Emerson ZPK3E Series User manual

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© 2015 Emerson Climate Technologies, Inc.
AE4-1331 R7
ZP16 to ZP44K3E and ZP14 to ZP61K5E R-410A
1.5 to 5 Ton Copeland Scroll™Compressors
AE4-1331 R7 July 2015
Safety
Safety Instructions................................................ 2
Safety Icon Explanation ....................................... 2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons...................................... 3
Safety Statements................................................ 3
Introduction............................................................. 4
Nomenclature....................................................... 4
Application Considerations
Internal Pressure Relief Valve.............................. 4
Discharge Temperature Protection....................... 4
Heat Pump Protection .......................................... 5
Discharge Line Thermostat .................................. 5
Air-Conditioning Unit Protection ........................... 5
High Pressure Cut-Out Switch ............................. 5
Shut Down Device................................................ 5
Discharge Check Valve ........................................ 6
Motor Overload Protection ................................... 6
Operating Envelope ............................................. 6
Power Supply ....................................................... 6
Accumulators ....................................................... 6
Charge Compensators ......................................... 6
Screens ................................................................ 7
Crankcase Heat-Single Phase ............................. 7
Crankcase Heat-Three Phase.............................. 7
Pump Down Cycle................................................ 7
Minimum Run Time .............................................. 7
Reversing Valves ................................................. 8
Low Ambient Cut-Out ........................................... 8
Oil Type ................................................................ 8
Contaminant Control ............................................ 8
Long Line Sets/High Refrigerant Charge ............. 8
 DischargeMufers ............................................... 9
Air-Conditioning System Suction Line
Noise & Vibration ................................................. 9
Mounting Parts ..................................................... 9
Single Phase Starting Characteristics.................. 9
PTC Start Components ....................................... 10
Electrical Connections......................................... 10
Deep Vacuum Operation..................................... 10
Shell Temperature ............................................... 10
Suction & Discharge Fittings ............................... 10
System Tubing Stress ......................................... 10
Three Phase Scroll Electrical Phasing ................ 10
Brief Power Interruptions..................................... 11
Manifolding Tandem Compressors...................... 11
Tandem Applications ........................................... 11
Maximum Tilt Angles ........................................... 11
Application Tests
Application Summary........................................... 11
Continuous Floodback Test................................. 12
Field Application Test .......................................... 12
Assembly Line Procedures
Installing the Compressor ................................... 12
Assembly Line Brazing Procedure ...................... 13
Tandem Assembly ............................................... 13
Pressure Testing ................................................. 13
Assembly Line System Charging Procedure....... 13
High Potential (AC Hipot) Testing........................ 13
Final Run Test ..................................................... 14
Unbrazing System Components ......................... 14
Service Procedures
Copeland Scroll Functional Check ...................... 14
Compressor Replacement After Motor Burn ....... 15
Start Up of a New or Replacement Compressor .. 15
Tandem Service..................................................... 15
Figures & Tables
Oil Dilution Chart ................................................. 16
Accumulator Piping ............................................. 17
Time Delay Wiring............................................... 17
Compressor Electrical Connection...................... 18
Discharge Thermostat ........................................ 18
Crankcase Heater ............................................... 18
R410A Scroll Operating Envelope....................... 19
Scroll Suction Tube Brazing ................................ 20
How a Scroll Works............................................. 21
Typical ZPK5 Tandem ......................................... 22
Tilted Tandem...................................................... 22
Field Application Test .......................................... 23
 DesignCongurations......................................... 23
Compressor Accessories ................................. 24-25
Compressor Refrigerant Charge Limits............... 25
TABLE OF CONTENTS
Section Page Section Page

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© 2015 Emerson Climate Technologies, Inc.
AE4-1331 R7
Safety Instructions
Copeland Scroll
™
compressors are manufactured according to the latest U.S. and European Safety
Standards. Particular emphasis has been placed on the user's safet
y. Safey 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 compesso
r. 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.
DANGER
WARNING
CAUTION
NOTICE
CAUTION

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© 2015 Emerson Climate Technologies, Inc.
AE4-1331 R7
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 in all ZP*K5 applications.
• Refer to original equipment wiring diagrams.
•
• 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 commponents.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury or
property damage.
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.
Safety Statements
• Refrigerant compressors must be employed only for their intended use.
•
install, commission and maintain this equipment.
•
• All valid standards and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
WARNING
WARNING
CAUTION

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© 2015 Emerson Climate Technologies, Inc.
AE4-1331 R7
Introduction
The ZP*K3E and ZP*K5E Copeland Scroll™
compressors include a wide range of capacities,
electrical options, and features. Typical model
numbers are ZP32K3E-PFV and ZP51K5E-PFV. This
bulletin describes the operating characteristics, design
features, and application requirements for these
models.
For additional information, please refer to our
Online Product Information, accessible from the
Emerson Climate Technologies website at www.
emersonclimate.com. Operating principles of the
Copeland Scroll compressor are described in Figure 9.
The ZP*K3 scrolls are older models introduced in 1996.
They were designed for 11+ SEER air conditioning
and heat pump usage ranging in size from 15,500 to
44,300 Btu/hr (4.5 to 13.0 kW). These models include
all of the standard 50 and 60 Hertz, single and three
phase voltages.
The ZP*K5E is the newest R-410A scroll family
designed for higher efciency and lower sound.
These compressors have features such as a Unitary
Shutdown Device (USD) and a new thermal disc
location for better high discharge temperature
response. The ARI capacity for these models ranges
from 14,500 to 61,000 Btu/hr (4.5 to 17.9 kW) with the
same voltage offering as the ZP*K3E.
The models include a number of features outlined in
the matrix below.
Nomenclature
The model numbers of the Copeland Scroll
compressors include the approximate nominal 60 Hz
capacity at standard operating conditions. An example
would be the ZP23K3E-TFD, which has 23,400 Btu/hr
(6.3kW) cooling capacity at the ARI high temperature
air conditioning rating point when operated at 60 Hz.
Note that the same compressor will have approximately
5/6 of this capacity or 19,000 Btu/hr (5.6kW) when
operated at 50 Hz. Please refer to Online Product
Information at www.emersonclimate.com for details.
Application Considerations
The following application guidelines should be
considered in the design of a system using ZP*K3 and
ZP*K5 scroll compressors. Some of this information
is recommended, whereas other guidelines must be
followed. The Application Engineering department will
always welcome suggestions that will help improve
these types of documents.
Internal Pressure Relief (IPR) Valve
The internal pressure relief valve is located between
the high and low side of the compressor. It is designed
to open when the discharge-to-suction pressure
differential exceeds 550 to 625 psid (38-43 bar).
When the valve opens, hot discharge gas is routed
back into the area of the motor protector to cause
a trip. During fan failure testing, system behavior
and operating pressures will depend on the type of
refrigerantmeteringdevice.Fixedoricedevicesmay
oodthecompressorwithrefrigerant,andthermostatic
expansion devices will attempt to control superheat
and result in higher compressor top cap temperatures.
Fanfailuretestingorlossofairowinbothcoolingand
heating should be evaluated by the system designer to
assure that the compressor and system are protected
from abnormally high pressures.
Discharge Temperature Protection
CAUTION
Compressor top cap temperatures can be very
hot. Care must be taken to ensure that wiring or
other materials which could be damaged by these
temperatures do not come into contact with these
potentially hot areas.
The Therm-O-Disc™or TOD is a temperature-sensitive
snap disc device located between the high and low
pressure side of the scroll or on the mufer plate.
It is designed to open and route excessively hot
discharge gas back to the motor protector when the
internal discharge gas exceeds 290°F (144°C). During
a situation such as loss of charge, the compressor
Model Motor
Frame Size*
Application IPR TOD Quiet
Shutdown
Discharge
Check Valve
Motor
Protector
Electrical
Connections
AC HP
ZP14-31K5 53 X X X X X X X MP
ZP34-61K5 63 X X X X X X X MP
ZP16-44K3 63 X X X X X X X MP, QC
* Approximate Shell Diameter (e.g. 53 = 5.5", 63 = 6.5")
MP = Molded Plug, QC = 1/4" Quick Connect

