AE4-1372 R6 May 2022

Copeland Scroll™ Compressors for CO2 Subcritical Refrigeration (R-744)

TABLE OF CONTENTS

Safety Instructions ....................................................... 2 Motor Protection ....................................................... 7

Safety Icon Explanation ........................................... 2 Operating Envelope .................................................. 7
Instructions Pertaining to Risk of Electrical Shock, Charging Procedure ................................................. 7
Fire, or Injury to Persons .......................................... 3 Deep Vacuum Operation .......................................... 7
Safety Statements .................................................... 3 Shell Temperature .................................................... 8
INTRODUCTION ......................................................... 4 Pump Down Cycle and Parallel Rack Application .... 8
CO2 FOR LOW TEMPERATURE APPLICATIONS Low Pressure Safety Control .................................... 8
SUB-CRITICAL DX SYSTEM ...................................... 4 Minimum Run Time .................................................. 8
Nomenclature ........................................................... 4 ASSEMBLY LINE PROCEDURES ............................... 8
Approved Oils & Refrigerants .................................. 4 Installing the Compressor ......................................... 8
Mounting Parts ......................................................... 4 Assembly Line Brazing Procedure ........................... 8
Safety Relief Valves ................................................. 5 New Installations ...................................................... 8
High-Pressure Safety Controls ................................ 5 ‘Hipot’ (AC High Potential) Testing ........................... 9
Active Oil Management ............................................ 5 MAINTENANCE AND REPAIR .................................... 9
Accumulators ........................................................... 6 Service Procedures .................................................. 9
Screens .................................................................... 6 Compressor Replacement After a Motor Burn ....... 10
Mufflers .................................................................... 6 General Guidelines and More Information ............. 10
Electrical Connection ............................................... 7
Crankcase Heaters .................................................. 7

FIGURES

Figure 1 CO2 Low Temp. Subcritical DX System ...... 12 Figure 5 Three Phase Power Circuit .......................... 15
Figure 2 Specially designed rubber rommets Kit # 527- Figure 6 - ZO Compressor Operating Envelope ........ 15
0157-00 ...................................................................... 13 Figure 7 Compressor Electrical Connection ............... 15
Figure 3 Oil Management Control OMC-CO2 ............ 13
Figure 4 Suction Side Pressure Relief Valve
Requirements ............................................................. 14

Revision Tracking R4
Pg. 2 New Pressure Safety Icon added Pg. 10 Table of AE-Bulletins and documentation
Pg. 4 Caution tag added to superheat requirement. related with this Bulletin.
Pg. 4 Notes about oil recharging values added. Pg. 10 Nomenclature details added.
Pg. 5 Model numbers chart moved to pag. 10 and Pg. 10 Oil and Refrigerant table added
ZOD34K3E and ZOD104KCE added. Pg. 10 Crankcase kit table added
Pg. 5 Regulatory Compliance reference updated. Pg. 11 OMC CO2 Specification Chart added
Pg. 5 ZO104KCE data updated. Pg. 11 Drawing of Subcritical DX System changed.
Pg. 5 High-pressure relief valve settings changed. Pg. 11 and Pg. 12 Mounting parts drawings added.
Pg. 6 Modified low pressure cut. Pg. 11 Oil Management drawing added
Pg. 7 Charging Procedures changed Pg. 13 Pressure Relief Valve drawing changed.
Pg. 9 Maintenance and Repair section added Pg. 14 Operating Envelop changed.

Revision Tracking R6
Pg.11 Updated Table 2

1
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

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
DANGER or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in

WARNING death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation
CAUTION which, if not avoided, could result in minor or moderate injury.

NOTICE NOTICE is used to address practices not related to personal injury.

CAUTION, without the safety alert symbol, is used to address practices not related
CAUTION to personal injury.

FLAMMABLE

PRESSURE indicates a dangerous proximity to high pressure section of the system.

2
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

ELECTRICAL SHOCK HAZARD

WARNING • 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

WARNING • 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
WARNING • 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.

COMPRESSOR HANDLING
CAUTION • 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.

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.

