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. 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 compressor. You are strongly advised to follow these safety
instructions.
Safety Icon Explanation
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
CAUTION
NOTICE
CAUTION
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.
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
AE4-1317 R10
WARNING
WARNING
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.
•
• 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.
•
install, commission and maintain this equipment.
•
• All valid standards and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
• 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.
3
Page 4
AE4-1317 R10
Application Engineering
BULLETIN
Introduction
The ZBKC/ZBKCE 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 at standard 60HZ ARI rating
conditions for medium temperature (20/120°F). For
additional information on this product, please refer
to the Online Product Information accessible from
the Emerson Climate Technologies web site at www.
emersonclimate.com.
Operating Envelope
The ZBKC/ZBKCE refrigeration scroll compressor
models can be used with a variety of refrigerants
depending on the model selected and the lubricant used.
(See Table 1 at the end of this bulletin.)
The ZBKC and ZBKCE models are intended for medium
temperature refrigeration type duty. The approved
operating envelopes for these models are such that they
are ideally suited for applications such as ice machines,
bulk milk and FCB/FUB. The models and operating
envelopes are depicted in Figures 1A, 1B and 1C at
the end of this bulletin.
Accumulators
Due to the scrolls’ inherent ability to handle liquid
refrigerant in fl ooded 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 suffi cient volume to prevent liquid
migration to the compressor is used.
Excessive liquid fl ood back or repeated fl ooded starts
will dilute the oil in the compressor causing inadequate
lubrication and bearing wear. Proper system design will
minimize liquid fl ood back, thereby ensuring maximum
compressor life.
In order 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 (11°C) superheat, measured on the
suction line 6 inches (152mm) from the suction valve,
to prevent liquid refrigerant fl oodback.
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 (27°C). 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 (27°C), 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°C)
difference.
Contact your Emerson Climate Technologies
representative regarding any exceptions to the above
requirements.
Crankcase Heaters
• Single-phase
No crankcase heaters are required on single-phase
scroll compressors.
• Three-phase – outdoor only
Crankcase heaters are required on three phase
compressors where the system charge exceeds
10 lbs.
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 3A. If there
are any questions concerning their application, contact
the Emerson Climate Technologies, Inc. Application
Engineering department.
Discharge Line Thermostat
Figures 1A, 1B, 1C and 1D show saturated suction
temperature, maximum condensing temperature,
maximum return gas temperature, and maximum
discharge line temperature. Operation beyond these
limits can cause high compression ratios or excessive
internal compressor temperatures. This will result in
overheating the scroll members, causing excessive wear
resulting in premature compressor failure.
If the system is designed where operation with in these
guidelines cannot be guaranteed, then the discharge line
thermostat is required in the compressor control circuit.
The thermostats have a cut out setting that will insure
discharge line temperatures below the 260°F maximum
limit. It should be installed approximately 7 inches from
the discharge tube outlet. If a service valve is installed
at the discharge tube, the thermostat should be located
5 inches from the valve braze.
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 4
for a list of discharge line thermostat kit numbers.
Pressure Controls
Both high and low-pressure controls are required on the
following models, (1.3-2 HP) ZB10-14KCE. Only lowpressure controls are required on the following models,
(2-7.5 HP) ZB15-57KC/E. See Table 5 for set points.
Application Note: There are exceptions to the pressure
settings listed in Table 5. Certain OEMs are approved
for LPC settings below our standard recommendations.
Pump Down Recommendations
Table 6 identifi es the “ZB” models that incorporate
the low-leak check valve suitable for pump-down
applications. The standard disc is not intended for use
with a pump down.
NOTICE
Typically, the compressors that use the low-leak
discharge check valve are suitable for pump down
applications. 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 ZB15 through
ZB29 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 5. If the differential
pressure setting is too close, this will increase the
possibility of short cycling.
3. 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.
NOTICE
The ZB10 through ZB14 models will require the following
recommendations for pump down applications:
1. Install an external check-valve in the discharge
line to prevent back-fl ow from the high side to low
side. Install check-valve as close to the compressor
discharge fi tting as possible to minimize discharge
gas volume.
2. Set low pressure to recommended settings in
Table 5.
3. Since these models are single-phase only, add
a time delay relay to prevent reverse rotation.
Refer to “Brief Power Interruptions” section of this
bulletin for additional information.
IPR Valve
Refrigeration scroll compressors (2-7.5 HP) ZB1557KC/E 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 motor from the line. The ZB10-14KCE
models DO require a high pressure control in addition
to a low pressure control, since these models do not
have an IPR valve.
Internal Temperature Protection
Refrigeration Scroll compressors (1.3-7.5 HP)
ZB10-57KC/E incorporate a thermo disc which is a
temperature-sensitive snap disc device located at the
scroll discharge port. It is designed to open and route
hot discharge gas back to the motor protector thus
removing the compressor from the line.
Motor Protection
Conventional inherent internal line break motor protection
is provided.