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© 2015 Emerson Climate Technologies, Inc.
AE4-1331 R7
will be protected for some time while it trips the
protector. However, as refrigerant leaks out, the mass
ow and the amperage draw are reduced and the
scrolls will start to overheat. A low pressure control
is recommended for loss of charge protection for the
highest level of system protection. The low pressure
cut-out can provide protection against indoor blower
failure in cooling, outdoor fan failure in heating, closed
liquid or suction line service valves, or a blocked
liquid line screen, lter, orice, or TXV. All of these
can starve the compressor of refrigerant and result in
compressor failure. The low pressure cut-out should
have a manual reset feature for the highest level of
system protection. If a compressor is allowed to cycle
after a fault is detected, there is a high probability
that the compressor will be damaged and the system
contaminated with debris from the failed compressor
and decomposed oil. If current monitoring of the
compressor is available, the system controller can
take advantage of the compressor TOD and internal
protector operation. The controller can lock out the
compressor if current draw is not coincident with the
contactor energizing, implying that the compressor
has shut off on its internal protector. This will prevent
unnecessary compressor cycling on a fault condition
until corrective action can be taken.
Heat Pump Protection
A low pressure control is highly recommended for
loss of charge protection and other system fault
conditions that may result in very low evaporating
temperatures. Even though these compressors have
internal discharge temperature protection, loss of
system charge will result in overheating and recycling
of the motor overload protector. Prolonged operation in
this manner could result in oil pump out and eventual
bearing failure. A cut out setting no lower than 20 psig
(1.4 bar) is recommended.
Operation near -25°F (–32°C) saturated suction
temperature is clearly outside the approved operating
envelope shown in Figure 7. However, heat pumps
in some geographical areas have to operate in this
range because of the low ambient temperatures. This
is acceptable as long as the condensing temperature
is not above 90°F (32°C) and the resulting discharge
temperature is below 275°F (135°C). Some liquid
oodback to the compressor under these conditions
can help keep the discharge temperature under
control.
Discharge Line Thermostat
Some systems, such as air-to-air heat pumps, may not
work with the above low pressure control arrangement.
A discharge line thermostat set to shut the compressor
off before the discharge temperature exceeds 260°F
(125°C) may have to be used to achieve the same
protection. Mount the discharge thermostat as close
as possible to the compressor discharge tting
and insulate well. See Figure 5 and Table 4 for
recommended Emerson Climate Technologies part
numbers.
Air Conditioning Unit Protection
Air-conditioning-only units can be protected against
high discharge temperatures through a low pressure
control in the suction line. Testing has shown that
a cut out setting of not lower than 55 psig (3.8 bar)
will adequately protect the compressor against
overheating from the aforementioned loss of charge,
blower failure in a TXV system, etc. A higher level
of protection is achieved if the low pressure control
is set to cut out around 95 psig (6.7 bar) to prevent
evaporator coil icing. The cut in setting can be as high
as 180 psig (12.5 bar) to prevent rapid recycling in
case of refrigerant loss. If an electronic controller is
used, the system can be locked out after repeated low
pressure trips.
High Pressure Control
If a high pressure control is used with these compressors
the recommended maximum cut out setting is
650 psig (45 bar). The high pressure control should
have a manual reset feature for the highest level of
system protection. It is not recommended to use
the compressor to test the high pressure switch
function during the assembly line test.
Shut Down Device
All scrolls in this size range have one of several types
of shutdown solutions that nearly eliminate shut down
noise. Single phase ZP*K3 scrolls use a cam-type
device that separates the scrolls when they are driven
backwards as high-pressure gas equalizes from the
high side of the compressor to the low side during
shutdown.ThreephaseZP*K3scrollsuseauidbrake
to mitigate reverse rotation sound after shutdown. The
new ZP*K5 scrolls incorporate a scroll discharge port
check valve that prevents high pressure gas trapped
in the dome from returning through the scroll set after
shutdown. All of these shut down solutions allow the
scroll compressor to restart immediately even if the
system is not equalized, eliminating the need for a time
delay. Development testing should include a review of
the shutdown sound for acceptability in a particular
system. Please refer to the section on Brief Power
Interruption.

