Emerson Copeland Scroll Installation Manual
AE4-1425 R4
May 2019
Application Guidelines for Low Temperature ZF**KAE 1-2.5HP
Copeland Scroll™ Refrigeration Compressors
TABLE OF CONTENTS
SAFETY ....................................................................... 3
Safety Instructions.................................................... 3
Safety Icon Explanation
Inst
ructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons
INTRODUCTION ......................................................... 5
Nomenclature ........................................................... 5
Operating Envelope ................................................. 5
APPLICATION CONSIDERATIONS ........................... 5
Accumulators ........................................................... 5
Superheat Requirements ......................................... 5
Crankcase Heaters .................................................. 5
ZF*KAE Low Temperature Liquid Injection .............. 5
DTC Valve Specifications ........................................ 5
Installation of DTC Valve ......................................... 6
Suggested Application Techniques for All Liquid
Injection Applications ............................................... 6
Discharge Line Thermostat ...................................... 6
Pressure Controls .................................................... 6
Pump Down Recommendations .............................. 6
IPR Valve ................................................................. 6
Internal Temperature Protection .............................. 6
Motor Protection ....................................................... 7
Oil Types .................................................................. 7
Oil Charges .............................................................. 7
Compressor Tubing and Mounting ........................... 7
Starting Characteristics ............................................ 7
.......................................... 3
........................................ 4
Fusite ........................................................................ 7
Shell Temperature .................................................... 7
Connection Fittings ................................................... 7
Three-Phase Rotation Direction ............................... 7
Brief Power Interruptions .......................................... 7
Deep Vacuum Operation .......................................... 8
ZF**KAE COMPRESSORS IN COPELAND™ ............ 8
CONDENSING UNITS ................................................. 8
Features.................................................................... 8
Condensing Unit Mounting ....................................... 8
Bump Start Protection .............................................. 8
Brief Power Interruptions .......................................... 8
Headmaster Refrigerant Selection Instructions ........ 8
Rack Applications ..................................................... 8
ASSEMBLY LINE PROCEDURES .............................. 8
Unbrazing System Components ............................... 8
High Potential (Hipot) Testing .................................. 9
SERVICE PROCEDURES ........................................... 9
Copeland Scroll Functional Check ........................... 9
New Installation ........................................................ 9
Field Service ........................................................... 10
General Guidelines and More Information ............. 10
Appendix:
TABLE OF FIGURES
Figure 1 - Scott-Tee Three Phase ............................... 9
Figure 2 - Scroll Tube Brazing ................................... 10
Figure 3 - ZF*KAE Application Envelope for R-404A/R-
507/R-407A/R-448A/R-449A ..................................... 12
Figure 4 - Small Refrigeration Scroll Condensing Unit
Mounting .................................................................... 13
Figure 5 - Motor Terminal (Fusite) Connections for
Single Phase and Three Phase Scroll Compressors 13
Figure 6 - Typical Suction Tubing .............................. 14
Figure 7 - DTC Valve Orientation .............................. 15
DTC Valve Installation Instructions
AE4-1425 R4
TABLES
Table 1 - Compressor Models and Approved
Refrigerants/Lubricants .............................................. 11
Table 2 - Charge Limitations ...................................... 11
Table 3 - Crankcase Heater ....................................... 11
Table 4 - Conduit Ready Heater Terminal Box Kits ... 11
Table 5 - Discharge Thermostat Line Kits ................. 11
Table 6 - Pressure Control Settings ........................... 12
Table 7 - Recommended Oil Charges by Model Family
................................................................................... 12
Table 8 - Voltage Ranges (Typical) ........................... 12
Revision Tracking R4
Pg. 6 – DLT position and general guideline Text
updated.
Added DTC Valve kit Setpoint and Table 6. Improve
DTC Installation Instructions.
Revision Tracking R3
All the document: ZF06KAE added to the list of
available compressor models.
Pg. 5 – Reference to °C changed to K (Kelvin scale).