Oil Types
Polyol ester lubricants must be provided if the scroll
compressor is to be used with HFC refrigerants. ZBKC
compressors are intended for use with R22 and are
supplied with mineral oil. See Form 93-11 for a complete
list of all Emerson approved lubricants.
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).
Oil Charges
The recommended oil charges for these compressors
are shown in Table 7.
Oil Management for Rack Applications
Copeland Scroll refrigeration compressors may be
used on multiple compressor parallel rack applications.
This requires the use of an oil management system
to maintain proper oil level in each compressor
crankcase. The sight glass connection supplied
can accommodate the mounting of the oil control
devices.
Unlike semi-hermetic compressors, scroll compressors
do not have an oil pump with accompanying oil pressure
safety controls. Therefore, an external oil level control
is required.
The Emerson OMB Oil Level Management Control
combines the functions of level control and timed
compressor shut-off should the level not come back to
normal within a set period of time. This device has been
found to provide excellent performance in fi eld tests on
Copeland Scroll compressors and is recommended for
parallel system applications.
Note: Emerson Climate Technologies' Application
Engineering Department should be contacted for
approved oil management systems.
Immediately after system start-up the oil reservoir level
will fl uctuate until equilibrium is reached. It is advisable to
monitor the oil level during this time to assure suffi cient
oil is available. This will prevent unnecessary trips of
the oil control system.
Note: If oil management problems are occuring
please refer to AE17-1320 or contact the Emerson
Climate Technologies, Inc. Application Engineering
Department.
Compressor Tubing and Mounting
Compressor mounting must be selected based on
application. Consideration must be given to sound
reduction and tubing reliability. Some tubing geometry
or “shock loops” may be required to reduce vibration
transferred from the compressor to external tubing.
Mounting for Rack Systems
For 1.3-7.5 HP compressors, specially designed
rubber grommets are available for refrigeration
scroll compressor applications. These grommets are
formulated from a durometer material specifi cally
designed for refrigeration applications. The durometer
limits the compressor motion, thereby minimizing
potential problems of excessive tubing stress. Suffi cient
isolation is provided to prevent vibration from being
transmitted to the mounting structure. This mounting
arrangement is recommended for multiple compressor
rack installations. See Figure 2A for a detail of this
mounting system.
NOTICE
The use of standard soft grommets is not recommended
for most refrigeration scroll rack installations. These
softer mounts allow for excessive movement that will
result in tube breakage, unless the entire system is
properly designed.
Condensing Unit Mounting
For 1.3-7.5 HP refrigeration scroll condensing unit
applications, soft mounts are recommended. See
Figure 2B.
Tubing Considerations – Proper tube design must be
taken into consideration when designing the tubing
connecting the scroll to the remaining system. The
tubing should provide enough “fl exibility” to allow normal
starting and stopping of the compressor without exerting
excessive stress on the tube joints. In addition, it is
desirable to design tubing with a natural frequency away
from the normal running frequency of the compressor.
Failure to do this can result in tube resonance and
unacceptable tubing life. Figure 3 shows examples of
acceptable tubing confi gurations.
CAUTION
These examples are intended only as guidelines to
depict the need for fl exibility in tube designs. In order to
properly determine if a design is appropriate for a given
application, samples should be tested and evaluated for
stress under various conditions of use including voltage,
frequency, and load fl uctuations, and shipping vibration.
The guidelines above may be helpful; however, testing
should be performed for each system designed.
Starting Characteristics
Single-phase scroll compressors are designed with PSC
type motors and therefore will start without the need
of start assist devices in most applications. However,
if low voltage conditions exist at start up, protector
trips can result. Therefore, start assist devices (start
capacitors and relays) are available to maximize starting
characteristics under abnormal conditions.
Fusite
Fusite pin orientation for single-phase and three- phase
refrigeration scroll compressors are shown in Figure 4
and inside the terminal box.
Shell Temperature
CAUTION
System component failure may cause the top shell and
discharge line to briefl y reach temperatures above 300°F.
Wiring or other materials, which could be damaged by
these temperatures, should not come in contact with
the shell.
Connection Fittings
Scroll compressors are provided with either braze
connections or roto-lock adapters depending on the bill
of material selected (reference AE4-1219 for roto-lock
torque values). Consult your District Sales Manager or
Application Engineer for details.
All ZBKC/E models have copper plated steel suction
and discharge fi ttings for a more rugged, leak resistant
connection.
See section on New Installation (see Figure 6) for
suggestions on how to properly braze these fi ttings.
Three-Phase Rotation Direction
Scroll compressors are directional dependent: i.e., they
will compress in one rotational direction only. On singlephase compressors, this is not an issue since they will
only start and run in the proper direction (except as
described in the Labeled Brief Power Interruptions).
Three-phase scrolls, however, will rotate in either
direction depending on the power of the phasing. So
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 Original Equipment Manufacturer.
Verifi cation of proper rotation can be made by observing
that the suction pressure drops and the discharge
pressure rises when the compressor is energized.
Additionally, if operated in reverse the compressor is
noisier and its current draw is substantially reduced
compared to tabulated values.
