. Rotation direction
Scroll compressors are directional dependent; i.e. they
will compress in one rotational direction only. Three
phase scrolls will rotate in either direction depending on
power phasing. Since there is a 50/50 chance of
connected power being “backwards”, contractors should
be warned of this. Appropriate instructions or notices
should be provided by the OEM.
Verification of proper rotation can be made by observing
that the suction pressure drops and the discharge
pressure rises when the compressor is energized.
There is no negative impact on durability caused by
operating three-phase Scroll compressors in the
reversed direction for a short period of time (under one
hour) but oil may be lost. Oil loss can be prevented
during reverse rotation if the tubing is routed at least 6”
above the compressor. After several minutes of
operation in reverse, the compressor protection system
will trip due to high motor temperature. The operator will
notice a lack of cooling or heating. However, if allowed
to repeatedly restart and run in reverse without
correcting the situation, the compressor will be
permanently damaged.
All three-phase scroll compressors are identically wired
internally. Therefore, once the correct phasing is
determined for a specific system or installation,
connecting properly phased power leads to the
identified compressor terminals will ensure proper
rotation direction.
5.6. Starting sound
During the very brief start-up, a clicking sound is
audible, resulting from initial contacting of the spirals
and is normal. Due to the design of the Copeland Scroll
compressors, the internal compression components
always start unloaded even if system pressures are not
balanced. In addition, since internal compressor
pressures are always balanced at start-up, low-voltage
starting characteristics are excellent for Copeland Scroll
compressors.
5.7. Deep vacuum operation
Vacuum operation! Compressor damage! Copeland
Scroll compressors should never be used to evacuate
refrigeration or air-conditioning systems.
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5.8. Shell temperature
The top shell and discharge line can briefly but
repeatedly reach temperatures above 300°F (150°C) if
the compressor cycles on its internal protection devices.
This only happens under rare circumstances and can be
caused bythe failure of system components such as the
condenser or evaporator fan or loss of charge and
depends upon the type of expansion control. Care must
be taken to ensure that wiring or other materials that
could be damaged by these temperatures do not contact
the shell.
5.8.1. Minimum Run Time
Emerson recommends amaximum of 10 starts per hour.
Recommend stating minimum 2-3 minutes run time is
required for adequate oil return. There is no minimum
off time because scroll compressors start unloaded,
even if the system has unbalanced pressures.
5.8.2. Shut-off sound
Scroll compressors incorporate a device that minimizes
reverse rotation. The residual momentaryreversal of the
scrolls at shut off will cause a clicking sound, but it is
entirely normal and has no effect on compressor
durability.
6. Maintenance & repair
Conductor cables! Electrical shock! Follow the
lockout/tag out procedure and the national regulations
before carrying out any maintenance or service work on
the system.
When opening the refrigeration equipment or working on
it avoid explosive atmosphere and ignition sources in
any case.
To maximize efficiency in controlling leaks when
opening the refrigeration equipment or working on it, it
is recommendedto use a leak detector designed for use
with R290 refrigerant.
Continuously check if the ambient atmosphere is non
explosive.
In case of explosive atmosphere:
•do not energize any electrical component in the
system;
•fire and smoking are strictly forbidden;
•no unshielded flame is allowed;
•power tools shall not be used.
Furthermore, before opening the refrigeration system or
working on it with an unshielded flame:
•continuously check if the ambient atmosphere
is non- explosive and ensure proper ventilation
of the room;
•if the atmosphere reaches a dangerous
concentration of flammable gas, avoid any
ignition source and ventilate the room further;
•if parts of the refrigeration system are charged
with flammable refrigerant, be sure that all the
valves are tightly closed and that the open pipes
after the valves are free of refrigerant and oil.
6.1. Disassembling system components
Continuously check if the ambient atmosphere is non
explosive.
During service make sure that:
•the area is well ventilated;
•the materials and equipment used are suitable
for use under explosive conditions;
•only non-sparking tools are used;
•antistatic gloves and clothes are used;
•build-up of electrostatic charges is avoided.
In case of explosive atmosphere:
•do not energize any electrical component in the
system;
•no unshielded flame is allowed.
Unshielded flame! Fire hazard! Oil-refrigerant
mixtures are highly flammable. Remove all refrigerant
before opening the system. Avoid working with an
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unshielded flame in a refrigerant charged system. Use
a pipe cutting tool to disassemble the compressor from
the system.
When disassembling system components please follow
the main steps described hereunder:
1. Recover refrigerant and evacuate system using a
hydrocarbons-dedicated recovery unit and vacuum
pump.
2. Flush system with dry nitrogen.
3. Disassemble components with a cutting tool.
4. Drain, recover and dispose of compressor oil as
appropriate.
To disconnect:
•Using a pipe cutting tool, cut off the suction and
discharge lines in such a manner that the new
compressor can easily be re-connected into the
system.
•Heat joint areas 2 and 3 slowly and uniformly until
the braze material softens and the tube end can be
pulled out from the fitting. See Figure 15
To reconnect:
•Recommended brazing material: SIL-FOS® 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.
6.2. Exchanging the refrigerant
In any case avoid air/R290 mixture in the refrigeration
system. Make sure that the system is filled with pure
R290. In the event that the refrigerant needs replacing,
the charge should be recovered using a R290 recovery
unit and dedicated cylinders.
Low suction pressure operation! Compressor
damage! Do not operate with a restricted suction. Do
not operate with the low-pressure limiter bridged. Do not
operate compressor at pressures that are not allowed
by the operating envelope. Allowing the suction
pressure to drop below the envelope limit for more than
a few seconds may overheat scrolls and cause early
drive bearing and moving parts damage.
See “Qualified refrigerant and oil
”section for a list of approved refrigerants and oils.
It is not necessary to replace the refrigerant with new
unless contamination due to an error such as topping up
the system with an incorrect refrigerant is suspected. To
verify correct refrigerant composition, a sample can be
taken for chemical analysis. A check can be made
during shut down by comparing the refrigerant
temperature and pressure using precision
measurements at a location in the system where liquid
and vapor phases are present and when the
temperatures have stabilized. If the refrigerant needs
replacing, the charge should be recovered using a R290
recovery unit and dedicated cylinders.
6.3. Replacing a compressor
Before beginning to work on R-290 systems read and
follow Safety Statements on page 5.
When opening the refrigeration system or working on it
avoid explosive atmosphere and ignition sources in any
case. When replacing the compressor avoid explosive
mixture (air/R290). Use a pipe cutting tool to
disassemble the compressor from the system.
6.3.1. Compressor replacement
Use a suitable cylinder for oil disposal as R290 may still
be solved in the oil.
Figure 15 - Suction tube connecting areas
CAUTION