Emerson ZBH38KJE, ZBH30KJE, ZRH49KJE, ZBH45KJE, ZBHV45KJE Application Manuallines
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Application Guidelines
Copeland Scroll™ Horizontal Compressors
for Air-Conditioning Applications
ZRH49K* to ZRH72K*, ZBH30K* to ZBH45K*
ZRHV45K* & ZRHV72K*
C6.2.7/1007-0619/E
About these guidelines ............................................................................................... 1
1 Safety instructions ........................................................................................... 1
1.1 Icon explanation ............................................................................................................... 1
1.2 Safety statements ............................................................................................................ 1
1.3 General instructions ......................................................................................................... 2
2 Product description ......................................................................................... 3
2.1 General information about Copeland Scroll™ compressors ........................................... 3
2.2 Nomenclature ................................................................................................................... 3
2.3 Application range ............................................................................................................. 3
2.3.1 Qualified refrigerants and oils .............................................................................. 3
2.3.2 Application limits ................................................................................................... 4
2.3.3 Comparison between ZRH* and ZBH* compressors ........................................... 4
2.4 Special requirements for transport applications............................................................... 4
2.5 Dimensions ...................................................................................................................... 5
3 Installation ........................................................................................................ 7
3.1 Compressor handling ....................................................................................................... 7
3.1.1 Transport and storage .......................................................................................... 7
3.1.2 Positioning and securing ...................................................................................... 7
3.1.3 Installation location ............................................................................................... 7
3.1.4 Mounting parts ...................................................................................................... 8
3.2 Brazing procedure ............................................................................................................ 8
3.3 Shut-off valves and adaptors ........................................................................................... 9
3.4 Accumulators ................................................................................................................. 10
3.5 Screens .......................................................................................................................... 10
3.6 Mufflers .......................................................................................................................... 10
4 Electrical connection ..................................................................................... 11
4.1 General recommendations............................................................................................. 11
4.2 Electrical installation ...................................................................................................... 11
4.2.1 Molded plug connection ..................................................................................... 11
4.2.2 Assembly of the molded plug cable ................................................................... 11
4.2.3 Removing the molded plug cable ....................................................................... 12
4.2.4 Wiring diagram ................................................................................................... 12
4.2.5 Motor winding ..................................................................................................... 12
4.2.6 Protection devices .............................................................................................. 13
4.2.7 Crankcase heater ............................................................................................... 13
4.3 Inverter operation ........................................................................................................... 13
4.4 Pressure safety controls ................................................................................................ 15
4.4.1 High-pressure protection .................................................................................... 15
4.4.2 Low-pressure protection ..................................................................................... 15
4.4.3 Internal pressure relief valve .............................................................................. 15
C6.2.7/1007-0619/E
4.5 Discharge gas temperature protection ........................................................................... 15
4.6 Motor protection ............................................................................................................. 16
4.7 High-potential testing ..................................................................................................... 16
5 Start-up & operation ....................................................................................... 17
5.1 Strength pressure test .................................................................................................... 17
5.2 Tightness/pressure test .................................................................................................. 17
5.3 System evacuation ......................................................................................................... 17
5.4 Preliminary checks – Pre-starting .................................................................................. 17
5.5 First start ........................................................................................................................ 18
5.6 Charging procedure ....................................................................................................... 18
5.7 Initial start-up ................................................................................................................. 18
5.8 Rotation direction ........................................................................................................... 18
5.9 Starting sound ................................................................................................................ 19
5.10 Deep vacuum operation ................................................................................................. 19
5.11 Refrigerant migration ..................................................................................................... 19
5.12 Pumpdown cycle ............................................................................................................ 19
5.13 Shell temperature ........................................................................................................... 20
5.14 Minimum run time .......................................................................................................... 20
5.15 Shut-off sound ................................................................................................................ 20
5.16 Oil level .......................................................................................................................... 20
6 Maintenance & repair ..................................................................................... 21
6.1 Exchanging the refrigerant ............................................................................................. 21
6.2 Replacing a compressor ................................................................................................ 21
6.2.1 Compressor replacement ................................................................................... 21
6.2.2 Start-up of a new or replacement compressor ................................................... 21
6.3 Lubrication and oil removal ............................................................................................ 22
6.4 Oil additives ................................................................................................................... 22
6.5 Unbrazing system components ..................................................................................... 22
7 Dismantling & disposal .................................................................................. 23
DISCLAIMER .............................................................................................................. 23
C6.2.7/1007-0619/E 1
About these guidelines
The purpose of these guidelines is to provide guidance in the application of Copeland Scroll™
horizontal compressors in users’ systems. They are intended to answer the questions raised while
designing, assembling and operating a system with these products.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the compressors. Emerson cannot guarantee the performance and reliability of
the product if it is misused in regard of these guidelines.