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© 2015 Emerson Climate Technologies, Inc.
AE4-1331 R7
Discharge Check Valve
A low mass, disk-type check valve in the discharge
ttingofthecompressorpreventsthehighside,high
pressure discharge gas from owing rapidly back
through the compressor after shutdown. This check
valve was not designed to be used with recycling pump
down because it is not entirely leak-proof.
Motor Overload Protection
Conventional internal line break motor overload
protection is provided. The overload protector opens
the common connection of a single-phase motor
and the center of the Y connection on three-phase
motors. The three-phase overload protector provides
primary single-phase protection. Both types of
overload protectors react to current and motor winding
temperature.
Operating Envelope
The ZP*K3 and ZP*K5 model families are approved
for use with R-410A only. See Figure 7 for the R-410A
operating envelope. The envelope represents safe
operating conditions with 20F° (11K) superheat in the
return gas. The line marked “95F° max” is the limit of
operation with a constant return gas temperature of
95°F (35°C). This illustrates that the warmer the return
gas, the more limited the operating envelope will be as
the external discharge temperature approaches 250-
275°F (120-132°C) danger zone. Use of refrigerants
other than R-410A voids the UL listing of these
compressor models. R-410A may only be used with
compressors tested and approved for this higher
pressure refrigerant and that contain polyol ester
(POE) oil. Compressors containing POE oil have an
“E” in the seventh place of the model number, e.g.
ZP31K5E-PFV.
Power Supply
All motors for the ZP compressors, whether single
or three phase, with the exception of the “PFV” 208-
230, 1Ø, 60 Hz motor, are designed to operate within
a voltage range of +/-10% of the voltages shown on
the nameplate. For example, a compressor with a
nameplate voltage of 200-230 volts can start and
operate within a range of 180-253 volts. Compressors
with a “PFV” designated motor such as ZP24K5E-
PFV, may only be operated in a range of 197-253 volts
under maximum load conditions.
Accumulators
The use of accumulators is very dependent on the
application. The Copeland Scroll compressor’s inherent
ability to handle liquid refrigerant during occasional
operating ood back situations make the use of an
accumulator unnecessary in standard designs such
as condensing units. Applications such as heat pumps
withoricerefrigerantcontrolthatallowlargevolumes
of liquid refrigerant to ood back to the compressor
during normal steady operation can dilute the oil to such
an extent that bearings are inadequately lubricated,
and wear will occur. In such a case an accumulator
mustbeusedtoreduceoodbacktoasafelevelthat
the compressor can handle. Heat pumps designed
with a TXV to control refrigerant during heating may not
require an accumulator if testing assures the system
designerthattherewillbenooodbackthroughoutthe
operatingrange.Totestforoodbackconditionsand
determine if the accumulator or TXV design is adequate,
please see the section entitled Application Tests.
Theaccumulatoroilreturnoriceshouldbefrom.040
to .055 inches (1 – 1.4mm) in diameter depending on
compressorsizeandcompressoroodbackresults.A
large-areaprotectivescreennonerthan30x30mesh
(0.6mm openings) is required to protect this small
orice from plugging. Tests have shown that a small
screen with a ne 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 sub cooling and
subsequent head pressure allowed by the refrigerant
control. System modeling indicates that heat pumps
that operate down to and below 0°F (-18°C) will require
an accumulator that can hold around 70% to 75% of
the system charge. Behavior of the accumulator and
its ability to prevent liquid slugging and subsequent oil
pump-out at the beginning and end of the defrost cycle
should be assessed during system development. This
will require special accumulators and compressors
with sight tubes and/or sight glasses for monitoring
refrigerant and oil levels.
Charge Compensators
Charge compensators are devices that store excess
refrigerant during the heating operation of a heat pump
withaTXVrefrigerantcontrol.Unlikeanorice,aTXV
will not allow excessive refrigerant to ood back to
the compressor. This means that the excess system
refrigerant will either have to back up in the indoor
coil during heating, causing high head pressure, or
be stored in a charge compensator until needed. A
charge compensator is normally a hollow vessel with
only one opening that is attached to the vapor line. The
shell is usually attached to the outdoor coil or has a
line from the outdoor coil running through it for extra
cooling during heating and to drive the refrigerant out
during the cooling cycle. The size is dependent on how
much refrigerant has to be removed from the system
throughout the system operating map.

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© 2015 Emerson Climate Technologies, Inc.
AE4-1331 R7
Screens
Screens ner than 30x30 mesh (0.6mm openings)
should not be used anywhere in the system with
these compressors. Field experience has shown
that ner 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ow of eitheroil
or refrigerant to the compressor. Such blockage can
result in compressor failure.
Crankcase Heat - Single Phase
A crankcase heater is recommended on single phase
compressors when the system charge is over the
charge limit shown in Table 4. A crankcase heater is
required for systems containing more than 120% of the
compressor refrigerant charge limit listed in Table 5.
This includes long line length systems where the extra
charge will increase the standard factory charge above
the 120% limit.
Experience has shown that compressors may ll
with liquid refrigerant under certain circumstances
and system congurations, notably after long off
cycles when the compressor has cooled. This may
cause excessive start-up clearing noise; or the
compressor may start and trip the internal overload
protector several times before running. The addition
of a crankcase heater will reduce customer noise and
dimming light complaints since the compressor will no
longer have to clear out liquid during starting. Table
4lists the crankcase heaters recommended for the
various models and voltages. WARNING! Crankcase
heaters must be properly grounded. To properly
install the crankcase heater, the heater should be
installed as low on the compressor shell as possible,
either above or below the lower bearing pin welds that
protrude from the compressor shell. Ideally the heater
would come together for clamping with the vertical
shell seam weld coming up through the area where the
crankcase heater is clamped together. See Figure 6
for details. Tighten the clamp screw carefully ensuring
that the heater is uniformly tensioned along its entire
length and that the circumference of the heater element
is in complete contact with the compressor shell. It's
important that the clamp screw is torqued to the range
of 20-25 in-lb (2.3-8 N m) to ensure adequate contact
and to prevent heater burnout. Never apply power
to heater in free air or before heater is installed on
compressor to prevent overheating and burnout.
Crankcase Heat - Three Phase
A crankcase heater is required for three-phase
compressors when the system charge exceeds the
compressor charge limit listed in Table 5 and an
accumulator cannot be piped to provide free liquid
drainage during the off cycle (See Figure 2 and
Table 4).
Pump Down Cycle
A pump down cycle for control of refrigerant migration is
not recommended for scroll compressors of this size. If a
pump down cycle is used, a separate discharge line
check valve must be added. The scroll compressor’s
discharge check valve is designed to stop extended
reverse rotation and prevent high-pressure gas from
leaking rapidly into the low side after shut off. The check
valve will in some cases leak more than reciprocating
compressor discharge reeds, normally used with pump
down, causing the scroll compressor to recycle more
frequently. Repeated short-cycling of this nature can
result in a low oil situation and consequent damage to
the compressor. The low-pressure control differential
has to be reviewed since a relatively large volume of
gas will re-expand from the high side of the compressor
into the low side on shut down. Pressure control
setting: Never set the low pressure control to shut
off outside of the operating envelope. The exception
to this rule is the heat pump as explained on Page
3. To prevent the compressor from running into
problems during such faults as loss of charge or
partial blockage, the control should not be set lower
than 5 to 10°F (3-6K) equivalent suction pressure
below the lowest design operating point.
Minimum Run Time
There is no set answer to how often scroll compressors
can be started and stopped in an hour, since it is
highly dependent on system conguration. Other
than the considerations in the section on Brief Power
Interruptions, there is no minimum off time because
Copeland Scroll compressors start unloaded, even
if the system has unbalanced pressures. The most
critical consideration is the minimum run time required
to return oil to the compressor after startup. To establish
the minimum run time, obtain a sample compressor
equipped with a sight tube (available from Emerson)
and install it in a system with the longest connecting
lines that are approved for the system. The minimum
on time becomes the time required for oil lost during
compressor startup to return to the compressor sump
and restore a minimal oil level that will assure oil pick
up through the crankshaft. Cycling the compressor for
a shorter period than this, for instance to maintain very
tight temperature control, will result in progressive loss
of oil and damage to the compressor. See AE17-1262
for more information on preventing compressor short
cycling.