3
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

INTRODUCTION
This bulletin describes the operating characteristics, ZO D 34 K 3 E - TFD - 269
design features, and application requirements for all Z= Compressor family: Scroll
Copeland Scroll™ compressors for refrigeration O= Refrigerant: R744, subcritical operation
applications using CO2 (R-744) for a subcritical D= Digital Model; Blank= Standard Model
operation. For additional information, please refer to the 34K = Nominal Capacity (kBTU/hr)
online product information accessible from the Emeson 3= Model variation
website at Emerson.com/OPI. E= Oil type: POE oil
TFD = Electrical Description:
Increasing environmental concerns about the T= Three Phases
potential direct emissions from HFC-based F= Internal Inherent Motor Protection
refrigeration systems into the atmosphere have led 5,7,D,E= Nominal Voltage Range
system designers to revisit refrigerant R-744 (CO2). In 269 = Bill of material
comparison with HFC refrigerants, the specific
properties of CO2 require changes in the design of the Please refer to Online Product Information at
refrigeration system. The ZO range of Copeland Emerson.com/OPI for details.
Scroll compressors has been designed to exploit the
characteristics of CO2 refrigeration systems. The Refer to Table 1 for a detailed list of ZO Family Models.
efficiency, reliability and liquid handling advantages
of Copeland Scroll technology make it ideal for these Approved Oils & Refrigerants
applications. Recommended quality for carbon dioxide purity
grade is 4.0 [(≥ 99.99 %) H2O≤10ppm, O2≤10ppm,
The comparably high pressure level and N2≤50ppm] or higher.
thermodynamic properties of the refrigerant CO 2 have
driven system designers towards low temperature Emkarate RL 68 HB is approved for new and service
cascade systems, where CO2 is used as a direct applications. Oil recharge values can be taken from
expanding refrigerant in the low temperature stage. In Copeland Scroll™ compressors brochures or
these subcritical cascade applications, the CO 2 Copeland® brand Products Selection Software.
compressor in the low temperature stage is still exposed
to pressure levels higher than in standard HFC-based
systems. However, they are limited to pressure levels
CAUTION
similar to those already known from air-conditioning The compressor superheat at suction should be
applications with refrigerant R-410A. An HFC refrigerant controlled such that it is always above 36°F (20K) to
is typically used in the medium temperature stage of the avoid oil dilution in the compressor but low return
cascade system. gas temperature enough to keep the compressor
discharge temperature below 250°F (121.1°C),
The challenges for CO2 compressors compared to HFC especially at high compressor ratios (high
compressors lie in the high pressure levels, the higher condensing and low evaporating temperatures).
mass flow for a given displacement, and designing for
proper lubrication. In terms of mechanical strength, ZO Note: A separate heat-exchanger may be required
scroll compressors benefit from many years of to maintain the recommended superheat.
experience with R-410A air-conditioning compressors,
which operate at similar pressure levels as CO 2 Refer to
compressors.
Table 2 for reference.
CO2 FOR LOW TEMPERATURE APPLICATIONS
SUB-CRITICAL DX SYSTEM Mounting Parts
Figure 1 at the end of this bulletin shows a cascade Specially designed rubber grommets are available for
system diagram with HFC refrigerant for the high side mounting (Kit 527-0157-00). These grommets are
and sub-critical CO2 for the low stage refrigerant. formulated from a high durometer material specifically
designed for refrigeration applications. The high
Nomenclature durometer limits the compressors motion thereby
The model designation contains the following technical minimizing potential problems of excessive tubing
information about the compressor: stress. Sufficient isolation is provided to prevent

4
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

vibration from being transmitted to the mounting Figure 4 represents the correct (a) and incorrect (b) way
structure. The use of standard soft grommets is not to apply the pressure relief valve. Failure to apply the
recommended. high-pressure relief valve correctly will void any UL
approval of the system.
Refer Figure 2 for details.
The high-pressure relief valve should be located such
Safety Relief Valves that the path between the valve and the low side of the
compressor is always open and cannot be shut off in
CAUTION any way by a valve. Note that the valve opens only
once and must be replaced if it opens.
In a closed system filled with CO2 the pressure can rise
above 725 psig (50 Bar) under some ambient A 500 psig (34.5 Bar) high-pressure relief valve kit is
conditions. The system must be equipped with safety shipped with the compressor. Contact Application
relief valves to ensure that the compressor’s low side Engineering for alternative pressure relief valves.
and high side pressures are not exceeded (see below).
If the unit is shut down for service or other reasons, the ZO compressors have Rotalock valve fittings. Rotalock
pressure will rise due to ambient heat. To prevent the shut-off valves are available for the suction as well as
loss of charge at shut down through the relief valves, it discharge side. Using either straight or angled adaptors
is recommended to provide additional cooling to keep provides a way to convert a Rotalock into a brazing
the pressure below the maximum standstill pressure of connection.
the suction side. This can be achieved using a small
Tightening Torques
auxiliary condensing unit connected to an
uninterruptable power supply, that removes heat from Torque Lbs
the R744 liquid receiver. The auxiliary condensing unit
will not be sufficient to maintain the low-stage system Rotalock 1"-1 UNF 60-70 ft.lb.
below the Maximum Allowable Operation Pressure if Rotalock 1"1/4-12 UNF 75-85 ft.lb
there is a load from the evaporators.
Refer to ANSI/ASHRAE Standard 15-2016, Section High-Pressure Safety Controls
9.7.5 and ANSI/ASHRAE 15 appendix C-2016,.

