ZPV*, ZHV*, ZHW* Copeland Scroll

™

variable speed service compressors

The following safety instructions must be strictly adhered to when servicing the system.

WARNING

ELECTRICAL SHOCK HAZARD

• Failure to follow these warnings could result in serious personal injury.

• Electrical connections must be made by qualified electrical personnel.

• Disconnect and lock out power before servicing.

• Allow drive components to electrically discharge for a minimum of two minutes before servicing.

• Discharge all capacitors before servicing.

• Use compressor with grounded system only.

• Molded electrical plug must be used when applicable.

• Refer to original equipment wiring diagrams.

WARNING

PRESSURIZED SYSTEM HAZARD

• Failure to follow these warnings could result in serious personal injury.

• Electrical connections must be made by qualified electrical personnel.

• System contains refrigerant and oil under pressure.

• Remove refrigerant from both the high and low compressor side before removing compressor.

• Use appropriate back up wrenches on rotalock fittings when servicing.

• Refer to original equipment wiring diagrams.

WARNING

BURN HAZARD

• Failure to follow these warnings could result in serious personal injury or property damage.

• Personal safety equipment must be used.

• Do not touch the compressor until it is cooled down.

• Ensure that materials and wiring do not touch high temperature areas of the compressor.

• Use caution when brazing system components.

CAUTION

COMPRESSOR HANDLING

• Use the appropriate lifting devices to move compressors.

• Personal safety equipment must be used.

• Failure to follow these warnings could result in personal injury or property damage.

The instructions provided below are general guidelines for the removal and installation of the compressor. The unit manufacturer’s instructions should always be consulted for specific information related to servicing the unit.

Removing the failed compressor from the unit

1. Disconnect and lock-out the power supply to the unit.

2. Allow drive components to electrically discharge for a minimum of two minutes before servicing.

3. Verify that the power supply has been disconnected and locked-out and use a volt meter to ensure that no voltage is present at the unit. If compressor uses a molded plug, remove molded plug. For terminal screw wires before disconnecting, label or mark all wires so they can be reconnected to the correct terminals on the new compressor. After the wires are marked, disconnect any other wires that may be spliced in the terminal box and disconnect any conduits and crankcase heater.

4. Using a service manifold gauge set, verify that the refrigerant charge has been completely recovered from the system.

5. If the compressor has rotalock connections, use the appropriate wrenches to loosen and disconnect the rotalock fittings. If the compressor has brazed connections, cut the suction and discharge tubes close to the compressor using a tubing cutter (do not use a hacksaw and do not attempt to unbraze the suction and discharge tubes).

6. Remove the compressor mounting bolts.

7. Using caution and the appropriate lifting device, remove the compressor from the unit.

8. Follow the instructions of the service compressor provider on what to do with the failed compressor. If the compressor is field scrapped, the oil must be drained from the compressor and properly disposed of.

If the compressor is returned to Emerson, the compressor tubes must be properly plugged and the compressor must be securely bolted to a skid, in the upright position, for shipping.

Installing the replacement compressor

1. Using caution and the appropriate lifting device, install the replacement compressor in the system and secure the compressor with the appropriate mounting hardware.

2. A new liquid line filter-drier must be used in all applications.

If the system is severely contaminated, a suction line filter should also be installed. Refer to Application Engineering bulletin AE-1105 for more information on system clean-up.

3. Use caution and standard brazing practices to connect the suction and discharge piping to the compressor.

4. Double check the power supply and make certain it is disconnected and locked-out.

5. The system contactor should be inspected and replaced if there are any signs of wear. The best service practice is to replace the contactor.

6. A U.L. recognized, molded plug wiring harness must be used with the compressor where applicable. Install the molded plug on to the compressor by hand, making sure it is completely seated. DO NOT use a hammer or blunt object to pound the plug on to the compressor. Refer to the system wiring diagram for instructions on wiring the replacement compressor.

7. Before reconnecting any wires, inspect the wire and terminals and replace the wire or terminal if its integrity is in question.

8. Ensure all electrical connections are secure. Oversized conduits that can allow warm, moist air to penetrate the terminal box must be sealed with silicon or a similar sealant.

Warm, moist air that can freely enter the terminal box may condense into water and cause problems.

9. If the compressor being replaced has a crankcase heater, the replacement compressor should also have a crankcase heater. A new crankcase heater of the correct voltage rating should be installed low on the shell of the compressor.

10. Follow the unit manufacturer’s instruction for evacuation and charging techniques.

CAUTION

CAUTION

ZPV*, ZHV*, ZHW* compressors are designed and qualified for use with R-410A only.

Polyolester (POE) compressor oil 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, polycarbonates, etc.).

This product contains a chemical known to the State of California to cause cancer and birth defects and other reproductive harm.

The contents of this publication are presented for informational purposes only and they 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. reserves the right to modify the designs or specifications of such products at any time without notice. Emerson Climate Technologies, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Climate Technologies, Inc. product remains solely with the purchaser and end-user.

2014ECT-18 R1 (12/16) Emerson and Copeland Scroll are trademarks of Emerson Electric Co. or one of its affiliated companies. ©2016 Emerson Climate Technologies, Inc. All rights reserved.