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© 2015 Emerson Climate Technologies, Inc.
AE4-1331 R7
Reversing Valves
Since Copeland Scroll compressors have very high
volumetric efciency, their displacements are lower
than those of comparable capacity reciprocating
compressors. CAUTION Reversing valve sizing must
be within the guidelines of the valve manufacturer.
Required pressure drop to ensure valve shifting
must be measured throughout the operating range
of the unit and compared to the valve manufacturer's
data. Low ambient heating conditions with low ow
rates and low pressure drop across the valve can
result in a valve not shifting. This can result in a
condition where the compressor appears to be
not pumping (i.e. balanced pressures). It can also
result in elevated compressor sound levels. During
a defrost cycle, when the reversing valve abruptly
changes the refrigerant ow direction, the suction
and discharge pressures will go outside of the normal
operating envelope. The sound that the compressor
makes during this transition period is normal, and the
duration of the sound will depend on the coil volume,
outdoor ambient, and system charge. The preferred
method of mitigating defrost sound is to shut down the
compressor for 20 to 30 seconds when the reversing
valve changes position going into and coming out of
the defrost cycle. This technique allows the system
pressures to reach equilibrium without the compressor
running. The additional start-stop cycles do not
exceed the compressor design limits, but suction and
discharge tubing design should be evaluated.
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 shutoff, suction and discharge pressures are
reversed to the compressor. This results in pressures
equalizing through the compressor which can cause
the compressor to slowly rotate backwards until the
pressures equalize. This condition does not affect
compressor durability but can cause unexpected sound
after the compressor is turned off.
Low Ambient Cut-Out
A low ambient cut-out is not required to limit air-to air
heat pump operation. Air-to-water heat pumps must
bereviewedsincethiscongurationcouldpossiblyrun
outside of the approved operating envelope (Figure 7)
causing overheating or excessive wear.
Oil Type
Polyol ester (POE) oil is used in these compressors.
See the compressor nameplate for the original oil
charge. A complete recharge should be approximately
four uid ounces (118 ml) less than the nameplate
value.Ifadditionaloilisneededintheeld,Copeland™
Ultra 32-3MAF, Lubrizol Emkarate RL32-3MAF, Parker
Emkarate RL32-3MAF/(Virginia) LE32-3MAF, or Nu
Calgon 4314-66 (Emkarate RL32-3MAF) should be
used. Copeland™ Ultra22 CC, Hatcol EAL22CC, and
Mobil EAL Arctic 22 CC are acceptable alternatives.
CAUTION! POE 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).
Contaminant Control
Copeland Scroll compressors leave the factory with
a miniscule amount of contaminants. Manufacturing
processes have been designed to minimize the
introduction of solid or liquid contaminants. Dehydration
and purge processes ensure minimal moisture levels
in the compressor and continuous auditing of lubricant
moisture levels ensure that moisture isn’t inadvertently
introduced into the compressor.
It is generally accepted that system moisture levels
should be maintained below 50 ppm. A lter-drier is
required on all R-410A and POE lubricant systems
to prevent solid particulate contamination, oil
dielectric strength degradation, ice formation, oil
hydrolysis, and metal corrosion. It is the system
designer’sresponsibilitytomakesurethelter-drieris
adequately sized to accommodate the contaminants
from system manufacturing processes that leave
solid or liquid contaminants in the evaporator coil,
condenser coil, and interconnecting tubing plus any
contaminants introduced during the eld installation
process. Molecular sieve and activated alumina are
two lter-drier materials designed to remove moisture
and mitigate acid formation. A 100% molecular sieve
lter can be used for maximum moisture capacity. A
more conservative mix, such as 75% molecular sieve
and 25% activated alumina, should be used for service
applications.
Long Line Sets/High Refrigerant Charge
Somesystemcongurationsmaycontainhigher-than-
normal refrigerant charges either because of large
internal coil volumes or long line sets. If such a system
also contains an accumulator then the permanent
loss of oil from the compressor may become critical.
If the system contains more than 20 pounds (9 kg) of
refrigerant, it is our recommendation to add one uid
ounce of oil for every 5 pounds (15 ml/kg) of refrigerant

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over this amount. If the system contains an accumulator
the manufacturer of the accumulator should be
consulted for a pre-charge recommendation.
Other system components such as shell and tube
evaporators can trap signicant quantities of oil and
should be considered in overall oil requirements.
Reheat coils and circuits that are inactive during part of
thenormalcyclecantrapsignicantquantitiesofoilif
system piping allows the oil to fall out of the refrigerant
owintoaninactivecircuit.Theoillevelmustbecarefully
monitored during system development, and corrective
action should be taken if compressor oil level falls below
the top of the lower bearing bracket for more than two
minutes. The lower bearing bracket weld points on the
compressor shell can be used as a low-oil-level marker.
Discharge Mufers
Flow through Copeland Scroll compressors is semi-
continuous with relatively low pulsation. External
mufers, where they are normally applied to
piston compressors today, may not be required for
Copeland Scroll compressors. Because of variability
between systems, however, individual system tests
should be performed to verify acceptability of sound
performance.Whennotestingisperformed,mufers
arerecommendedinheatpumps.Ahollowshellmufer
such as the Emerson Flow Controls APD-1 or APD-054
willworkquitewell.Themufersshouldbelocateda
minimum of six inches (15 cm) to a maximum of 18
inches (46 cm) from the compressor for most effective
operation. The farther the mufer is placed from the
compressor within these ranges the more effective it
may be. If adequate attenuation is not achieved, use a
muferwithalargercross-sectionalareatoinlet-area
ratio. The ratio should be a minimum of 20:1 with a
30:1ratiorecommended.Themufershouldbefrom
four to six inches (10 -15 cm) long.
Air Conditioning System Suction Line Noise and
Vibration
Copeland Scroll compressors inherently have low sound
and vibration characteristics. However, the sound and
vibration characteristics differ in some respects from
those of reciprocating compressors. In rare instances,
these could result in unexpected sound complaints.
One difference is that the vibration characteristics of the
scroll compressor, although low, include two very close
frequencies, one of which is normally isolated from the
shell by the suspension of an internally suspended
compressor. These frequencies, which are present in all
compressors, may result in a low level “beat” frequency
that may be detected as noise coming along the suction
line into a house under some conditions. Elimination
of the “beat” can be achieved by attenuating either
of the contributing frequencies. The most important
frequencies to avoid are 50 and 60 Hz power supply line
and twice-line frequencies for single-phase compressors
and line frequency for three phase compressors. This is
easily done by using one of the common combinations
ofdesigncongurationdescribedinTable 3. The scroll
compressor makes both a rocking and torsional motion,
and enough exibility must be provided in the line to
prevent vibration transmission into any lines attached to
the unit. In a split system the most important goal is to
ensure minimal vibration is all directions at the service
valve to avoid transmitting vibrations to the structure to
which the lines are fastened.
A second difference of the Copeland Scroll compressor
is that under some conditions the normal rotational
starting motion of the compressor can transmit an
“impact” noise along the suction line. This may be
particularly pronounced in three-phase models due to
their inherently higher starting torque. This phenomenon,
like the one described previously, also results from the
lack of internal suspension, and can be easily avoided
by using standard suction line isolation techniques as
described in Table 3.
The sound phenomena described above are not usually
associated with heat pump systems because of the
isolation and attenuation provided by the reversing
valve and tubing bends.
Mounting Parts
All ZP16-44K3 and ZP34-61K5 compressors
have extruded grommet mounting holes, so the
grommet must have a relief cut into the main body to
accommodate the down-turned lip of the hole. Table
4lists the mounting parts kits to be used with these
compressors. Many OEM customers buy the mounting
parts directly from the supplier, but Emerson’s
grommet design and durometer recommendation
should be followed for best vibration reduction through
the mounting feet. Please see AE4-1111 for grommet
mounting suggestions and supplier addresses.
Single Phase Starting Characteristics
Start assist devices are usually not required, even if a
system utilizes non-bleed expansion valves. Due to the
inherent design of the Copeland Scroll compressor, the
internal compression components always start unloaded
even if system pressures are not balanced. In addition,
since internal compressor pressures are always
balanced at startup, low voltage starting characteristics
are excellent for Copeland Scroll compressors. The
starting Locked Rotor Amperage (LRA), also referred
to as inrush current, is normally six or more times higher