ZO Maximum Operating pressures

A CO2 approved ASME safety pressure relief valve(s)
Suction side 500 psig (34.5 Bar) with a setting of 500 psig (34.5 Bar) is required to be
Discharge side 625 psig (43.1 Bar) pre-installed for standstill conditions.

The requirements for Copeland Scroll compressors with All sections that can be isolated in the system must have
CO2 per Underwriters Laboratory (UL) state that a relief valves pre-installed by the system manufacturer
system with a CO2 compressor must be installed with an with a 500 psig (34.5 Bar) setting.
approved suction pressure relief valve. ASME high-
pressure relief valves are the only valves currently These high-pressure cut-outs should have a manual
approved for use with the Copeland Scroll CO2 models. reset feature.
The installation of the above valve must meet the
following criteria: Additional Requirements:
1. There must be an open flow path from the Low Pressure Cut-Out on Suction Side:
compressor suction sump to the relief valve. This 80 psig (5.5 bar)
is accomplished by connecting the relief valve to High Pressure Cut-Out on Discharge Side: 625 psig
the correct port on the suction Rotalock valve. (43.1 Bar)
This port is open to the compressor sump no
matter what position the valve stem is located. Discharge Temperature Protection
The relief valve itself can be remotely located as External discharge line thermostat 998-7022-02
long as the path from compressor suction sump
and the valve is always open. Active Oil Management
2. This flow path cannot be shut off in any way by a An OMC CO2 electronic oil level management system
valve. should be used that is suitable for both high and low
5
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

pressure oil management systems. The differential - OMB Adapter Instruction Sheet
pressure required for sufficient oil flow from the oil
reservoir to the compressor crankcase depends upon https://climate.emerson.com/documents/omb-
adapter-instructions-en-4924792.pdf
the system. However, 20 psig (1.4 Bar) can be used as
a minimum pressure differential value. Refer to Figure
3 and Table 4

For more details about OMB-CO2 Oil Management

Devices scan the QR codes below or follow the links
available.

- Emerson OMC Video

Accumulators
Irrespective of system charge, oil dilution may occur if
large amounts of liquid refrigerant repeatedly flood back
to the compressor during normal running cycles, defrost,
and varying loads.

If adequate Compressor Superheat cannot consistently

be maintained at minimum of 36°F (20K) an
accumulator may be required, as well as the addition of
- Emerson OMC Specification Sheet liquid to suction heat exchanger or other means as
https://climate.emerson.com/documents/omc- assuring 36°F (20K) Superheat.
specification-sheet-en-us-3584550.pdf
Screens
The use of screens finer than 30 x 30 mesh (0.6 mm
openings) anywhere in the system should be avoided
with these compressors. Field experience has shown
that finer mesh screens used to protect expansion
valves, capillary tubes, or accumulators can become
temporarily or permanently plugged with normal system
debris and block the flow of either oil or refrigerant to the
compressor. Such blockage can result in compressor
failure.
- OMB/C Instructions Mufflers
https://climate.emerson.com/documents/omb- External mufflers, normally applied to piston
c--pa-00388-en-4858298.pdf compressors in the past, may not be required for
Copeland Scroll compressors.

Individual system tests should be performed to verify

acceptability of sound performance. If adequate
attenuation is not achieved, use a muffler with a larger
cross-sectional area to inlet area ratio. A ratio of 20:1 to
30:1 is recommended.

