1. Safety Information
This manual provides essential information for the safe and efficient installation, operation, and maintenance of the Copeland Scroll Compressor ZR28K5PFV800. Only qualified and authorized personnel should perform installation, commissioning, and servicing procedures. Failure to adhere to these instructions can result in property damage, personal injury, or death.
- Electrical Hazards: Ensure all power is disconnected and locked out before performing any work on the compressor or associated electrical components. High voltage can cause severe injury or death.
- Refrigerant Handling: Refrigerants must be handled by certified technicians. Improper handling can lead to frostbite, chemical burns, or environmental damage. Always use appropriate personal protective equipment (PPE).
- Pressure Hazards: The compressor operates under high pressure. Do not attempt to repair or modify pressurized components. Ensure system pressure is safely relieved before servicing.
- Hot Surfaces: The compressor and discharge lines can become extremely hot during operation. Allow components to cool before handling.
2. Product Overview
The Copeland Scroll Compressor ZR28K5PFV800 is a hermetic scroll compressor designed for use in air conditioning (A/C) and heat pump (H/P) systems. It is compatible with R-22 refrigerant and operates on a 208-230 Volt, single-phase, 60 Hz power supply, delivering 2.25 horsepower. This compressor is engineered for reliable performance and efficiency in residential and light commercial HVAC applications.
Image 1: Copeland Scroll Compressor ZR28K5PFV800. This image displays the gray cylindrical compressor unit with its electrical connection box, suction and discharge line connections, and mounting feet. The Copeland Scroll logo and product label are visible on the side.
3. Setup and Installation
3.1 Pre-Installation Checks
- Inspect the compressor for any shipping damage. Do not install a damaged unit.
- Verify that the compressor model (ZR28K5PFV800) matches the system requirements for refrigerant type (R-22), voltage (208-230V), and capacity.
- Ensure all necessary tools, safety equipment, and materials are available.
3.2 Mounting
Mount the compressor on a level, stable surface capable of supporting its weight (approximately 50 lbs). Use the provided mounting dimensions of 7.5 inches x 7.5 inches to secure the compressor firmly. Utilize vibration isolation pads to minimize noise and vibration transmission to the structure.
3.3 Electrical Connections
- All electrical wiring must comply with local and national electrical codes.
- Connect the compressor to a dedicated 208-230 Volt, single-phase, 60 Hz power supply.
- Refer to the compressor's wiring diagram (typically found on the unit's label or in accompanying documentation) for correct terminal connections.
- Ensure proper grounding of the compressor.
- A qualified electrician should perform all electrical connections.
3.4 Refrigerant Line Connections
- Connect the 1/2 inch discharge line and the 3/4 inch suction line to the corresponding ports on the compressor.
- Use proper brazing techniques to ensure leak-free connections. Protect the compressor valves and internal components from excessive heat during brazing by using wet rags or heat-absorbing paste.
- Ensure the system is clean and free of contaminants before making connections.
3.5 Evacuation and Charging
- Evacuate the entire refrigeration system to a deep vacuum (typically 500 microns or less) to remove all non-condensable gases and moisture.
- Charge the system with R-22 refrigerant according to the HVAC system manufacturer's specifications. Use a charging scale for accurate refrigerant measurement.
- Never overcharge or undercharge the system, as this can lead to reduced efficiency and compressor damage.
3.6 Initial Startup
- Before starting, double-check all electrical and refrigerant connections.
- Verify that all safety devices (e.g., high/low pressure switches, thermal overload protectors) are correctly installed and functioning.
- Monitor system pressures, temperatures, and current draw during initial startup to ensure proper operation.
4. Operating Instructions
The Copeland Scroll Compressor ZR28K5PFV800 operates as an integral component of an HVAC system. Its operation is typically controlled by the system's thermostat and control board. Users should ensure the HVAC system is set to the desired mode (cooling or heating) and temperature.
- Normal Operation: The compressor will cycle on and off as required to maintain the set temperature.
- Monitoring: While direct user interaction with the compressor is not required during operation, pay attention to any unusual noises, vibrations, or changes in system performance (e.g., reduced cooling/heating capacity).
- Environmental Conditions: Ensure the outdoor unit (where the compressor is typically located) has adequate airflow and is free from obstructions.
5. Maintenance
Regular maintenance is crucial for the longevity and efficient operation of your Copeland Scroll Compressor and the overall HVAC system. All maintenance should be performed by qualified HVAC technicians.
- Annual Professional Inspection: Schedule annual inspections by a certified HVAC technician. This includes checking refrigerant levels, system pressures, electrical connections, and overall compressor health.
- Coil Cleaning: Ensure the outdoor condenser coils are kept clean and free of debris to allow for proper heat exchange.
- Filter Replacement: Regularly replace or clean air filters in the indoor unit to maintain optimal airflow and prevent strain on the compressor.
- Visual Inspection: Periodically check the compressor for any signs of leaks, corrosion, or unusual wear.
6. Troubleshooting
This section outlines common issues and basic troubleshooting steps. For complex problems, always contact a qualified HVAC technician.
| Problem | Possible Cause | Action |
|---|---|---|
| Compressor does not start | No power, tripped breaker, faulty thermostat, safety lockout, motor overload. | Check power supply and circuit breaker. Verify thermostat settings. If problem persists, contact a technician. |
| Low cooling/heating capacity | Low refrigerant charge, dirty coils, restricted airflow, faulty expansion valve. | Check and clean air filters and outdoor coils. Contact a technician to check refrigerant levels and system components. |
| Unusual noise or vibration | Loose mounting, internal compressor issue, fan motor issue, refrigerant line vibration. | Ensure compressor is securely mounted. If noise persists or is severe, shut down the system and contact a technician immediately. |
| Compressor cycles on and off rapidly | Low refrigerant, dirty coils, oversized unit, electrical issue. | Contact a technician for diagnosis and repair. |
7. Specifications
| Feature | Specification |
|---|---|
| Model Number | ZR28K5PFV800 |
| Brand | Copeland |
| Refrigerant | R-22 |
| Voltage | 208-230 Volts |
| Phase | Single-phase |
| Frequency | 60 Hz |
| Horsepower (HP) | 2.25 HP |
| Application | A/C or H/P (Air Conditioning or Heat Pump) |
| Discharge Line Size | 1/2 inch |
| Suction Line Size | 3/4 inch |
| Mounting Dimensions | 7.5 inches x 7.5 inches |
| Weight | Approximately 50 lbs |
| Recommended Uses | Air Conditioning, Heating and Cooling |
| Power Source | Electric, Corded Electric |
| Special Feature | Silent Operation, Designed for installation flexibility |
8. Warranty and Support
For warranty information, please refer to the documentation provided with your purchase or contact your authorized Copeland distributor or service center. Technical support and service should always be sought from qualified HVAC professionals.
For further assistance, please visit the official Copeland website or contact their customer service department.