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than the rated running amperage of the compressor
and lasts from 100 to 300 milliseconds until the rotor
starts turning. This high starting current may result in
signicant“sag”involtagewhereapoorpowersupplyis
encountered. Low starting voltage reduces the starting
torque of the compressor and subsequently increases
the time the compressor is in a locked rotor condition.
This could cause light dimming or a buzzing noise
where wire is pulled through conduit. Start components
will substantially reduce start time and consequently
the magnitude and duration of both light dimming and
conduitbuzzing.Speciedstartingcomponentscanbe
found in the Online Product Information section of www.
emersonclimate.com.
PTC Start Components
For less severe voltage drops or as a start boost, solid
state Positive Temperature Coefcient (PTC) devices
rated from 10 to 25 ohms may be used to facilitate
starting for any of these compressors.
Electrical Connections
WARNING
Molded electrical plug (Emerson p/n 529-0060-04
or OEM equivalent) must be used with all -1XX and
- 8XX bills of material.
The orientation of the electrical connections on the
Copeland Scroll compressors is shown in Figure 4.
Two electrical connection options are available for
these compressors. These include the “Molded Plug”
one piece push-on connection, available in certain
models;and“QuickConnect”agterminationavailable
only on the ZP*K3 scrolls. CAUTION Never operate
the compressor without the terminal box cover
installed.
Deep Vacuum Operation
Copeland Scroll compressors incorporate internal low
vacuum protection and will stop pumping (unload) when
the pressure ratio exceeds approximately 10:1. There
is an audible increase in sound when the scrolls start
unloading.
CAUTION Copeland Scroll compressors (as with
any refrigerant compressor) should never be used
to evacuate a refrigeration or air conditioning
system. The scroll compressor can be used to pump
down refrigerant in a unit as long as the pressures
remain within the operating envelope shown in Figure 7.
Prolonged operation at low suction pressures will result
in overheating of the scrolls and permanent damage
to the scroll tips, drive bearing and internal seal. See
AE24-1105 for proper system evacuation procedures.
Shell Temperature
CAUTION
Compressor top cap temperatures can be very
hot. Care must be taken to ensure that wiring or
other materials which could be damaged by these
temperatures do not come into contact with these
potentially hot areas.
Certain types of system failures, such as condenser or
evaporator fan blockage or loss of charge, may cause
thetopshellanddischargelinetobrieyorrepeatedly
reach temperatures above 350°F (177°C) as the
compressor cycles on its internal overload protection
device. Care must be taken to ensure that wiring or
other materials which could be damaged by these
temperatures do not come into contact with these
potentially hot areas.
Suction and Discharge Fittings
Copeland Scroll compressors have copper plated
steel suction and discharge ttings. These ttings
are far more rugged and less prone to leaks than
copper ttings 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. See Figure 8 for assembly line
andeldbrazingrecommendations.
System Tubing Stress
System tubing should be designed to keep tubing
stresses below 9.5 ksi (62 MPa), the endurance limit
of copper tubing. Start, stop and running (resonance)
cases should be evaluated.
Three Phase Scroll Compressor Electrical
Phasing
Copeland Scroll compressors, like several other types
of compressors, will only compress in one rotational
direction. Direction of rotation is not an issue with
single phase compressors since they will always start
and run in the proper direction (except as described in
the section “Brief Power Interruptions”). Three phase
compressors will rotate in either direction depending
upon phasing of the power. Since there is a 50%
chance of connecting power in such a way as to cause
rotation in the reverse direction, it is important to
include notices and instructions in appropriate
locations on the equipment to ensure that proper
rotation direction is achieved when the system
is installed and operated. Verication of proper
rotation direction is made by observing that suction
pressure drops and discharge pressure rises when the
compressor is energized. Reverse rotation will result in

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no pressure differential as compared to normal values.
A compressor running in reverse will sometimes make
an abnormal sound.
There is no negative impact on durability caused by
operating three phase Copeland Scroll compressors in
the reversed direction for a short period of time (under
one hour). After several minutes of reverse operation,
the compressor’s internal overload protector will trip
shutting off the compressor. If allowed to repeatedly
restart and run in reverse without correcting the
situation, the compressor bearings will be permanently
damaged because of oil loss to the system. All three-
phase scroll compressors are wired identically
internally. As a result, once the correct phasing is
determined for a specic system or installation,
connecting properly phased power leads to the
identiedcompressorelectrical(Fusite™) terminals will
maintain the proper rotational direction (see Figure
4). It should be noted that all three phase scrolls will
continue to run in reverse until the internal overload
protector opens or the phasing is corrected.
Brief Power Interruptions
Brief power interruptions (less than ½ second) may
result in powered reverse rotation of single-phase
Copeland Scroll compressors. This occurs because
high-pressure discharge gas expands backward
through the scrolls during interruption, causing the scroll
to orbit in the reverse direction. When power is reapplied
while reverse rotation is occurring, the compressor
may continue to run in the reverse direction for some
time before the compressor’s internal overload trips.
This will not cause any damage to the compressor, and
when the internal overload resets, the compressor will
start and run normally.
To avoid disruption of operation, an electronic control
that can sense brief power interruptions may be used
to lock out the compressor for a short time. This control
could be incorporated in other system controls (such
as defrost control board or the system thermostat), or
canbeastand-alonecontrol.Functionalspecications
for this control as well as a suggested wiring diagram
are shown in Figure 3. No time delay is necessary for
three phase models since the motor starting torque is
high enough to overcome reverse rotation.
Astartkit(speciedstartcapacitorandrelay)isanother
effective means of mitigating a powered reverse
condition that is caused by a brief power interruption.
Manifolding Tandem Compressors
All of the ZPK5 compressors are available for
manifolding with another ZPK5 compressor of equal
capacity. These compressors are designated with a
-4XX bill of material number at the end of the model
number (e.g. ZP25K5E-PFV-498). See Figure 10 for a
picture of an assembled tandem showing the hardware
and parts required for assembly. Drawings of tandem
tubing assemblies are available from Emerson Climate
Technologies by contacting your Applications Engineer.
Tandem Applications
Tandem compressors following the same application
guidelines as single compressors outlined in this
bulletin. The refrigerant charge limit for tandem
compressors is shown in Table 5. A three-phase unit
with a charge over this limit must have crankcase
heaters applied to both compressors.
The compressors in a tandem set can be started/
stopped in any desired sequence. To help reduce the
probability of light dimming, starting the compressors
individually is recommended.
Maximum Tilt Angle
OEms and end-users often ask about the maximum
allowable tilt angle of the compressor. Some
applications, such as transportation air-conditioning or
mobile radar applications, may require the compressor
to operate at some angle from vertical. Or, service
personnel may be required to maneuver a unit through
a stairwell or other cramped area that might require
tilting the unit. The maximum allowable tilt angles from
horizontal are summarized below:
Max Tilt Angle With Compressor Running = 15°
Max Tilt Angle With Compressor Not Running = 60°
APPLICATION TESTS
Application Test Summary
There are a minimal number of tests the system
designer will want to run to ensure the system operates
as designed. These tests should be performed during
system development and are dependent on the system
type and amount of refrigerant charge. These application
tests are to help identify gross errors in system design that
may produce conditions that could lead to compressor
failure. The Continuous Floodback Test and Field
Application Test, both outlined below, are two tests to
run to help verify the design. When to run these tests
can be summarized as follows:
Continuous Floodback:
Required on all heatpumps.
Field Application Test:
Required for any unit where both the design system
charge is higher than the compressor refrigerant