A hollow shell muffler will work quite well. Locate the

muffler 6-18 inches from the compressor for the most
effective operation. The farther the muffler is placed
from the compressor within these ranges, the more
effective. Choose a muffler with a length of 2-6 inches.

6
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

Electrical Connection Motor Protection

For the ZO range of compressors, conventional inherent
internal line break motor protection is provided.
The compressor terminal box has a wiring diagram on
the inside of its cover. Before connecting the Operating Envelope
compressor, ensure the supply voltage, the phases and Figure 6 at the end of this bulletin shows the CO2
the frequency match the nameplate data. Refer to cascade operating envelope in relation to R-410A and R-
Figure 5 for details. 404A.
The terminal box is IP21 for all models from ZO21K* to
ZO104K*. The ZO Scroll compressors have three- Charging Procedure
phase induction motors connected in star. Copeland
Scroll compressors, like several other types of
compressors, will only compress in one rotational Do not operate compressor without enough system
direction. Three phase compressors will rotate in either charge to maintain at least 87 psig (6 Bar) suction
direction depending upon phasing of the power. Since pressure.
there is a 50% chance of connecting power in such a
way as to cause rotation in the reverse direction, it is
important to include notices and instructions in
appropriate locations on the equipment to ensure that Do not operate with a restricted suction.
proper rotation direction is achieved when the system is
installed and operated. Verification of proper rotation
direction is made by observing that suction pressure Do not operate with the low-pressure cut-out bridged.
drops and discharge pressure rises when the
compressor is energized. Reverse rotation will result in
no pressure differential as compared to normal values. Vapor initial charge should be 145 PSIG (10 Bar). Do
not allow a pressure under 87 psig (6 Bar), otherwise
A compressor running in reverse will sometimes make it might cause CO2 solidification and blocked valves or
an abnormal sound. There is no negative impact on pipes and consequently, the scrolls may overheat and
durability caused by operating three phase Copeland cause early drive bearing damage.
Scroll compressors in the reversed direction for a short
period of time (under one hour). After several minutes of Do not use the compressor to test the opening set point
reverse operation, the compressor’s internal overload of the high-pressure cut-out. Bearings are susceptible to
protector will trip shutting off the compressor. If allowed damage before they have had several hours of normal
to repeatedly restart and run in reverse without running in. Ensure charging equipment is approved for
correcting the situation, the compressor bearings will be at least 1300 psig (89.6 Bar).
permanently damaged because of oil loss to the system.
The system should be charged through the liquid-
All three phase scroll compressors are wired identically receiver shut-off valve or through a valve in the liquid
internally. As a result, once the correct phasing is line. The use of a filter drier in the charging line is
determined for a specific system or installation, connecting highly recommended.
properly phased power leads to the identified compressor
electrical (Fusite™) terminals will maintain the proper Because there may be several valves in the system it is
rotational direction (see Figure 7). All three phase scrolls recommended to charge on both the high and low sides
will continue to run in reverse until the internal overload simultaneously to ensure a positive refrigerant pressure
protector opens or the phasing is corrected. is present in the compressor before it runs. The majority
of the charge should be placed in the high side of the
Crankcase Heaters system to prevent bearing washout during first-time
start.

Deep Vacuum Operation

A crankase heater is always required. The crankcase
heater ust be turned on a minimum of 12 hours prior to Copeland Scroll compressors should never be used to
starting the compressor and must remain energized evacuate a refrigeration or air-conditioning system. The
during the compressor off cycle. scroll compressor can be used to pump down refrigerant
in a unit as long as the pressures remain within the
See Table 3 for reference. operating envelope. Low suction pressures will result in
7
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