These application guidelines cover stationary applications. For transport or rail applications, other
considerations such as high vibration and shocks, power supply characteristics, high ambient
temperatures, frequent cycling etc. may apply. It is the responsibility of the system designer/planner
to define the individual requirements to qualify the compressor and the complete system for their
specific needs. Please contact the Application Engineering department at Emerson or your local
Emerson representative for additional support.
1 Safety instructions
Copeland Scroll compressors are manufactured according to the latest European safety standards.
Particular emphasis has been placed on the user’s safety.
These compressors are intended for installation in systems according to the EC Machinery Directive
MD 2006/42/EC. They may be put to service only if they have been installed in these systems
according to instructions and conform to the corresponding provisions of legislation. For relevant
standards please refer to the Manufacturers Declaration, available at www.climate.emerson.com/en-
gb.
These instructions should be retained throughout the lifetime of the compressor.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to avoid
property damage and possible
personal injury.
High voltage
This icon indicates operations with a
danger of electric shock.
IMPORTANT
This icon indicates instructions to avoid
malfunction of the compressor.
Danger of burning or frostbite
This icon indicates operations with a
danger of burning or frostbite.
NOTE
This word indicates a recommendation
for easier operation.
Explosion hazard
This icon indicates operations with a
danger of explosion.
1.2 Safety statements
▪ Refrigerant compressors must be employed only for their intended use.
▪ Only qualified and authorized HVAC or refrigeration personnel are permitted to install,
commission and maintain this equipment.
▪ Electrical connections must be made by qualified electrical personnel.
▪ All valid standards for connecting electrical and refrigeration equipment must be
observed.
▪ The national legislation and regulations regarding personnel protection must be observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.
2 C6.2.7/1007-0619/E
1.3 General instructions
WARNING
System breakdown! Personal injuries! Never install a system in the field
and leave it unattended when it has no charge, a holding charge, or with the
service valves closed without electrically locking out the system.
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils must be used.
WARNING
High shell temperature! Burning! Do not touch the compressor until it has
cooled down. Ensure that other materials in the area of the compressor do not
come into contact with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without
refrigerant charge or without being connected to the system.
CAUTION
Contact with POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE must not come into contact with any surface
or material that it might damage, including without limitation, certain polymers,
eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.
C6.2.7/1007-0619/E 3
2 Product description
2.1 General information about Copeland Scroll™ compressors
These application guidelines deal with Copeland Scroll horizontal compressors for airconditioning and other applications with HFC refrigerants. This compressor range consists
of models ZRH49KJE to ZRH72KJE and ZBH30KJE to ZBH45KJE fixed speed, and models
ZRHV45KJE and ZBHV72KJE variable speed.