Pg. 7 – Reference to °C changed to K (Kelvin scale).
Pg. 11 to Pg. 12 –
Compressor model added.
Table 1 to Table 8: ZF06KA
Revision Tracking R2
Pg. 6 – Script and Caution to Warning about POE Oils
updated.
Pg. 6 – Additional Pump Down Recommendations
added.
Pg. 10 – A new section added: “General Guidelines
and More Information”
AE4-1425 R4
DANGER
WARNING
CAUTION
NOTICE
CAUTION
SAFETY
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 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.
AE4-1425 R4
Inst
WARNING
WARNING
ructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
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
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.
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.
AE4-1425 R4
INTRODUCTION
The Low Temperature ZF**KAE Copeland Scroll™
compressor represents the latest generation of
compliant scroll technology for the refrigeration industry.
Nomenclature
The refrigeration scroll model numbers include the
nominal capacity with R-404A at standard 60HZ ARI
rating conditions for low temperature (-25/105ºF). For
additional information on this product, please refer to the
Online Product Information at Emerson.com/OPI
Z = Scroll
F = Low Temperature Application
07K = nominal Capacity (x 1,000 Btu/hr)
A = Compressor Generation
E = POE Oil
Operating Envelope
The ZF**KAE refrigeration scroll compressor models
can be used with a variety of refrigerants depending on
the model selected and the lubricant used. (See Table
1) The ZF**KAE models are intended for low
temperature refrigeration type duty.
The approved operating envelope for these models are
such that they are ideally suited for applications such as
walk in and reach in freezers. The models and operating
envelopes are depicted in Figure 3.
.
APPLICATION CONSIDERATIONS
Accumulators
Due to the scrolls’ inherent ability to handle liquid
refrigerant in flooded start and defrost cycle operation
conditions, accumulators may not be required. An
accumulator is required on single compressor systems
when the charge limitations exceed those values listed
in Table 2. On systems with defrost schemes or
transient operations that allow prolonged uncontrolled
liquid return to the compressor, an accumulator is
required unless a suction header of sufficient volume to
prevent liquid migration to the compressor is used.
Excessive liquid flood back or repeated flooded starts
will dilute the oil in the compressor causing inadequate
lubrication and bearing wear. Proper system design will
minimize liquid flood back, thereby ensuring maximum
compressor life
Superheat Requirements
To assure that liquid refrigerant does not return to the
compressor during the running cycle, attention must be
given to maintaining proper superheat at the
compressor suction inlet. Emerson recommends a
minimum of 20°F (11K) superheat, measured on the
suction line 6 inches (152mm) from the suction valve
inlet, to prevent liquid refrigerant flood back.
Another method to determine if liquid refrigerant is
returning to the compressor is 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 (27K). This “crankcase differential
temperature” requirement supersedes the minimum
suction superheat requirement in the last paragraph. 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 (27K), 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 (14K) difference.
Contact your Emerson representative regarding any
exceptions to the above requirements.
Crankcase Heaters
Crankcase heaters are required on all ZF**KAE scroll
compressors where the system charge exceeds charge
limit.
The listed crankcase heaters are intended for use only
when there is limited access (See Table 3). The heaters
are not equipped for use with electrical conduit.
Where applicable, electrical safety codes require lead
protection, a crankcase heater terminal box should be
used. Recommended crankcase heater terminal box
and cover kit numbers are listed in Table 4. If there are
any questions concerning their application, contact your
Emerson representative.
ZF*KAE Low Temperature Liquid Injection
The low temperature models are provided with an
injection port that can be used for liquid injection.
Liquid Injection is required when using the ZF*KAE
scrolls for liquid injection operation, a discharge
temperature control (DTC) valve must be applied.
The purpose of the DTC valve is to maintain safe
internal operating temperatures.
DTC Valve Specifications
The following components are not required, but they are
recommended for liquid injection.
AE4-1425 R4
• Sight Glass - A sight glass can be installed
before the DTC valve to allow for visual
inspection for the presence of liquid refrigerant.