overheating of the scrolls and permanent damage to the unbalanced pressures. The most critical consideration
compressor drive bearing. ZO scrolls incorporate is the minimum run time required to return oil to the
internal low vacuum protection, the floating seal unloads compressor after start-up. To establish the minimum run
when the pressure ratio exceeds approximately 10:1. time, obtain a sample compressor equipped with a sight
tube (available from Emerson Climate Technologies)
Shell Temperature and install it in a system with the longest connecting
lines that are approved for the system. The minimum on
time becomes the time required for oil lost during
compressor start-up to return to the compressor sump
The top shell and discharge line can briefly but and restore a minimal oil level that will ensure oil pick-
repeatedly reach temperatures above 350°F (176.7 °C) up through the crankshaft. Cycling the compressor for a
if the compressor cycles on its internal protection shorter period than this, for instance to maintain very
devices. This only happens under rare circumstances tight temperature control, will result in progressive loss
and can be caused by the failure of system components of oil and damage to the compressor.
such as the condenser or evaporator fan or loss of
charge and depends upon the type of expansion control.
Care must be taken to ensure that wiring or other ASSEMBLY LINE PROCEDURES
materials that could be damaged by these temperatures Installing the Compressor
do not come in contact with the shell. Copeland Scroll compressors leave the factory
dehydrated and with a positive dry air charge. Plugs
Pump Down Cycle and Parallel Rack Application should not be removed from the compressor until the
A pump down cycle for control of refrigerant migration compressor has had sufficient time to warm up if stored
may be used in conjunction with a crankcase heater outside and is ready for assembly in the unit. The
when the compressor is located so that cold air blowing suggested warm up time is one hour per 4°F (2K)
over the compressor makes the crankcase heater difference between outdoor and indoor temperature. It
ineffective. is suggested that the larger suction plug be removed
first to relieve the internal pressure. Removing the
If a pump down cycle is used on a parallel rack system, smaller discharge plug could result in a spray of oil out
a separate external check valve must be added. The of this fitting since some oil accumulates in the head of
scroll discharge check valve is designed to stop the compressor after Emerson’s run test. The inside of
extended reverse rotation and prevent high-pressure both fittings should be wiped with a lint free cloth to
gas from leaking rapidly into the low side after shut off. remove residual oil prior to brazing. A compressor
The check valve will in some cases leak more than containing POE oil should never be left open longer than
reciprocating compressor discharge reeds, normally 5 minutes.
used with pump down, causing the scroll compressor to
recycle more frequently. Repeated short-cycling of this Assembly Line Brazing Procedure
nature can result in a low oil situation and consequent Following are the proper procedures for brazing the
damage to the compressor. The low-pressure control suction and discharge lines to a scroll compressor. It is
differential has to be reviewed since a relatively large important to flow nitrogen through the system while
volume of gas will re-expand from the high side of the brazing all joints during the system assembly process.
compressor into the low side on shutdown. Nitrogen displaces the air and prevents the formation of
copper oxides in the system. If allowed to form, the
Low Pressure Safety Control copper oxide flakes can later be swept through the
Never set the low-pressure control to shut off outside of system and block screens such as those protecting
the operating envelope. To prevent the compressor from capillary tubes, thermal expansion valves, and
running into problems during such faults as loss of accumulator oil return holes. Any blockage of oil or
charge or partial blockage, the control should not be set refrigerant may damage the compressor resulting in
lower than -60°F (-51.1°C) equivalent suction pressure failure.
(80 PSIG, 5.51 bar) below the lowest design operating
point. New Installations
• The copper-coated steel suction tube on scroll
Minimum Run Time compressors can be brazed in approximately the
Emerson recommends a maximum of 10 starts per hour. same manner as any copper tube.
There is no minimum off time because scroll
compressors start unloaded, even if the system has
8
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

• Recommended brazing materials: Any SIL-FOS® should be operated for a brief period of time to
material is recommended, preferably with a redistribute the refrigerant to a more normal
minimum of 5% silver. However, 0% silver is configuration and the system hipot tested again. See
acceptable. AE4-1294 for megaohm testing recommendations.
Under no circumstances should the hipot test be
• Be sure suction tube fitting I.D. and suction tube performed while the compressor is under a vacuum.
O.D. are clean prior to assembly. If oil film is
present wipe with denatured alcohol, Dichloro- MAINTENANCE AND REPAIR
Trifluoroethane or other suitable solvent.
Service Procedures
• Using a double-tipped torch apply heat in Area 1.
As tube approaches brazing temperature, move
torch flame to Area 2. Copeland Scroll Compressor Functional Check: A
functional compressor test during which the suction
service valve is closed to check how low the compressor
will pull the suction pressure is not a good indication of
how well a compressor is performing. Such a test will
damage a scroll compressor in a few seconds.