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charge limit listed in Table 5; and a capillary tube,
xedorice, orbleed-typeTXVisused oneither
the indoor or the outdoor coil of the unit.
Continuous Floodback Test
It is expected that the design would not ood during
standard air conditioning operation. Running a partially
blockedindoorairlterorlossofevaporatorairowtest
and comparing the sump temperature results to Figure
1 is recommended. The use of a TXV in heating does
notguaranteeoperationwithoutoodbackinthelower
end of the unit/TXV operating range.
Totestforexcessivecontinuousliquidrefrigerantood
back, it is necessary to operate the system in a test
roomatconditionswheresteadystateoodbackmay
occur (low ambient heating operation). Thermocouples
should be attached with glue or solder to the center of
the bottom shell and to the suction and discharge lines
approximately 6 inches (15 cm) from the shell. These
thermocouples should be insulated from the ambient air
with Permagum® or other thermal insulation to be able
to record true shell and line temperatures. If the system
isdesignedtobeeldcharged,itshouldbeovercharged
by 15% in this test to simulate overcharging often found
ineldinstallations.
The system should be operated at an indoor temperature
of 70°F (21°C) and outdoor temperature extremes of
10°F(-12°C)orlowerinheatingtoproduceoodback
conditions. The compressor suction and discharge
pressures and temperatures as well as the sump
temperature should be recorded. The system should
be allowed to frost up for several hours (disabling the
defrost control and spraying water on the outdoor coil
may be necessary) to cause the saturated suction
temperature to fall below 0°F (-18°C). The compressor
sump temperature must remain above the sump
temperature shown in Figure 1 or design changes
mustbemadetoreducetheamountofoodback.Ifan
accumulator is used, this test can be used to test the
effectiveness of the accumulator. Increasing indoor coil
volume,increasingoutdoorairow,reducingrefrigerant
charge, decreasing capillary or orice diameter, and
adding a charge compensator can also be used to reduce
excessivecontinuousliquidrefrigerantoodback.
Field Application Test
Totestforrepeated,excessiveliquidoodbackduring
normal system off-cycles, perform the FieldApplication
Test that is outlined in Table 2. Obtain a sample
compressor with a sight-tube to measure the liquid level
in the compressor when it is off.
Note: The sight-tube is not a good liquid level indicator
when the compressor is running because the top of the
sight-tube is at a lower pressure than the bottom causing
a higher apparent oil level.
Set the system up in a conguration with the indoor
unit elevated several feet above the outdoor unit with
a minimum of 25 feet (8 meters) of connecting tubing
with no traps between the indoor and outdoor units. If
thesystemisdesignedtobeeldcharged,thesystem
should be overcharged by 15% in this test to simulate
eldovercharging.Operatethesysteminthecooling
mode at the outdoor ambient, on/off cycle times, and
numberofcyclesspeciedinTable 2. Record the height
of the liquid in the compressor at the start of each on
cycle, any compressor overload trips, or any compressor
abnormal starting sounds during each test. Review
the results with Application Engineering to determine
if an accumulator or other means of off cycle migration
control are required. This test does not eliminate the
requirement for a crankcase heater if the system
charge level exceeds the values in Table 5. The
criteria for pass/fail is whether the liquid level reaches
the level of the compressor suction tube connection.
Liquid levels higher than this can allow refrigerant/oil
to be ingested by the scrolls and pumped out of the
compressor after start-up.
The tests outlined above are for common
applications of compressors in this family. Many
other applications of the compressor exist, and tests
to insure those designs can’t possibly be covered
in this bulletin. Please consult with Application
Engineering on applications outside of those
outlined above for the appropriate application tests.
ASSEMBLY LINE PROCEDURES
Installing the Compressor
WARNING
Use care and the appropriate material handling
equipment when lifting and moving compressors.
Personal safety equipment must be used.
Copeland Scroll compressors leave the factory
dehydrated and with a positive dry air charge. Plugs
should not be removed from the compressor until
thecompressorhashadsufcienttimetowarmupif
stored outside and is ready for assembly in the unit.
The suggested warm up time is one hour per 4°F (2K)
difference between outdoor and indoor temperature. It
is suggested that the larger suction plug be removed
rst to relieve the internal pressure. Removing the
smaller discharge plug could result in a spray of oil out
ofthisttingsincesomeoilaccumulatesinthehead
of the compressor after Emerson’s run test. The inside
of both ttings should be wiped with a lint free cloth