Compressor
Cooling capacity
[kW]
Displacement
[m³/h]
Motor
R407C
R134a
ZBH30KJE
10.0
7.0
11.7
TFD/TF5
ZBH38KJE
12.6
8.6
14.4
TFD/TF5
ZBH45KJE
14.8
10.2
17.1
TFD/TF5
ZBHV45KJE
14.8
10.2
17.1
TFD/TF5
ZRH49KJE
10.2
7.1
11.8
TFD/TF5
ZRH61KJE
13.0
8.9
14.5
TFD/TF5
ZRH72KJE
15.0
10.5
17.1
TFD/TF5
ZRHV72KJE
15.0
10.5
17.1
TFD/TF5
Table 1: Cooling capacity at 5°C/50°C/10K/0K
2.2 Nomenclature
The model designation contains the following technical information about the compressor:
ARI conditions:
Evaporating temperature ........ 7.2°C Liquid sub-cooling ........... 8.3K
Condensing temperature ........ 54.4°C Ambient temperature ....... 35°C
Suction gas superheat ............ 11K
2.3 Application range
2.3.1 Qualified refrigerants and oils
IMPORTANT
It is essential that the glide of refrigerant blends (primarily R407C) be carefully
considered when adjusting pressure and superheat controls.
Oil recharge values can be taken from Copeland Scroll compressors brochures or Copeland™ brand
products Select software available at www.climate.emerson.com/en-gb.
Qualified refrigerants
R407C & R134a
Copeland brand
products standard oil
Emkarate RL 32 3MAF
Servicing oils
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
Table 2: Qualified refrigerants and oils
4 C6.2.7/1007-0619/E
2.3.2 Application limits
CAUTION
Inadequate lubrication! Compressor breakdown! The superheat at the
compressor suction inlet must always be sufficient to ensure that no refrigerant
droplets enter the compressor. For a typical evaporator-expansion valve
configuration a minimum stable superheat of at least 5K is required.
NOTE: The application envelopes for all horizontal compressor models covered in these
guidelines are available in Copeland brand products Select software at
www.climate.emerson.com/en-gb.
2.3.3 Comparison between ZRH* and ZBH* compressors
ZRH* and ZBH* horizontal compressor models are basically available in two BOM variations:
▪ BOM 650 Compressor with brazing stub tubes, electrical box ready for molded plug IP65
▪ BOM 651 Compressor with Rotalock connections, electrical box ready for molded plug IP65
Table 2 below describes the differences and similarities between ZRH* and ZBH* models:
Compressor
version
BOM 650
BOM 651
ZRH*
Brazing stub tubes
Electrical connection ready for
molded plug IP65
Without oil sight glass
Without oil service Schraeder valve
Rotalock connections
Electrical connection ready for molded
plug IP65
Without oil sight glass
Without oil service Schraeder valve
ZRHV*
Brazing stub tubes
Electrical connection ready for
molded plug IP65
Without oil sight glass
Without oil service Schraeder valve
Variable speed
Rotalock connections
Electrical connection ready for molded
plug IP65
Without oil sight glass
Without oil service Schraeder valve
Variable speed
ZBH*
Brazing stub tubes
Electrical connection ready for
molded plug IP65
Oil sight glass
Oil service Schraeder valve
Rotalock connections
Electrical connection ready for molded
plug IP65
Oil sight glass
Oil service Schraeder valve
ZBHV*
Brazing stub tubes
Electrical connection ready for
molded plug IP65
Oil sight glass
Oil service Schraeder valve
Variable speed
Rotalock connections
Electrical connection ready for molded
plug IP65
Oil sight glass
Oil service Schraeder valve
Variable speed
Table 3: Differences and similarities between ZRH* and ZBH* horizontal scroll compressors
2.4 Special requirements for transport applications
Transport air-conditioning or refrigeration applications can be particularly sensitive and require
experience and thorough case-by-case analysis. Compared to static applications, additional
demands in terms of applicability to specific norm and standard requirements can arise. The system
designer must pay particular attention to higher demands with regard to shock stress, high vibration
levels, power supply and other installation characteristics.
The qualification for the parts and individual requirements, like system components, piping, piping
layout, fixation, as well as a study about shock, vibration and load requirements must be carried out
by the unit designer for the whole system. Emerson can provide support and assistance with
individual projects.
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2.5 Dimensions
Figure 1: Dimensions of models ZBH30KJE to ZBH45KJE and ZBHV45KJE
6 C6.2.7/1007-0619/E
Figure 2: Dimensions of models ZRH42KJE to ZRH72KJE and ZRHV72KJE
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