The following diagnostic procedure should be used to

evaluate whether a Copeland Scroll compressor is
functioning properly:

1. Proper voltage to the unit should be verified.

Scroll Suction Tube Brazing
2. Determine if the internal motor overload has
• Heat Area 2 until braze temperature is attained, opened or if an internal motor short or ground fault
moving torch up and down and rotating around has developed. If the internal overload has
tube as necessary to heat tube evenly. Add braze opened, the compressor must be allowed to cool
material to the joint while moving torch around sufficiently to allow it to reset.
joint to flow braze material around circumference.
3. Check that the compressor is correctly wired.
• After braze material flows around joint, move
torch to heat Area 3. This will draw the braze 4. Proper indoor and outdoor blower/fan operation
material down into the joint. The time spent should be verified.
heating Area 3 should be minimal.
5. With service gauges connected to suction and
• As with any brazed joint, overheating may be discharge pressure fittings, turn on the
detrimental to the final result. compressor. If suction pressure falls below
normal levels the system is either low on charge
‘Hipot’ (AC High Potential) Testing or there is a flow blockage in the system.
Copeland Scroll compressors are configured with the
6. Three phase compressors – If suction pressure
motor down and the pumping components at the top of
does not drop and discharge pressure does not
the shell. As a result, the motor can be immersed in
rise to normal levels, reverse any two of the
refrigerant to a greater extent than hermetic
compressor power leads and reapply power to
reciprocating compressors when liquid refrigerant is
make sure the compressor was not wired to run in
present in the shell. In this respect, the scroll is more like
reverse. If pressures still do no move to normal
semi-hermetic compressors that have horizontal motors
values, either the reversing valve (if so equipped)
partially submerged in oil and refrigerant.
or the compressor is faulty. Reconnect the
compressor leads as originally configured and
When Copeland Scroll compressors are hipot tested
use normal diagnostic procedures to check
with liquid refrigerant in the shell, they can show higher
operation of the reversing valve.
levels of leakage current than compressors with the
motor on top. This phenomenon can occur with any 7. To test if the compressor is pumping properly, the
compressor when the motor is immersed in refrigerant. compressor current draw must be compared to
The level of current leakage does not present any safety published compressor performance curves using
issue. To lower the current leakage reading, the system the operating pressures and voltage of the
9
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

system. If the measured average current deviates contacts and replaced if necessary. It is highly
more than +/-20% from published values, a faulty recommended that the run capacitor be replaced when
compressor may be indicated. A current a single phase compressor is replaced.
imbalance exceeding 20% of the average on the
three phases of a three-phase compressor should General Guidelines and More Information
be investigated further. A more comprehensive For general Copeland Scroll compressor and CO2
trouble-shooting sequence for compressors and refrigerant please log in to Online Product Information at
systems can be found in Section H of the Emerson.com/OPI, refer to the Application Engineering
Emerson Climate Technologies Electrical bulletins listed below, or contact your Application
Handbook, Form No. 6400. Engineer.
8. Before replacing or returning a compressor, be
certain that the compressor is actually defective. AE4-1294 Megaohms Values of Copeland®
As a minimum, recheck compressors returned Compressors
from the field in the shop or depot by testing for a
grounded, open or shorted winding and the ability AE24-1105 Principles of Cleaning Refrigeration
to start. The orange tag in the service compressor Systems
box should be filled out and attached to the failed
AE11-1297 Liquid Line Filter-Driers
compressor to be returned. The information on
this tag is captured in our warranty data base. AE4-1396 Application Guidelines for Copeland™
Semi-Hermetic Compressors for
Compressor Replacement After a Motor Burn Transcritical CO2 Applications
In the case of a motor burn, the majority of contaminated
oil will be removed with the compressor. The rest of the Commercial CO2 Refrigeration Systems Guide
oil is cleaned with the use of suction and liquid line filter
driers. A 100% activated alumina suction filter drier is
recommended but must be removed after 72 hours. See
AE24-1105 for clean up procedures and AE11-1297 for
liquid line filter-drier recommendations. It is highly
recommended that the suction accumulator be replaced
if the system contains one. This is because the
accumulator oil return orifice or screen may be plugged
with debris or may become plugged shortly after a
compressor failure. This will result in starvation of oil to
the replacement compressor and a second failure. The
system contactor should be inspected for pitted/burnt

10
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

Table 1 ZO Family Models

Motors
Nominal Displacement Capacity Weight TF5 TF7 TFD TFE
Model EER
Horse-power CFH BTU/hr lb(kg) 200/230-3Ø-60Hz 380-3Ø-60Hz 460-3Ø-60Hz 575-3Ø-60Hz
200/220-3Ø-50Hz 480/420-3Ø-50Hz