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to remove residual oil prior to brazing. A compressor
containing POE oil should never be left open longer
than 5 minutes.
Assembly Line Brazing Procedure
WARNING
Personal safety equipment must be used during
brazing operation. Heat shields should be
used to prevent overheating or burning nearby
temperature sensitive parts. Fire extinguishing
equipment should be accessible in the event of a
re.
Figure 8 discusses the proper procedures for brazing
the suction and discharge lines to a scroll compressor.
NOTICE It is important to ow nitrogen through the
system while brazing all joints during the system
assembly process. Nitrogen displaces the air and
prevents the formation of copper oxides in the system.
If allowed to form, the copper oxide akes can later
be swept through the system and block screens such
as those protecting capillary tubes, thermal expansion
valves, and accumulator oil return holes. Any blockage
of oil or refrigerant may damage the compressor
resulting in failure.
Tandem Assembly
WARNING
When lifting tandem compressor assemblies,
both compressors must be lifted by their
respective lifting rings. Use care and exercise
extreme caution when lifting and moving
compressors. Personal safety equipment must
be used.
The rst step in the tandem assembly process is to
securely mount both compressors to the rails using
the appropriate mounting hardware listed in Table 4.
After both compressors are mounted to the rails, the
suction, discharge, and gas equalization manifolds
can be brazed to the appropriate stub tubes of each
compressor using standard brazing practices with a
nitrogen purge. Special consideration needs to be given
to the oil equalization line that connects the oil sumps
of the two compressors. The oil in the single, tandem
ready compressor is located at the center of the oil
equalizationtting.Afterbothcompressorsaremounted
to the compressor rails and prior to removing the rubber
plug in the oil equalization stubs, the assembly should
be tilted back a minimum of 12° from horizontal (see
Figure 11) to move the oil level away from the oil
equalizationttingforbrazing.Theoilequalizationstubs
of both compressors should be wiped clean with a lint
free towel to remove any oil residue before brazing.
Pressure Testing
WARNING
Never pressurize the compressor to more than
475 psig (32.8 bar) for leak checking purposes.
Never pressurize the compressor from a nitrogen
cylinder or other pressure source without an
appropriately sized pressure regulating and relief
valve.
The pressure used on the line to meet the UL burst
pressure requirement must not be higher than 475
psig (33 Bar). Higher pressure may result in permanent
deformation of the compressor shell and possible
misalignment or bottom cover distortion.
Assembly Line System Charging Procedure
Systems should be charged with liquid on the high
side to the extent possible. The majority of the charge
should be pumped in the high side of the system to
preventlowvoltagestartingdifculties,hipotfailures,
andbearingwashoutduringtherst-timestartonthe
assembly line. If additional charge is needed, it should
be added as liquid to the low side of the system with
the compressor operating. Pre-charging on the high
side and adding liquid on the low side of the system
are both meant to protect the compressor from
operating with abnormally low suction pressures during
charging. NOTICE Do not operate the compressor
without enough system charge to maintain at least
55 psig (3.8 bar) suction pressure. Do not operate
the compressor with the low pressure cut-out
disabled. Do no operate with a restricted suction
or liquid line. Depending on the discharge pressure,
allowing pressure to drop below 55 psig (3.8 bar) for
more than a few seconds may overheat the scrolls and
cause early drive bearing damage. NOTICE Do not
use the compressor to test the opening set point
of a high pressure cutout. Bearings are susceptible
to damage before they have had several hours of
normal running for proper break in.
“Hipot” (AC High Potential) Testing
CAUTION
Use caution with high voltage and never hipot
when compressor is in a vacuum.
CopelandScrollcompressorsareconguredwiththe
motor down and the pumping components at the top
of the shell. As a result, the motor can be immersed
in refrigerant to a greater extent than hermetic
reciprocating compressors when liquid refrigerant is
present in the shell. In this respect, the scroll is more
like semi-hermetic compressors that have horizontal

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motors partially submerged in oil and refrigerant.
When Copeland Scroll compressors are hipot tested
with liquid refrigerant in the shell, they can show higher
levels of leakage current than compressors with the
motor on top. This phenomenon can occur with any
compressor when the motor is immersed in refrigerant.
The level of current leakage does not present any
safety issue. To lower the current leakage reading,
the system should be operated for a brief period of
time to redistribute the refrigerant to a more normal
congurationandthesystemhipottestedagain.See
AE4-1294 for megohm testing recommendations.
Under no circumstances should the hipot test
be performed while the compressor is under a
vacuum.
Final Run Test
Customers that use a nitrogen nal run test must be
careful to not overheat the compressor. Nitrogen is not
a good medium for removing heat from the compressor,
and the scroll tips can be easily damaged with high
compression ratios and/or long test times. Copeland
Scroll compressors are designed for use with refrigerant,
and testing with nitrogen may result in a situation where
the compressor does not develop a pressure differential
(no pump condition). When testing with nitrogen, the
compressor must be allowed to cool for several minutes
between tests.
Single phase scrolls with an electrical nomenclature of
“PFV” (208-230 volt, 1Ø, 60 Hertz) at the end of the
model number are guaranteed to start at 187 volts or
higher and must have a voltage no lower than 197 volts
once the compressor is running under load. All other
compressor voltages, both single and three phase, 50 &
60 Hertz are guaranteed to start and run at 10% below
the lowest voltage shown on the nameplate.
Variable transformers used on assembly lines are
often incapable of maintaining the starting voltage
when larger compressors are tested. To test for
voltagesagduringstarting,therstcompressorina
production run should be used to preset the voltage.
Remove the start wire from the compressor and apply
200 volts to the compressor. With the start winding
removed, the compressor will remain on locked
rotor long enough to read the supply voltage. If the
voltage sags below the minimum guaranteed starting
voltage, the variable transformer must be reset
to a higher voltage. When discussing this starting
amperage it should be noted that “inrush current” and
locked rotor amps (LRA) are one and the same. The
nameplate LRA is determined by physically locking
a compressor and applying the highest nameplate
voltage to the motor. The amperage that the motor
draws after four seconds is the value that is used on
the nameplate. Since there is a direct ratio between
voltage and locked rotor amperage, the lower the line
voltage used to start the compressor, the lower the
locked rotor amperage will be.
Unbrazing System Components
WARNING
Before attempting to braze, it is important to
recover all refrigerant from both the high and low
side of the system.
If the refrigerant charge is removed from a scroll-
equipped unit by recovering one side only, it is very
possible that either the high or low side of the system
remains pressurized. If a brazing torch is then used
to disconnect tubing, the pressurized refrigerant and
oil mixture could ignite when it escapes and contacts
the brazing ame. Instructions should be provided
in appropriate product literature and assembly (line
repair) areas. If compressor removal is required, the
compressor should be cut out of the system rather than
unbrazed. See Figure 8 for proper compressor removal
procedure.
SERVICE PROCEDURES
Copeland Scroll Compressor Functional Check
A functional compressor test during which the suction
service valve is closed to check how low the compressor
will pull the suction pressure is not a good indication
of how well a compressor is performing. Such a test
will damage a scroll compressor in a few seconds.
The following diagnostic procedure should be used
to evaluate whether a Copeland Scroll compressor is
functioning properly:
1. Propervoltagetotheunitshouldbeveried.
2. Determine if the internal motor overload has
opened or if an internal motor short or ground
fault has developed. If the internal overload has
opened, the compressor must be allowed to cool
sufcientlytoallowittoreset.
3. Check that the compressor is correctly wired.
4. Proper indoor and outdoor blower/fan operation
shouldbeveried.
5. With service gauges connected to suction and
dischargepressurettings,turnonthecompressor.
If suction pressure falls below normal levels the
systemis either lowon charge orthere is a ow
blockage in the system.