Although operation of scroll in reverse direction for brief
periods of time is not harmful, continued operation could
result in failure.
All three-phase compressors are wired identically
internally. Once the correct phasing is determined for
a specifi c system or installation, connecting properly
phased power leads to the same fusite terminals will
maintain the proper rotation.
Brief Power Interruptions
Brief power interruptions (less than ½ second) may
result in powered reverse rotation of single-phase
refrigeration scroll compressors. High-pressure
discharge gas expands backward through the scrolls
at power interruption causing the scroll to orbit in
the reverse direction. If power is reapplied while this
reversal is occurring, the compressor may continue to
run noisily in the reverse direction for several minutes
until the compressor internal protector trips. This has no
negative effect on durability. When the protector resets,
the compressor will start and run normally.
Emerson strongly encourages the use of a timer
which can sense brief power interruptions and lock the
compressor out of operation for two minutes. A typical
timer circuit is shown in Figure 5.
No time delay is required on three phase models to
prevent reverse rotation due to power interruptions
Deep Vacuum Operation
WARNING
Do not run a refrigeration scroll compressor in a
vacuum. Failure to heed this advice can result in
permanent damage to the compressor.
A low-pressure control is required for protection against
vacuum operation. See the section on pressure controls
for the proper set points. (See Table 5)
Scroll compressors (as with any refrigeration compressor)
should never be used to evacuate refrigeration or air
conditioning systems. See AE24-1105 for proper system
evacuation procedures.
Unbrazing System Components
CAUTION
If the refrigerant charge is removed from a scroll unit
by bleeding the high side only, it is sometimes possible
for the scrolls to seal, preventing pressure equalization
through the compressor. This may leave the low side shell
and suction line tubing pressurized. If a brazing torch is
then applied to the low side, the pressurized refrigerant
oil mixture could ignite as it escapes and contacts the
brazing fl ame. It is important to check both the high and
low sides with manifold gauges before unbrazing. In the
case of an assembly line repair, remove the refrigerant
from both the high and low sides. Instructions should
be provided in appropriate product literatures and
assembly areas.
High Potential (Hipot) Testing
Many of the Copeland brand compressors are
confi gured with the motor below the compressor. As a
result when liquid refrigerant is within the compressor
shell the motor can be immersed in liquid refrigerant to
a greater extent than with compressors with the motor
mounted above the compressor. When Copeland brand
compressors are Hipot tested and liquid refrigerant is
in the shell, they can show higher levels of leakage
current than compressors with the motor on top because
of the higher electrical conductivity of liquid refrigerant
than refrigerant vapor and oil. 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 confi guration and the system Hipot
tested again. See bulletin AE4-1294 for Megohm
testing recommendations. Under no circumstances
should the Hipot or Megohm test be performed while
the compressor is under a vacuum.
Copeland Scroll Functional Check
Refrigeration scroll compressors do not have internal
suction valves. It is not necessary to perform functional
compressor tests to check how low the compressor will
pull suction pressure. This type of test may damage a
scroll compressor. The following diagnostic procedure
should be used to evaluate whether a Copeland Scroll
compressor is functioning properly.
1. Verify proper unit voltage.
2. Normal motor winding continuity and short to
ground checks will determine if the inherent
overload motor protector has opened or if an
internal short to ground has developed. If the
protector has opened, the compressor must cool
suffi ciently to reset.
3. With service gauges connected to suction
and discharge pressure fi ttings, turn on the
compressor. If suction pressure falls below normal
levels, the system is either low on charge or there
is a fl ow blockage.
4a. Single-Phase Compressors
If the suction pressure does not drop and the
discharge pressure does not rise to normal levels
the compressor is faulty.
4b. Three-Phase Compressors
If the suction pressure does not drop and the
discharge pressure does not rise, reverse any
two of the compressor power leads and reapply
power to make sure the compressor was not wired
to run in the reverse direction.
The compressor current draw must be compared to
published compressor performance curves at the
compressor operating conditions (pressures and
voltages). Signifi cant deviations (±15%) from published
values may indicate a faulty compressor.
New Installation
• The copper-coated steel suction, discharge, and
injection tubes on scroll compressors can be
brazed in approximately the same manner as any
copper tube.
• Recommended brazing material – Any Silfos
material is recommended, preferably with a
minimum of 5% silver. However, 0% silver is
acceptable.
• Use of a dry nitrogen purge to eliminate possibility
of carbon buildup on internal tube surfaces is
recommended.
• Be sure process tube fi tting I.D. and process tube
O.D. are clean prior to assembly.
• Apply heat in Area 1. As tube approaches brazing
temperature, move torch fl 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
circumference.
• After braze material fl 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 fi nal result.
Note: The oil level of refrigeration scroll compressors
should be adjusted to the mid-point of the sightglass
during normal operation.
The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees,
express or implied, regarding the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or
its affi liates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifi cations of such products at any time without
notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use
and maintenance of any Emerson product remains solely with the purchaser or end user.