ZO21K5E 1.3 112 20,800 15 49 (22) X X X

ZO34K3E 2 172 32,000 15 60 (27) X X X X

ZOD34K3E 2 172 32,000 15 60 (27) X X X X
ZO45K3E 2.5 228 42,700 17 62 (28) X X X
ZO58K3E 3.5 291 55,000 17 65 (29) X X X X
ZOD58K3E 3.5 291 55,000 17 65 (29) X X X X
ZO88KCE 5 431 85,300 16 88 (40) X X X X
ZO104KCE 6 498 95,500 16 90 (41) X X X X
ZOD104KCE 6 498 95,500 16 90 (41) X X X X
Capacity with R-744 at -31°F (-35°C) evap, 14°F (-10°C) cascade cond, 5°F (-15°C) RG, 14°F (-10°C) liquid

Table 2 Qualified Refrigerants and Oils

Qualified Refrigerants CO₂ (R-744)

Copeland™ Standard Oil POE-68 / Emkarate RL 68 HB
Servicing Oil POE-68 / Emkarate RL 68 HB
Alternative Oil PAG-68 / RFL 68EP
Note: Refer to form 93-11 for the latest approved
refrigerants and lubricants for Copeland products.
Table 3 Crankcase Number Kits

Model OEM Part # Description Aftermarket #

018-0094-00 240V, 40W 918-0052-00
018-0094-01 120V, 40W 918-0052-01
ZO21K5E
018-0094-03 480V, 40W, 21.25" Lead Length 918-0052-03
018-0094-04 575V, 40W, 21.25" Lead Length 918-0052-04
018-0095-00 240V, 70W, 21" Lead Length 518-0024-06
018-0095-01 480V, 70W, 21" Lead Length 518-0024-07
ZO34K3E
ZOD34K3E 018-0095-02 575V, 70W, 21" Lead Length 518-0024-08
ZO45K3E 018-0095-03 240V, 70W, 32" Lead Length 995-0018-00
ZO58K3E 018-0095-04 240V, 70W, 48” Lead Length 918-0043-00
ZOD58K3E 018-0095-05 480V, 70W, 48” Lead Length 918-0043-01
ZO88KCE 018-0095-06 575V, 70W, 48" Lead Length 918-0043-02
ZO104KCE
018-0095-07 120V, 70W, 48" Lead Length 918-0043-07
ZOD104KCE
018-0095-08 400V, 70W, 48" Lead Length -
018-0095-09 277V, 70W, 21" Lead Length -

11
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

Table 4 OMC CO2 Specifications

SPECIFICATIONS OMC CO2
Maximum Working Pressure (MWP) 1885 PSIG (130 Bar)
Solenoid min/max OPD 1/1450 psig
Supply Voltage 120 V or 220-240V, 50/60 Hz
Solenoid Coil EMF
Current Consumption 0.15 Amp (120V), 0.07 Amp (220-240V)
Time Delay for Low Level Signal 10 seconds
Time Delay After Setpoint Recovery 5 seconds
Alarm Delay Time (Including Alarm
120 seconds
Contact)
Alar Switch SPDT
10A @ 120VAC 50/60Hz, 5A @ 250VAC 50/60 Hz,
Alarm Contact Rating
3A@ 30 VDC
Refrigerant Temperature -40° to 180°F (-40°C to 82.2°C) Maximum
Ambient Temperature - Storage -40° to 120°F (-40°C to 48.9°C) Maximum
Ambient Temperature - Intermittent
-40° to 120°F (-40°C to 48.9°C) Maximum
Duty
Oil Supply Fitting 1/4" Male SAE (Brass)

Figure 1 CO2 Low Temp. Subcritical DX System

12
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

Figure 2 Specially designed rubber rommets Kit # 527-0157-00

Figure 3 Oil Management Control OMC-CO2

13
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

Figure 4 Suction Side Pressure Relief Valve Requirements

14
© 2019 Emerson Climate Technologies Inc.
AE4-1372 R6

Figure 5 Three Phase Power Circuit

Figure 7 Compressor Electrical Connection

Figure 6 - ZO Compressor Operating Envelope

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 affiliates (collectively
"Emerson"), as applicable, reserve the right to modify the design or specifications 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.

15
© 2019 Emerson Climate Technologies Inc.