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6. Single phase compressors – If the compressor
starts and the suction pressure does not drop
and discharge pressure does not rise to normal
levels, either the reversing valve (if so equipped)
or the compressor is faulty. Use normal diagnostic
procedures to check operation of the reversing
valve. Three phase compressors – If suction
pressure does not drop and discharge pressure
does not rise to normal levels, reverse any two of
the compressor power leads and reapply power to
make sure the compressor was not wired to run
in reverse. If pressures still do no move to normal
values, either the reversing valve (if so equipped)
or the compressor is faulty. Reconnect the
compressorleadsasoriginallyconguredanduse
normal diagnostic procedures to check operation
of the reversing valve.
7. To test if the compressor is pumping properly,
the compressor current draw must be compared
to published compressor performance curves
using the operating pressures and voltage of
the system. If the measured average current
deviates more than +/-20% from published values,
a faulty compressor may be indicated. A current
imbalance exceeding 20% of the average on the
three phases of a three-phase compressor should
be investigated further. A more comprehensive
trouble-shooting sequence for compressors and
systems can be found in Section H of the Emerson
Climate Technologies Electrical Handbook,
Form No. 6400.
8. Note that ZP20K5-ZP31K5 three-phase models
use uniquely designed motors that do not
have equal resistances on all three windings.
Resistance may differ from leg-to-leg as much
as 30%. Refer to related data in Online Product
Information (OPI) for published resistance
specications for a specic model. Carefully
compare measured motor resistance values to
published values before replacing the compressor
as being defective. Resistance values and other
technical data can be found at emersonclimate.
com or from the Copeland Moblie App. The larger
ZP34K5-ZP61K5 and older ZP*K3 compressors
have conventional three-phase motors with equal
resistances in each winding.
9. Before replacing or returning a compressor, be
certain that the compressor is actually defective.
As a minimum, recheck compressors returned
fromtheeldintheshopordepotbytestingfora
grounded, open or shorted winding and the ability
to start. The orange tag in the service compressor
boxshouldbelledoutandattachedtothefailed
compressor to be returned. The information on this
tag is captured in our warranty data base.
Compressor Replacement After a Motor Burn
In the case of a motor burn, the majority of contaminated
oil will be removed with the compressor. The rest of the
oiliscleanedwiththeuseofsuctionandliquidlinelter
driers.A 100% activated alumina suction lter drier is
recommended but must be removed after 72 hours. See
AE24-1105 for clean up procedures and AE11-1297 for
liquid line lter-drier recommendations. NOTICE It is
highly recommended that the suction accumulator
be replaced if the system contains one. This is
becausetheaccumulatoroilreturnoriceorscreenmay
be plugged with debris or may become plugged shortly
after a compressor failure. This will result in starvation
of oil to the replacement compressor and a second
failure. The system contactor should be inspected for
pitted/burnt contacts and replaced if necessary. It is
highly recommended that the run capacitor be replaced
when a single phase compressor is replaced.
Start-Up of a New or Replacement Compressor
It is good service practice, when charging a system
with a scroll compressor, to charge liquid refrigerant
into the high side only. It is not good practice to dump
liquid refrigerant from a refrigerant cylinder into the
crankcase of a stationary compressor. If additional
charge is required, charge liquid into the low side of
the system with the compressor operating. CAUTION
Do not start the compressor while the system is in
a deep vacuum. Internal arcing may occur when any
type of compressor is started in a vacuum. NOTICE
Do not operate the compressor without enough
system charge to maintain at least 55 psig (3.8 bar)
suction pressure. Do not operate with a restricted
suction or liquid line. Do not operate with the low
pressure cut-out disabled. Allowing suction pressure
to drop below 55 psig (3.8 bar) for more than a few
seconds may overheat the scrolls and cause early
drive bearing damage. Never install a system in the
eldandleaveitunattendedwithnocharge,aholding
charge, or with the service valves closed without
securely locking out the system. This will prevent
unauthorized personnel from accidentally ruining the
compressorbyoperatingwithnorefrigerantow.
Tandem Service
Should a compressor fail in the tandem set the
complete tandem should be removed from the unit and
replaced with a new tandem set. Replacing individual
compressors is discouraged because of the care that
must be used when installing the oil equalization tube
and the availability of manifolds to the aftermarket.

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Note 1: Operation in this refrigerant dilution area is safe in air-to-air heat pump heating mode. For other applications, such as
AC only, review expansion device to raise superheat. A cold sump may result in high refrigerant migration after shut down.
Figure 1
Oil Dilution Chart
-30 -25 -20 -15 -10 -5 0 5 10
-24
-14
-4
6
16
26
36
-10
0
10
20
30
40
50
60
70
80
90
100
110
-20 -10 0 10 20 30 40 50
Evaporating Temperature (°C)
Compressor Sump Temperature (°C)
Compressor Sump Temperature (°F)
Evaporating Temperature (°F)
200°F (93.3°C)
Max Oil Temp
Acceptable
Unacceptable
(Too Much Refrigerant Diluon)
*See Note 1

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Figure 3
Time Delay Wiring
C
Line Voltage
Typical Solid State Timer
(if used)
Discharge Line
Thermostat (if used) Compressor Contactor
Other Protective
Devices (if used)
System Operating
Thermostat
Fuse
A
B
Ti
me Delay Relay Specifications
Ti
mer Opens: 1 Electrical Cycle Timer Closes: Greater than 5 seconds later, whether
(.016 Sec. With 60 HZ Operation) power is restored or not
after power is removed
Topreventoodedstartdamageduetooffcyclemigration,theaccumulatormaybeconguredon
some systems to allow free drainage from the compressor to the accumulator during the off cycle. When
theabovecongurationisnotpossibleandtheunitchargeisoverthechargelimitshowninTable5,a
crankcase heater is required.
Liquid
Level
Scroll Accumulato
r
Drainage
In Off
Cycle
Figure 2
Accumulator Piping

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Discharge Thermostat
Figure 5
Kit Part No. Max.
Voltage
Max. Contact
Rating
998-0540-02 240 5A @ 240V
998-7022-02* 240 5A @ 240V
*For conduit use.
Figure 5
Discharge Thermostat
Figure 4
Compressor Electrical Connection
T1,C
T2,S
T3,R
ZR16-32K
5Z
R38-54K5
Connect the heater so that the connection point straddles the compressor seam weld
Seam WeldSeam Weld
Figure 6
Crankcase Heater
ZP14-31K5 ZP34-61K5
ZP16-44K3
WARNING
Verify the correct crankcase heater
voltage for the application and ensure
heater is properly grounded.

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Figure 7 – R-410A Scroll Operating Envelope
-29 -24 -19 -14 -9 -4 1 6 11
21
26
31
36
41
46
51
56
61
66
70
80
90
100
110
120
130
140
150
160
-20 -10 0 10 20 30 40 50 60
Evaporating Temperature (°C)
Condensing Temperature (°C)
Condensing Temperature (°F)
Evaporating Temperature (°F)
Note:
ZP51-61K5E-PFV Compressors
Are Limited To 145°F Condensing
For -5% Voltage Tolerance
See Note

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New Installations
• The copper-coated steel suction tube 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suctiontubettingI.D.andsuctiontube
O.D.are clean prior toassembly.  If oillm is
present wipe with denatured alcohol, Dichloro-
Triuoroethaneorothersuitablesolvent.
• Using a double-tipped torch apply heat in Area 1.
As tube approaches brazing temperature, move
torchametoArea2.
• Heat Area 2 until braze temperature is attained,
moving torch up and down and rotating around
tube as necessary to heat tube evenly. Add
braze material to the joint while moving torch
around joint to ow braze material around
circumference.
• After braze material ows around joint, move
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nalresult.
Field Service
WARNING
Remove refrigerant charge from both the low
and high side of the compressor before cutting
the suction and discharge lines to remove
the compressor. Verify the charge has been
completely removed with manifold gauges.
• To disconnect: Reclaim refrigerant from both the
high and low side of the system. Cut tubing near
compressor.
• To reconnect:
○Recommended brazing materials: Silfos
with minimum 5% silver or silver braze
materialwithux.
○Inserttubingstubsintottingandconnect
to the system with tubing connectors.
○Follow New Installation brazing
Figure 8
Scroll Suction Tube Brazing
}
}
}
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