• Filter/Drier - A filter/drier can be installed
upstream of the injection circuit to avoid the
possibility of the DTC screen blockage due to
contaminants.
Installation of DTC Valve
The valve bulb must be installed in the top cap thermal
well to adequately control scroll temperatures. The valve
must be brazed into the injection fitting on the
compressor
For Installation Instructions see Appendix A.
The capillary tube connecting the valve to the bulb
should be positioned such that it does not contact the
compressor during operation. Do not bend the capillary
tube within 1” (25.4mm) of the valve.
The DTC valve comes with an insulating cap. If this
additional height from the cap is an issue, the valve cap
could be replaced with high temperature insulation. This
should be applied to insulate and protect the valves
remote bulb assembly. This will reduce the total height
requirement by 0.5” (12.7mm) The DTC valve kit part
number is 998-0746-00 (liquid line 3/8" sweat tube,
250°F set point).
Suggested Application Techniques for All Liquid Injection Applications
For the most efficient thermal sensing, spread a thin film
of thermal grease around the DTC valve bulb/thermistor
before installing into the top cap well. However, for
proper functioning of the valve this is not required.
• For service purposes, a mechanical ball valve
(not provided by Emerson) is also
recommended in the liquid line. For the liquid
injection system to be effective, a minimum of
5°F subcooled liquid at the at the DTC inlet is
required.
NOTE: To ensure adequate temperature control,
take care to not damage the DTC valve
bulb/thermistor when installing. Damage of DTC
valve bulb/thermistor could result in improper
injection.
Discharge Line Thermostat
If the system is designed where operation within these
guidelines cannot be guaranteed, then a discharge line
thermostat is required in the compressor control circuit.
When installed approximately 6 inches from the
discharge tube outlet, the thermostats have a cut-out
setting that will ensure the external discharge line
temperature does not exceed the 240°F limit. If a
Rotalock service valve is installed on the discharge port
connection, the thermostat should be located
approximately 5 inches from the valve braze connection.
Kits have been set up to include the thermostat, retainer,
and installation instructions. These thermostats must be
used with ½” O.D. discharge lines to ensure proper
thermal transfer and temperature control. They work
with either 120 or 240-volt control circuits and are
available with or without an alarm circuit capability. See
Table 5 for a list of discharge line thermostat kit
numbers.
Pressure Controls
Both high and low-pressure controls are required on all
models. See Table 6 for set points.
Pump Down Recommendations
All the ZF**KAE scrolls have an internal spring loaded
low-leak discharge check valve suitable for pump down
application. This valve prevents system pressures from
equalizing and pump down can be achieved. However,
during laboratory testing, we have observed a potential
short cycling condition on the ZF**KAE models. This
phenomenon can be attributed to several factors:
1. Location of low-pressure control sensor. If it is
located right at the suction inlet of the compressor,
it will be more sensitive to pressure spikes.
2. Actual low-pressure setting. Refer to our
recommended setting in Table 6. If the differential
pressure setting is too close, this will increase the
possibility of short cycling.
3. The type of low-pressure control can have an effect
on cycling. The encapsulated non-adjustable type is
more susceptible to causing excessive cycling due
to tolerances.
4. If short cycling cannot be avoided, using a 3-minute
time delay will limit the cycling of the compressor to
an acceptable level.
IPR Valve
Refrigeration scroll compressors (1 - 2.5 hp)
ZF03,04,05, 06, 07KAE have internal pressure relief
valves, which open at a discharge to suction differential
pressure of 375 to 450 psi. This action will trip the motor
protector and remove the compressor from the line.
Internal Temperature Protection
Refrigeration scroll compressors (1 - 2.5 hp)
ZF03,04,05,06, 07KAE incorporate a thermo disc which
is a temperature-sensitive snap disc device located at
the muffler plate port. It is designed to open and route
hot discharge gas back to the motor protector thus
removing the compressor from the line.
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